No spark

[Bayboy87]

Good morning everybody my name is Bruce and I am proud new owner of a 1986 Kawasaki KDX 200. I got the bike for a pretty good deal and started digging into it. After realizing it wouldn't start I stripped it down to bare Bones and started trying to figure out why I didn't have spark. No power at the ignition coil, nothing at the CDI, so I moved on to the stator wiring. My test light shows some power coming out of the stator, from both the yellow and the blue wire but the light on the tester barely lights up so I'm guessing that that's my problem. I'm thinking about getting a new stator from Ricky stator I heard his name a lot and nothing but good things to say. Thanks for letting me in this KDX crew and get back to me when you can with any input please. At this point I'm only looking for the bike to run and turn off. No need for front light back light or anything special thanks guys.

[KDXGarage]

Welcome!

Are the flywheel and four magnets OK?

The OEM service manual is usually pretty cheap on eBay. It will be lime green with the title "Owner's Manual & Service Manual". Make sure it is for the KDX200-C1. It will show it on the back.

[Bayboy87]

I haven't quite got that far yet. Had to order a flywheel puller and a new stator just in case. They are officially in the mail and on the way. As soon as I get those I'm going to crack her open pull the flywheel and check everything out. Also since the CDI wasn't receiving the power or the correct amount of power, I ordered one but it's for a newer KDX I'm wondering if it'll work. what do you think?

[KDXGarage]

Which puller did you buy?

Magnet damage has killed several air cooled KDX's over the years.

I am not sure on the CDI. It may work. but not as well as the correct one.

[SS109]

Like KDXGarage mentioned, the flywheel magnets are infamously known for self destructing. I really hope that's not the issue. Otherwise, I would be leaning towards the source coil (ignition stator) as well.

I'm pretty sure you can get the CDI to work. Whether it runs well with it or not is another question. You'll only know after you try it!

[KDXGarage]

The reason I ask on the puller is because it is not the 27 mm LH threaded puller that is sold everywhere by everyone, claiming it fit every KDX ever built. :-)

[Bayboy87]

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Who can spot the problem. I talked to Ricky stator after I ordered the stator. He let me know it was the wrong one and asked if I wanted to swap it out for an source coil and that should fix me up. The customer service is awesome anyhow. I was on the old interweb looking over some wiring diagrams and noticed that these two do not match that's an even bigger problem than not having ignition right get back to me when you can.

[Bayboy87]

I also noticed via the wiring diagram that the way the wires were set up in the diagram were different than the wires coming out of this particular CDI. The colors were the same except they were in a different order. Maybe somebody took it apart once not sure.

[KDXGarage]

Those are not the stock connectors. Someone cut them.

[Bayboy87]

This is the wiring diagram I was looking at

[Bayboy87]

So it looks like I have a C1 magneto or stator with a C2 CDI. These both originally came on this bike that I bought and the wiring was butchered like all of it. I pulled the tank and there was wiring cut up attached to nothing for what I'm assuming was the front headlight and rear light

[Bayboy87]

Any advice where I can get a CDI for the C1

[KDXGarage]

The CDI and the stator plate is the same for 1986 - 1988.

This Kawasaki 21119-1199 IGNITER fits the following models and components:

Kawasaki Motorcycle 1988 KDX200 - KDX200-C3 GENERATOR

Kawasaki Motorcycle 1986 KDX200 - KDX200-C1 GENERATOR

Kawasaki Motorcycle 1987 KDX200 - KDX200-C2 GENERATOR



This Kawasaki 21003-1178 STATOR fits the following models and components:

Kawasaki Motorcycle 1988 KDX200 - KDX200-C3 GENERATOR

Kawasaki Motorcycle 1986 KDX200 - KDX200-C1 GENERATOR

Kawasaki Motorcycle 1987 KDX200 - KDX200-C2 GENERATOR


https://www.partzilla.com/catalog/kawas ... /generator

[KDXGarage]

[Bayboy87]

Nice. Do you think using my own connection will be an issue. The originals weren't on the wires when I bought the bike? If needed I can get the whole stator at partzilla.com?

[KDXGarage]

I think it will be fine, jusy got to make sure they match up.

What does the wiring coming off the stator look like? $348.34 at Partzilla. I would try to rebuild what is there or buy used.

[SS109]

Hmm, I wonder what the Blue wire actually did on the '83-'85 bikes and what was different about the stator that it needed a 4 wire setup? Sorry, not helpful.

Yes, as long as you connect the wires from the stator/chassis to the CDI where they are supposed to go any decent connector should work for hooking it up.

[Bayboy87]

Thanks guys you are awesome and that's a big relief. As of now I'm waiting on parts. As soon as I get that source coil and install it I should have power. I'll definitely keep you guys posted thanks again.

[KDXGarage]

You're welcome. Good luck with it.

[Bayboy87]

I think it will be fine, jusy got to make sure they match up.

What does the wiring coming off the stator look like? $348.34 at Partzilla. I would try to rebuild what is there or buy used.

These are the stator wire's. Black, blue, white with red and yellow.