PVL - intermittent spark

[Rossvickicampbell]

I am a bit laid up at the moment and can't get to the bike as much as I wish - trying to fix another small problem which will then allow me to get onto the spark.  However did have a look at the plug cap and the connection between plug and lead is pretty ordinary so will also play with that whilst it is not going.

[kdx 175]

i have a NEW pvl on my ktm no spark al all its forked

[FourstrokeForever]

Have you made sure there is a bare metal earth and that the kill button wires are the correct polarity Russel?

[kdx 175]

i ran a wire from earth on pvl to plug cap back to motor there is one plug to connect you cant get it wrong 

[PEZBerq]

I hear that PVL's need a fair bit of cranking speed to spark. Some bikes have a low degree of crank rotation per kickstart swing and are not great PVL candidates. Do you get a full turn out of the engineer on the kickstart Russell?

[PEZBerq]

Russell try a non resistor plug, non resistor cap set up also.

[Freakshow]

take the cap off and let the bare wire jump to the motor, if its a new one i doubt its the PVL its more lickly the fitting.

[Brian Watson]

There are two different types of PVL.. one has more windings than the other.. one is meant for 125/20 and the other for Open class bikes.. so.. check the stator to the crankcases.. make sure all clean.. obviously coil to frame ..all good.. then take about 10mm off the end of the high tension lead.. make sure the copper is clean and visible.. should be all good Ross..

[Rossvickicampbell]

Watto - are you going Wednesday night?

[Brian Watson]

um.. yeah.. only if you are going to be there.. and Wilfred..

[Rossvickicampbell]

catch ya then........................if I get a pass out 

[ozktm]

I run PVL's on all my vintage KTM's. No issues.

1. I always run an dedicated earth wire from the stator backing plate to the coil/kill switch earth.
2. I have seen the wires that run through the back of the stator plate get pinched when mounted. I usually unbolt the stator off the mounting plates and reroute the cables so they don't run through the hole in the plate.
3. I usually buy a new NGK red resistor-less cap and solder on the HT lead. but my last bike i used the original cap supplied and haven;t had any issues.
4. Yes there are different number of winding stators, and got caught out with a second hand one off a go cart once. You will not start by kick starting...swapped out for the right number of turns, and it runs first kick. Also there are analogue and digital setups...

To test a used ignition, i have set them up in my drill press using a bolt through the rotor, and stator setup in the vice. Just to prove it works.

Earth wire on stator plate.

[Rossvickicampbell]

hopefully may have found the problem - "broken" wire between CDI and coil - was not 100% broken until I removed to check all the connections again - looks like an earth wire.  Will try and respade and join see what happens.  If I have to add some wire length any special wire needed?

cheers

Rossco

[Rossvickicampbell]

OK - CDI/coil earth wire fixed.........................and timing issue corrected - started second kick 

Who is a happy camper now!

[FourstrokeForever]

OK - CDI/coil earth wire fixed.........................and timing issue corrected - started second kick 

Who is a happy camper now!

And you managed all that without any Suzuki tool? Commonly known as a 5lb hammer