Cdi Unit; Checking The Ignition Coil; Trouble Shooting In The Ignition System - KTM 400-660 LC4 1998-2005 Repair Manual

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CDI unit

Check the cables and plug and socket connections of the CDI unit
The CDI unit function can only be checked on an ignition test bench.
!
N
EVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE
C
OMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC
.
COMPONENTS

Checking the ignition coil

– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature of
20° C.
Replace the ignition coil if the measured values deviate significantly
from the setpoint values.
MEASUREMENT
primary coil blue/white – ground
secondary coil blue/white – ignition wire

Trouble shooting in the ignition system

Before checking the ignition system check:
● if the ignition lock is in position
● if the emergency off switch is in position
● if the neutral control lamp is on
● if the motorcycle can be started with the clutch pulled
● 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 from
ground.
– A strong spark should be visible when the electric starter is now
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.
– Twist out the spark plug and insert it into the spark plug connector.
– Connect the spark plug to ground. A strong spark should be visible
at the electrode when the electric starter is now operated. If this is
not the case, the spark plug connector or the spark plug is defect.
– If no spark is produced during the first test, perform the following
checks:
● Does the ignitionís power supply line (orange) carry battery voltage?
● If this is not the case, check the ignition lock, the emergency OFF
switch and, if applicable, the side stand relay as well as the
corresponding parts of the cable tree.
– If the ignition is sufficiently supplied with power and no spark is
produced, check:
● ground connection of CDI unit and ignition coil
● the cable between CDI unit and ignition coil
● pulse generator
● stator
● ignition coil
NOTE: The CDI unit can't be tested with simple devices. It can only be
replaced. It can only be tested on an ignition test bench.
CAUTION
COLOURS RESISTANCE
0,425 – 0,575 Ω
10,80 – 16,20 kΩ
or
7-16E
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CDI .
UNIT