desperately seeking a spark

[Jud]

--- In DSN_KLR650@yahoogroups.com, Cengiz Tanc wrote:

> > I recently came in to owning a 1997 KLR650 that hasn't been through > the best of times. A string of bad mechanics and lots of falls. I live > in Turkey and a gasket that would cost 75cents in the US is around $5 > here. So the poor bike was sealed up with all sorts of liquid > gaskets including regular household clear silicone. Lots of wood > screws instead of bolts, welds here and there including on a camshaft > bracket. The brake pads were still original! Instead of replacing > brake pads as a whole, new pieces of pad were bonded to the pad > baseplate. > > The bike was apparently running before its 3 year storage after which > i acquired it. I rebuilt most of its systems (brakes, carburetor, > cooling etc.) with original parts. Unfortunately I am still unable to > get a proper spark. Never heard her run. Its a feeble spark that > disappears altogether after 3-5 turns of the engine. > > Here's what i've done so far: > I replaced the old stator that was out of spec according to resistance > tests i performed per the Clymer manual, with a new Electrosport > version, not the high amp one. The exciter coil, the main winding on > the old stator had been restrung or wrapped as it were. > The CDI unit i had a guy fix here, he said there was a burnt diode in > it, (there is whole branch of mechanics here called "brainers" who > dig out and fix CDI type units from all sorts of vehicles) but i > bought a working one off ebay anyway... The resistance tests on both > are identical. I think the burnt out diode was a result of a short in > the three yellow wires coming from the old stator that had fused > together. > > I have new plugs, new starter relay, battery and replaced the ignition > coil with a working one from ebay just in case. > > Removed the wiring harness, checked all grounds, but didn't unwrap it > completely, looked for shorts or damage in the bendy areas etc. and > reattached. > > Pick-up coil, diode, and rectifier are all within spec. > > Yet the spark is still feeble. Is it normal that when i press the > starter button it turns over the engine a maximum of 6-8 times before > it runs out of steam, the headlights dim, and i have to wait half a > minute before trying again. This is only my second bike, so > sometimes i'm not sure what's the norm. > Thanks for any help in advance, > > Cengiz >

That sounds like a weak battery. Charge it overnight on a trickle charger. Fully charged, the voltage at the terminals should be about 12.6v. Cranking voltage should not drop below 10v. If you don't get those readings the battery is bad. If the battery tests ok, look to connections or the starter motor.

[kenneth bish]

Please remove my name and email address from your mailing list. Kenneth Wm. Bish [Non-text portions of this message have been removed]