Dt125 RE DE06 no spark

[StallO.one]

Hi together.

I'm not getting a spark on my dt 125RE DE06 (2005).

So I was doing a short trip to a car dealer and everything was pretty normal. But when I wanted to return home the bike turned on normal but turned off directly. After 1h trying to start it again I finally made it home. During this hour it turned on every now and then but always died immediately. Approaching my house I decided to do some rounds between two roundabouts where everything appeared to be fine till it died directly in front of my house. When it died I was on the gas exiting the roundabout. So it died the last time with some revs like maybe 2000 - 3000.

After that I've checked and or exchanged several things:

First I checked and finally exchanged the spark plug. I tried a standard BR8ES and one iridium BR8EIX.

Then I checked the ignition coil and the spark plug cap. All seemed as described in the service manual. Then I ordered a new one.

After that I checked the interlock line, all switches the stator coil and the pickup. All readings from the multimeter in the tolerance described in the manual.

I found one pin bend in the plug from the kill switch and the red battery pin was also looking bad so I thoughts that's it and I bout a crimp tool and replaced the pins.

But guess what, still no spark. So I checked the rest of the harness and I found the harness coming from the CDI going under the seat being a bit flatted from the seat. So I thought that's the issue. So I took out the harness and checked each cable from continuity. But that was also fine so I also checked all wires with 3Amps of load measuring the voltage across to check for higher resistance. Still everything seemed fine.

Before buying a new CDI I decided to measure the outputs of the stator, pickup and the orange cable (CDI) against mass with an oscilloscope. The stator and pickup signals looked fine to me but maybe they are to low?

Pick up looks like one negative followed by a positive pulse with a 5v peak each (10vpp). The stator signal looks like Sinus with 30v peak (60vpp). Both were measured open with the plugs unplugged. The CDI output looked a bit off to me. A negative pulse cut off at -18V and some ripple with the stator sine frequency. More like spikes.

Does anyone know how it should be? I could provide the images of the measurements once I found out how to upload them.

The CDI signal looked bad enough to me to order a zeeltronic PCDI-10VT. But guess what. Still no spark.

So now I'm pretty much clueless what to check more. Any suggestions?

[Calum]

Oh that's frustrating.

There really isn't an awful lot to these engines. I've never heard of a stator go bad. I've had a bad ignition coil and I've had an aftermarket (bike sadly got stolen from me) ignition barrel disintegrate and cause this problem.

A common one is the side stand switch, similarly the neutral switch and the DTRE has the clutch switch.

Check the plugs from the ignition barrel to the wiring loom as they can have a tendency to trap water and destroy the connections.

Did you say whether the engine is healthy or not? Is it making a good PSI? Are the intake and exhaust pathways clear?

[StallO.one]

Hi, thanks for your reply. The side stand sw and the whole interlock chain should be good. I even bypassed all of that by grounding the blue yellow wire to the CDI directly.

The crimp contacts of the orange and black cable to the ignition coil is also new (forgot to mention).

I have nothing to measure the compession. But the engine was always making good power. Also just 1min before it died. I mean in the end is bad compression not preventing spark or am I mistaken?

Edit: Water issues could be excluded. I live in South Spain and if it rains two weeks per year that's a lot. And I never drive in wet conditions. I also never really wash it with lots of water.

The only other thing I realized ove the past year is that I needed the choke to start it more and more. But it was always perfectly running after 1min driving. So I thought it could be something like weak spark issue. Like something died over time till it's finally dead.