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  #11  
Old 1 Week Ago
goose202 goose202 is offline
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Yeah unplugging the kill switch was the first test.

Fortunately I have an old oscilloscope laying around.

The stator tests at 10 ohm resistance, with 20 volts p-p on a nice sine wave, turning the engine with the cordless drill on the crank.
The exciter tests at 98.8 ohms, with 10 volts p-p on the positive and negative spikes.

These resistances match up with expected test values.

The scope does pick up a signal on the kill switch wire.

The CDI coil output shows a spike-like output but it's < 10V. Some quick googling suggests a CDI coil would normally see 40-60V on input.

So if I'm expecting more like 100V on the stator, I guess the symptoms make sense - there's just not enough voltage for the CDI to properly energise the coil and therefore no spark.

Is it possible that the stator resistance checks out ok but is still faulty?
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  #12  
Old 6 Days Ago
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gasser nate gasser nate is offline
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Quote:
Originally Posted by goose202 View Post
Yeah unplugging the kill switch was the first test.

Fortunately I have an old oscilloscope laying around.

The stator tests at 10 ohm resistance, with 20 volts p-p on a nice sine wave, turning the engine with the cordless drill on the crank.
The exciter tests at 98.8 ohms, with 10 volts p-p on the positive and negative spikes.

These resistances match up with expected test values.

The scope does pick up a signal on the kill switch wire.

The CDI coil output shows a spike-like output but it's < 10V. Some quick googling suggests a CDI coil would normally see 40-60V on input.

So if I'm expecting more like 100V on the stator, I guess the symptoms make sense - there's just not enough voltage for the CDI to properly energise the coil and therefore no spark.

Is it possible that the stator resistance checks out ok but is still faulty?
Yep! Extremely common, get it rewound and you’ll be sweet! I loved my 04. I put about 25000 kms on it.
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  #13  
Old 6 Days Ago
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Rebuild Rebuild is offline
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try disconnecting the voltage regulator, then see if it starts.
My KTM300 had an intermittent short between lights and ignition on the stator a while back.Took a while to find as the short was hidden from view.Ohm tests were ok IIRC.I usually just disconnected the reg to ride it.
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Last edited by Rebuild; 4 Days Ago at 11:04 AM.
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  #14  
Old 6 Days Ago
goose202 goose202 is offline
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Yes that's a good point.
What I also haven't done yet is measure resistance between the stator and ground.
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  #15  
Old 6 Days Ago
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and check ohms between ignition and lights.Should be no connection.
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  #16  
Old 4 Days Ago
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Also if you haven't tried, remove plug cap(unscrews) and try bare wire to cylinder bolt.

If you can borrow another coil, i'd try that too.

Unusual for CDI's to go, so I'd be trying easy/cheap stuff first
BTW this is my and a mates'(Q) CDI dodgy measurements for KTM300 all measured to gnd pin2,IIRC
Pin__________Colour_________My 2009 CDI____Q's 2013 CDI

1___________wht/blu________inf____________inf_____________to coil
2___________brown___________-______________-_____________gnd
3___________n/c____________inf____________inf
4___________grey___________inf____________inf_____ _______dual ignition
5___________blk/ylw________inf____________inf____________kill button
6___________blk/red________7.6 Kohm_______7.5 Kohm_______exciter
7___________red/wht________inf____________inf____________exciter
8____________n/c___________0-2M @2mins____0-2M @2mins
9____________n/c___________inf____________inf
10____________red___________3.08 Kohm______3.08 Kohm______pulser
11____________green_________0______________0______ ________pulser
12____________n/c___________1.57 Kohm______1.5 Kohm
13____________n/c___________154 Kohm_______151 Kohm
14____________blk/wht_______0______________0______________dual ignition
15____________n/c___________1.2 Kohm_______2.4 Kohm_______throttle pos sensor for 4st??
16____________n/c___________11.4 Kohm______11.4 Kohm______"
17____________n/c___________11.6 Kohm______11.5 Kohm______"
18____________n/c___________inf____________inf
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Ariel MCC
Covering SA in singletrack since 1928
09 KTM300EXC-E
89 KTM125EXC

Last edited by Rebuild; 4 Days Ago at 11:12 AM.
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  #17  
Old 1 Day Ago
goose202 goose202 is offline
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Only just noticed your last post Rebuild, thanks for that.

The stator resistance to ground and to the lighting side all checks out fine.
Can't see anything burned or the like looking at the stator.

Considering options now, I'm not in a huge hurry because it's a second bike these days. I even researched rewinding the stator myself, might even try that, although getting the epoxy off without soaking all the windings in acetone and having to redo them too sounds like it might be a challenge.

I've also only checked the stator voltage (which apparently is low) with no load on it. I might check it again with the CDI plugged in - if it's then very low, I guess it's confirmation of the stator.

I would like to try another coil too, but the other coils I have access to are all COP 4 stroke items, don't know if they're compatible.
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  #18  
Old 6 Hours Ago
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Voicing aloud... Nah... It's maybe not a challenge at-all... Yet, I'm not-gonna comment on that: Since I know F-all... Having never-done that.
If I were to attempt such; I'd strip the existing wiring... source the replacement wiring & do the Maths for the overall length, in coils, for that.

Edit: The length needed, by the coiling, can-likely be done/sussed with/by using Maths too... That's well-above my pay-grade... Even for free.
Edit2: If you do send it away & I likely would; you should be able the check what is returned via a multimeter b4 fitting it: Google's your friend.
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