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Thread: 525 EXC - Sudden No Spark

  1. #1

    Default 525 EXC - Sudden No Spark

    Hey guys! Im baffled by this and need some help.

    Went for a normal ride and all is 100% okay. Load the truck up and throw it on the truck. Get home and try to fire the bike up and it's just cranking and not trying to fire at all. Normally barely takes one second to fire. I figure something is up and I pull it apart to check for spark. No spark but the plug looked a bit old so I swapped it with a fresh one and still nothing. I tried disconnecting the kill switch to see if there was a short (black and yellow wire) NOTHING. I checked all the wires for frays etc and I can't figure anything out. I tried cutting the plug wire a bit and re-installing the boot and that didn't help either.

    I'm pretty stuck as this is the extent of my knowledge of electrical. I figured it would be something easy as it went without any signs or anything.

    Any guesses? Thanks

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  3. #2

    Default Re: 525 EXC - Sudden No Spark

    Replaced 3 plug caps they have a high failure rate along with the plug wire corroding and it will be green inside, trim 1/4" off each end and it the cap screw has rusted away replace it.
    present bikes
    2006 KTM 450 EXC
    2006 KTM 400 EXC
    1999 Kawasaki Concours
    1983 Husqvarna 250WR
    1968 Honda CT90 trail 90
    1971 Suzuki RV90
    1964 Honda CT200 Trail 90
    member Great Lakes dual sporters
    www.gldsmc.org
    AMA charter life member-663466A

    District 14 ama- #0025

  4. #3

    Default Re: 525 EXC - Sudden No Spark

    Quote Originally Posted by dirtbikeace View Post
    Replaced 3 plug caps they have a high failure rate along with the plug wire corroding and it will be green inside, trim 1/4" off each end and it the cap screw has rusted away replace it.
    Don't think it's the plug cap. I took the cap off and tried to get a spark to the motor and it was a no go. I snipped it back and reattached but it doesn't seem like it did anything.

    All the internal wires look really clean to me. Nothing corroded.

  5. #4

    Default Re: 525 EXC - Sudden No Spark

    Made some slight progress. Was starting to check resistance and the plug with the Green/Red wires leading from the pulse generator coming from the case has no resistance. Could this be the issue? It's reading as 0 and my meter is reading fine on other connections.

  6. #5
    KTMTalk Member
    Join Date
    Aug 2005
    Location
    Santa Clarita
    Posts
    678

    Default Re: 525 EXC - Sudden No Spark

    Try pushing the wires into the cdi when you push the button. Several of us have had the wires loosen there
    Ben
    Santa Clarita Ca
    2005 525 EXC
    2002 Yamaha FZ1
    2010 XC 250
    2001 YZ 250 Smokey Son's

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