81 Trailfire

[Vader440]

I have a 1981 Trailfire with the fan cooled Kawasaki 440 engine. I removed it, took it apart and installed new seals. It went back together very smoothly. I reinstalled into the sled today and now it doesn't have spark. Any thoughts? Stumped!

[nick80lf]

Try unplugging the wire harness (5 pin connector) from motor and check for spark.

[jdjock]

If the key switch and the emergency switch are both good, you may have a pinched wire on the stater reassembly.

[Vader440]

Try unplugging the wire harness (5 pin connector) from motor and check for spark.

Should it have spark with the wiring unplugged?

[Vader440]

If the key switch and the emergency switch are both good, you may have a pinched wire on the stater reassembly.

Okay, I'll check those thanks!

[nick80lf]

Yep....when you turn the key it grounds the ignition. Unplugging the harness from the motor will remove that connection. If the motor starts with the harness disconnected the kill switch or key switch will not work.

[Vader440]

Yep....when you turn the key it grounds the ignition. Unplugging the harness from the motor will remove that connection. If the motor starts with the harness disconnected the kill switch or key switch will not work.

I found the problem. When I was pulling the flywheel I must have put one of the puller bolts too deep at it damaged the coil.

[nick80lf]

Ouch....bolt depth always makes me nervous pulling flywheels. A few years ago i finally gave in and purchased a SLP flywheel puller. It's been awhile since i have used it but I think the bolts they included are just the right length to prevent that from happening.

[Vader440]

I'll not make that mistake again.............I hope