94 Kawasaki Mojave 250 - No spark, Very confused

[justent_88]

Hello, im looking for some input on this situation i have. My 94 Mojave has no spark, and i have no idea what it is. Ive replaced/tested the magneto, the pickup coil, cdi, the ignition coil. Even the key and Killswitch. I haven't tested the harness its self, but i have tried another harness and still nothing. The only thing i can think of is the fly wheel itself. I have found a lot of metal shavings in the fly wheel and have cleaned it the best I could. But nothing happened afterwards. I am truly stumped here and hoping some of yous could shed some knowledge/ideas that could help get this thing to fire. 

[Mech]

It only takes a single flake of steel, bridging between the trigger coil's steel core and the flywheel, to short out the magnetic field between the flywheel and the trigger coil's pole, and the cdi won't fire. A build up of iron dust on the trigger pole can do the same thing.

You need to get an analogue volt gauge and check there is a pulse of voltage getting to the cdi. A digital gauge won't always detect the brief pulse but the needle on the analogue gauge will flicker so you see it.

Some kawasaki use a 12v system of ignition so if the trigger pulse is getting through and it still isn't sparking then we need to get a manual and check the resistances and output voltages of the stator.

If there is no pulse from the trigger coil then you check there is continuity from the cdi unit to the trigger coil and if that's ok you need to take the side cover off and get every flake of steel off the flywheel and stator pole. Steel flakes or dust can also short out the charging cores of the stator. The best way I've found for getting dust or flakes off is to use a rag and grab it and wipe it off. It takes a while fighting the magnetism but eventually it's possible to get every little flake out and enough dust off to prevent it bridging the gap between pole and flywheel.

[justent_88]

Thank you for the reply, Mech. I'll have to go and try this later. I was struggling to remove some of the flakes last week, but i guess i need to go back and get it as spotless as possible. I really appreciate your response. Hopefully everything works out.

[Mech]

Simple test is to look for a pulse of voltage coming out of the stator plug. Most of the wires will have a regular AC voltage and be insulated from the earth, and one wire or a pair of wires will have a pulse.