04 fe450 won't start.

OK so I've had this 04 fe450 since it was nearly new, 1200miles/70hrs. When I bought it the mains were gone but before that it ran great.
I stripped a rebuilt the engine back on 09 or something but never got it running before the bike went into storage and I went traveling.
Ive finally dug the bike back out and have been trying to get it going with no luck. So far I've tried.

Fresh fuel (it was dry).

Cleaning the carb and going back to factory settings with pilot screw and idle screw/knob, I've also tried everything from them both out by 1 turn right up to out by 3 turns, no go.
(Think the default is 2turns out on the idle and 1.5 on the pilot?)

Checked the valve lash/tappets, seemed good but set them again anyway.

Spark seems pretty good and plug is new, I've tried various plug gaps too.

I've ran a few extra earths between, coil, frame, engine and starter.

I've tried with and without choke or hot start, I've tried with an without a blip of throttle, with and without part throttle, I've tried every combination lol

One issue might be that I've not got a kick start, its been lost somewhere over the years and right now I can't justify spending £100 on one since Ive no work right now. So I've got car battery hooked up to the bike and the electric start seems to turn it over pretty good (it does spin a good bit faster with the plug out tho). It can spin the engine at pretty much the same speed with and without the manual decomp pulled so I'm assuming my auto decomp it working ok.

I've had some backfires, not all the time but occasionally, I think maybe even ones or twice out the carb.

The best I've had is when it sort of half fires, I had it doing it over and ove but just wouldn't come life.

I don't have an air filter at the moment ( in the mail), this wouldn't stop it running at all tho would it?

Any ideas? I'm pulling my hair out.

Yeah I've been reading every thread I find that seems relevant, been lurking for the last week or 2 reading and trying stuff.
Just finally had enough and thought it was time to ask, maybe someone cannspot something I've been missing.
My next thing is to check what voltages I'm getting while cranking, I've checked the resistance of the stator and it all seemed ok.

It seems so close to running when it does the half fire/hickup it hurts.

And I'll part the bike out before taking it to a mechanic LOL

I'm pretty sure I set all the timing up right while doing the rebuild but that's one of the next things I'm going to check.

Thanks

It has spark yes, I get about a 10mm spark using the old screwdriver in the plug lead test and a nice strong (I think) spark with the plug on the lead. I haven't checked the spark with the plug in as I've only got the one plug at the moment, I've got a spare on its way.

It doesn't fire pouring fuel into the carb, I'll check the carb slide gap but when I was cleaning the carb out I think it looked OK.

Slide is in the right way, timing is bang on.

Couldn't check the voltages from the stator as my digital voltmeter doesn't have peak hold and I can't find my analogue meter, I'll need to hunt it out.

All I'm getting is the odd pop and puff of smoke out the exhaust apart from that nothing.

Think I might have found the problem.
Tested my coil and between the HT lead and bkue /white seem OK at 5.9k (manual says 6.3k +- 1.2k) but with my NGK lead end on its upto 10k tested across just the end part and it reads the extra 4k on its own, surely that's not right?
Across ground and the blue/white I'm getting 0.1ohms (manual says 0.3 +- 0.05) so that reading is off.

Been doing a bit of googling and found out the plug cap should have about 4-5k resistance for noise suppression, so that's not a problem.
I don't really thing the low resistance reading between blue/white and ground should cause a problem even tho it is out of spec but I don't know where else to go from here.

Can anyone say for sure if a lower than spec reading on he primary coil would actually cause a problem? Anyone checked there coil before?

I know wish I had another running bike to try my coil on would save spending 30quid on a part I don't need . The 30 could go on one of the many bits I do need for the bike lol
I'm in Glasgow.

Thanks for the offer Taffy I'll keep it in mind.
I've got a few more things I want to try before calling it. The spark looks good!!!

I'm beginning to wonder if the e-start just isn't spinning it fast enough to get going and I don't have a kick start lever.
I would try bump starting it but right now I don't have a gear lever and the clutch isn't hooked up so might try 24v on the starter.

I just want the thing to fire then I'll not be so reluctant to spend cash on it (kick start!)
If I can't get it going without replacing expensive parts (not that the coil is expensive at £30 from KTM) that I don't know are broken I'm just going to break the thing for spares.

Its alive!

24v got her going. Think 12v just wasn't spinning fast enough, hooked up another battery between the solenoid and there was huge increase in speed.

After it fired up I hit the kill switch and connected up the radiator etc. So I could run it for longer, it dumped all the water straight into the oil lol

Now I know the thing actually runs I'll be buying one ASAP.