1996 Kawasaki Mojave KSF250 No Spark

[Frank Angerano]

So you got spark!! That’s great!!!! The cooling system fan will only work when the engine temp gets to its set point.  On the right side of the bike the radiator bottom should have a sensor on it. There should be two wires connected to it.   Take them two wires off of the sensor.  When the engine is running use a jumper wire and jump the two wires. That fan should come on, if so that’s good news as far as the fan working and the power going to it.  The only thing next is to see if the sensor is working. My guess is it’s working fine.  My bike took a while to heat up and come on.  If in doubt swap it out for a new one. I will get back to you with the wire colors for that fan and the wires your talking about that are loose.  

[Frank Angerano]

The wires going to the fan and the sensor are circled. Test them as I indicated and see if the fan comes on.  Meantime send me a pic of the wires and the area that they are located in I will see where they go on my machine.  

[Chris2018]

Ok thank your you. I will be going out and send them pictures in a few minutes. The sensor you speak off. I believe my is ontop of my radiator. So I just take the two wires off the sensor and tuch the two together ?

[Chris2018]

Any ideas why the ignition switch is working backwards lol

[Frank Angerano]

The sensor should be lower right side of the radiator  if your sitting on the bike.  

As far as ignition switch is it an oem switch ? 

[Chris2018]

Here are the pictures of the 2 spots the two blue and brown wires are located and the third is my sensor 

[Frank Angerano]

That would be the fan sensor. Jump them and the fan should come on. But the bike needs to be running obviously. As far as the other two I’m going to take a look now.  

[Frank Angerano]

The fan sensor, the wires all in tact ? The blue wires that I see as per the diagram are a 12v positive. The browns I’m not really seeing except for the stator wires.  Double check that it’s not a brown with a stripe on it.  Meantime put a tester on the blue wires and see if the test for 12v positive. 

[MarkinAR]

If the Mojave is like the Bayou, and I suspect it's pretty close, there are spare wires at the front for accessories.  a 97 Bayou has a few extra brown and blue wires.  Brown is 12V electric ground (not frame ground) post ignition switch I think and blue is 12V lighting maybe?  Been a minute and can't remember for sure but they are usually listed in the wiring diagram as accessory or Canada version maybe?

[Frank Angerano]

Yes I agree, it’s for an accessory add on maybe.  I will look at my own bike this afternoon to verify.  But that was my take as well.  

[MarkinAR]

I was wrong on the brown if I understand the partial wiring diagram above correct.  Looks like brown is a metered 12V post rectifier and blue is from the magneto which would indicate likely lighting. So probably spares.  The Bayou had like 3 extra browns and at least one blue...they were all for accessory.  Good place for a winch or extra lighting i guess!

[Frank Angerano]

Maybe extra lighting at best because this bike has no battery. It’s self reliant as far as power goes so you really couldn’t add much more onto it.  

[Chris2018]

Ok I just wasn't sure. Is there any other test Incan check to make sure the switch works correctly so I don't have any issues with it getting hot on me

[Frank Angerano]

Have you jumped the fan to see if it runs ?  

If so the second test would be to remove the sensor from the radiator and connect a tester to both leads of the sensor and put the tester on continuity. There should be no reading while it’s cool.  Then put it in a small pot of water (just the sensor part) and as the water heats up the sensor should close giving you a reading. It should close at about 185-190 deg. 

Edited September 9, 2019 by Frank Angerano

[Frank Angerano]

Ok figured the blue and brown wires.  They are for your rear brake light. One is by the carburetor should run to a brake switch on the rear brake petal.  The second set up by the front goes to the right brake handle lever.   

Edited September 9, 2019 by Frank Angerano

[Chris2018]

Thanks for the help, everything seems to be in working order for the most part. Just trying to figure out this crab. I got it all cleaned up, it was real bad on the inside. But for some reason as soon as you put it in gear and give it gas it spits and sputs  but if it's just in neutral it's fine@MarkinAR

[Frank Angerano]

Double check and don’t make the same mistake I made. Make sure you put the right jets back in the right spot. When putting the carb back together the pilot jet and the main jets are the same thread. I reversed them and the bike died at as soon as I put it in gear.   

Edited September 9, 2019 by Frank Angerano

[Chris2018]

I thought I might have mixed them up. One is actually shorter then the other but can't see what one goes where lol

[MarkinAR]

Ha. I did that on a big bear. 2nd pilot is a 74 and main is a 115 or something. Doesn't run quite right with them backwards. Identical jets though...

[Frank Angerano]

The one with the larger hole goes on the main. 

[Chris2018]

I couldnt get it to run right for nothing run great at standstill but as soon as I put it in gear just spit and sputter. It would go but just kept cutting out. I kept trying the mixture screw and nothing would fix it. I'm checking now to see if that's what happened

[Chris2018]

I went out last night and bought some paint. I was just going to beat it around but figured I have this much time into it already why not fix what needs to be fixed clean it up nice and go from there. I've never actually painted one or gone full out to fix them the right way. Normally cut corners and beat it until it's done. But going to put some effort into it. Will post some pictures later for befor and afters

[Frank Angerano]

Let me know if you need the paint color. I found an oem dead on match. 

How did the carburetor work out ?

 

[Chris2018]

I'm getting ready to put it together now and go try it. As far as paint I had my girl pic it up while she was out last night. I told her Kawasaki green she came back with. I mean it does match what someone else already used to paint it once but not what I'm looking for I don't think. She tries though 

[Frank Angerano]

Here are a few pics of the work I did. The color I found on eBay and Amazon. 

PJ1 Color Matched Frame Paint 99-02 Kawasaki Green 12 oz. https://www.amazon.com/dp/B00230IC3M/ref=cm_sw_r_cp_api_i_UO6DDbBDAQ4ZW

The other colors are standard gloss black for nerf bars and then high heat satin finish on the exhaust.  

The aluminum portion (silencer)  I used an aluminum polish called mother’s.  It’s great for all soft metals.  

Mothers 05101 Mag & Aluminum Polish - 10 oz https://www.amazon.com/dp/B0009H519Y/ref=cm_sw_r_cp_api_i_GT6DDb4RMNXGF

[Chris2018]

That looks sick. You did a nice job. You use a spray gun or cans. Oh and the main hey is the one with the needle coming in from the other side right? And that gets the smaller hike correct?

[Frank Angerano]

The main is the one with the needle. It gets the larger of the two jets. They have numbers on them. Mine were not legible due to being what looks to be worn or sanded maybe during the cleaning process of the previous owner. So if you can read the numbers then lol at the carburetor section of your manual and it clearly explains where they go.  But for sure the larger hole jet is at the needle location.     

Yes all can spray. Wire wheel in a drill and sand paper. I spray a good prep coat on before and spray away!  The prep coat is a clear type coat that helps the new paint stick well.  

And FYI all of this material I bought on line for $125 bucks. That includes the new color matching chain and I was missing the air factory box.  That air box assembly was $45 so really it cost me $80 if I wasn’t missing that air box.  That chain was only $20 bucks. 

Edited September 10, 2019 by Frank Angerano

[Chris2018]

Well I think I might have had them in wrong. I seen one was shorted then yhr other so just guessed that it was on top of the other piece lol. And the pain does look real good. I don't think I will be able to do as well but give it what I got 

[Frank Angerano]

You will do just fine. Mine took me a week to do.  A little each day.   

Let me know how the jets work out. 

[Chris2018]

Still not working right actually a little worse this time. But if I stick a rag in the end of the air filter box everything works great