Motorcycle Repair: 82 kawasaki Kz440 electrical, kawasaki kz 440, kawasaki kz440

Question
QUESTION: Hi Mike, i have a 1982 Kawasaki kz 440 that sometimes gets spark, but usually does not get any fire. the few times that it has, it was a blue spark. i would like to test all components before i just start replacing stuff. I read in one of your answers that you would send him some repair sheets. would you send me the same? any help would be much appreciated.

ANSWER: I don't recall offering to send anyone repair sheets, but I do remember advising someone where to find a proper repair manual online. For your bike, check out this link:

http://www.repairmanual.com/motorcycles/1982/34/0/4672

How exactly have you been testing for spark? If not done correctly this can give a misleading impression. Are you sure the spark plugs, wires, coil, CDI are in good shape and the battery is fully charged? I need to know this before I can help you find the problem.

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QUESTION:

Hi Mike,

Sorry, i was reading anothers response. I know the plugs and the wires are good(new) the batt is fully charged. I have a manual ordered, just has not made it here yet. As for the cdi and the coil, i dont know. What i am looking for is a way to test the cdi and the coil before i just start buying parts. The way i have been testing for spark is by taking a screw driver in the plug wire to a paint less bolt on the frame. any help at all would b appreciated.

Answer
A better way of testing for spark is to use the spark plug itself. With it plugged into the wire, place the threaded part of the plug firmly against a bare metal surface (the cooling fins on the motor should do), making sure the center electrode doesn't touch anything. Make sure you wear gloves so as not to get a shock. You will get a much better idea of what the spark looks like this way, as a screwdriver has different electrical properties and, because it is impossible to hold it the exact same distance away from the metal every time, it will not allow for a consistent and proper spark.

Try checking all the plugs using this method, then you'll be able to better diagnose the problem. If the spark is weak and intermittent, I would suspect the CDI unit. If the spark is consistently weak, chances are it's the coil.