KDXRIDER.NET

Just picked up a 97 220 yesterday. All excited to take my first ride and won't you know it. Bike doesn't start. PO said he had spark issues but fixed it with a new stator coil and plug cap. When it wouldn't start with s new plug and stater fluid I knew I was in trouble. Sure enough no spark. Any quick suggestions to trace problem?

Supect it's something simple since most compontants have been replaced. Is it safe to swap Electricals between the 97 220 and the 06 200?

IIRC, 97 and 06 KDX 200 and 220 electrical are all the same for bikes imported into USA, unless of course somebody swapped in aftermarket parts or something non-standard.

A common problem with electrical stuff is good ground connections. Also, I would check the kill switch to see it's not shorted to ground.

Make sure the new plug boot is making a good connection to the wire

get a shop manual that will tell you how to use a meter to check the ignition coil and stator coil winding

Don't have the manual at the moment. It's on my list of things to buy. I pulled one of the the wires from the kill switch to the harness hoping that would eliminate it but not sure if that's enough.

Disconnecting the kill switch will rule out the switch if it still has no spark than its something else.

Try threading the plug boot further into the wire or taking it back off and cutting .25 inch off the end of the wire and threading it back in to make certain your getting good contact.

make sure the red/white wire under the seat is plugged in to the cdi. iirc there are only three wires needed to gain spark, can the red/white, blue, and ground. not 100%sure, someone will correct me shortly.

it's a really simple bike to fix electrically.

The kdx are a hardy & reliable bike..
Firstly I'd make sure the wiring from the stator up is in good & unmolested order ( check all terminals in & around that area including the coil )
Next I'd replace the spark plug cap for a waterproof rubber item, next fit a new plug ... Replace the cheap items first before you waste your time & money on the more expensive stuff !
I would also check the kill switch before you do any of the above...disconnect it from the loom & see if it sparks .

I disconnected the kill switch.... It's not that. There is voltage coming out of the stater as I got shocked and meter showed AC when I kicked it. The coil is new. Removed plug cap and pushed multi meter lead into coil wire the other to ground.... Nothing. I think it my be CDI... Most expensive part. Funny how that would go the day I buy the bike. Is there any way I can test CDI with my meter?

I see there is an aftermarket Caloric CDI for $60 on eBay. Is this a good buy? If I bring my CDI unit to the dealer I wonder if they could check it for me quickly? What do you think they would charge me?

I believe there's a member on here who sells modified CDIs for the kdx ( dragonfly75 ? )) however im not sure if it's possible to test a faulty CDI , I'm sure someone on here maybe able to tell you for sure.
If you know someone with a kdx then you could swop yours for theirs just to see if that works.....?
There are plenty of kdx CDI's on eBay for a reasonable price if yours has blown ....if the stator,coil have been replaced then it looks like the CDI is the culprit .

Has anyone tried one of these?

https://www.ebay.com/ulk/itm/281757514349

You have an H series 200 right? Same igniter (CDI) as the 220. Pop it off and plug it in and see what you get.

I do but the electricals on that bike have not been messed with and still has the factory tape on all the wires. I don't want to touch it and risk opening a can of worms ore damaging the CDI putting it on the other bike. Just curious if anyone has tried that aftermarket CDI unit. As I want to get something on its way tomorrow. Someone on here must have tried it.

Do a search on this site for JAGUAR ADJUSTABLE CDI. Jaguar is your go to guy for KDX ignition and electrical.

New CDI unit showed up today! Bike still has no spark. Another thing I noticed which I should have checked before. The headlight doesn't light up when you kick the bike over. And yes the button is depressed.... As am I. About to pull the flywheel now.

Took the flywheel cover off. Water poured out of the motor... $#@&ing pissed!

And of course I can't get the flywheel bolt off and if I did my generic puller doesn't look like it's going to work.

Since I have no clue how I'm going to get this flywheel off and of course the bike shops are all closed on Sunday and Monday all I can hope for it the coils might dry out on there own and the bike will spark. Wish I had a hair dryer.

The flywheel puller is 27.0 mm x 1 mm, Left Hand thread. They are 12.50 or so on ebay for: