1996 Kawasaki Mojave KSF250 No Spark

[Chris2018]

So I set the valves at .20 mm, the tip of 22mm will fit but 24 won't fit at all. Starts up nice runs ok still need to figure out air fuel mixture for some reason the manual specs are not really working. But I just noticed that my exhaust is turning red coming off the motor. What would be the cause of this.

[Frank Angerano]

Double check that the exhaust is not backed up.  Even if you have to pull the silencer off and run it. The silencer could be clogged and causing this. Make sure you have the proper spark plug in the machine and not a hot plug.   

What did you set the air fuel screw at ? Spec says it’s 1-3/4 I went to 2 in mine and it ran good. 

 

 

[Chris2018]

Thats about where i am at 2 turns out. When I did the valves do I make the screw tight on the 20mm or so it will slide on and out with a stiff ease

[Frank Angerano]

You put the gauge in tighten the adjustment until it takes a slight pull  for it to come out. Not tight where you have to yank the gauge out but enough where you need to pull it out out and it slides right out.  
 

If your 2 turns out go back a quarter to 1-3/4 and  see if it runs better. If not go 2-1/4 out and see how that goes.  Trial and error my friend.   How about that exhaust,any luck? 

[Chris2018]

I read that the top end should make a light ticking if valves are correct is this true

I haven't been able to get back out and take the muffler off yet.  I should be out in about an hour and will let you know

[Chris2018]

Is there supposed to be a cover/cap that goes over the snorkel? 

[Frank Angerano]

If your referring to the air duct at the front of the atv that’s under the plastic the answer is no. The plastic has a cap built in that allows air to get in.   

[Chris2018]

Well I wasn't able to get back out lastnight. Getting around to check things out now. I'm going to recheck my valve settings timing ect. I forgot to mention that the couple times I did test ride it not long after riding it would just quit shut off. I would have to wait and clean the plug. Could I just nock the insides out of the muffler rather then run it without one 

[Frank Angerano]

I would pull the silencer off leave the pipe on from the engine and see if the exhaust pipe goes to glowing again while it’s running or pull the silencer off and inspect it to see if there is a blockage.   

[Chris2018]

I was able to get out today and pole the silencer off. It didn't seem to get as read. The top-end has a soft light ticking since I've adjusted the valves. I read this is normal is this correct. But for some reason it seems to run the best when I have the air fuel mixture screw all the way in, I have already bought a rebuild kit. The only thing I didn't get was the air/fuel screw but it came with a new rubber seal and washer for it. And the other thing the spark plug wire gets so hot it feels like it may melt. When I have the air fuel screw turned 13/4 out it spits and sputters when i put it in gear and let the clutch out

Edited October 23, 2019 by Chris2018
Miss type

[Frank Angerano]

The air fuel screw is an important item on a rebuild kit. The tip of the screw gets worn down and that’s why your not getting an adjustment. Quick question, your coolant is full in the engine ? Thermostat and water pump are working including the fan ? It sounds like it’s got no coolant. If that exhaust silencer is not backed up then it’s running extremely hot for some reason.   Check your oil and make sure no discoloring as if coolant is mixed in with the oil as well.  

[Chris2018]

The fan does work. And there is water anf coolent in it. I will check the o right now to see if it's got anything in it. Whats a good way to check if waret pump is working 

[Frank Angerano]

Pull the cap off ya radiator and run the bike. After the engine gets warm the thermostat opens and you see water circulating through the system.   

Or you can pull the thermostat out and put housing back on without the thermostat and run the engine and see if it still gets hot. 

[Chris2018]

I just drained the oil and it looks the normal dark color almost like a black. Whqt color discoloration am I looking for? I can send you a video of it being pored or pictures if it helps

Would to much oil cause any of  this 

[Frank Angerano]

A grey color, usually means water or coolant in the oil.  You didn’t have to drain it just take a bit out but if it’s black it could use a change anyway.   So that’s a good thing then if it’s a dark color. Moving on ! How about the thermostat housing? FYI you can take the thermostat out and use high heat silicone if the gasket gets torn or messed up as a temporary seal to test weather the water is circulating through the system.  Me personally I would put a new thermostat in because it’s open but you can test it the way I explained for now to see if the engine runs cool without the thermostat.  
If there is no circulation then the water pump is not spinning but that’s the next step. 
 

[Chris2018]

After i checked the oil I put new oil in it. Then I tested it with just the radiator cap off not real sure what looki for but I believe the water actually moves in a circular motion. I didn't notice it moving but she when I pressed the throttle it pushed sone of it out. I then tried it with the thermostat out. I really didn't get to try it long bc of my nabiours bitching. So I will run that test a second time in an. Is there a test that can be done on the pump it's self?

 

 

 

But I was able to turn the fuel mixture screw out 2 turns with it out and it ran ok. It didn't feel like it wanted to die when put in gear and given gas

[Frank Angerano]

Not really a test on he pump I can think of other then the ones I mentioned.  What your looking for is coolant pushing out of the ports inside the radiator.  Drain a little coolant out if you have to maybe an inch or two so you can look down into the radiator. When the engine runs the pump spins and your coolant circulation happens.  That’s without the thermostat, when the thermostats installed the engine needs to reach temperature for it to open and then circulation begins.  Some engines have a small bypass hose to allow minor circulation to happen I don’t think that’s on the Mojave.  
I’m assuming you put the silencer back on since it was clear ? 
Here is a pic of the name of the carb rebuild kit I use. 
I know you said you pulled the screw out to 2 turns and it works but if you decide to change that screw at least you have a kit with the air fuel screw. 
I piss my neighbors off all the time until they need something lol. Snow blowers don’t start, pressure washers car problems etc.  

[Chris2018]

So I finally went out last night and litterly started from scratch. All the way down to piston and rings just to see if there is a chance I fu**** something up.. I got it all tore down, then back together looking over everything and doing everything I could to be certain. Started it up and the same thing starts to get hot. I then took the fan off and put it on the other side of the radiator so it would help blow the cool air at the motor rather then help direct it away from the motor likeit normally does I guess, it helped a little but not much. Finally I downloaded the manual and just looked and stared until finally it clicked I had the coolent hoses switched

[Frank Angerano]

Hahaha no way !!! That’s funny as heck and also great news as well.  So it’s running cool? 

[Chris Stokes]

On 9/5/2019 at 11:55 AM, Frank Angerano said:

Ok well maybe it truly is your cdi. Here  my crazy trick in mentioned earlier It works! If your cdi is damp inside this truck will fix it temporarily but allows you to see if this is the problem.   I did it before and it worked. Don’t laugh.  Do exactly what is shown here then go install it and give it a shot. 

 

So is the CDI box basically a "coil" like you have on a modern automotive engine?

[Chris2018]

Its running ok. I haven't had a change to actually get out and get out and really get on it yet but it's nit getting hot. It has a small back fire not alot but enough to make you think. Abd sti cuts out a tad but I will put that on the air fuel screw

[Chris2018]

So I have a question about changing my jetting. I'm not real sure what I need to change to or what ones I need to change. What I can say is it runs the best when I have the starter jet and the main jet around the same size, which is I believe # "125 or 135. And it turned out 2 1/2 to 3 turns 

[Frank Angerano]

Should be 125. Look up ex caliber oem carb kit.  It’s factory sized jets and also includes the air/fuel screw.  Should be 125 if I remember right.    

[Chris2018]

Yes  it is 125. But I was wondering why, or what would cause it to run good with both the starter and main jet set the same. I use just doing trial and err just to if it would fix it and it cleaned up with both of them Jets set the same, 125.

[Frank Angerano]

I don't know why the jets are the same but my guess over all would be the air/fuel mixture screw being worn.   Put the oem rebuild kit in from ex caliber and see what happens. 

[Chris2018]

Ok thanks. I'm going to go buy one tomorrow and install it. I will let you know how I make out. You have been a huge help throughout this project. And I really do appreciate it

[Frank Angerano]

No worries, that’s what we are here for! 
keep us posted.  

[Chris2018]

Anyone know if someone selling top-end for a Mojave 250 at a reasonable price. Could really use the cylinder head.

[Frank Angerano]

Hey @Chris2018 haven't seen you post in a while.  
Whats going on with the top end ?

[Chris2018]

I apologise for not getting back sooner things are hectic to say the least. I was going to just sell the old Mojave but my son likes it and enjoys being in the garage tinkering too. But to answer your question we were buying small parts as we could to fix it up since we are now keeping it. We were going to change out the valves and one of the bolts that hold the rocker arsm down broke off 

So now he is bummed out. Bc even with doing our small repairs he was able to ride it a little bit