92 KE 100 No Spark, good generator and coil

Jake7482 · 07-30-2009

I am completely new to both motorcycle repair and Forums, so I appreciate any help I can get.
I got my little 100 when I was 14 years old and it has been a wonderful bike. However it has not started in 8 years, and I would like to change that. The problems started when I put marine 2 cycle oil in it, the engine just did not run well on it and I eventually parked it. A year later I came back to it, drained the marine oil out of it and put proper oil back in, however it would not start. I didn’t have much patience back then so I warped it in a Tarp and stored it in an outdoor shed where it sat for the next 7 years. It did not get wet, but it was exposed to extremely cold weather.
I have the bike in my garage now and have discovered that the plug is not sparking at all. I tried a gap tester, but no luck. I know that electricity is being generated because the Neutral light comes on when I kick it. Also I took the spark plug cap off the cable, held the copper coil, and pulled the kick start down and got a good little jolt. I bought a new spark plug, but still not spark. If I put my hand on the threads of the plug and pull the kick start, I don’t feel a thing.

My question is, if electricity is getting to the plug ( I have tried 2 new plugs) put it is not sparking, what is wrong? Is the generator not producing enough electricity, or is the coil not amplifying it enough?

I did a multimeter test of the coil and it seems to be in tolerance.

Thanks in Advance!

t conroy · 08-01-2009

you need to check the plug wire up to the coil.If it has a slight break in it then it will ground out on the frame and cause a problem.Make sure it is not touching the body anywhere.Try to start it in the dark and maybe you can see arching somewhere.Also might cut a little off the end where the spark plug boot screws on and see if you get a better connection.Did you clean the carb out? After sitting that long you will need to.The spark plug has to touch the head of the bike or something when you try to start it or you wond get any spark.It has to be grounded.spark plug caps can go bad too.

Jake7482 · 08-02-2009

The Spark plug wire and boot all seem to be in good condition. Is the boot critical to get a spark?

I did see a good spark once at the plug, but i can not repeat it. I decided to check out the generator and when I pulled the cover off, about 3 cups of liquid (maybe water mixed with oil) spilled onto the floor. So I am thinking maybe something is wrong with the generator. Is it possible that it still produces some electricity but not enough for a spark to jump the gap? Or is it either functional or non-functional? If i hold the bare spark plug wire against the block it sparks every time.

I went ahead an ordered a new coil to start the process of elimination.

Thank you for your help!

t conroy · 08-02-2009

Quote:

Originally Posted by Jake7482

The Spark plug wire and boot all seem to be in good condition. Is the boot critical to get a spark?

I did see a good spark once at the plug, but i can not repeat it. I decided to check out the generator and when I pulled the cover off, about 3 cups of liquid (maybe water mixed with oil) spilled onto the floor. So I am thinking maybe something is wrong with the generator. Is it possible that it still produces some electricity but not enough for a spark to jump the gap? Or is it either functional or non-functional? If i hold the bare spark plug wire against the block it sparks every time.

I went ahead an ordered a new coil to start the process of elimination.

Thank you for your help!

the boot is very critical to get a spark.Put the plug in the boot and place it on the cylinder.Make sure the threads of the spark plug touch the cylinder head and then turn it over.You should see spark on the spark plug electrode.If not you have a bad boot.Go with the simple first.Your getting spark to the bar wire and there is nothing between the wire and plug but the boot.Get a new boot and try that first.Make sure to cut about a 1/4 inch of the plug wire to screw the new boot onto so you get good contact.It could be as simple as that.most stators or generators as you call it are oil bath cooled.If you have taken it off make sure you replace the gasket if torn and CHECK THE OIL LEVEL!!!! You probably took about a quart of more out of the crankcase.You could take the old coil to the auto parts store or a bike shop and have it tested to see if it is good.they can be tested.Let me know what yo find out.

Jake7482 · 08-02-2009

The boot on my bike is just a piece of rubber, it just slips over the wire. It houses a small copper coil which has prongs touching the HT wire coming out of the coil.

Unfortunately I have already paid for a new coil, because I just couldn't see how a simple piece of rubber could effect the spark, but of course I don 't know what I'm doing. The new coil comes with a new boot so hopefully when I put it on the problem will be solved. The coil cost $100 and should be here in a week. I will let you know if that solves the problem, though for some reason I have a feeling it won't. I will let you know what happens.

Also, I wrapped the bare wire around the plug and put the plug on the block and kicked it.. Nothing. If electricity is flowing down the wire to the plug why wouldn't it spark? Would having the rubber boot around the whole setup help?

Thank you very much for your expertise!

Jake

t conroy · 08-03-2009

Quote:

Originally Posted by Jake7482

The boot on my bike is just a piece of rubber, it just slips over the wire. It houses a small copper coil which has prongs touching the HT wire coming out of the coil.

Unfortunately I have already paid for a new coil, because I just couldn't see how a simple piece of rubber could effect the spark, but of course I don 't know what I'm doing. The new coil comes with a new boot so hopefully when I put it on the problem will be solved. The coil cost $100 and should be here in a week. I will let you know if that solves the problem, though for some reason I have a feeling it won't. I will let you know what happens.

Also, I wrapped the bare wire around the plug and put the plug on the block and kicked it.. Nothing. If electricity is flowing down the wire to the plug why wouldn't it spark? Would having the rubber boot around the whole setup help?

Thank you very much for your expertise!

Jake

look at your spark plug and see it the top piece screws off.That could be your problem.This just does not make sense.

Jake7482 · 08-03-2009

I agree that it doesn't make sense. I have tried it both with the little screw on top off, and with it on. I am starting to think that maybe I defied the odds and bought 2 bad brand new spark plugs. I will stop on my way home tonight and buy a thrid. Hopefully this works.

t conroy · 08-03-2009

Quote:

Originally Posted by Jake7482

I agree that it doesn't make sense. I have tried it both with the little screw on top off, and with it on. I am starting to think that maybe I defied the odds and bought 2 bad brand new spark plugs. I will stop on my way home tonight and buy a thrid. Hopefully this works.

If you have a lawn mower or anything else with a plug just stick it in the boot and ground to the head and see what happens.

Jake7482 · 08-03-2009

Thanks for the tip. I tried the plugs on my lawnmower and although I could not pull the cord and look at the plug at the same time I do not believe it was sparking because I did not see anything in a dark garage and did not hear anything. I will buy the new plugs tomorrow. As far as you know was there any change in plugs from the early 90s until today, that could explain why new plugs don't seem to work?

I will buy the new plug tomorrow and see if it makes a difference.

I very much appreciate your time, thank you!

t conroy · 08-04-2009

should not make a difference.Does this bike have a battery??? there is no reason not to have spark at the plug if you are getting spark to the end of the plug wire unless there is a crack in the plug wire. Electricity will follow the path of least resistance which could be a small cut in the plug wire or near the coil where is connects.Inspect the wire very carefully for any breaks.

Jake7482 · 08-05-2009

Yes the bike does have a battery, but I have it disconnected. I have essentiallly disconnected all wireing except the path to the spark plug, including the kill switch and ignition key. Could this be a problem? As far as I can remember the bike always had a dead battery, it would never hold a charge. If the wire is grounding out it must be doing it somwhere else, besides the plug wire which is in great shape,

You have a good point about electricity traveling the path of least resistance, Maybe when I hold the wire I am the path of least resistance, but when the spark plug is connected another area is less resistant then the spark plug.

That could explain this whole situation...

Thank You!! I am going to inspect everything and see if it is grounding itself.

Jake

t conroy · 08-05-2009

when you hold the wire YOU are the ground.Put the battery back in and hook up your kill switch.The battery is probably the ground for the bike unless you have a ground wire that connects to the frame somewhere.Check all wire that are connected to the frame and see if one is broken or loose.If you have a fuse somewhere I would check that too.

Mike900 · 08-06-2009

I can't remember if a battery is needed on the smaller bikes or not. Hopefully someone else will chime in.

If the battery isn't required & the new coil doesn't help then I would try changing the condenser next.

t conroy · 08-06-2009

Quote:

Originally Posted by Mike900

I can't remember if a battery is needed on the smaller bikes or not. Hopefully someone else will chime in.

If the battery isn't required & the new coil doesn't help then I would try changing the condenser next.

It is a newer bike and I dont think he has points and condenser but if so than I would change both.

Jake7482 · 08-07-2009

It does have points, and the coil grounds to the frame..It is actually a very simple system. There are no broken wires anywhere. I always thought that it doesn't need the battery because the battery was never charged and it would always start right up. The battery does serve as a ground for the lights but not the coil. Hopefully my new coil will get her soon and that will eliminate that as the potential problem. I will keep you guys posted, thank you much for the responses!

Jake7482 · 08-16-2009

I got the new coil yesterday and put it on. It did not come with a boot or end wire so I had to use the old stuff. After I put it on I was getting a spark and I even got the bike to run for a few seconds with starter fluid, however for some reason, the spark stopped and I couldn't get it back. I think I have narrowed the problem down to the little coil of wire that sticks out of the coil lead wire and makes actual contact with the spark plug. It is essentially a copper coil that looks like a spring with each end sticking out of the spring and sharpened to a point. the sharpened ends of the copper wire are actually pushed through the rubber insulation of the lead to make contact with the bare wire in the lead. I think that if the coil of copper wire is not pushed into the coil lead exactly right the electricity does not flow through it into the spark plug correctly. My questions is, is there a better way? Is there an after market part I can get that will be less faulty then the copper wire stuck into rubber insulation that the bike currently has. I noticed my lawn mower has a much more secure looking cap at the then of the lead.

thanks for your help!

Jake

t conroy · 08-16-2009

1992 Kawasaki KE100 KE100B11 OEM Parts, 1992 Kawasaki KE100 KE100B11 OEM Replacement Parts - BikeBandit.com this is what you are talking about.You could order one from this sight or go to the auto parts store and get a boot and cut the lead then put the new boot on.That would eliminate the use of the coiled wire thingy thas is probably giving you trouble.

Jake7482 · 08-17-2009

At the site you sent me, they sell the little wire thingy and a thing called a "grommet" listed in the box for Canada parts. What is a grommet and will a part for Canada bikes work on mine?

t conroy · 08-19-2009

Quote:

Originally Posted by Jake7482

At the site you sent me, they sell the little wire thingy and a thing called a "grommet" listed in the box for Canada parts. What is a grommet and will a part for Canada bikes work on mine?

there are 2 differnt models of your bike. One is 92 100 KE b11 and the other is 92 100KE b11A. You need to know which one you have.Did you get it started???

Jake7482 · 08-31-2009

I have now replaced the ignition coil, the boot, and the wire lead. I did initially get a spark out of the spark plug and even fired the motor with starter fluid but that was a fleeting moment of success. I can not produce another spark. I am beginning to think that the generator is simply not producing a strong enough charge to make the spark jump the air gap on the spark plug. I have disconnected all other grounds except for the spark plug and the one built into the generator, but still no luck. If I press part of my finger into the spark plug gap and crank it I get a shock. Is replacing the generator something I can do on my own, or do I need to take it to a shop? Will I have to adjust timing?

Thanks!

07-30-2009	#1 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	92 KE 100 No Spark, good generator and coil I am completely new to both motorcycle repair and Forums, so I appreciate any help I can get. I got my little 100 when I was 14 years old and it has been a wonderful bike. However it has not started in 8 years, and I would like to change that. The problems started when I put marine 2 cycle oil in it, the engine just did not run well on it and I eventually parked it. A year later I came back to it, drained the marine oil out of it and put proper oil back in, however it would not start. I didn’t have much patience back then so I warped it in a Tarp and stored it in an outdoor shed where it sat for the next 7 years. It did not get wet, but it was exposed to extremely cold weather. I have the bike in my garage now and have discovered that the plug is not sparking at all. I tried a gap tester, but no luck. I know that electricity is being generated because the Neutral light comes on when I kick it. Also I took the spark plug cap off the cable, held the copper coil, and pulled the kick start down and got a good little jolt. I bought a new spark plug, but still not spark. If I put my hand on the threads of the plug and pull the kick start, I don’t feel a thing. My question is, if electricity is getting to the plug ( I have tried 2 new plugs) put it is not sparking, what is wrong? Is the generator not producing enough electricity, or is the coil not amplifying it enough? I did a multimeter test of the coil and it seems to be in tolerance. Thanks in Advance!

08-01-2009	#2 (permalink)
t conroy just cruzin by! BTK Expert Join Date: Oct 2008 Location: kcmo. Posts: 845	you need to check the plug wire up to the coil.If it has a slight break in it then it will ground out on the frame and cause a problem.Make sure it is not touching the body anywhere.Try to start it in the dark and maybe you can see arching somewhere.Also might cut a little off the end where the spark plug boot screws on and see if you get a better connection.Did you clean the carb out? After sitting that long you will need to.The spark plug has to touch the head of the bike or something when you try to start it or you wond get any spark.It has to be grounded.spark plug caps can go bad too. __________________ 900 LT.crash bar,lowers.phattII's mustang seat, pass. floorboards,luggage rack,HK's

08-02-2009	#3 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	Thanks for the Reply The Spark plug wire and boot all seem to be in good condition. Is the boot critical to get a spark? I did see a good spark once at the plug, but i can not repeat it. I decided to check out the generator and when I pulled the cover off, about 3 cups of liquid (maybe water mixed with oil) spilled onto the floor. So I am thinking maybe something is wrong with the generator. Is it possible that it still produces some electricity but not enough for a spark to jump the gap? Or is it either functional or non-functional? If i hold the bare spark plug wire against the block it sparks every time. I went ahead an ordered a new coil to start the process of elimination. Thank you for your help!

08-02-2009	#5 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	The boot on my bike is just a piece of rubber, it just slips over the wire. It houses a small copper coil which has prongs touching the HT wire coming out of the coil. Unfortunately I have already paid for a new coil, because I just couldn't see how a simple piece of rubber could effect the spark, but of course I don 't know what I'm doing. The new coil comes with a new boot so hopefully when I put it on the problem will be solved. The coil cost $100 and should be here in a week. I will let you know if that solves the problem, though for some reason I have a feeling it won't. I will let you know what happens. Also, I wrapped the bare wire around the plug and put the plug on the block and kicked it.. Nothing. If electricity is flowing down the wire to the plug why wouldn't it spark? Would having the rubber boot around the whole setup help? Thank you very much for your expertise! Jake Last edited by Jake7482 : 08-02-2009 at 10:17 PM.

08-03-2009	#7 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	I agree that it doesn't make sense. I have tried it both with the little screw on top off, and with it on. I am starting to think that maybe I defied the odds and bought 2 bad brand new spark plugs. I will stop on my way home tonight and buy a thrid. Hopefully this works. Last edited by Jake7482 : 08-03-2009 at 03:36 PM.

08-03-2009	#9 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	Thanks for the tip. I tried the plugs on my lawnmower and although I could not pull the cord and look at the plug at the same time I do not believe it was sparking because I did not see anything in a dark garage and did not hear anything. I will buy the new plugs tomorrow. As far as you know was there any change in plugs from the early 90s until today, that could explain why new plugs don't seem to work? I will buy the new plug tomorrow and see if it makes a difference. I very much appreciate your time, thank you!

08-04-2009	#10 (permalink)
t conroy just cruzin by! BTK Expert Join Date: Oct 2008 Location: kcmo. Posts: 845	should not make a difference.Does this bike have a battery??? there is no reason not to have spark at the plug if you are getting spark to the end of the plug wire unless there is a crack in the plug wire. Electricity will follow the path of least resistance which could be a small cut in the plug wire or near the coil where is connects.Inspect the wire very carefully for any breaks. __________________ 900 LT.crash bar,lowers.phattII's mustang seat, pass. floorboards,luggage rack,HK's

08-05-2009	#11 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	Yes the bike does have a battery, but I have it disconnected. I have essentiallly disconnected all wireing except the path to the spark plug, including the kill switch and ignition key. Could this be a problem? As far as I can remember the bike always had a dead battery, it would never hold a charge. If the wire is grounding out it must be doing it somwhere else, besides the plug wire which is in great shape, You have a good point about electricity traveling the path of least resistance, Maybe when I hold the wire I am the path of least resistance, but when the spark plug is connected another area is less resistant then the spark plug. That could explain this whole situation... Thank You!! I am going to inspect everything and see if it is grounding itself. Jake

08-05-2009	#12 (permalink)
t conroy just cruzin by! BTK Expert Join Date: Oct 2008 Location: kcmo. Posts: 845	when you hold the wire YOU are the ground.Put the battery back in and hook up your kill switch.The battery is probably the ground for the bike unless you have a ground wire that connects to the frame somewhere.Check all wire that are connected to the frame and see if one is broken or loose.If you have a fuse somewhere I would check that too. __________________ 900 LT.crash bar,lowers.phattII's mustang seat, pass. floorboards,luggage rack,HK's

08-06-2009	#13 (permalink)
Mike900 Third Gear And Gaining BTK Intermediate Join Date: May 2009 Location: Western New York Posts: 133	I can't remember if a battery is needed on the smaller bikes or not. Hopefully someone else will chime in. If the battery isn't required & the new coil doesn't help then I would try changing the condenser next. __________________ 1976 KZ900-A4

08-07-2009	#15 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	It does have points, and the coil grounds to the frame..It is actually a very simple system. There are no broken wires anywhere. I always thought that it doesn't need the battery because the battery was never charged and it would always start right up. The battery does serve as a ground for the lights but not the coil. Hopefully my new coil will get her soon and that will eliminate that as the potential problem. I will keep you guys posted, thank you much for the responses!

08-16-2009	#16 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	Some Success, but still a problem I got the new coil yesterday and put it on. It did not come with a boot or end wire so I had to use the old stuff. After I put it on I was getting a spark and I even got the bike to run for a few seconds with starter fluid, however for some reason, the spark stopped and I couldn't get it back. I think I have narrowed the problem down to the little coil of wire that sticks out of the coil lead wire and makes actual contact with the spark plug. It is essentially a copper coil that looks like a spring with each end sticking out of the spring and sharpened to a point. the sharpened ends of the copper wire are actually pushed through the rubber insulation of the lead to make contact with the bare wire in the lead. I think that if the coil of copper wire is not pushed into the coil lead exactly right the electricity does not flow through it into the spark plug correctly. My questions is, is there a better way? Is there an after market part I can get that will be less faulty then the copper wire stuck into rubber insulation that the bike currently has. I noticed my lawn mower has a much more secure looking cap at the then of the lead. thanks for your help! Jake

08-16-2009	#17 (permalink)
t conroy just cruzin by! BTK Expert Join Date: Oct 2008 Location: kcmo. Posts: 845	1992 Kawasaki KE100 KE100B11 OEM Parts, 1992 Kawasaki KE100 KE100B11 OEM Replacement Parts - BikeBandit.com this is what you are talking about.You could order one from this sight or go to the auto parts store and get a boot and cut the lead then put the new boot on.That would eliminate the use of the coiled wire thingy thas is probably giving you trouble. __________________ 900 LT.crash bar,lowers.phattII's mustang seat, pass. floorboards,luggage rack,HK's

08-17-2009	#18 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	At the site you sent me, they sell the little wire thingy and a thing called a "grommet" listed in the box for Canada parts. What is a grommet and will a part for Canada bikes work on mine?

08-31-2009	#20 (permalink)
Jake7482 Newbie Join Date: Jul 2009 Location: Virginia Posts: 16	frustrated I have now replaced the ignition coil, the boot, and the wire lead. I did initially get a spark out of the spark plug and even fired the motor with starter fluid but that was a fleeting moment of success. I can not produce another spark. I am beginning to think that the generator is simply not producing a strong enough charge to make the spark jump the air gap on the spark plug. I have disconnected all other grounds except for the spark plug and the one built into the generator, but still no luck. If I press part of my finger into the spark plug gap and crank it I get a shock. Is replacing the generator something I can do on my own, or do I need to take it to a shop? Will I have to adjust timing? Thanks!

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