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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)

  5. #4
    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
    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

  6. #5
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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)

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