Wilsons Sandbox

At 2:49 PM +0000 3/6/05, kevin wrote:

>My klr has no spark. Changed CDI and coil and plug. Any idea what >is wrong? Need info again.

I'm guessing it's your magneto pickup coil. Either a bad coil, or it's misaligned. Mark

Plug the two primary wires back onto the ignition coil. HIH Norm

>i adjusted my valvs now i have no spark

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I've been on a 2 week ride down here in Utah visiting with Fred and riding some of the best dualsport trails in the world and had a blast till yesterday.....I was on the way back home to New Mexico by way of the Grand Canyon when I pulled up to a scenic overlook (with NO cell service) and my KLR died.....Luckily there were also lots of nice folks stopping too to offer help and advice as the nearest real town was Kanab and was 50 miles away.... I did some troubleshooting and had fuel but NO SPARK.....being prepared with spare parts i replaced the coil and CDI unit and still NO SPARK !!!! All the wire had good connections and continuity. I finally got a wrecker to come (via carrier pidgeon) and haul me and my bike to Kanab.....Fred and I did some troubleshooting over the Phone and E-mail and I'm thinking I may have a bad Stator....The pickup coil ohms out OK and the yellow charging wires ohm OK too...It's the other red and white wires that go to the CDI that I'm wondering about.....How do I test those and what are there function in the circuit. here's the link to the Schematic Fred sent me.... http://www.angelfire.com/ut/moab/images/Wiring_Schematic_A4.jpg Any Ideas ???? Mike Huber Kanab Utah (not by choice) [Non-text portions of this message have been removed]

Plug wire? Robert P Wichert, P.Eng LEED AP +1 916 966 9060 FAX +1 916 966 9068 ================================================================================

On 9/25/2011 7:10 AM, Mike Huber wrote: > > > > I've been on a 2 week ride down here in Utah visiting with Fred and > riding some of the best dualsport trails in the world and had a blast > till yesterday.....I was on the way back home to New Mexico by way of > the Grand Canyon when I pulled up to a scenic overlook (with NO cell > service) and my KLR died.....Luckily there were also lots of nice > folks stopping too to offer help and advice as the nearest real town > was Kanab and was 50 miles away.... > > I did some troubleshooting and had fuel but NO SPARK.....being > prepared with spare parts i replaced the coil and CDI unit and still > NO SPARK !!!! All the wire had good connections and continuity. > > I finally got a wrecker to come (via carrier pidgeon) and haul me and > my bike to Kanab.....Fred and I did some troubleshooting over the > Phone and E-mail and I'm thinking I may have a bad Stator....The > pickup coil ohms out OK and the yellow charging wires ohm OK > too...It's the other red and white wires that go to the CDI that I'm > wondering about.....How do I test those and what are there function in > the circuit. > > here's the link to the Schematic Fred sent me.... > > http://www.angelfire.com/ut/moab/images/Wiring_Schematic_A4.jpg > > Any Ideas ???? > > Mike Huber > Kanab Utah (not by choice) > > > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

Mike, The red and white wires are from the exciter coil. I *think* this is what generates the energy for the spark. An ohmmeter set to R x 10 should read 100 to 200 ohms with one lead connected to the red wire and the other lead to the white wire. Quoting my 1987-2006 Clymer manual, "If the exciter coil is not within specification, check the plug and wiring harness for obvious damage and shorting. If necessary, remove the alternator cover and recheck the wiring harness and coil." (The photo points to one of the fatter coils in the stator assembly). "Individually check the full length of the harness wires for continuity. There should be near zero resistance in all wires. Flex the harness during the check to detect erratic continuity. "If the harness is not shorted, check the coil at the white and red wire connections on the stator. If the coil fails the check, unsolder the harness connections and recheck the coil. If the coil is within specification, a solder joint was poor, or the wiring harness is actually shorted. If the coil fails the check, replace the stator. "Measure the resistance between the coil and ground as follows: "Set the ohmmeter to R x 1 ohm. "Ground one of the meter probes to the engine (or the alternator cover, if removed). Touch the other probe to the white wire, then to the red wire. The resistance should be infinity. Any other reading indicates a short, and the stator should be replaced." I feel your pain. HTH, Mike Martin, Louisville, KY ________________________________ From: Mike Huber To: dsn_klr650@yahoogroups.com Sent: Sunday, September 25, 2011 10:10 AM Subject: [DSN_KLR650] NO SPARK .The pickup coil ohms out OK and the yellow charging wires ohm OK too...It's the other red and white wires that go to the CDI that I'm wondering about.....How do I test those and what are there function in the circuit. [Non-text portions of this message have been removed]

When this happened to me the culprit was the kill switch. I'd cycle it from run to the two stop positions and would blow compressed air into the (unsealed!) switch. From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of Mike Huber Sent: Sunday, September 25, 2011 7:10 AM To: dsn_klr650@yahoogroups.com Subject: [DSN_KLR650] NO SPARK I did some troubleshooting and had fuel but NO SPARK.....being prepared with spare parts i replaced the coil and CDI unit and still NO SPARK !!!! All the wire had good connections and continuity. [Non-text portions of this message have been removed]

I know you said "no spark" but you didn't say that if it would / would not turn over. I see some are talking about the kill switch (may as well through in the clutch saftey switch and the kick stand switch). My experience is if there is a problem with them, the engine doesn't turn over. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, Mike Huber wrote: > > > > > I've been on a 2 week ride down here in Utah visiting with Fred and riding some of the best dualsport trails in the world and had a blast till yesterday.....I was on the way back home to New Mexico by way of the Grand Canyon when I pulled up to a scenic overlook (with NO cell service) and my KLR died.....Luckily there were also lots of nice folks stopping too to offer help and advice as the nearest real town was Kanab and was 50 miles away.... > > I did some troubleshooting and had fuel but NO SPARK.....being prepared with spare parts i replaced the coil and CDI unit and still NO SPARK !!!! All the wire had good connections and continuity. > > I finally got a wrecker to come (via carrier pidgeon) and haul me and my bike to Kanab.....Fred and I did some troubleshooting over the Phone and E-mail and I'm thinking I may have a bad Stator....The pickup coil ohms out OK and the yellow charging wires ohm OK too...It's the other red and white wires that go to the CDI that I'm wondering about.....How do I test those and what are there function in the circuit. > > here's the link to the Schematic Fred sent me.... > > http://www.angelfire.com/ut/moab/images/Wiring_Schematic_A4.jpg > > Any Ideas ???? > > Mike Huber > Kanab Utah (not by choice) > > > > [Non-text portions of this message have been removed] >

There's a little known (but highly problematic) resistor in the spark plug boot. I don't think it's common, but being a resistor, it can go bad (happened to me once)! Check the fuse and/or plug wire for continuity through the boot. (I think the resistor is ~ 5K.) If you unscrew the boot from the spark plug wire, you can see the slot for a screwdriver in the contact for the spark plug. Unscrew that contact, and a spring and resistor should fall out. The resistor can be replaced by a wad of foil or other conductive substance in a pinch (that's what I did).

--- In DSN_KLR650@yahoogroups.com, Mike Huber wrote: > > > > > I've been on a 2 week ride down here in Utah visiting with Fred and riding some of the best dualsport trails in the world and had a blast till yesterday.....I was on the way back home to New Mexico by way of the Grand Canyon when I pulled up to a scenic overlook (with NO cell service) and my KLR died.....Luckily there were also lots of nice folks stopping too to offer help and advice as the nearest real town was Kanab and was 50 miles away.... > > I did some troubleshooting and had fuel but NO SPARK.....being prepared with spare parts i replaced the coil and CDI unit and still NO SPARK !!!! All the wire had good connections and continuity. > > I finally got a wrecker to come (via carrier pidgeon) and haul me and my bike to Kanab.....Fred and I did some troubleshooting over the Phone and E-mail and I'm thinking I may have a bad Stator....The pickup coil ohms out OK and the yellow charging wires ohm OK too...It's the other red and white wires that go to the CDI that I'm wondering about.....How do I test those and what are there function in the circuit. > > here's the link to the Schematic Fred sent me.... > > http://www.angelfire.com/ut/moab/images/Wiring_Schematic_A4.jpg > > Any Ideas ???? > > Mike Huber > Kanab Utah (not by choice) > > > > [Non-text portions of this message have been removed] >