KLF300B No spark and electrical issues (quad)

[MarlinHemi]

Sorry to post another electrical problem thread but... i have recently acquired a klf300 with no spark and when I connect a power source the neutral doesn't come on and no power seems to get anywhere, i get 5ish volts to the coil an ignition switch when i spin the motor (by hand) but the battery voltage wont get to the coil or front of the wiring harness? wiring looks fine, could a bad starter relay or starter circuit relay cause this? Any ideas greatly appreciated

Wiring diagram: https://cdn.instructables.com/FN3/VT6W/I7CCCS3T/FN3VT6WI7CCCS3T.LARGE.jpg

EDIT: I have also tested ignition and kill switches which seem to work

[FJRider]

Sorry to post another electrical problem thread but... i have recently acquired a klf300 with no spark and when I connect a power source the neutral doesn't come on and no power seems to get anywhere, i get 5ish volts to the coil an ignition switch when i spin the motor (by hand) but the battery voltage wont get to the coil or front of the wiring harness? wiring looks fine, could a bad starter relay or starter circuit relay cause this? Any ideas greatly appreciated

Wiring diagram: https://cdn.instructables.com/FN3/VT6W/I7CCCS3T/FN3VT6WI7CCCS3T.LARGE.jpg

EDIT: I have also tested ignition and kill switches which seem to work

See if you can get the simple electrical things like horn or (any) lights to work. Direct power to individual components will confirm they do (or don't) work.

Could be a (Main) fuse issue. But no spark often is caused by a dud plug.

[MarlinHemi]

Thanks for that :) The main fuse is okay, and the bike doesn't have any lights or a horn but i did try and get the nuetral light working but the volage doesn't get from the battery to that, but when the stator spins i get voltage (low but still) through everything but the battery terminals

[jato]

Ok , on these bikes the battery runs the ignition so first of all you need to get a multimeter (or test bulb) and check for certain if 12v is getting to the ignition switch and out of it when its turned on. (to make fault finding simple i'd ignore the charging aspect for the time being.) the neutral light is a simple system and assuming the bulb is good the fact it doesn't work as well as the ignition is a likely lead... i wouldn't be surprised if the power isn't getting past the ignition switch. i have a klf300 c model and the ignition switch has played up a few times over the last 27 years. i once had to clean the cdi conectors due to a bit of corrosion on them also . see how you get on - we need to confirm power is getting to the cdi - if not how far does it get?

[FJRider]

Thanks for that :) The main fuse is okay, and the bike doesn't have any lights or a horn but i did try and get the nuetral light working but the volage doesn't get from the battery to that, but when the stator spins i get voltage (low but still) through everything but the battery terminals

I assume then that lights are not a priority then ... if not .. set up a basic "loom" to direct power to where it's needed. If it has a kick/pull start ... it can be wired to not need a battery ... just a kill switch. Little effort would be required to wire a starter motor in to turn the engine over to start it.

[MarlinHemi]

Okay awesome, tommorow i will check for power at the ignition switch, im pretty sure i dont have it and will check at the CDI

Thanks for the info will update tommorow

[Drew]

Clean the main positive terminal where it bolts on to the starter solenoid.

[MarlinHemi]

IT RUNS!!! I tried hooking the positive battery terminal straight to the ignition switch wire and she worked neutral light and it ran for 5 secondsish thanks for all the help everyone now i move onto carby, i was also thinking of just running a wire with a switch straight from the positive wire to the ignition wire (bypassing main wiring) is this safe to do if i fuse it? Cheers -Marlin

[FJRider]

.... i was also thinking of just running a wire with a switch straight from the positive wire to the ignition wire (bypassing main wiring) is this safe to do if i fuse it? Cheers -Marlin

if the worst that could happen is you blow a fuse ... :shifty: But if that is the worst that could happen ... :jerry:

[MarlinHemi]

Okay awesome thanks! what amp fuse should i use? cheers :banana:

[FJRider]

Okay awesome thanks! what amp fuse should i use? cheers :banana:

No more than the existing (if correct) main fuse ... probably ... :scratch:

[jato]

Great you've got spark with a jury rig - now you've got the chance to (easily) fix it properly or do a patch-up...

[MarlinHemi]

For now it will just be a patch up until i know the bikes gearbox rings steering and diff are okay then i might be bothered doing it properly :clap: