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  #1  
Old 30-04-2014
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wosat wosat is offline
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KTM 300 won't start - No Spark

OK as the subject says... I have a 2009 KTM 300 that won't start.

Bike was running fine and just died.. There is no spark at the plug.
This bike has been running with a dead/flat (not sure why) battery for the last couple of years.

Here is what I have done so far - All have made no difference

Swapped the spark plug with new one.
Unplugged the yellow and black wire for the kill switches near the coil.
Tested and swapped out the coil with a known good one. Old one tested OK on another bike.
Put the CDI in a running bike and there was spark at the plug (Wasn't game enough to put good CDI in broken bike in case it fried it)
Connected up a good battery.

Continuity checked between the coil and CDI - Seems OK
Continuity checked between the pickup and CDI - Seems OK
Continuity checked between the stator and CDI - Seems OK
I also checked these wires with the meter for a short to earth and got nothing.

If the stator is not working, will the CDI fire off the battery voltage or does it need the AC voltage from the stator?

Any help/advice would be appreciated.

Cheers,
Brett

Last edited by wosat; 30-04-2014 at 03:17 PM.
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  #2  
Old 30-04-2014
2banga 2banga is offline
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Resistor cap. Unscrew it off the lead, bare some fresh wire and screw it back on.
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Old 30-04-2014
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WHS, but check for spark with the bare wire first.
CDI does not use the battery at all, completely separate.

Kokusan 2K-3
Pulser coil______red & green_______________100ohms +/- 15%
Exciter______black/red & red/white_______12.7ohms +/- 15%
Charge coil(lighting)__yellow to ground_____0.65ohms +/- 15%
white to yellow________________ 0.16ohms +/- 15%

Coil:
Primary: white/blue - ground: .425 - .575 ohm
Secondary: white/blue - ign wire: 10.8 - 16.2 kilohm

I have had probs with spark a while back with the CDI connector playing up and intermittent spark.If i pushed the connector towards the frame, it would have spark.
white/blue(to the coil) and red/white(from the stator) were the main culprits, quite loose on the pins.Squashed the connectors slightly and all good.

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09 KTM300EXC-E
89 KTM125EXC

Last edited by Rebuild; 30-04-2014 at 11:17 PM. Reason: stuff
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  #4  
Old 30-04-2014
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Quote:
Originally Posted by wosat View Post
If the stator is not working, will the CDI fire off the battery voltage or does it need the AC voltage from the stator?
It needs the AC charging pulse from the little coil, not the main AC feed. Sounds like an open circuit armature winding in the ignition supply coil or an open circuit connector.

The bike will run with the thick Yellow and White AC feeds disconnected and no battery. The SX model has neither.
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Old 30-04-2014
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wosat wosat is offline
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Thanks all for the replies.

I will have a look at the stator and the CDI connector in the morning.
Swapped the rec/reg too after posting with no change.

I will put the meter across the stator now that I have the test values an I have a stator from an 2012 bike to put in it to confirm.

I will let you know how I go.

Cheers,
Brett
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  #6  
Old 01-05-2014
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wosat wosat is offline
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OK... An update :-)

Tested the stator and the stator from the problem bike read 6 ohms across the exicter compared to 14 across the good stator.

Put the good stator in the bike, kicked it and the plug sparked.

Does anyone know if there is a common root cause for the exciter to fail?
Also is there a consensus regarding rewinding or replacing the stator? What do you reckon?


Cheers,
Brett
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  #7  
Old 02-05-2014
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Quote:
Originally Posted by wosat View Post
Also is there a consensus regarding rewinding or replacing the stator? What do you reckon?
Trailtech in US do uprated DC replacements for around $200, seems like a good deal to me.
When my stator died, had it rewound locally at Bettabikes ( Google if you want, he does a lot of SA "24hr" lights), but was more expensive
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89 KTM125EXC
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