KTM 400-660 LC4 1998-2005 Repair Manual page 151

1
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
Check 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
secondary coil
Spark plug connector
– Check the spark plug connector for cracks and fissures.
– Measure spark plug connector resistance.
Checking the side stand relay
Preparation:
– Remove the seat, the right side cover. Swing the headlight mask
forward.
– Disconnect the power supply from the CDI (orange cable).
– To check the current status of the relay connect the orange cable
coming from the cable tree either to the positive line of a voltmeter
or to a test lamp.
– The negative line of the voltmeter or test lamp is connected to
ground.
– Switch on the ignition lock and the emergency OFF switch.
Perform the following tests in the order indicated below:
– The relay must connect in either of the following three cases:
● Put a gear in but do not pull the clutch. Slowly swing up the side
stand. When the side stand is approximately halfway up, the side
stand relay should respond. If this is not the case, please check the
relay, the side stand switch
the cable tree.
● With the side stand down and a gear put in, slowly pull the clutch
lever. The side stand relay should respond when the lever is pulled
approximately half of the overall distance. If this is not the case,
please check the diode in the connector with the yellow and the pink
cable and the neutral switch.
● With the side stand down and the clutch not pulled, switch the
transmission to neutral. The relay should connect when the
transmission is switched to neutral and be tripped when a gear is
put in. If this is not the case, please check the diode in the connector
with the yellow and the green/black cable and the neutral switch.
NOTE: Responding of the relay is accompanied by a faint clicking sound
2
and the CDI's power supply is switched on. The voltmeter or the test
lamp indicates a battery voltage. After testing, reconnect the CDI unit's
power supply (orange cable).
!
CAUTION
.
COLOURS
blue/white – ground
blue/white – ignition wire
Setpoint value: 3.0 – 7.5 kΩ
2
as well as the corresponding parts of
7-40E
1
.
!
CDI .
UNIT
RESISTANCE
0,425 – 0,575 Ω
10,80 – 16,20 kΩ