Results 1 to 10 of 10

Thread: No Spark Bad Flywheel

  1. #1
    KTMTalk Member wizard's Avatar
    Join Date
    Dec 2002
    Userid
    3661
    Location
    Conestoga Pennsylvania
    Posts
    280

    Default No Spark Bad Flywheel

    My KTM 525 lost spark in the middle of a ride. Ohmed all components which tested in spec except secondary on ignition coil showed an open circuit. Replaced coil, still no spark. Wellllll, I have seen this before and usually just replace the stator and the trigger at once. Replaced both and checked air gap and still no spark. Actually, I could get a spark by kicking, but not electric start. Kicking will generate a higher RPM than starter will. I never in over fifty years have seen a flywheel that was the reason for an ignition issue. I had already switched the CDI and was out of options. Tried another flywheel and Its alive again LOL. The flywheel that was on it was about fifteen years old and was a Trailtech Lighter Flywheel. I borrowed one from a friend and now need to replace it if anyone has an OEM that they would sell me?
    2013 Christini 300
    2005 KTM MXC 525 Christini Conversion
    My You Tube Channel
    http://www.youtube.com/user/Kingtrevorton
    You don't stop riding when you grow old,you grow old when you stop riding!

  2.    Sponsored Links



    LOGIN AND CLICK THE SHOP ONLINE LINK FOR THE DISCOUNT


  3. #2
    KTMTalk Member dirtbikeace's Avatar
    Join Date
    Jul 2007
    Userid
    77500
    Location
    Alger Michigan
    Posts
    10,801
    Images
    44

    Default Re: No Spark Bad Flywheel

    2006 400 EXC I have found when the battery drops below 12.7Vdc it will not e-start but will start by kicking. I have found if the flywheel mounting is only .010 off location will result in 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

  4. #3
    KTMTalk Member wizard's Avatar
    Join Date
    Dec 2002
    Userid
    3661
    Location
    Conestoga Pennsylvania
    Posts
    280

    Default Re: No Spark Bad Flywheel

    New Yuasa YTZ7S and the air gap is .030". Strangest thing I have ever seen mechanicaly. The old flywheel magnetism seems to be the same as the OEM replacement. Even the very slight magnetism on the protrusion that triggers the Trigger Coil seems to be the same as the OEM.
    2013 Christini 300
    2005 KTM MXC 525 Christini Conversion
    My You Tube Channel
    http://www.youtube.com/user/Kingtrevorton
    You don't stop riding when you grow old,you grow old when you stop riding!

  5. #4
    KTMTalk Member
    Join Date
    Jan 2014
    Userid
    155655
    Location
    WA/ AZ
    Posts
    178

    Default Re: No Spark Bad Flywheel

    If you decide to do an autopsy on the Trail tech please post photos. I have 3 of them that work fine but they don't look to be put together as well as the Japanese ones.

  6. #5
    KTMTalk Member dirtbikeace's Avatar
    Join Date
    Jul 2007
    Userid
    77500
    Location
    Alger Michigan
    Posts
    10,801
    Images
    44

    Default Re: No Spark Bad Flywheel

    I have read where a flywheel can lose magnetism.
    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

  7. #6
    Lifetime Team KTMTalk TravisD37's Avatar
    Join Date
    May 2002
    Userid
    819
    Location
    Gardnerville Nevada
    Posts
    9,986
    Images
    10

    Default Re: No Spark Bad Flywheel

    It sounds like a cracked magnet
    Thumper Racing
    1292 Industrial Ct.
    Gardnerville NV 89410
    775-309-4956
    Email: ThumperRacing
    Self help Videos:
    RFS Valve adjustment
    Water pump seal change
    10% KTMTalk member discount
    must be asked for at T.O.P.

  8. #7
    KTMTalk Member wizard's Avatar
    Join Date
    Dec 2002
    Userid
    3661
    Location
    Conestoga Pennsylvania
    Posts
    280

    Default Re: No Spark Bad Flywheel

    I imagine the lack of magnetism is the issue. I feel a weak magnetic signal at the trigger pickup protrusion is the problem. If I cycled the kill switch while cranking I could get a spark. I have used this method to check the trigger coil on other brands many times. Although I never thought it would be a bad flywheel instead of the trigger coil.
    Attachment 41085
    2013 Christini 300
    2005 KTM MXC 525 Christini Conversion
    My You Tube Channel
    http://www.youtube.com/user/Kingtrevorton
    You don't stop riding when you grow old,you grow old when you stop riding!

  9. #8
    KTMTalk Member wizard's Avatar
    Join Date
    Dec 2002
    Userid
    3661
    Location
    Conestoga Pennsylvania
    Posts
    280

    Default Re: No Spark Bad Flywheel

    2013 Christini 300
    2005 KTM MXC 525 Christini Conversion
    My You Tube Channel
    http://www.youtube.com/user/Kingtrevorton
    You don't stop riding when you grow old,you grow old when you stop riding!

  10. #9
    KTMTalk Member DJH's Avatar
    Join Date
    Oct 2002
    Userid
    2370
    Location
    Kirkland Washington
    Posts
    32,239

    Default Re: No Spark Bad Flywheel

    I have a good used OEM flywheel if you need one
    [URL=http://www.djhcyclesport.com
    Former Husky Dealer in the '70's, currently Sell Real Estate, Seattle area and as a hobby business I manufactor cam chain tensioners for the KTMs, do Carburetor modification & setup and valve work on KTM & Husky 4 strokes. Full stock of parts for the KTM's. My rides are; Cadillac Escalade (the 1/2 pickup version), 72 ElCamino 454SS, and Triumph 1050 Sprint ST, Iron Butt member

  11. #10
    KTMTalk Member wizard's Avatar
    Join Date
    Dec 2002
    Userid
    3661
    Location
    Conestoga Pennsylvania
    Posts
    280

    Default Re: No Spark Bad Flywheel

    Yes, I need one to replace the one I borrowed from a friends bike. PM a price and I will Paypal you if that is ok.

    Thank You, Don
    2013 Christini 300
    2005 KTM MXC 525 Christini Conversion
    My You Tube Channel
    http://www.youtube.com/user/Kingtrevorton
    You don't stop riding when you grow old,you grow old when you stop riding!

Similar Threads

  1. KTM 65 Flywheel and No Spark
    By jlhalbrooks in forum KTM 65SX, 85SX and 105 SX
    Replies: 3
    Last Post: 03-23-2016, 05:59 PM
  2. Flywheel for 2008 KTM 250SX (suggested Flywheel weight)
    By ktmracer201 in forum 2 Stroke KTMs
    Replies: 2
    Last Post: 01-31-2012, 11:49 PM
  3. No spark after replacing flywheel key and timing?
    By pcorssmit in forum 2 Stroke KTMs
    Replies: 3
    Last Post: 07-13-2002, 02:50 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •