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03 fe400 decompression issue?

Joined Apr 2004
13 Posts | 0+
B.C. Canada
Hey guys, its been a long time since I posted on this site, I always lurk and find the answers I need. I have an 03 400 fe with 115 hours of hard riding, with no problems until now.
It started with a tapping at the front top of the head, assumming it was the auto decompression cause it just tapped for a second and went away right after starting, A KTM dealer let me know that most of their bikes do it too. So I have ridden it lke that for 6 hours and then 2 days ago after starting up fine, 15 minutes of riding, loss of power, no start off the button, and kiccking it using manual decompression, it fired up, rode fine for 5 minutes, once I idled down it stalled, wouldn't start again. It would fire up if I bomb started it(coasting popping clutch) but would only run if the rear wheel was keeping the compression going, pull in the clutch and it would stall again.
Its in the shop now, since I tried looking at things and it doesn't make sense to me.
Does it sound like I am on the right track? Maybe an exhaust valve stuck open, do to a decompression issue?
If your bored, let me know what you think.

Oh ya, Thanks to BOSS for the two sets of rad guards shipped up to Vancouver, I have already tested them out.
 
I don't think its an autodecompression issue. The device weight is located inside the cam sprocket and is spring activated. Once the motor spins up after kick starting the weight and spring work against centrifugal force and is easliy deactivated.

A broken valve spring would not be unheard off.

A new stator is probably in your future also based on age and hours.

Let us know what happened.
 
Valve springs looked fine, stator had a lot of rust on the contacts...neglect after cleaning on my part. I cleaned them up a bit, but no luck on the restart. I will post the results after the shop finishes up with it.
 
Firstberg,

At 115 hours you are due for replacing the rocker arm cam follower roller bearings.

When they start making noise like that they start puking needle rollers and sliding on the cam journal and that will ruin the cam etc.

You might as well replace the cam bearings, cam chain, cam sprocket and chain tension blade with the newer model parts while you are in there.

Regards,

Joe
 
Valves were tight, but everything is still in good shape, leak down was good. The issue now is the stator, it just happened to fail at the same time I was having valve/decompression issues(or so I thought).
Thanks for the input guys.
 
JoeUSA said:
Firstberg,

At 115 hours you are due for replacing the rocker arm cam follower roller bearings.

When they start making noise like that they start puking needle rollers and sliding on the cam journal and that will ruin the cam etc.

You might as well replace the cam bearings, cam chain, cam sprocket and chain tension blade with the newer model parts while you are in there.

Regards,

Joe

My '03 400 has just surpassed the 100 hour mark as well. I'm getting ready to dig into it to replace some wear items and was wondering about the cam chain and slider. If I put in an '05 chain and slider are there any mods needed besides taking the end off the of tensioner arm?
 
oooh good question cause mines done about 130 hours and the stator is dead so I might as well sort the rest out in one hit.
 
I am putting the stator in at the end of the week if it shows up in time, and ride it until the snow flys here, then its tear down time.
 

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