Spark for 2-3 seconds then nothing.

Bergenstein said:

I could really use some help and input. I am at a loss. I only have 80 hours on my 2010 570 FE and am the orginal owner. I am having starting issues after a river crossing. The details of what I have done are below.

I broke it all the way down to check clearances, piston wear, crank, etc. everything is within spec. I replaced fuel pump as in the past it has always been the pump. hindsight I Should've checked the spark first.

checked V at the plug, new plug, ignition coil, pulse generator, All tested fine prior and after. I just wanted to rule out any issues.

After reading on the forums, I checked and cleaned the wiring harness for broken or split wires. cleaned and dielectric greased all the connectors, checked fuses. Cleaned ground and checked all the wiring plugs for V and Ω according to the manual. I am only getting spark for about 3 seconds. I even tested the CDI unit for the pulse generator according to one of the forum posts. Talked to the mechanic at KTM and he said he is at a loss and he doesn't think it is the CDI.

Why am I getting spark for only 2-3 seconds and then it quits. is there a setting in the CDI that does that? Ive never run into that before. If I had an extra CDI Id just change. and test and see if that was the problem. As you know they are very hard to come by. I have been looking at aftermarket ones as they don't make them anymore that I can find, but it has been really hard to find any. where everything is mechanically sound, and Ive tested everything electrical, it seems like that is the only thing it could be.

I am in the process of putting it back together today to try to pull start it tonight and see if maybe it just needs to reset somehow. I am sure I missed something or some test so I am just reaching out to see if anyone has anymore ideas.

Thank you in advance for any guidance.

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AussieBlue said:

I'm no expert. Have seen stupid things like sparkplug connector losing contact with wiring from coil or kill switch earthing somewhere

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Bergenstein said:

Thank you. It is a new wire with the ignition coil and a new plug. it seems to get power and completes the circuit. I just cant figure out why it is stopping the spark.

I will check the kill switch. maybe it is just grounding or engaging and killing the spark. I swear I have gremlins in there somewhere, .

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ManitouMoto said:

My mechanic and I are in the same boat (2011 fe390 ) in this case no spark no fuel injection codes. All components including ECU, CDI, stator coil, stator pickup, have been tested for voltage and resistance and also have swapped all electrical system components with known good units. We have opened up the wiring harness to check for splice connections that all look good. All connectors have been cleaned and Dielectric greased. Kill start switch has been checked, spark plug wire, coil, spark plug boot Etc. We are at the end of our rope and may have to just replace the wiring harness and hope for the best.

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Husacheeseburg said:

I had a similar issue with my FE 501. Turns out it was a faulty Rollover sensor for me. As far as I know when the sensor gets triggered it cuts fuel pump, injector and ignition coil off.
If you haven't already, I would unplug the sensor and see if the bike runs. Bike will run without the sensor but will throw a FI fault code. This code will go away when you plug a sensor back in. Good luck!

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