75' G4TRE or KM100

[meatness]

First off,

Hello and great forum.

I picked myself up my first kawasaki the other day. As stated in the title it's a 75 G4TRE, it doesn't have the high/low 10 speed gearbox, just a normal 5 speed. My neighbor was going to toss it and I figured it was in too good of shape to just let go to the junk heap. Especially since he had the title!

So far I haven't been able to get spark. I tried cleaning up the stator and some of the connections but honestly I am not much of a motorcycle mechanic yet. I am thinking the coil is bad since I do get a small amount of current when I kick it over out of the coil wire.... ouch. But not enough to arc across the gap in a known good spark plug.

Any general information anyone can give me about this bike would be appreciated but more than anything I need help trouble shooting this no spark issue.

Here is what I have done so far.
- Cleaned and adjusted the points.
- Took some fine grit sand paper to the inside of the flywheel and to the stator coils? Is that what they are called?
- Connected a 6v battery charger to the battery terminals, the battery is completely dry so that's no good.
- Completed disconnected the kill switch wires just in case the kill switch was bad.

It is my understanding that coils rarely go bad but as you can see from the pictures it is very rusty and doesn't look great.

I know there is a way to test if the coil is bad with a multimeter and I do have one, but I keep getting mixed messages on what the proper method is.

Well I think that is about all of the information I got. On with the pictures. You can click on them to make them bigger of course.

[meatness]

[StarGate]

Hope your not disappointed, but that is not a 75. You have a 76 KM100-A1. Some general info on it.

Color Candy Green
Frame serial # KM100A-000001 - 006900
Engine serial # KM100AE000001 - 006902 found on LH side crankcase below air intake duct.
Cylinder Mark 99CC found on RH side Engine
Engine Type 2 stroke, single cylinder, rotary disc valve, air cooled.
Displacement 99cc
Bore X Stroke 49.5 X 51.8 mm
Compression Ratio 7.3:1
Maximum HP 8.5 at 6500 rpm
Maximum torque 0.96 kg-m at 5500 rpm
Carburetor Mikuni VM19SC
Lubrication System Superlube (port injection)

Ignition System Flywheel magneto
Clutch Type Wet, multi-disc, Manual
Ignition Advance Fixed
Transmission 5-speed,constant mesh, return shift
Crankshaft Rotation Counterclockwise from ignition (LH) side
Shift Pattern N-1-2-3-4-5 bottom up
Cylinder Material Ferrous
Fuel Min 91 Research/87 average oct, unleaded OK
Gear ratios
1st 2.92 (35/12)
2nd 1.76 (30/17)
3rd 1.30 (26/20)
4th 1.09 (24/22)
5th 0.96 (23/24)
Engine Oil 2-stroke oil for air cooled engines
Cylinder Head Torque Nuts Cross-tighten: 2.2 kg-m
Primary Ratio 3.52 (74/21)
Final Ratio 2.57 (36/14)
Overall Ratio 8.68 top gear
Compression Pressure 9.0 kg/cm² STD 6.3 kg/cm² service limit
Spark Plug NGK B7HS 0.6 - 0.7 mm gap
Ignition Timing 20° BTDC (1.96mm) - Flywheel mark aligns with crankcase mark at 12 o'clock position
Point Gap 0.30 - 0.40 mm
Wheelbase 1100 mm
Seat Height 700 mm
Air Screw 1¼ turns out
Ground Clearance 160 mm
Idle Speed Lowest stable RPM (usually 1300 ± 100 RPM)
Dry Weight 77 kg
Transmission Oil SE Class SAE 10W30 or 10W40- Capacity 0.6 liter
Fuel Tank Capacity 6.0 liters
Tire Size Front 2.50-16 4PR Tube-Type Rear 3.00-14 4PR Tube-Type
Fork Oil SAE 5W20
Brake Type Front Mechanical Drum (Leading/Trailing)
Rear Mechanical Drum (Leading/Trailing)
Brake Size Front 110 X 30 mm
Rear 110 X 30 mm
Tire Pressure Front 1.75 kg/cm² cold
Rear 2.00 kg/cm² cold
Suspension Stroke Front 75 mm
Rear 65 mm
Drive Chain Slack 15 - 25 mm (On side stand, tightest point, STD)

[meatness]

Wow thanks for the quick reply StarGate and lots of great information.

No I am not disappointed at all, in fact I was very confused about that because I was handed a title for a G4 yet all of the markings on the bike told me it was something else. The only thing I am a little disappointed about is that I now know I do not have the correct title.

Hopefully he has the correct title for it.

At any rate I would still like some help trouble shooting this no spark issue.

Thanks again.


This is going to be a Christmas present for the boy if I can get it together by then. I know I know, I'm shameless...

[StarGate]

With magento an no battery you may have problems getting any spark. The first thing I would do is get a battery for it. Then you can start with the troubleshooting. I would also use premixed fuel in the tank since you don't know if the injection system is working yet.

P.S. As a kid I would have killed to get something like that for xmas.

[herk]

Just providing a couple links.

Dan's MC Repair Course
Dan's MC - 2-Stroke Oil

[meatness]

After reading through Dan's website and the advice given by StarGate, I have decided to buy a battery and a new set of points to start with. Where do you guys go for parts on this old bikes? My google kung-fu must be weak today because I didn't find much as far as a set of points goes.

[herk]

Ebbaayy will have some of the parts for your bike. I just did a search for the contact breaker assy part number which yielded a dozen results. Z1Enterprises.com is where I get stuff for my KZ650, but I don't believe they carry anything for the really small bikes. However, if the oem part is available, they should be able to get it. So...

Kawasak.com has diagrams in the Owner Info section where parts can be cross-referenced. It seems easiest to search by year only without entering a vin or anything. Just pick a year, click continue, then choose a bike from the list.

Once you're into the diagrams, the reference numbers are clickable, which makes getting to the part number faster. Clicking the part number opens a new window w other info. If something is listed as Active, it may be available at the dealer (or Z1). Click the yellow/black ? for the cross-ref.

Since the Kawasaki site doesn't supply prices, you can search the part number at RonAyers.com or Babbitts Online to get an idea of the cost. Keep in mind that those places will show a price for everything, but they won't have, nor can they get, a lot of stuff. The only reason I mention Babbitts is that their diagrams show the full part numbers (other places only show the diagram reference numbers - not very helpful). Others have been disappointed in Babbitts' way of handling orders - I've never purchased anything there.

At ebbaayy, when searching by using the part number, be sure to check the include-title-and-description box.

[meatness]

your kung-fu is strong. Thanks for the advice!

[zoro]

Originally Posted by meatness

your kung-fu is strong. Thanks for the advice!

US economy is weak! Try to keep your business within the US! "Badbits" is Canadian, and has a history of lousy employee treatment not to mention high shipping costs! Many here will not do business with them for those reasons. Buying "American made" and doing business with US based companies is more important now more than ever since WWII! Z1-Enterprises,ebay and the "host of this fine forum" are good places to shop! These are my "not so humble opinions"! We must ALL do our part!

[meatness]

I agree with you. Keeping the economy local will help and I will keep that in mind while shopping.

[herk]

I forgot to mention that this site's owner is Beartooth Kawasaki - see banner ad above.
You can submit a parts request - I guess you just start a new topic in the following forum:

Beartooth Kawasaki - click
Here you will be in contact with the sales department at Beartooth Kawasaki, where members receive a 15% discount on O.E.M. parts and accessories and most aftermarket parts and accessories. You will find our staff to be very friendly and helpful! Please be patient as we check this periodically through out the day and not at night or weekends. If you need assistance immediatly call 1-800-556-3098. Thanks

[meatness]

What do you guys think about this CD manual being sold on ebay? Anyone ever tried it?

Kawasaki Shop KD80 KM100 KM90 MC1 80-100 Master Manual:eBay Motors (item 120480007252 end time Nov-11-09 10:35:46 PST)

[herk]

It looks good to me. Being the cautious sort, even though the description says you can zoom in for detailed parts viewing, I would ask if it has photos. Also, it appears to be a facsimile of a genuine Kawasaki manual: I might ask about that, although it may not matter too much at that price.

[Airoyster]

Originally Posted by zoro

US economy is weak! Try to keep your business within the US! "Badbits" is Canadian, and has a history of lousy employee treatment not to mention high shipping costs! Many here will not do business with them for those reasons. Buying "American made" and doing business with US based companies is more important now more than ever since WWII! Z1-Enterprises,ebay and the "host of this fine forum" are good places to shop! These are my "not so humble opinions"! We must ALL do our part!

Yeah,God forbid you do business with us Canadian foreigners....we run slave labor camps up here! I guess us Canadian foreigners aren't really the largest trading partner the United States has(not to mention neighbors).And as for WWII...I guess we weren't fighting right there beside the USA huh?....that must have been someone else.What ever you do....don't deal with the Canadians!!!...they are a horrible bunch!!!

[zoro]

Originally Posted by Airoyster

Yeah,God forbid you do business with us Canadian foreigners....we run slave labor camps up here! I guess us Canadian foreigners aren't really the largest trading partner the United States has(not to mention neighbors).And as for WWII...I guess we weren't fighting right there beside the USA huh?....that must have been someone else.What ever you do....don't deal with the Canadians!!!...they are a horrible bunch!!!

Easy there Big, My shot was aimed at "BADBITS" and not Canada or Canadians! Dont take that post to an ugly personal level! Theres no border war, only very good reasons I wont do business with that Tyrant babbit!

[benjamin n]

I have a similar bike with the same problem.no spark. I was told it was a KD80 but im not sure. The serial number is MCE 028775. Does anybody know what it is?

[kawah1c]

MCE is an engine number.

[benjamin n]

it is stamped on neck as well. it is the only number on the bike

[benjamin n]

can you identify my bike if i post pictures?
[IMG][/IMG]