Question about kawasaki KLX 300 Motorcycles

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19-95 KLF300 ATV Kawasaki 4x4 no spark put new ignitor unit on.

Wiring loom -soldered crimp joints, HT coil load test ok, other elec components check out with ohm meter to approx values .Only have 87manual.No info on volts to IC Ignitor with ignition on. very light tickle from plug wire on engine crank no plug. I must be missing something as it ran previous to a pressure clean and faulty ignitor unit .Bike would go well then cut out poping and backfiring on restart-week spark. flywheel magnet strong,alternator good rectifier good ,flywheel pulse coil in ohm limits.

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  • pwebb191 Jan 01, 2009

    I have the same problem, KLF300 runs fine and then backfires and misfires. It can tick over and clear itself and run well or just stop and be a pig to start. either way its real hard work and depressing me badly

  • Roscoe007 May 11, 2010

    Is that the outside magnet on the flywheel your talking about or the inside magnets?

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I ******* hate my kawasaki kdx 125 1992 there is no spark and i dont no wot it needs ive bought a cdi for it an it wernt that and i bought a new coil and it wernt that either could anyone help me please

Posted on Sep 11, 2009

  • Jason Whitbeck
    Jason Whitbeck May 17, 2016

    You try the stator or pickup coil

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You said the motor cut out and popped and backfired when it quit, this is almost always one of two things; either the low speed pulse coil or the actual CDI "black" box. You will almost never lose a main coil. One thing I would also check to make sure did not happen is shearing a flywheel mag key. When the motor backfires you can easily shear a mag key if you have a heavy flywheel, (external). However when this happens you don't usually lose spark but it will certainly cause the backfire.
One other item of importance is that the bike you are in question about does not emit a bright spark when you are checking for fire. Make sure you are using a brand new plug and ground it on the head. Try to make sure you are in a dark environment when you check the spark.

Posted on Dec 16, 2008

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Colours of the cdi do not match the colour on the rest of the loom

Posted on May 24, 2013

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1988 klf300 bayou no spark, installed a new cdi voltage regulator,stator,and coil ran for four days and now no spark. what do you think is wrong.


Hi, Jeff sounds like you have a faulty wire connection somewhere otherwise the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting, leaking, spark plug cable connections loose check for spark leakage in the dark.
6. Faulty ignition coil or electronic control module.
7. Faulty CKP, CMP, or BAS sensor.
8. Faulty ignition switch.
9. Tilt sensor needs a reset.
10. Security alarm failing to disarm needs reset
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
Another no spark bayou any help left out there
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https://www.tradebit.com/usr/valuablemanuals/pub/9003/1986-2006KawasakiKlf300Bayoufree.pdf
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Where is the fuse located on my 1997 Kawasaki bayou 300?


Hi, Edward for this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Kawasaki, despair not, for a mere $8 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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My JD SX 320 misfires under load (one cylinder only)


plugs will not spark under compression if they are faulty or the HT lead id off too high a resistance. or mixture is incorrect
In the real old times when plugs were cleaned and tested one of the tests were to test spark in a dry compressed air chamber where if there was a problem they failed to spark
as you have fitted new plugs it comes back to the ht lead
they are carbon tracked lined internally, the connection for the plug and cap is just a steel pin shoved up into the carbon track
try using copper ht leads where the copper wire comes out to the connection
there could be a valve seating problem or weak valve springs on that cylinder that is not allowing proper seating under compression
if you have 2 carbies then the float level for that cylinder may be too low and under load starving for fuel

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1 Answer

2002 Kawasaki bayou klf300 4x4 missies at half to full throttle cleaned the carb and bought new cdi,rectifier still misses


Hi, Ellis and the usual suspects are:
1. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Spark plugs in bad condition or partially fouled.
4. Spark plug cables in bad condition and leaking.
5. Spark plug gap too close or too wide.
6. Faulty ignition coil, module, and or sensor.
7. Loose, dirty, or corroded ignition module connector at crankcase.
8. Faulty CKP or CMP, MAP, ETS, ATS, TPS, O2 sensor.
9. Intake air leak.
10. Water, dirt, or rust in the fuel system, carburetor and/or filter.
11. Fuel tank vent system plugged or carburetor vent line closed off.
12. Vacuum line from intake manifold to fuel valve is broken, cracked, pinched, or missing.
13. Carburetor controls misadjusted.
14. Damaged carburetor.
15. Incorrect valve timing.
16. Weak or broken valve springs.
17. Damaged intake or exhaust valve.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have nice a day.
http://www.kawasakimotorcycle.org/forum/mechanics-corner/35765-89-bayou-300-backfires-coughs-above-idle-speed.html
Kawasaki carb problem Gurus please help
https://www.tradebit.com/filedetail.php/118245427-kawasaki-bayou-300-service-manual-repair-1986-2006

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#1cylinder not firing on 2003 3010 Kawasaki mule


if its firing ok on other cylinders, unlikely to be pump or fuel filter, focus on electrics, plug, ht lead etc

Dec 08, 2013 | 2003-2007 Kawasaki Kaf620 Mule 3010 4x4...

3 Answers

I have a 2004 Suzuki LT-A400 Eiger ATV. It ran until the battery was replaced. Now there is no spark. I have experiance in repairing bikes and this one is stumping me. I have the factory service manual and...


I suggest replacing the cap and rotor (check the inside of cap for wear on the "points"
I am not expereinced with bikes, however when it comes to electrical/spark, I have always been able to find the issue, as there are only a few things that it can be. You have your power source (battery), your ground, and your source (any units/components powered by the battery). There aren't many things in between any of these that could be the issue.
Also, check the wiring harness to the distributor. Make sure it is plugged in all the way (if it "plugs in"), if it's hard wired, the opposite end should have a connection. Check that as well. Make sure you have no wires bare, or touching the frame or other part of the bike, as this could be causing it to short out, which will limit or prevent spark.
Please let me know if you need further assistance.
carsandcomps,
Guru, Premium Expert, Phone Support, Live Chat @ Fixya.com

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1 Answer

Can't get any spark on rear left ignition coil


I didn't notice the year of the bike but
the orange wire comes directly from your TCI ignitor unit.
It might be a faulty pickup coil or the ignitor unit itself.
the pickup coils are in the right engine case and
have about 110 ohms resistance.
If there is no ohms reading on the pickup coil then
it is faulty.
If the pickup pulse coils are good then your
main ignitor unit is probably faulty.
Sometimes the solder joints can crack in them.

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