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  #16  
Old 9 Mar 2011
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what about putting the original pick up coil back on ?
just wondering if somehow its sparking ok but on the wrong stroke
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  #17  
Old 11 Mar 2011
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non start kle500a1
i could try this but not convinced its this as the one taken off was out of spec . i going to go over eveything this weekend . failing that i am taking the head and barrels off to check in side etc
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  #18  
Old 12 Mar 2011
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ok dude
let us know how you get on
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  #19  
Old 17 Mar 2011
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non start kle500a1
well i give up . just checked had a spark and went to try to start it . and the starter relay stopped working .my lucks not 2 good at the moment with this bike
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  #20  
Old 17 Mar 2011
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Take a break from the bike from a while, come back to it fresh and maybe you'll see the problem having a little distance from the bike. One can only hope.
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  #21  
Old 17 Mar 2011
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So have you done a compression check yet ??

You said it had a spark but was it a good one ??

If it won't run even with "powerstart" into the inlets then it's got to be ignition or compression.
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  #22  
Old 18 Mar 2011
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non start kle500a1
well the spark was not 2 bad . not a nice blue spark if you like it was more of an orange colour . i convinced this is ignition related not comppresion or timing . still got to get a relay now .
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  #23  
Old 18 Mar 2011
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I just read the first post..

"it was running fine until I used carb cleaner"

So it was fine until you removed the carbs and replaced them ??

If you're sure the carbs are fine and I mean REALLY REALLY sure , then maybe you dislodged a connector or pulled a wire out..

It won't be compression or timing if it was fine before you stripped the carb..

You didn't answer if you have tried spraying carb cleaner into the throttle boddies of the carb or into the airbox while turning the engine.
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  #24  
Old 19 Mar 2011
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if the spark is more yellow than blue i'd suspect ignition components.
have you tried putting the original pick up coil on ?
reason i'm asking is i know you said you bought a new one but there's a slim chance thats knackered out the box.

Something else to check.

The main power for the loom is routed through the connector block on the solenoid. The main fuse is also located here. The wires in this connector block are prone to corrosion, especially where the big white wire attaches to the fuse itself. If you pull the red connector off, any corrosion should be obvious.

You can also pull any connector blocks apart to check for signs of corrosion and inspect the loom for any worn spots where there could be an intermittant short. You can easily test the coils with a multimeter (and check their connectors too). Check the plugs while you have the tank off.

Early GPZs had a problem where the magnets for the alternator became detached from the casing due to dodgy glue and effectively trash the rotor. I don't know if they used the same glue on the KLE.
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  #25  
Old 19 Mar 2011
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non start kle500a1
i tryed spraying easy start straight into the intakes this didnt work . i have also tryed a second set of carbs that i have this was also no good . i have had the loom apart this all looks ok apart from 2 wires connected to the fuse box these had corroded right through . . unfortunately i am going to have to wait till the end of next week to get a relay to try it again . the coils are also well within spec . but i may even replace these with new as well . think the bike could do with an overhall anyway . thinking back i did spray the connectors under the tank at the front with wd40 so it could be something to do with this . will be going over the wire again tomorrow if i get time
Last edited by wildmetal; 19 Mar 2011 at 20:22. Reason: added
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  #26  
Old 23 Mar 2011
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non start kle500a1
well i now have all the wiring stripped . found that the white wire that goes to the start solinoid is corroded and hanging by a thread where it joins 2 in to one . so i will be replacing the complete wire for this on friday (hope this is it ) and checking all the other junctions . makes me think that the coils etc wernt getting enough juice for a good spark
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  #27  
Old 28 Mar 2011
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any joy?
had me fingers crossed
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  #28  
Old 29 Mar 2011
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non start kle500a1
nope no joy . looks like its an engine out job . or replacement might just strip it and do it up for next year . still think its some thing stupid that making it not run . still i got 3 days and i am back on my zxr750 . cant wait
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  #29  
Old 31 Mar 2011
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No Go1
Change the supressor cap or, try an old trick, connect the HT lead directly to the top of the plug (a bodge but see if it works just to eliminate the cap).
Dave.
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  #30  
Old 4 Apr 2011
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non start kle500a1
nope just tryed that still nothing
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