[augiedoggie]

Hello and welcome. You may find the XC or SX stator will work. Your bike doesn't need charging or lighting coil. Hope you checked your spark plug resistor cap first. They can give a no spark.

 

[augiedoggie]

Rattle gun will work fine if used with care. Do not attempt rotor removal without correct tool. Do not install rotor bolt/nut with rattle gun unless you use it very carefully. Don't rattle the pizs out of it a few braaps is plenty tight.

 

[augiedoggie]

A few afterthoughts. Be sure to oil puller threads and thread puller into rotor by hand. You can apply pressure on puller screw with careful use of rattle gun in short bursts. If it fails to remove rotor easily,STOP. Apply moderate pressure to puller screw and give the puller screw a few sharp raps with a hammer. You are only trying to set up a vibration, not beat it into submission. A handful of sharp hammer taps with a quick braap with rattle gun in-between hammer taps should send rotor flying across workshop for you. If it's a real bitchy removal, you can use a small propane torch to heat rotor center while puller holds tension on rotor. After heating for a minute or two increase puller tension and give it another hammer tap or 10. Check back as needed for assistance

 

[augiedoggie]

Resistance test should tell the story. Inspect wires where they enter stator for breaks or damage to insulation. Factory shop manual has resistance values for your tests. Stator can test good on bench and fail once engine is warm and thermal expansion inside causes a no spark. I have used several of the generic Chinese stators from ebay with good results. The factory KTM stators are fairly expensive.

 

[augiedoggie]

Windings expand with heat. Potting epoxy helps control expansion

 

[augiedoggie]

Nope. Those are the alternator windings. They run hotter.

 

[augiedoggie]

Sorry. I own 6 torque wrenches and seldom use them unless I'm trying to impress my friends. I oil threads and put tiny tiny drop of locktite on oiled threads and give er a few quick raps with the rattle gun. My torque wrenches are mostly for decoration and critical torque stuff. Triple clamps, suspension parts and engine case fasteners get torqued to spec. Everything else gets tightened by feel. Flywheel gets a light rat a tat tat with rattle gun. Don't much care what anyone else does. My stuff goes together and stays together for a long time