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KTM 250 EXC RACING 400/450 SX,MXC,XC,XC-W,EXC,SMR,SXS RACING 520/525 SX,MXC,XC,XC-W,EXC,SMR RACING 540 SXS, 560 SMR, 610 CRATE ignition system repair TROUBLESHOOTING GUIDE

Troubleshooting in the ignition system
Before checking the ignition system check:
– if the emergency off switch is switched on
– if the battery is charged
– the main fuse
Check if an ignition spark is produced when the starter is operated. Proceed as follows:
– Pull off the spark plug connector.
– Disconnect the spark plug connector from the ignition cable.
– Hold the free end of the ignition cable approximately 5 mm (0.1968 in) from the ground.
– A strong spark should be visible when the electric starter is operated. If the battery level is low, turn off the light, and use the
kick starter.
– If a spark is visible, replace the spark plug connector.
– Unscrew the spark plug and insert it into the spark plug connector.
– Connect the spark plug to the ground. A strong spark should be visible at the electrode when the electric starter is operated.
If this is not the case, the spark plug connector or the spark plug is defective.
– If no spark is produced during the first test, perform the following checks:
– emergency off switch and
– corresponding parts of the cable tree
– If the ignition is sufficiently supplied with power and no spark is produced, check:
– the ground connection of CDI unit and ignition coil
– the cable between the CDI unit and the ignition coil
– the pulse generator
– the stator
– the ignition coil
– the short circuit button
NOTE: The CDI unit cannot be tested with simple devices. It can only be replaced. It can only be tested on an ignition test bench.

Ignition
General information
The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Ensure the correct measuring range is selected when performing measurements. Check stator and pulse generator Use an ohmmeter to perform the following measurements:

IGNITION MEASURE CABLE COLOURS RESISTANCE
4K-3A pulse generator red – green 100 Ω ± 20 Ω
ground – red ∞ Ω
charging coil ground – yellow 0,74 Ω ± 0,15 Ω
stator black/red– red/white 26 Ω ± 5,2 Ω
ground – black/red ∞ Ω
Stator (SMR starting with the 2006 model) black/red– red/white 32 Ω ± 4,8 Ω
black/red – ground ∞ Ω
4K-3B pulse generator red – green 100 Ω ± 20 Ω
ground – red ∞ Ω
charging coil ground – yellow 0,65 Ω ± 0,15 Ω
white – yellow 0,16 Ω ± 0,03 Ω
stator black/red– red/white 15 Ω ± 3 Ω
ground – black/red ∞ Ω

 

NOTE:
– The measuring must be performed at a temperature of 20° C. Otherwise significant deviations must be expected. Replace the stator and/or the pulse generator if the measured values deviate significantly from the setpoint values.
– The 4K3A ignition system no longer has a charging coil from the 2004 model.

Replacing the stator 4K-3A
– Remove the bolt 1 and dismount the retaining plate.
– Remove the 2 bolts 2 and take the stator out from the ignition cover.
– Place a new stator in the ignition cover. Degrease the threads of all 3 bolts and apply Loctite 243.
– Mount the bolts and tighten them to 6 Nm.
– Place the wire harness in a non-energized condition and secure it with the retaining plate. Do not forget the cable socket 3.
NOTE: in case of damage, convert to the newer 4K-3A version (see SMR from the 2006 model). When converting, always replace both the stator
and the rotor.

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Replacing the stator 4K-3B

– Remove the bolt 4 and dismount the retaining plate.
– Remove the 2 bolts 5 and take the stator out from the ignition cover.
– Place a new stator in the ignition cover. Degrease the threads of all 3 bolts and apply Loctite 243.
– Mount the bolts and tighten them to 10 Nm.
– Place the wire harness in a non-energized condition and secure it with the retaining plate.

 

Main fuse

The following loads are connected to it:
– E-starter system
– Horn
– Flasher lights
The fuse 2 serves as a spare fuse.
– To replace it, remove the left trim panel and pull the cover off the start relay.
– Pull out the fuse and replace it with a new one.

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Checking the electric starter motor
– Disconnect the negative pole of the battery and remove the electric starter motor.
– Connect the negative pole of a 12 V battery to the housing of the
E-starter motor and briefly connect the positive pole of the battery to connection 3 of the electric starter motor (use thick cables).
– The starter must turn as soon as the circuit is closed.
– If this is not the case, replace the starter motor.

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Checking the starter relay
– Remove the seat and the left side cover and disconnect the  combination connector of the starter relay.
– Disconnect the negative terminal at the battery and the two cables at the starter relay.
– Connect the starter relay to a 12 V battery as indicated in the diagram.
– Check continuity between terminals C and D using an ohmmeter.

Reading: 0 Ω OK
Reading: ∞ Ω defective
NOTE: The response of the starter relay is accompanied by a faint clicking sound.

For more information, please download the relevant fault KTM  repiar service manual pdf

Related files:

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