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magnumsmydog September 20th, 2017 03:09 PM

2009 fe390 weak spark spark falling off
as the title shows, it will once in a great while just pop or idle for just a second then die, what has been done...

new computer, pickup coil, stator, rectifier/regulator, anti gravity battery, fuel pump is running, new main relay. wiring found lots of bad connections and wires all fixed and rerouted, went through harness again found nothing. all the related issues have been fixed and addressed. any thoughts im about at wits end with thing.

Rainerio September 20th, 2017 05:30 PM

Try pouring A little fuel into the throttle body and try running it. If you can keep it running this way then it's fuel related. Check all fuel filters 4 of them , spray of injector also fuel pressure regulator

magnumsmydog September 20th, 2017 06:47 PM

failed to mention swapped coil with no change from a running bike, also everything fuel delivery related is new including filters and all, spark plug is new, i'm not real familiar with this fuel injection system and wondering if any sensors would cause this. also no flashing errors from light. and timing chain redone before it slowly died.

magnumsmydog September 20th, 2017 06:48 PM

still intermittent if primed with fuel

magnumsmydog September 21st, 2017 02:53 PM

so after doing my due diligence and testing sensors for hours and troubleshooting i have found that i have continuity between ground and input of ignition coil....could this be the problem

nsman September 21st, 2017 05:24 PM

no fault codes?
New stator or a rewind...?

magnumsmydog September 21st, 2017 08:02 PM

wss not a rewind just new, my thoughts at first was oil coming in was grounding out stator....i could be wrong so i ordered new one from dealer, still confused about the continuity of input and ground on the ignition coil....... puzzled

jon andersson September 21st, 2017 09:18 PM

What happened before the bike started to act up? If I understand right you cant start it now?

nsman September 22nd, 2017 03:23 AM

should be a small number between the plus and minus poles on the coil usually .5 ohms

Uncaged September 22nd, 2017 05:08 AM

Did u check the spark plug boot? They are known to gap where the boot pushes onto the wire, symptoms you describe

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magnumsmydog September 22nd, 2017 04:20 PM

the bike just started cutting out and slowly got to where it just wint run it will hit once in awhile and run for a second once in awhile other than that weak weak spark then spark dies if u keep cranking it after 5 seconds

magnumsmydog September 22nd, 2017 04:21 PM

the ohms were right on the coil but it also has continuity between the ground and voltage input

magnumsmydog September 27th, 2017 05:52 PM

well thanks to you all i feel as if im nearing the end of a year end battle. i have found the plug boot and wire are definitely letting it arc all over and while cranking and twisting boot it fire more often. next on the list is i think thier is a fuel problem as im not seeing any mist in throttle body while cranking. the fuel pump had been replaced with a factory one long ago. i hear it whine but not putting out much pressure. tomorrows goal is to diagnose the fuel system and hopefully get it squirting gas. :eek:

jon andersson September 28th, 2017 09:05 AM

If you open the throttle to see the spray the ecu cuts the fuel. It will only give fuel with closed throttle when it's not running.

magnumsmydog September 28th, 2017 10:00 AM

just keeps getting more complex haha, but i sure love a berg when its right

magnumsmydog September 28th, 2017 05:10 PM

guess i should start by setting tps

jon andersson September 29th, 2017 01:27 AM

Yes tps is good to check. Did you change the sparkplug and sparkplug boot?

magnumsmydog September 29th, 2017 02:05 PM

just picked up new coil and boot today

magnumsmydog September 29th, 2017 02:06 PM

and plug is new

fe390vt October 4th, 2017 04:06 AM

No spark
Sounds to me like your tps is fried. Know anyone with a fuel injected ktm? Swap out tps. You will need a multimeter to reset, but should work regardless.

As previously stated... bad plug cap, sometimes bad plug wire. Plug wire can arc to rads if damaged. Test: turn off lights off in garage, spray water around plug wire, start, you will see it arc. Bike will run poorly or cut out during water crossings. I have also had to snip off part of wire where it meets cap because of rusting. You ride alot of wet stuff?

fe390vt October 4th, 2017 04:14 AM

Just make sure tps is connected. Because of its position it is pretty hard to get the connector on. You need to hear an audible "click" when it connects.

magnumsmydog October 4th, 2017 11:20 AM

1 Attachment(s)
i dont have anyone to borrow tps from. but today i started to check fuel delivery after wrestling the fuel pump and lines i found the filter to be black along with the fuel in the system.

magnumsmydog October 4th, 2017 11:21 AM

im thinking maybe from the plastic lines

magnumsmydog October 14th, 2017 01:02 PM

well ive installed a new intank fuel filter and ca cycleworks pump kit, cleaned injector and tested it with it out of the throttle body looks like a great mist. still noticing weak spark and the spark quitting intemittently it did actually start and run for a second or two with choke pulled out.

magnumsmydog October 16th, 2017 03:13 PM

has anyone seen where if bike sits for a period of time will run and have bright spark. but as soon as oil starts pumping into stator area it loses spark and spark gets very weak?

magnumsmydog October 22nd, 2017 05:59 PM

Another update on the berg, the new tps came in yesterday and I installed it today, set it to .603 it ran longer than it has in a year but was still only about 5-6 seconds, still losing spark after it ru s

nsman October 22nd, 2017 06:17 PM

Was the new stator a OEM unit or a new aftermarket?

magnumsmydog October 23rd, 2017 06:42 AM

Oem ordered through dealer

magnumsmydog October 23rd, 2017 02:24 PM

All three stator I have " two old and one new all oem ohm out at .7 across all three gray wires. Bike is acting and smelling like it's flooding out but then starts backfiring, maybe flywheel woodruff key?

magnumsmydog October 23rd, 2017 03:33 PM

Checked key it is alright

magnumsmydog October 23rd, 2017 03:36 PM

Think tomorrow I will pull valve cover and see what I can find

jon andersson October 23rd, 2017 09:20 PM

This is interesting. Been following your thread since start as I'm curious too see what the problem is.

magnumsmydog October 24th, 2017 03:31 PM

I took the fuel assembly back out and appears the return line from regulator was kinked I don't know if that will cause an over pressure flood and starve the pump bucket at the same time.

nsman October 24th, 2017 06:33 PM

Sort of confused.
Have you actually determined that you have a no spark condition,?Have you done a spark strength test ? Have you watched the spark go away on your timing light when it runs?
If you do have a spark problem then chasing fuel problems will not be a fix.
One thing at a time..;)

magnumsmydog October 24th, 2017 07:30 PM

I never thought about hooking up a timing light while it runs that's a good idea, I just wanted to double check fuel tank components while I had tank unhooked just to be positive it was all good.....thanks for the idea nsman will try that tomorrow.

magnumsmydog October 26th, 2017 02:12 PM

Ok so tonight the fuel system is done I had injector cleaned and tested and I'm running a steady 52 psi with the cycleworks pump kit, I bought an inline spark tester and hooked it up to my jaw it hits with a very bright burst of light every time. I hook it up to the berg and every now and then it's bright other than that it is dim but constant. So I'm getting weak spark and only thing that hasn't been replaced is the ecu, bought to just take it to the dealership and be done if no body has any ideas

magnumsmydog October 26th, 2017 02:13 PM

Kawi not jaw lol

magnumsmydog October 26th, 2017 03:03 PM

Another update I pulled the plug on the ecu to tighten up connectors and noticed the coil wire pin was still in the plug and in the ecu nothing but a semi-melted hole where it used to a search for another ecu.....

jon andersson October 26th, 2017 09:31 PM

Ok, atleast you found a definite problem! Now the question is why it melted..?

Rainerio October 26th, 2017 09:38 PM

Check all connections for being loose or corroded , exposed wires maybe grounding before you put in an other ECU. Good Luck

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