1996 KTM 620 RXC dying problem

RXC620 · Apr 23, 2008

Hello I am new here so be gentle...

I know this is not a Husaberg bike, but you all seem so knowledgeable with bikes, I thought I'd give you all a try... hehehe

O.k. here goes,

I have a 1996 KTM 620 RXC LC4 bike with a dying problem, I fire the bike up cold and it fires right-up usually two kicks sometimes one. I let it idle for two minutes, then I ride it around for awhile, then all of a sudden when idling the bike dies. I kick and kick but nothing. After about 10 to 15 minutes I kick it again it starts almost right away. it has done this to me about six or seven times already and when it dies I don't sit there a kick I wait again almost the exact wait time as before it will fire right-up.

I spoke with my mechanic, and he say's the SEM stator that I have is going bad, I read on this forum that there is a certain guy who fixes the flaws of the stator. So I spoke with him and he confirms the issue. I send the stator to the guy; he fixes it and sends it back to me. I install the stator perfectly and I fired up the bike, it took a lot of kicks, but finally started. I drove it around and it started doing it again, same problem as before fires-up cold let it idle for little bit drive it around shuts of when idling. 10 to 15 minutes
Fires right up.

I can't find why it is doing this, I checked the gas, its brand new gas, the filter is brand new as well, and all the hoses are brand new. I have a new FCR 41 on the bike.

PLEASE HELP!!! 8O 8O

Thanks
-RXC620

sparks · Apr 24, 2008

RXC620 said:
Hello I am new here so be gentle...

I know this is not a Husaberg bike, but you all seem so knowledgeable with bikes, I thought I'd give you all a try... hehehe

O.k. here goes,

I have a 1996 KTM 620 RXC LC4 bike with a dying problem, I fire the bike up cold and it fires right-up usually two kicks sometimes one. I let it idle for two minutes, then I ride it around for awhile, then all of a sudden when idling the bike dies. I kick and kick but nothing. After about 10 to 15 minutes I kick it again it starts almost right away. it has done this to me about six or seven times already and when it dies I don't sit there a kick I wait again almost the exact wait time as before it will fire right-up.

I spoke with my mechanic, and he say's the SEM stator that I have is going bad, I read on this forum that there is a certain guy who fixes the flaws of the stator. So I spoke with him and he confirms the issue. I send the stator to the guy; he fixes it and sends it back to me. I install the stator perfectly and I fired up the bike, it took a lot of kicks, but finally started. I drove it around and it started doing it again, same problem as before fires-up cold let it idle for little bit drive it around shuts of when idling. 10 to 15 minutes
Fires right up.

I can't find why it is doing this, I checked the gas, its brand new gas, the filter is brand new as well, and all the hoses are brand new. I have a new FCR 41 on the bike.

PLEASE HELP!!! 8O 8O

Thanks
-RXC620

Hi Jason, I have replied to you on email possible causes, but I want to get one thing straight here, do you remember the mail I sent you saying your stator has turned up OK

Picked your ignition up from the post office this afternoon and it looks like it's had a bit of a hard life to say the least but it is repairable. Regarding the gasket you require I don't stock this kind of thing, main agent job.
Should get around to starting it early part of next week.

The test on the stator between Red and Black was Zero so I can't see how it was running before you sent it in plus the phisical state most of the plastic had come away as though water had got in frozen and blown the plastic covering.
Hence the words in my email reply.

I would say your problem is carburation or possibly valve clearences.
Not to say that it could be a problem down to me but I run all my rewinds under various conditions and speeds before sending them out.

Is the carb you are running standard to the bike or is it an after market one you have aquired, if so what did it come off which model of FCR is it and how old, what are the internal settings.

Sorry to be so out spoken but I have already taken a bit of a kicking in the last two weeks.

Regards

Sparks.

whosahberg · Apr 24, 2008

the only reason you have taken a kicking is some people dont know what they are talking about . we know you are made of good stuff SPARKS =D>

nsman · Apr 24, 2008

I have no experience with the sem equipped 620 rxc,but a bit of Lc4 time.One thing we have found is that because this motor shakes a bit any unsupported wiring starts to break at the connectors.Very carefully check the wiring harness under the headlight and where it connects to the key switch(assuming this bike has those).Also(if it has a battery)check all connections there as well.

RXC620 · Apr 24, 2008

Sorry if I fluffed anyoneÃ¢â‚¬â„¢s feathers here, especially yours sparks

last thing I need is for you to be upset with me.

I know it is not your stator, and I was not saying it was, you did an AWSOME job,

all I was saying is it must be something else.

My Stator was terrible when I took it out of the bike, I swear I saw a fish jump in there all that water that came out.
The carb on the bike is aftermarket carb it is a keihin FCR 41 it was on the bike when I got it. Not sure what the settings are in there.

How can I found out what settings I have and what the factory setting should be?

Thanks
-RXC620

sparks · Apr 24, 2008

RXC620 said:
Sorry if I fluffed anyones feathers here, especially yours sparks

last thing I need is for you to be upset with me.

I know it is not your stator, and I was not saying it was, you did an AWSOME job,

all I was saying is it must be something else.

My Stator was terrible when I took it out of the bike, I swear I saw a fish jump in there all that water that came out.
The carb on the bike is aftermarket carb it is a keihin FCR 41 it was on the bike when I got it. Not sure what the settings are in there.

How can I found out what settings I have and what the factory setting should be?

Thanks
-RXC620

Jason, don't worry about it, Ive just got a bit defensive. Two years ago Sherco had very much the same problem with there 4t, Sherco thought it was the ignition failing when thins got hot and I asked the factory if I could help two days later they sent me a bike down for me to look at, to cut a long story short the ignition was fine the problem was the carburation grossly over rich but still they insisted there was an ignition fault causing the problem. I turned up a new needle from an Dyno jet kit and got it running pretty good, and eventually had it dynoed in the Uk and made up a jet kit of which I sold quit a few.
Sherco gave some bull **** excuse called them all in and the new version comes with a Keihin as opposed to the Dellorto.
You could be having the same problem running very rich, strip the carb and make a note what is in there
MJ PL needle.

Regards

Sparks.

RXC620 · Apr 24, 2008

Thanks sparks I will do that.

-RXC620

Coastie · Apr 24, 2008

Have you checked for a spark when it dies???
What conditions is it when it stops - wet or dry??
The reason I ask is that I had a strange electrical problem where if I went thru water or it rained it would stop. No spark at all. Let it dry out for a short while and it would start up again. Finally I took apart and cleaned every connection, put it all back together and no more problem. I found that the main ground connection was a bit corroded. Could have been that or something else but the problem went away.
If there is a spark then check the simple things - blocked breather tubes on both the carb and tank.

Coops

mule75 · Apr 28, 2008

my 03 501 is doing the exact same symptoms.
last time it eventually stoped so i tested the stator and it read open circuit. i had the stator rewound and put it back together and went fine............. for about 20mins.
it breaks down mainly under heavy accelleration like on long, steep hills.
i'm starting to think it might be a broken or shorting wire somewhere?? hopefully i find out before i fry another stator.

philis · Apr 28, 2008

First thing i would do is change the plug and ignition lead

mule75 · Apr 28, 2008

it has a new plug.
how do you test the lead????? resistance??!!

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