Motorcycle Repair: 03 ktm 125sx replaced stator generator, idles then backfires and dies., ktm 125 sx, stator coil


Question
Hi thanks for doing this by the way, i thinks its awesome your helping out us motor junkies for free. So i recently drove my ktm 125 sx into my shed after it ran great for a few hours, let it idle in neutral, held the kill switch til it died just like always, and everything was usual. a few days later i went to fire it up and it wouldn't start. at all. I tried roll starting it and after that didn't work i figured i somehow fowled the plug, even though it had just been sitting (locked in a garage btw, none of my friends went for joyride). i replaced the plug, and still nothing. so i grabbed my spark tester and realized i wasn't getting any spark. I pulled out my om meter and did some testing: the killswitch wasn't stuck grounded, i was getting a charge through the stator coil (even tested later with a different one and it didn't change anything), i was reading current through the cdi and once i pulled off the ignition cover and tested the flywheel magneto, i was reading a pulse each time the magnet passed and could feel the piston at tdc. so i pulled off the flywheel and got to the stator generator behind that and as i tested the wires that run from each side of the wire coil, i wasn't getting a connection. So i replaced the stator generator with one that was supposed to be an enhanced stator generator for my bike with an upgrade to power a 50w light as well. Once i put it in, the bike fired up after a few kicks, and idles fine. once i give it gas, it hardly revs, eventually backfires and dies. i thought it was timing and fooled with the adjustment on the new generator, just shifting it left and right. it would sound a bit different but not by much, and would always still backfire and die. i drove it slowly a couple times just to make sure i hadn't retarded the timing so much that it was running in reverse. Could it be that this stator generator is bad for my bike? Thanks a lot, really appreciate the help.

Answer
Justin, This is one of those cases that can really burn you. Its possible that the stator is not compatible but it sounds more like the CDI is maybe getting ready to go south on you. Even though when you shut the ignition system down it really just grounds the coil so that the electricity goes to groung by the easiest path. The plug still shows its got spark but could be misfiring then fires at the wrong time to give you the back fire. Also on the lighter side it could even be the reeds,one of the petals could be sticking and does not seal all the time. I dont think its the stator this time as you have replaced it and the problem is not totally solved.