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Thread: 1999 KTM 380 EXC - No Spark Troubleshooting

  1. #1
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    Default 1999 KTM 380 EXC - No Spark Troubleshooting

    This is a new to me bike that I purchased recently in non-running condition. The ignition died on the owner while riding. Initial test shows no spark. The owned described the failure as "it just stopped, as though you hit the kill switch". He prepped the bike for storage, tossed a cover over it in his basement, with the intentions of fixing it the next riding season, but it sat for 4-5 years, before I purchased it. I am going through the bike system by system for inspection, fluid changes, etc. But I am starting with the know problems first.

    I found a KTM Engine Repair manual online and started going through the test procedures for the Kokusan system.

    The results for the coil are as follows:
    • Primary Coil Spec is 0.425 - 0.575 Ohms. Mine measured 0.7 Ohms
    • Secondary Coil Spec is 10.8 -16.2 K Ohms. Mine measured 6.3 K Ohms


    So mine is clearly out of spec - is it enough out of spec to cause the no spark?
    Mike in Cary, NC

    Bikes
    1999 KTM 380 EXC
    2012 Honda CRF250R
    Cars
    2006 BMW M3, Cabriolet
    2014 Volkswagen Sportwagen TDi
    2016 Honda Pilot (Wife's Driver)

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  3. #2
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    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    Don't how the answer for sure but I have fouled out spark plugs and the bike just shuts down and won't start. Maybe also possible the kill switch or wire to it is shorted to ground.
    Might be best to disconnect the wire to the kill button and see if anything changes.
    Since you tested coil and its out of spec. It would seem logical to buy a new one.
    Is there anyway to check the pulse from the ignition system that triggers the coil
    To release its charge?
    2005 450 exc
    1996 620 rxc
    1986 250 mxc

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    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    Thanks for the reply. Yes, I removed the kill switch from the circuit when testing for spark. I ordered a new coil, and will report back if this cures the problem.
    Mike in Cary, NC

    Bikes
    1999 KTM 380 EXC
    2012 Honda CRF250R
    Cars
    2006 BMW M3, Cabriolet
    2014 Volkswagen Sportwagen TDi
    2016 Honda Pilot (Wife's Driver)

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    KTMTalk Member dirtbikeace's Avatar
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    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    Have you checked the air gap for the pulsar pickup if its more than .030" will cause a no start condition.
    present bikes
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    1983 Husqvarna 250WR
    1968 Honda CT90 trail 90
    1971 Suzuki RV90
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    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    Thanks for the heads up about checking the pick-up gap. I will take a look this weekend.
    Mike in Cary, NC

    Bikes
    1999 KTM 380 EXC
    2012 Honda CRF250R
    Cars
    2006 BMW M3, Cabriolet
    2014 Volkswagen Sportwagen TDi
    2016 Honda Pilot (Wife's Driver)

  7. #6
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    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    Update:

    The new coil arrived and the measured resistance of the primary and secondary sides of the new coil are are about the same as the old coil. So I am reasonably sure the coil is not the problem.

    On to the Stator.

    The manual has three measurements
    • Pulse Coil 85-115 Ohms
    • Exciter 20.4 - 27.6 Ohm
    • Charge Coil 0.63 - 0.85 Ohms



    My measurements for the Pulse Coil and the Exciter are smack in the middle of the range.
    My Charge Coil measures well outside the range at 17 Ohms.

    The NOTE in the manual says that if any one the three measurements are out of range, the Stator must be replaced.

    Looks like the stock Stator (Kokusan, 2K-2, PN 54739004100) is no longer available. Any suggestions on a later model KTM stator that might work or perhaps an after market unit?

    Thanks,
    Last edited by 380Dude; 09-22-2020 at 07:51 PM.
    Mike in Cary, NC

    Bikes
    1999 KTM 380 EXC
    2012 Honda CRF250R
    Cars
    2006 BMW M3, Cabriolet
    2014 Volkswagen Sportwagen TDi
    2016 Honda Pilot (Wife's Driver)

  8. #7

    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    There should be plenty of those stators used on Ebay.

    Where the coil mounts to the frame, is the metal on the frame clean an bare? (No rust or paint) If it dont make a ground there you will not get spark.

    Have you tried a different CDI? I wish you were closer, we could swap some parts around.
    1999 300 MXC
    1999 250 EXC

  9. #8
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    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    RodC - Thanks for the reply.

    Since my Charge Coil within the stator assembly tested out of spec, I ordered a new stator from RICK's Motorsport Electrics. Realizing that the Exciter Coil tested OK, and this is the part of the Stator that is the source of the ignition, I will continue to troubleshoot all the connections and grounds and you mentioned above.

    Regarding the CDI unit, if all other components test good, and all of my connects have been inspected and cleaned, then by process of elimination, it may be the CDI unit. I do not have a spare CDI. I may have to look for one from a newer 300 EXC and see if I can adapt it to my bike (or get lucky and find a used CDI on Ebay for a 380 EXC).

    This is my plan for now, I'll know more (and post more) when I take the system apart this weekend. Thanks!
    Mike in Cary, NC

    Bikes
    1999 KTM 380 EXC
    2012 Honda CRF250R
    Cars
    2006 BMW M3, Cabriolet
    2014 Volkswagen Sportwagen TDi
    2016 Honda Pilot (Wife's Driver)

  10. #9

    Default Re: 1999 KTM 380 EXC - No Spark Troubleshooting

    If you have to go the CDI route, the 300 of that era was the same. There is also a chart KTM provided with suggested CDI boxes. Most of the newer ones will work. I have a 2012 model on one of my 1999 300s with a map switch installed.

    The PDF is in several threads here, this is one of them.

    https://ktmtalk.com/showthread.php?5...lible-from-KTM
    1999 300 MXC
    1999 250 EXC

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