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Old 04-22-2013, 07:14 PM   #106
Queen of Spades OP
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Location: Decatur, GA
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After getting the lights working, I decided it was time to press the Red Button. Performed a cursory check of all connections and fittings, and put the tank back on thinking I'd be riding down the street in a few minutes. Rolled bike outside and hit the starter. No spark. Confirmed with timing light on plug wire (made sure timing light worked by testing on my car). No spark, no joy..

So I've rewired half the bike, replaced a $$$ CDI, and am back where I started. I'm convinced the old CDI was bad or going bad because it was buzzing when I turned the key on. The new one is silent.

If anyone is reading this in the Atlanta area who is A) an electrical whiz and B) eager to make a few bucks and C) more eager to help a fellow inmate.. please PM me.
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Queen of Spades screwed with this post 04-22-2013 at 07:24 PM
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Old 04-22-2013, 07:39 PM   #107
bmwktmbill
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Sweet Jesus!!!

Check the ground for the CDI box...or you have lost power.
bill
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'02 KTM 640 Adventure-lowered
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The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 04-23-2013, 04:11 AM   #108
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Quote:
Originally Posted by gunnerbuck View Post
A few pages back I mentioned for you to visually inspect the stator and pickup coil, have you done that?
I hadn't checked this yet as I was sure the CDI was culprit. I'm going to slip out in the shop before work this morning for a quick visual inspection.
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Old 04-23-2013, 04:11 AM   #109
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Quote:
Originally Posted by bmwktmbill View Post
Sweet Jesus!!!

Check the ground for the CDI box...or you have lost power.
bill
Will do. Everything looked tight there but I didn't actually put my fingers on the green wire.
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Old 04-23-2013, 05:57 AM   #110
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Bill: coil screws were snug.

On to the next step:



Ignition cover.


Cover removed. Gasket broke, so added one to my cart:




Pulser coil and wires appeared to be in good shape externally.




Stator & wires looked OK as well.




I pulled the pulser coil from the case and noticed two small cracks - probably from bending the wires during removal. KTM Parts Warehouse sells replacement pulsers for $45, so that's on order as well.

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Old 04-23-2013, 07:42 AM   #111
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Old 04-23-2013, 07:58 AM   #112
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Quote:
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Thanks for your contribution.
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Old 04-23-2013, 09:02 AM   #113
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Quote:
Originally Posted by Kawidad View Post
Quote:
Originally Posted by Queen of Spades View Post
Thanks for your contribution.
C'mon.......you gotta have good popcorn when you are reading these threads

I hope the cracked wires sort the problem!

Cheers
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Old 04-23-2013, 07:57 PM   #114
bmwktmbill
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Somebody shake Luke loose from where ever he is and let's get him to help.

LUKE..LUKE???

bill
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 04-26-2013, 06:15 PM   #115
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Bluhduh

With the bike leaning to the left, is it safe to remove the two oil hose flanges on the right side of the engine without losing oil? I have to disconnect these two to replace the pulsar coil.
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Old 04-26-2013, 08:08 PM   #116
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Quote:
Originally Posted by Queen of Spades View Post
With the bike leaning to the left, is it safe to remove the two oil hose flanges on the right side of the engine without losing oil? I have to disconnect these two to replace the pulsar coil.

Yes, you can remove those lines, very little oil will flow out from there as it needs the oil pump working to bring it up from the sump...
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Old 04-27-2013, 12:22 AM   #117
mountaincadre
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Those wires dont look good, whether its those two that are the culprits remains to be seen, but i would replace it anyway as those are bound to go leaving you stranded.
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Old 04-27-2013, 12:29 PM   #118
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Well, it finally runs.

Damage list:
New CDI (old one made buzzing noise)
New pulse coil (old one had a couple cracks in wiring)
New ignition coil (old one may have been OK, got a new one just in case/spare)
New plug cap
New plug
New internal oil filter
New rear brake switch (old one bad)
New molex connectors in rats nest behind headlight
New bullet connectors throughout

Additions:
Water resistant USB charger
Hyperlight brake lights with custom mounting brackets

To do:
Valve adjustment
Oil change with new external oil filter
New fork seals
Foldable mirrors
Squadron LED headlight with dimmer switch
New front tire


LIke I mentioned earlier, I've never worked with electrical issues other than changing bulbs. This was frustrating and tried my patience. But it's finally running and hopefully I won't have to worry about electrical issues again!

Thanks to everyone who chimed in to help.

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Old 04-27-2013, 02:40 PM   #119
dolphins13
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Cool2

Quote:
Originally Posted by Queen of Spades View Post
Well, it finally runs.

Damage list:
New CDI (old one made buzzing noise)
New pulse coil (old one had a couple cracks in wiring)
New ignition coil (old one may have been OK, got a new one just in case/spare)
New plug cap
New plug
New internal oil filter
New rear brake switch (old one bad)
New molex connectors in rats nest behind headlight
New bullet connectors throughout

Additions:
Water resistant USB charger
Hyperlight brake lights with custom mounting brackets

To do:
Valve adjustment
Oil change with new external oil filter
New fork seals
Foldable mirrors
Squadron LED headlight with dimmer switch
New front tire


LIke I mentioned earlier, I've never worked with electrical issues other than changing bulbs. This was frustrating and tried my patience. But it's finally running and hopefully I won't have to worry about electrical issues again!

Thanks to everyone who chimed in to help.


Thats cool it runs. How's it run? Does the carb need to be cleaned, and or rejetted? I believe you have the same bike as mine? 99 lc4e. No snorkel, 157.5 main jet, and open exhaust, and it really runs good. Oh ya and moved the needle 1 notch up. kenda 270's are ok all around tire?
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Old 04-27-2013, 09:39 PM   #120
bmwktmbill
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Happy for you.
b
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley
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