89 KX500 WITH ALL NEW ELECTRONICS AND STILL NO SPARK?

[Sandblaster]

Hi all,

I am having issues with an 89 KX500 rebuild i have been working on for a while now. I've just got back into the project after a 8 months of not touching it. Anyway.... I have no spark what so ever. Here is what I've done:

- Replaced stator / pulser coils
- Replaced CDI
- Replaced coil
- New spark plug
- Made sure coil is earthing

I haven't adjusted my timing, the stator plate is bolted up inline with the marking on the casing. For the time being, I'm not concerned about timing, as even if it is slightly out I should still see a spark. Can anyone explain to me abit about how the KX ignition wiring works? What the stator, pulser, CDI and each components relevant wire actually does?

I have the following colour wires on my bike:

Stator & pulser coil plate:
- Black / yellow (Earth I think)
- Black / red
- Red / white
- Green / white

CDI:
- Black
- Black / white
- Black / white
- Red / White
- Green / white
- Yellow / black

Coil:
- Decent earth!
- Black (To black from CDI)

My CDI unit has two black / white wires, one of which is for the kill switch and the other I'm guessing runs to the back / red on the stator? I have tried swapping these round. For such a basic ignition system, it really seems to have stumped me. No wires are shorting and all connectors are good. I have even tried two different flywheels. Does anyone have a wiring diagram or can anyone suggest anything I have missed?

Cheers,
Jim

[Sandblaster]

I am still in the middle of writing an article for electrical troubleshooting.
You can find the article here:
viewtopic.php?f=42&t=160

In this case I suggest that all the components be tested.
Starting with the Coil:
F6T536 FITS 83-04 KX500 -
The reading for the Secondary lead (Black spark plug Wire) should be 2.6K -3.6K ohms.
the reading for the Primary lead (Orange Wire) should be 0.26-0.36 ohms

Next the Stator:
(2 coil style) 87-89 KX500 - 21003-1169 - 432-648 OHMS: BLACK/WHITE TO BLACK/YELLOW - 4.0-6.0 OHMS: WHITE/RED TO BLACK/YELLOW
I do not have the specs for the single coil style.
90-04 KX500 - 153-230 OHMS: BLACK/WHITE TO BLACK/YELLOW - 7.9-11.9 OHMS: WHITE/RED TO BLACK/YELLOW

According to the Kawasaki Manual you can't test the CDI as it requires special equipment.
Here is a quote: "The I.C. Igniter can only be tested with special electrical equipment and improper testing may damage it. Refer all testing to a Kawasaki dealer".