1. Ignition Coil Failure: The ignition coil is responsible for generating the high voltage needed to create a spark at the spark plug. A faulty or damaged coil can lead to intermittent spark or complete loss of spark. Check the ignition coil for any visible signs of damage or corrosion, and test its resistance using a multimeter.
2. Spark Plug Wire: Inspect the spark plug wire that connects the ignition coil to the spark plug. Ensure it is properly seated on both ends and free from any damage or cracks. A damaged spark plug wire can hinder proper electrical flow and result in a loss of spark.
3. Spark Plug Gap: Incorrect spark plug gap can affect the ignition process. Check the gap between the spark plug's center electrode and the ground electrode using a feeler gauge. Adjust it if necessary to meet the specifications provided in your bike's owner's manual.
4. Kill Switch: Verify that the kill switch on the handlebars is not accidentally engaged, as this can instantly cut off the spark. Ensure it is in the "Run" position.
5. Electrical Connections: Check all electrical connections related to the ignition system for any loose, corroded, or damaged wires. Ensure that all connectors are securely fastened.
6. Ignition Module/Stator: If the ignition coil, spark plug wire, and spark plug are all functioning properly, the issue could be related to the ignition module or stator. These components are responsible for generating and distributing electrical power to the ignition system. Diagnosing and repairing issues with the ignition module or stator may require professional assistance.
Since you mentioned that the spark plug sparks on a different bike, it is less likely that the spark plug itself is the problem. However, if the other bike uses a different ignition system or spark plug type, it's still possible that the spark plug is not compatible with your KTM 520.
If you are unable to identify or fix the problem on your own, it is advisable to consult with a qualified motorcycle mechanic or refer to your bike's service manual for further diagnostic and repair instructions.
