Motorcycle Repair: Ignition shutdown after warm up., electrex usa, lighting coils

Question
I have a 1984 Kawasaki 600 KLR. It will start and run for about 2-5 minutes then it will just quit.No backfire no popping or sputtering. The stator cover seems to get really hot. After cooling down it will start again. The coil does not get hot.  Could it be breaking down internally or do you feel the problem is deeper. I had the coil checked by two cylce repair people. One said the coil is good, the other said it was firing intermittently  Thanks in advanced for your expertise. Jim . from Niehenke1@aol.com

Answer
Hi Jim,

Visit "www.electrexusa.com" and review their Troubleshooting Chart.

I recommend Electrex USA's fine replacement parts.

Obtain a copy of the service manual and perform electrical diagnosis. The tests are easy. You'll need a multimeter/ volt-ohm meter (VOM).

I suspect the source coil is causing the heat due to high resistance further up the line. Usually caused by the Regulator-Rectifier, or a loose or corroded connector.

Check the charging and lighting coils, regulator-rectifier, and output voltage.

Check battery voltage and specific gravity. You must have a fully charged battery in good condition.

Check all electrical connectors for clean tight connections.

Check ignition system components; coil primary and secondary resistances, pick-up coil resistance, plug wires, and caps.  

Remove corrosion and apply dielectric grease to connectors to prevent corrosion and water shorting.

Respectfully,
Mark Shively