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I replaced the original stator assembly of my 1992 KDX with a stator from a 2005 model. I know the part # are different but they look exactly the same except for the timing marks. I am missing something ?
It has spark, but doesn't start.

Try to center the screws in the holes. The timing is probably off.

you should be okie. i install a 2006 kdx200 in my 1993 kdx. works great. it got to do with the stator timing i guess.

At least now I know it has been done. I am still using the stock 1992 flywheel. I changed the timing to the center mark of the stator. Still no start and a constant wet spark plug sindrome. When the plugs are dry it shows a good spark. I have this bike since new and worked out the worst river drowning you could imagine with some kiking but nothing like this.

Try bumping it?

I bumped it with my truck, it did not respond.

Try going to the other end of the holes?

Is timing that critical? At least it should sputter or kick back and I did not get any on the three positions. I can put a timing light on it but the flywheel don't have a mark to match the one on the case and in the service manual there is no mention of this procedure.

Maybe it is getting too much gas? The timing light might give you an idea if it is getting spark once the plug is installed. Maybe a bad plug wire that is loosing connection once the plug is installed? Why are you replacing the stator?

The original stator stopped working. Close inspection showed nothing. It just didn't spark. This one looks new and sparks ok.

Cturbo wrote:Is timing that critical?

Yes, it is extremely critical.

Cturbo wrote:At least it should sputter or kick back and I did not get any on the three positions.

Not necessarily. It depends on if the timing is that far out. BTW, have you tried a fresh plug?

The three timing marks on the stator seems to be in a different place by a couple of degrees in comparasion with the stock one. It is my guess that they calibrate the marks once the coil is mounted on the stator to compensate for stator casting or other variances. A poorly made stator will move your timing enough to cause probems. I know this from a previous experience with an aftermarket stator. I am using new plugs. When they get wet, I clean them with solvent and test them on another bike. That make me notice that the KDX has a weaker spark than my other bikes. I can't jump a spark more than 3 mm by kick. I don't remember it been so weak before.

it might be jetting or CDI problem?

I tried anoter coil and the spark still week. Tested the Cdi with a multimeter and the readings were all wrong. It was reading ok a year ago when I tested. I know what has been said of the good reliability of the KDX cdi on this site, but there is some logic on the way the bike is behaving. Is there an alternative beside a old used or old new stock one? Will an H series cdi work?

yes an hseries cdi work well on the e series. i have used it on my e for a few years with no problem.

I preffer to use a newer model electronics for reliability reasons.

Update: after changing the CDI for one from a running 1993 KDX the bike has spark and started at the first kick.
Yes, KDX CDI's do go bad.

Glad you got it sorted!