KTM Duke 125 - Battery not charging, Diagnosis and repair!

My son bought a KTM Duke 125 for spares or repair. It was a non runner.
He managed to get it running, but it doesn't appear to be charging the battery when running.
Come with me as we diagnose the problem and repair it!
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#ktmduke #electronicsrepair #ktm
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[@johnmolnar2957]

I just started watching your videos a few weeks ago. I truly enjoy them all. I'm amazed at some of the stuff you figure out. glad to see the young lad is buying stuff that needs fixing instead of all new like so many do nowadays

[@BuyitFixit]

Thanks very much for your kind words John. Much appreciated 👍

[@francoisg9154]

I'm very happy to found your video about electric diagnostic. Thanks to share your experience.

[@BuyitFixit]

My pleasure

[@Mymatevince]

Nicely done Mick 👍

[@BuyitFixit]

Thanks Vince.

[@ralphj4012]

Well done, person of many talents. As well as being burnt the stator looked very oily, which struck me as odd.

[@BuyitFixit]

Thanks Ralph. Yes I thought it was odd too. I did do a search and it seems it's normal.

[@Arachnoid_of_the_underverse]

@@BuyitFixit Its probably leaking slightly through the shaft oil seal on the casing.

[@BuyitFixit]

Thanks Andi, I'll let him know.

[@wisher21uk]

No end to you’re talents thanks mate 😊

[@BuyitFixit]

Thanks Cucumber man! Yes I'll have a go at pretty much anything!

[@wisher21uk]

@@BuyitFixit good on you 😁

[@briancalvey4997]

Satisfying to watch. Thanks.

[@BuyitFixit]

Thanks 👍

[@UserUser-ww2nj]

Great fix but that engine sounds rough . Someone said that there should be oil around the stator for cooling , that is wrong , it should be oil free . That bike needs a good going over and tune up , hope it works out for your son

[@BuyitFixit]

Thanks 👍I'm not sure if he got bored and sold it since 😂😂

[@nathanw851]

Have you got in to banking? Just wondering why there's a bale out in the background.

[@BuyitFixit]

Lmao. Unfortunately not, and seeing as it's indoors it's more of a 'bale in' 😂😂😂

[@ralphj4012]

Make hay while the sun shines.

[@BuyitFixit]

Lol

[@Wil-q2p]

Voltage regulator is out or the generators out

[@MrEwool]

Great looking motorcycle, and really enjoying all the different types of videos you make, I learn something new every time. Could you perhaps show us the motorcycle when he's finished with it

[@BuyitFixit]

Sure, although I'm not sure how popular that would be, even this video hasn't been too popular :(

[@MrEwool]

@@BuyitFixit that's what's wrong with KZbin sometimes, not being able to do what you want

[@BuyitFixit]

We'll I'm trying to make a channel that's helpful for people to repair stuff or sometimes interesting electronic hacks or teardowns. Next video is a tear down of a weather balloon a farmer friend found in his field..

[@MrEwool]

@@BuyitFixit that's sound like a interesting video hope it's not one of those from America hehe

[@sp523]

Great video! I enjoyed watching.

[@BuyitFixit]

Thanks SP! 👍

[@MattBrownbill]

Nice to see you away from the 'healing bench'.

[@BuyitFixit]

😂😂😂

[@f64k74]

Was there oil inside the stator case? I have the same problem on my duke 125 and it is probobly the stator and wondered do i need to drain the engine oil before opening the case.

[@BuyitFixit]

There wasnt any oil in where the stator was. Not sure if that's normal though..

[@f64k74]

Alright i need to check mine

[@Stryker-qw4bp]

I believe that it's normal to have oil in there. The oil cools the stator I believe. You can best give a KTM dealership a call and ask them to be completely sure but I know it's the case on my Suzuki motorcycle. Nice and interesting video nonetheless!

[@BuyitFixit]

@Stryker-qw4bp Thanks for that and Thanks for commenting.

[@Rahul.patel48]

Yes we need to drain the engine oil before opening The case.

[@MechanicsDIY]

so fare so good but long term ... here is some important notes 1 the stator bolts need locktite . - vibration can get them to loose free 2 the top stator wires port leaks oil with the non oem part (need to be seald ) 3 the voltage regulator and stator need to be replacet at the same time , if not it can burn again after 1- 3 month of use it might last longer but it will not last . 4 change your engine oil + oil filter and coolant .. so the engine will not overheat and coock the new coil

[@BuyitFixit]

Thanks for that 👍 I'll pass that info onto my son as he's taken the bike away now. I think he was talking about replacing the seal behind the stator as it seemed to have a bit oil in there.

[@MechanicsDIY]

@@BuyitFixit the overall repair was quite good . thees small details help the long term . the chineese stator dose leak from the yellow wires port

[@BuyitFixit]

@@MechanicsDIY Thanks Mechanics DIY 👍

[@Rahul.patel48]

Why would one replace the RR unit if its working fine.?

[@terjanin]

When measuring the regulator, I had voltages of 0.6 0.4 0.6, I changed the poles and the middle one had 36MOhm, should I replace the regulator?

[@BuyitFixit]

Been a long time since I looked at this, I'd first check the stator windings are ok, if not then the regulator is the likely culprit

[@wherami]

Thank you for this

[@BuyitFixit]

No problem j s!

[@richardtaylor7199]

Well done Dad, who paid for the new stator? Don't answer that.🤣🤣🤣

[@BuyitFixit]

😂😂😂😂👍

[@ibrahimkocaalioglu]

good job

[@BuyitFixit]

Thanks 👍

[@fredwooding599]

Is there anything you won't fix ??

[@BuyitFixit]

Just bike intercoms 😂😂No seriously I'm going to look at that next. I was editing my latest video until 2AM last night so I had something to put out today, didn't get to sleep until around 3:30am, up at 7:30am and then at the repair cafe all day. Then I got a call from a good friend asking for help with a car that had a problem with the crankshaft sensor not working after he replaced the engine. The CS sensor was a 2 pin and the one on the original engine was 3 pin. I did wire it up to the ECU the same way as the original engine and then it showed other faults. That turned into replacing the ECU, clocks, BCU, and key transponder from the donor vehicle as it turns out the engine was slightly different. I only just got back about an hour ago and now it's midnight.. and I'm replying to YT comments...

[@Wil-q2p]

The stater coil?

[@BuyitFixit]

Yes, or generator if you prefer (from your previous comment) 👍

[@599miata]

Nice job !

[@BuyitFixit]

Thanks mate👍

[@secretsix6]

an easy way to test the stator is to start the engine an test the voltage between any 2 yellow wires working through them all they all should output roughly the same voltage

[@BuyitFixit]

I thought I had done that, perhaps I accidentally edited that bit out. I remember there was an AC voltage but it didn't seem quite right.

[@Rahul.patel48]

All three wires AC output should be the same??? In my case, two wire output is going up to 120 as rpm increases bu one wire show 80-90v. Battery is not charging I replace new bAttery. What do i do n0w?

[@Kevin-us7jc]

How much should the reading be then ?

[@secretsix6]

@@Kevin-us7jc it depends on how fast the engine is revving but they all should be the same'ish voltage that's the main thing

[@simonrawle7885]

A quick way to call a bad stator is to the coils to the case. Kawasaki want you to do this with a test light. But a multi meter as never let me down

[@BuyitFixit]

Thanks for that Simon 👍

[@Rahul.patel48]

Why stator coil burn?

[@BuyitFixit]

Could have been a faulty rectifier. I think the previous owner may have changed it before my sone got it.

[@woodywoodbridge8669]

Why would you not put something under the cover! Look at all the scratches in the paintwork!!!

[@BuyitFixit]

Yes very good point. I really should have, but I guess we all learn from our mistakes.

[@woodywoodbridge8669]

Can’t lie, we have all been there.. only once though :)

[@garyhart6421]

Sounds quite meaty for a 125.

[@BuyitFixit]

Indeed! 😂😂

[@snipersquad100]

It probably burnt up as there was no oil in there. It probably won't last that long either if you didn't put any in.

[@BuyitFixit]

I'm not sure about this particular engine, but I don't think I've seen them submerged in oil. For instance your car alternator isn't. I don't think he has it now as I think he sold it.

[@snipersquad100]

@@BuyitFixit"I think I was mistaken. I now believe that there is a jet that sprays oil around the cogs, which comes from the other side, and then the oil makes its way back to the sump. I was just wondering, as there seems to be an oil fill cap on top, and what other purpose could the gasket be serving.

[@BuyitFixit]

I'm no expert, but perhaps the gaskets are to keep dirt and debris out. I could totally be wrong on this. I'd probably have to download a service manual to be sure. Seeing as he hasn't got it anymore I'll just leave it as a mystery 😂👍

[@kennybacchus1488]

KTM. Duke. 125. Battery. Not. Charging. Diagnosis and. Repair!