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2003 FS 650 E help me please!!!

Joined May 2004
7 Posts | 0+
My 2003 FS 650 E has been at the top KTM dealer in south africa 4 months now. It went in for a service and they test rode it and gave it the thumbs up. I sent it to their sales dept to sell and 2 weeks later they said it's smoking. I booked it in and they said the pistoon was cracked and the stator wasn't working properly. They changed the piston, stator and flywheel cause the new stator requires the newer fylwheel. Now the bike has a splutter which starts anywhere from 3000 rpm onwards. the young mechanic is at a loss for words or ideas.

Is there some incompatibility between my current coil and the new stator? Is the current coil damaged? Is the float level incorrect? the bike ran fine before the new piston, stator and flywheel.

the mechanic changed the plug, plug wire, stator again. He also cleaned the carb many times. He checked the valve timing, clearance.

The bike repsonds iratticl when you grab a hand full but slightly better reponse from a more controlled throttle, which makes me believe it's a fueling problem.

Guy, give me some ideas for the mechaic to try please!
 
Since 03 was the last year for the SEM stator I really do not understand what you mean when you say your dealer installed the later stator as really there is not one.If you have installed a 04 stator it will unlikey be compatible with the rest of you ign system as it is a different brand .Cracked pistons are not a problem we hear of often,did your mech determine a cause?
...bruce
 
try and raise the needle one clip.

also has he got the bike to TDC and checked the cam timing?

regards

Taffy
 
They told me that the stator had to be replaced and that the new stator could not work with the old flywheel., so the stator and flywheel was replaced.

The mech said he didn't touch the carb setting, he only washed it. he said playing with the carb settings was his next step.

Thanks NSMAN, TAFFY for the quick reply. I'll question the mech on the points you all made.
 
yep

the cam should look symetrical at TDC ok? and also look at the ignition timing section of the doc. it sounds like it's not advanced enough. the idle will rise if the ignition timing improves - a sure sign.

regards

taffy
 

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