The Kawasaki KLR650 uses a AC-CDI (Capacitor Discharge Ignition) system. The ignition timing is set at the factory and is not adjustable. To see if the ignition system is working, connect an inductive timing light to the spark plug wire and crank the electric starter. If the timing light does not flash, the ignition system is not sparking the plug. Perform the following checks.
SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Spark Plug
Check the spark plug to see if it is the correct type and gapped properly. If the spark plug is black and fouled, replace it. See the Spark Plug topic for more information.
Ignition Coil
Caution: Do not touch the spark plug wire while cranking or running the engine as this can result in a severe shock.
To test the ignition coil you will need a digital multimeter set to Ohms of resistance. The ignition coil can be tested while still mounted on the frame or it can be removed.
The ignition coil has two blade connectors made into it that the primary leads connect to and a large diameter spark plug wire called the secondary lead.
Primary Resistance
Touch one of the meter leads to one of the blade connectors and the other meter lead to the other blade. Polarity of the meter leads does not matter. Replace the ignition coil if your measurement does not meet specification.
primary resistance is .1 to .3 Ohms)
Secondary Resistance
Remove the plastic spark plug cap from the spark plug wire by unscrewing it. Touch one of the Ohmmeter leads to the inside of the spark plug wire and touch the other meter lead to either one of the blade connectors. Polarity of the meter leads does not matter. Replace the ignition coil if your measurement does not meet specification.
ignition coil secondary resistance is 3.8k to 5.8k Ohms)
Spark Plug Cap Resistance
Remove the spark plug cap by unscrewing it from the ignition coil secondary lead, then touch one of the Ohmmeter leads to the metal end of the spark plug cap that fits onto the spark plug and the other meter lead to the metal end of the spark plug cap that screws into the secondary lead. Polarity of the meter leads does not matter. Replace the spark plug cap if it is not within specification.
spark plug cap resistance is 3.75k to 6.25k Ohms)
Pickup Coil Resistance (Crankshaft Sensor)
Unplug the three pin plastic coupler with the black wire and the black/yellow wire pickup coil leads. There is also a light green wire in the coupler, which goes to the neutral switch.
Touch one meter lead to the black wire and the other meter lead to the black/yellow wire, using the half of the coupler that leads down to the engine. Polarity of the meter leads does not matter. Replace the pickup coil if the measurement is not within specification.
pickup coil resistance is 100 to 150 Ohms)
Exciter Coil
Unplug the six pin plastic coupler with the red wire and the white wire exciter coil leads.
Touch one meter lead to the red wire and the other meter lead to the white wire, using the half of the coupler that leads down to the engine. Polarity of the meter leads does not matter. Replace the exciter coil if the measurement is not within specification.
exciter coil resistance is 100 to 200 Ohms)
CDI Box
There is no accurate way to test the CDI box other than to substitute with a known good component.