No spark

[Bayboy87]

I've got the 1983 to 1985 stator. I've got the 1986 CDI. I bought a source coil for a 1986 stator that didn't work out because one it was the wrong stator and two I had the additional lighting coil stacked on top of it. The plates from the 83 to 85 and 86 look the same. The timing mark looks like it's in the same spot. So if I disassemble my stator which is the 83 to 85 and replace the source and lighting coil with the ignition coil for the 86 I should be okay right?

[KDXGarage]

I am not sure on that one. I have never had a need to try it.

[Bayboy87]

Update time: so got the 83-85 CDI and wired it in thinking this was gonna be another failure.
Low and behold I have spark. I reassembled and two kicks later she fired up. After blowing out all the old smoke she ran decent. I found the exhaust has a leak at the head. A piece of the outer head is broken off from a previous owner crash. I'm repairing it. I noticed after idling for awhile the motor revving up by itself. I looked for vac leaks and surely found them. Tears around the intake manifold along the collar are being sealed up with some gasket maker and curing. I noticed after pulling the carb that the float was out of adjustment and took care of that as well. Possibly that's were the vac leak got that extra fuel to rev with. This old carb is a trip. Other then adjusting the slide from the side of the carb, rejetting, or moving up and down the needle up and down I don't see any other way to manipulate the air fuel mixture. I'm probably missing something. I'm doing my best with my limited knowledge and can do. So stator is rebuilt and wired to the 83-85 CDI. I now have spark and ignition. Get back to me with all input. Thanks have a great day. I guess I can't upload more so no Video of it running. If I can figure out how to convert it I'll upload it.

[Bayboy87]

https://photos.app.goo.gl/H7nN99gmTHqoX3di8

[SS109]

Awesome! Glad you got at least that part fixed. Now time to track down any other issues. What carb do you have on it? Post some pics if you don't know.

[Bayboy87]

It's an old mikuni. 44mm on the intake manifold side. 60mm maybe a little less on the filter side. The adjustable needle in the slide broke. I think it said it was an 6fl5. I haven't tracked one down yet so instead I cut a new slot in it and replace the c-clip. I'm pretty sure this was the original carburetor. I threw in some pictures of the intake manifold as well as the head repair hoping this works. I got two new o-rings and springs on the way as well and some of this muffler and tail pipe sealer silicone to prevent leaks after everything secured. Any suggestions on a replacement carburetor if I need to? You guys are awesome talk to you later.

[KDXGarage]

The needle is OEM only. You might get close with an original Mikuni needle.

VM34SS is the carburetor. It is not the standard one, as the choke lever is on the other side.

I don't think the current air filter is going to work too well. Maybe if you only rode it on clean pavement on a dry day.

[Bayboy87]

Yeah the filter is 100% temporary. Bike didn't come with one. I found this needle on eBay. If I can't get it to work with what I got I'll pick this up. Or just get another carb.

[SS109]

Man, that needle is super expensive. I think I would order through Jets-R-Us and save a few bucks. Plus, you'll know it's a genuine part.

[KDXGarage]

Actually, get that needle. That is the exact one to get. That place custom makes them. I forgot about a guy two years ago getting that needle from them. The buyer has posts on here about it.

The needle is a copy of the OEM needle. There is no where else to get that needle in that exact shape. When I say OEM only, I mean Kawasaki only actually. Mikuni does not sell it.

[Bayboy87]

Here's the head repair so far.

Edit by KDXGarage to show the pic:

IMG_20220320_202551.jpg (100.57 KiB) Viewed 1751 times

https://photos.app.goo.gl/WzPrwWsSVca4G1Sz6