Can you help a mate with his dead KTM?

[(RIP) sherpa]

My mate has a KTM 520 EXC. year 2002 which has died on him.

He was riding it as normal when it just stopped as though somone had turned off the key (it doesn't have one though!)
He seems to be getting a spark when kicking it and has checked fuel.
Suspecting the CDI unit he swapped that with a mates identical bike but it doesn't even spark with that fitted.

His mates bike works fine now back together.
I know a few of you have KTM's so thought it might be worth asking

Thanks
Sherpa

 

[harry]

Start with simple things,batt connections+&- at both ends, fuse, side stand cut-out if fitted, waggle looms. Good luck

 

[HOGDAWG]

My mate has a KTM 520 EXC. year 2002 which has died on him.

He seems to be getting a spark when kicking it...

I thought you were meant to flog an dead horse not kick it!

 

[(RIP) philgunn]

Dead KTM

a friend had a KTM EXC 450 with similar problems , it turned out to be a Cracked piston ,

gunner

 

[(RIP) sherpa]

update

Just had a memo from owner - apparently there isn't a spark.
I don't think it has a battery.

appologies for the misleading info - I asked for the story but got very little initially!

Thanks again
sherpa

 

[IainMac]

sounds like an ignition pick up problem if no spark, the enduro versions do have batteries but it should still start if flat. mite be worth searching out a workshop manual of t'interweb for some pointers on the low and hi tension ignition circuits.

 

[Cookson]

I assume he has tried a different plug.

 

[GEOFFREY DEACON]

I had a problem like that on my old 640, turned out to be a bad connection for the ignition under the seat?, As the seat got moved around whilst in motion, It would disturb the 4 ply connector and cut the ignition??. I just changed the multi plug for 4 seperate single connectors.
Hope this helps!!.

 

[TaffyScouser]

Make sure the plug cap is in good nick and check that the cap is actualy firmly and well attached to the HT lead. These bikes are left wet after washuing and this is a problem on some of them. Side stand switch also bad one. Kill switch needs to be checked for bad contacts as these also corrode and stop any stanrting procedure. Go for the simple ones first and ignore the scaremongers till you have iliminated the cheap and simple probs first.

 

[BLUE(UK)]

Make sure the plug cap is in good nick and check that the cap is actualy firmly and well attached to the HT lead. These bikes are left wet after washuing and this is a problem on some of them. Side stand switch also bad one. Kill switch needs to be checked for bad contacts as these also corrode and stop any stanrting procedure. Go for the simple ones first and ignore the scaremongers till you have iliminated the cheap and simple probs first.

Bollox....beat me to it!!

Plug and plug cap mate.(try your mates on it cos they breakdown inside).
I do know for a FACT that the 03-05's suffered from the plug cap breakdown but cant say i know on the older ones but i would try that mate.Simple job as well.
If not,try the other suggestions by ANDY MELTON.
If it aint that then i would drain the gas out the carb and retry.
Next i would be going down to check the valve clearances(90mins job).

 

[Nin]

Happened to me and a mate and a new plug cap was the solution - which we found after going through everything esle sadly.

It's easy enough to test the cap resistance with a multimeter - it should have the spec stamped on the side.

Of course, it might be something completely different ....

 

[Mezza]

I had a 03 450 SX and had a similar problem. I checked everything including confirming that there was a spark. Turned out to need a replacement HT lead / cap. Even though it produced a spark it was'nt of sufficient power. Went like a good 'un after that
Rich