Need help with mates 05 450 KTM out of ideas ( hehehhehehe)

faktor · May 3, 2007

Hi Guys,

We need some help have a read and get back to us 8)

05 450 KTM Problem

The symptoms.....
If you Start bike it runs at idle. It operates at 1/4 Thorttle then when increasing to 1/2 or full throttle the enginge will die so we then release throttle back to 1/4 and engine idles. If you then repeat the process again the engine will rev over 1/2 and even to full for short period then go back to dying again. And continues to do this on and off. Never properly as it should.

Here is what we have tried so far....

1. Problem 05 KTM 450 Cleaned fuel tank out and put fresh fuel in as well as check fuel tank flow. Problem still there.

2. Cleaned Carby of Problem 05 KTM 450 (fully dismantled and cleaned all of carby and checked float, needle and seat and jets, mixture screws, fuel pump, and checked that they were all operational with no visible wear). The problem still persisted when we put it all back together so we took a brand new carby off mates 06 450 KTM (which runs fine) and same problem occured.

3. New spark plug installed in Problem 05 KTM 450. Problem still there.

4. Pulled all the electrical connections off of the Problem 05 KTM 450 cleaned and installed electrical conductivity grease. Problem still there.

5. Changed Stator from the working 06 450 KTM to the Problem 05 KTM 450. Problem still there.

6. Changed CDI unit from the working 06 450 KTM to the Problem 05 KTM 450. Problem still there.

7. Changed Ignition coil from the working 06 450 KTM to the Problem 05 KTM 450. Problem still there.

And now we sit here waiting to see what anyone else can think of???????
Pulse coil?
Could it be intake valves?
Timing? (has not been altered though)

whosahberg · May 3, 2007

it might be sucking in air somewhere , at idle or small throttle it's ok and then as the level of vacuum increases the air leak appears .

just my 0.02 :2cool:

nsman · May 3, 2007

Put a timing light on the plug wire and rev it up to see if the light goes out.If it does your prob is ign related.
Try it without the air filter

ORANGEBERG · May 3, 2007

Re: Need help with mates 05 450 KTM out of ideas ( hehehhehe

faktor said:
Hi Guys,

We need some help have a read and get back to us 8)

05 450 KTM Problem

The symptoms.....
If you Start bike it runs at idle. It operates at 1/4 Thorttle then when increasing to 1/2 or full throttle the enginge will die so we then release throttle back to 1/4 and engine idles. If you then repeat the process again the engine will rev over 1/2 and even to full for short period then go back to dying again. And continues to do this on and off. Never properly as it should.

Here is what we have tried so far....

1. Problem 05 KTM 450 Cleaned fuel tank out and put fresh fuel in as well as check fuel tank flow. Problem still there.

2. Cleaned Carby of Problem 05 KTM 450 (fully dismantled and cleaned all of carby and checked float, needle and seat and jets, mixture screws, fuel pump, and checked that they were all operational with no visible wear). The problem still persisted when we put it all back together so we took a brand new carby off mates 06 450 KTM (which runs fine) and same problem occured.

3. New spark plug installed in Problem 05 KTM 450. Problem still there.

4. Pulled all the electrical connections off of the Problem 05 KTM 450 cleaned and installed electrical conductivity grease. Problem still there.

5. Changed Stator from the working 06 450 KTM to the Problem 05 KTM 450. Problem still there.

6. Changed CDI unit from the working 06 450 KTM to the Problem 05 KTM 450. Problem still there.

7. Changed Ignition coil from the working 06 450 KTM to the Problem 05 KTM 450. Problem still there.

And now we sit here waiting to see what anyone else can think of???????
Pulse coil?
Could it be intake valves?
Timing? (has not been altered though)

im sure that model had a recall on the starter/stop switch, we were sent one for every bike we sold to be replaced. shorting inside the switch, simply pull headlight of and disconnect the black/yellow wire and plug theres 2 one for the kill switch on the light switch as well. then kickstart and try again.
inlet valves could be tight, get on TDC remove cover check for clearance if theres any its not that, if there riding you will feel the weight on the tappet screw as you back it off.
if not familiar with how to find TDC take off tappet cover, remove spark plug, put on stand and raise rear wheel and select 6th gear, turn wheel slowly until inlet valves compress, put a screwdriver in plug hole and feel the piston come up until its on the rock
( starting downward movement) check clearance 6 thou.
you can use locator bolt into crankshaft on front of motor for TDC as well but can be hard to find unless youve done a few. GOOD LUCK
ORANGEBERG

faktor · May 3, 2007

RE: Re: Need help with mates 05 450 KTM out of ideas ( heheh

Thanks guys we will take a look....

schwim · May 3, 2007

RE: Re: Need help with mates 05 450 KTM out of ideas ( heheh

Also, check for a pinched breather line from the carb. very well could be creating a vacuum where none should exist.

thanks,
json

doctorcorey · May 10, 2007

Throttle position sensitivity

Have you checked the exhaust system. I've seen 'moveable' restrictions that could cause som ething such as you described. When you describe the condition, are you riding the bike through the gears, or sitting and revving? I'd really look close at that wiring harness, too.That would make an analysis easier for us. Anyhooo, please let us know what you find..........really, do it. 8) DC

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Need help with mates 05 450 KTM out of ideas ( hehehhehehe)

faktor

whosahberg

nsman

ORANGEBERG

faktor

schwim

doctorcorey

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