I need electrical help! My ignition coil is melting with the ignition switch ON and engine NOT running. I have ohms checked the wiring harness and didn't find anything wrong(that I could tell). I have replaced most of the electrical components(Coil, CDI box, rectifier, stator, starter circuit and relay). I verified the battery terminals are correct. I have checked all connections and ground wires and fuses. I am getting 12 volts to the wires that connect to the coil (Which I'm not sure about.....is it supposed to get 12 volts even when the engine is OFF with switch ON?) But after a minute or 2 with the switch ON the coil will start hissing and melting. There is no spark when I try to crank it....Coil may have already fried,,,? This would be the second coil.....the first one DID fry!.... I am going to order a new coil but I really need some help so I don't ruin anymore new parts....this gets expensive! Please help!! Its a great little bike and I hate to give up on it.

 

I've just checked the diagram for the Lakota (haven't got one for the KLF 300) and it is DC ignition like a car, so has 12v to the coil. The negative side on these is pulsed, a hangover from the old points system of ignition, so should only be earthed once a revolution of the flywheel. I would get a workshop manual and do the ignition circuit tests.

 

That helps some, Thanks. I work weekends so I will check it Monday and get back to you. Do you think it could be the CDI box is bad? If its supposed to be 12 volts, I can't imagine what is causing it to get so hot as to boil....????

 

Like I wrote above, it is the negative side that is pulsed, if that is shorted to earth, your coil is going to get hot.