I’m working on a Kawasaki Bayou KLF400 for a family member that doesn’t have spark. I’ve already replace the ignition switch and the stator which were defective. The stator had a melted connector and one of the phase had low resistance and low VAC output.



What I’ve figured out so far is that I’m not getting 12V to the ignition coil when I turn the key to the ON position. From what I understand, the 12V should come from the CDI. I’ve resistance tested both wires going from the CDI to the ignition coil (Green/white and black/yellow). They are fine. The only 12V coming from the ECU is on the yellow/red wire.

I don’t have the wiring diagram for the 400 but I’m working with the one for the Bayou 300 which looks pretty similar except for the wire color between the CDI and ignition coil. On the 300 diagram, the yellow/red wire goes to the ignition coil, not the black/yellow… All the other wires color match except for this one. Not sure if that’s normal?

Thanks!

 

If it is the same as the KLF300 it has a 1980s "contactless" car ignition system, not strictly CDI. The trigger coil on flywheel and "ignitor box" mimics the old points system, sending a negative pulse to the ignition coil, which is being fed 12v positive all the time the ignition switch is on. This pos comes from ignition switch, but also goes to the ignitor to power it.

 

There's no wire coming directly from the ignition switch to the ignition coil. The green/white and black/yellow on the ignition switch are both coming from the ignitor. So that means I should get 12VDC from the green/white wire coming out of the ignitor? I don't. Would that point to the igniter being the probrem? There 12V coming into the igniter from the ignition switch (yellow/red wire)

Thanks for the help!

 

Can't find the KLF300 diagram but the KEF Lakota is similar to it and has a yellow/red positive from ignition switch, through kill switch, to both igniter and coil. Blue and black/white come from trigger coil on flywheel to igniter, black/yellow is earth to igniter and the green/white goes from igniter to coil to provide that negative pulse. If the 400 is different, it may not be this type of ignition system, either normal CDI like the KLF220 or DC CDI which has the coil earthed and pulses a positive voltage spike from CDI. Your best bet is to get a KLF400 wiring diagram or manual to work out what system you have.