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5/3/2018
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Fayetteville, NC
US
2013 KTM 300 XC: Electrical Troubleshooting Advice badly needed for fairly new KTM owner who just reinstalled electric starter parts. WARNING! Long read and some Electrical knowledge required. Comment or PM with details please!
Issue: INTERMITTENTLY not getting any ignition spark (wire or cap), but most times when moving the CDI/ECU box around I'm able to get spark again! But sometimes it goes out longer as if the CDI box was in some kinda protective mode.
Background: bought bike without E-starter kit. It had a Baja Designs voltage regulator and stator mod for DC voltage (unknown to me during initial troubleshooting) to run lights I didn't get with bike. Installed E-starter and new battery but it wouldn't start with E-start on cold engine, only by kickstarter. But it would not produce more than 13.4 Volts with bike running. I even de-modded the stator back to OEM standard (AC v) and OEM voltage regulator. But not much improvement. Then I started having the no-spark issue, especially after E-start attempts, which I attributed to a combination of bad stator/pick-up coil and ignition coil since some of the readings were borderline off.
I decided to get a new stator and voltage regulator and while at it new ignition coil. Installed all the new stuff and it cranked much stronger and even E-started it a couple times on a somewhat cold engine. Then it would lose spark again. I tested everything I could with a multimeter (ohms) and it passed the continuity tests as per the manual. However, I haven't found any data on troubleshooting the CDI box. I know I got continuity between pins 2 (ground, br) and 11 (pick-up coil/CPS, gn) in the CDI box. Not sure if CDI pin 11 should be grounded to pin 2 internally or if any other terminals should be grounded to each other in the CDI. All wiring harness wires have continuity and no shorts. I even moved them around while checking. Wiring harness connector to CDI was a little questionable cuz it slips out a little on one side but even while pressing it I'm still not getting spark at the ignition when cranking (intermittently). I'm leaning toward CDI box with a slight change it could be the connector. Thoughts? guidance? recommendations?
New Parts: OEM stator, OEM voltage regulator, OEM ignition, Neuron starter, Shorai battery
Used Parts: CDI/ECU box, bendix, wiring harness, starter relay
Issue: INTERMITTENTLY not getting any ignition spark (wire or cap), but most times when moving the CDI/ECU box around I'm able to get spark again! But sometimes it goes out longer as if the CDI box was in some kinda protective mode.
Background: bought bike without E-starter kit. It had a Baja Designs voltage regulator and stator mod for DC voltage (unknown to me during initial troubleshooting) to run lights I didn't get with bike. Installed E-starter and new battery but it wouldn't start with E-start on cold engine, only by kickstarter. But it would not produce more than 13.4 Volts with bike running. I even de-modded the stator back to OEM standard (AC v) and OEM voltage regulator. But not much improvement. Then I started having the no-spark issue, especially after E-start attempts, which I attributed to a combination of bad stator/pick-up coil and ignition coil since some of the readings were borderline off.
I decided to get a new stator and voltage regulator and while at it new ignition coil. Installed all the new stuff and it cranked much stronger and even E-started it a couple times on a somewhat cold engine. Then it would lose spark again. I tested everything I could with a multimeter (ohms) and it passed the continuity tests as per the manual. However, I haven't found any data on troubleshooting the CDI box. I know I got continuity between pins 2 (ground, br) and 11 (pick-up coil/CPS, gn) in the CDI box. Not sure if CDI pin 11 should be grounded to pin 2 internally or if any other terminals should be grounded to each other in the CDI. All wiring harness wires have continuity and no shorts. I even moved them around while checking. Wiring harness connector to CDI was a little questionable cuz it slips out a little on one side but even while pressing it I'm still not getting spark at the ignition when cranking (intermittently). I'm leaning toward CDI box with a slight change it could be the connector. Thoughts? guidance? recommendations?
New Parts: OEM stator, OEM voltage regulator, OEM ignition, Neuron starter, Shorai battery
Used Parts: CDI/ECU box, bendix, wiring harness, starter relay
Also your charge voltage is low.
Paw Paw
The Shop
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