NO SPARK! KLR 650 ignition system troubleshooting and repair

I bought this 1992 Kawasaki KLR 650 purely for it's colour scheme. It did not run and the previous owner thought it was the CDI box. In this video we work through the ignition system from the spark plug back and find that the bike has a bad exciter coil. Thanks for watching!

[@OlmanEg]

This is an awesome quick reference to diagnose your klr650 problems! Thank you for posting. Really got me out of a bind. 👍👍👍👍

[@paulwojnar2291]

Excellent, informative methodical troubleshooting video.
Been a used KLR 650 since 2003.
On my second one a 2003.
I lost ignition last year.
Turned out to be the ignition coil.
I replaced it , the secondary spark plug lead and cap which comes with replacement OEM coil from Kawasaki.
I am now a subscriber and will watching all of your videos.
Thank you so very much.

[@carbs66]

thanks for the heads up...i'm checking mine for no spark tomorrow
Steve in Ontario.. cheers!

[@skye5132]

Thanks for this walkthrough! My bike ended up having exactly the same issue, double the typical resistance on the spark plug cap and a broken exciter coil. My KL650 is running beautifully now.

[@scramblinman7156]

Great troubleshooting video. Now I gotta go figure out my issue with mine. 👍🏼

[@joenodetail3499]

I bought an 01 a few months ago, first klr but have wanted one for awhile. Learned a lot about them in the past few months, rebuilt the carb, suspension, bearings, lots of little nuts and bolts too. After finally getting it back together with my new crash bars and getting on the rode I lost spark as well, I haven’t tore into mine yet but I feel pretty confident from your video that I can figure it out.

[@austinreed2822]

P pl

[@Pilledskin]

Very useful, helped me troubleshoot my own klr. It appears i might have the same issue.

[@grahamdavey3597]

Thanks for your tutorial. Good luck. Graham.

[@jeironamobey8136]

My chain popped and cut the red and 1 yellow. Chain was jammed in the engine case and sprocket. No spark now. Wire coulda of got yanked when chain pulled the wires a little. Ill open up thr stator side and see what happens next. Great video by the way

[@stealhty1]

Im working on a 2005 KLR 650 , with no spark same wiring colors , im going to check your values ,thx for share

[@Goran2551]

Awesome tech info…you have a new subscriber….

[@BESTO1215]

Nice job with diagnosis...I hate when people throw parts / money until they get it....your good I am the same way...verify then replace....

[@beckettevans7228]

Hey great video, the community appreciates the time and effort it takes to edit these videos.
Question, I saw in your video that the spark you had @ t=1357 looked odd to me.
Looks like it's sparking 4-8x per revolution and mine's doing the same thing.
I thought it was supposed to spark once per revolution

[@justins8089]

Great video man!! Another one for TH-cam university:)

[@ianstorms3149]

No spark on my 00. Boy was I happy to find this video until YOU FOUND the issue way too soon lol. My exciter coil check checked out. 134 ohms. I don’t have another bike to swap the CDI so I’m stuck now

[@miras7382]

Did you find the issue? Im stuck too

[@ah802tube]

Waited through the video for info on how you were going to handle the re-decal or paint, I have the same issue.

[@JanRebel11]

Great video, thanks!

[@apostoliw]

I really liked the electrical job you did on the klr maybe you can give an idea on a problem I got with mine as I did the same job on mine then it developed a new slight problem the oil light (red) on the dash doesn't go of when the motorcycle starts mine is a model C9 2004 it doesn't have temperature gauge just a green light for neutral and a red for the oil on check position it light up and when running normally goes off the harness and engine have been rebuilt and this problem didn't existed before either After the rebuilt it started when changed the stator ECU and the spark plug coil

[@scottshafer9813]

Very well Done!
Thank You :)

[@smoothoperator7306]

Thank you very much.

[@doctorhfuhruhurr4380]

Nice. I've never had any electrical issues with my 1985 KLR600 but if I do I know how to debug it.

[@mbrad2669]

Good ol KLR exhaust note🥰🥰

[@dougclampitt386]

i have a 91 love the color

[@donaldkondi2979]

When I try to get a reading on the exciter coil red and white wire I get nothing just OL, however when I crank it and set the meter to voltage I get 50-60v per crank. Is it possible the stator is bad ? It was working fine yesterday now no life. It goes seem to shoot a spark every now and then but it’s rare

[@MotorheadRedo]

Wow! The stator is over $500 from a Kawasaki dealer and it's around $40 on ebay.

[@seanhammon6639]

Thanks man! What was the name of that manual?

[@andreserta]

Hey mate. Can you give any idea. My KLR650 have no spark also. I did all your steps but all the measurements are good and on rand as you sad. So i still stuck with no spark. Can you give me any other tips to check if i can solve my problem? Great job with this nive video.

[@mrnoone7377]

i had a klr 98 and it wasn't getting any spark. The issue was an aftermarket igniton switch

[@abczyx2102]

Heat gun for the faded plastics will bring back the color.

[@unclequack5445]

Man you wasted a bunch of time go straight to the coil if that dont work then start back tracing I did it all before when it was the coil the whole time.