Hoping the gurus of Cafe Husky have some wisdom to pass on regarding my issue with no spark when my bike gets hot. Bike: 2006 TE510 Problem: No spark once the engine gets hot, comes back once the bike is allowed to cool for a period of time Scenario: Trail riding on slow going rocky, muddy trails where the engine heats up more than a normal trail ride would get it. First gear rocky trail crawling type hot. Experienced the condition on Saturday during a two day trail ride. Saturday night replaced the following items. - Coil - Wire - Spark Plug Cap - Spark Plug - Condenser - Voltage Regulator Only Items I Can Think Of Not Changed: - Stator and Pickup - Flywheel Sunday morning, same issue, once the bike gets heat soaked there is no spark until such a time as the bike cools off significantly. Once cooled off the bike will run until such a time as it again gets excessively warm. One suggestion I have received is that the pulser coil in the stator could be the culprit. Is there a way to test this theory? I need to add a cooling fan to this bike, I'm sure there are posts about this and I will search but if someone has a link I would appreciate it. Thanks for reading, hopefully I'll get this figured out, the bike was fun to ride on the trails other than this pain of an issue. Thanks Joel
Forgot to add that I also changed the CDI box, or ignition module if CDI is the wrong term, on Saturday when all the other parts were swapped. Joel
Test the exciter coil by measuring the resistance between the black-red and red-white wires. It should be 12.7 ohms cold, +/-15% When the bike is hot, the resistance should go up by around 50%. Test the pulser coil by measuring the resistance between the red and green wires. I can't find a spec for that, so just measure it when it's cold and measure it again when it's hot. It should go up by about 50% too. Likely, if it's bad it will go completely open. Supposedly KTMs use the same pulser coil, and the spec for those is 100 ohms +/- 20 ohms, cold.
I have seen that exact issue (non-husky) and it was the stator pickup coil. It varies between running crappy when hot to not running when hot. Unless you can borrow a spare to try, you need to test the coil then get the bike hot enough to not run, then quickly test the coil again. Cam.
Wound up changing out the stator with a couple of "spares" that I had laying around. First spare, no good, bike didn't even try to start. Second spare, Woohooo, first time I touched the start button the bike fired right up. Looking at two spares that I have that I know are no good and the third one that was in the bike and stops working when it gets hot it looks like the coating on the pulser coils show signs of having been extremely warm at some point in their lives. All of these stators have been in motors that have been run long and hard on a roadrace track. What are the chances of rebuilding or having these stators rebuilt by another company? Seems lousy that they just get thrown away when this happens. Thanks Joel
You can rebuild the stators but you need to find a replacement for the pickup coil as those are special hall effect sensors and cant be fixed. There is a place in the UK that sells the sensors. Cam.
Do you think that it is the pickup coil that is damaged or do you think it is the pulser coil that is part of the stator that is the issue? Curious how I would test each of those items to determine what is the cause of the issue. Thanks Joel
So Did you read Jtrain's thread, I guess he also had a bad stator, so yours and his make 2 burnt out stators on big block bikes.
Yes sir, I saw the post you are referring to last week. Good read for anyone having these types of issues. Thanks for the heads up. Joel
