Miner, my old friend ;-)
Cant answer any of your questions, but I know that I have seen the small o-rings. They came with the Keihin FCR gasket kit for an EXC 450. They are not sold separately. The kits number was 57331099000, you can find it in the spare parts manual or ktm spareparts finder. Pretty sure that's what you need.

 

Cheers steveman, aye that looks to be the one..... half hour job turned into an age trying to find the leak and stripping, then leak testing various bits.... I was so annoyed I tidied the garage at least (eventually)!

One of the guys in our off-road WhatsApp group stays 5mins up the road from me and has a couple of KTMs and a large selection of o-rings, going to swing by and try to fit something up. Fecking 4T and their fancy carbs......

 

I know that the fuel connections can leak, but I never saw it happen.
Didn't even know that there were o-rings fitted to the little brass tube until a mate replaced them during a complete carb overhaul.

Wuhaaa! I did the same today, we had brilliant weather from Monday to Friday evening, nice and warm, about 20°. But I had to work so planned to test some PV-springs and have a good day in the gravel pit. I left work at 4pm. Arrived at home at 4.45 and it started to rain and didnt stop till today 1pm. Bloody hell... the weather forecast for next week says 16° for coming Friday and 2° for Saturday plus SNOOOOOOOWAAAAAAARRRRGH

WTF is wrong with the weather?

 

Got some off my neighbour there, odd size as well, looks like a square ring.... either that or just now that shape. Got one thinner original one and two fatter, closest size ones in it, then seated with a little gentle persuasion. No leaks..... try it in the bike and see how it goes.


Sent from my iPhone using Tapatalk

 

Glad to hear it worked!

 

Definitely no leaks now.... just need the feckin thing to start now....[emoji51]


Sent from my iPhone using Tapatalk

 

Ah...ok, it still doesnt fire up. That's the bloody quad, right?

 

It's due to be on fire..... [emoji51]feckin four strokes! Neither the 200 or 300 have moved since I got my hand pinned and I bet I could get them going first or second kick!


Sent from my iPhone using Tapatalk

 

LOL, I can imagine how you feel. Had a very similar problem once. I worked about 15 days on a Honda and could not get it running...

 

Still won't start..... tried it again there.... filter off as well.... just churning but not really firing!

+10days for plug cap, plug tool and different idle jets..... mrs will be thrilled. [emoji51] Trackday on Friday anyway though....[emoji12]


Sent from my iPhone using Tapatalk

 

My money is still on plug cap or dissolving insides of the tank to carb fuel pipe.

 

10d lead time for the plug cap Pindie.....[emoji849]

Dissolving fuel hose?


Sent from my iPhone using Tapatalk

 

Miner, have you replaced the spark plug already? Or still no wrench?

Put a cotter in the cap and see if you get a spark when you crank the engine with the e-start. Are you sure you get fuel into the engine? The spark plug should be wet when you crank and it doesnt fire up.
Checked compression and valve clearance?

 

Still no wrench..... they gave us the wrong one. Got spare plugs to spark test though.

Plug chop would be ideal..... [emoji849]

Compression if I can get the plug out.... [emoji51]

Was working ok before..... only variables:

- pilot jet screw adjuster (forgot to count, was definitely more than 1 - out at 2.5 now.... no joy)

- Clip moved from 4 to 3 (main jet)

- changed air filter (won't start without either)

- TPS not removed

RFS now stands for Rarely Feckin Starts!

It has always been tricky to start, there was a nack to pumping/priming and firing. Always idled high, difficult to fire on low idle. Had it adjusted ok eventually though.

Ordered the bits, plug tool, cap, pilot jets, fuel hose and carb gasket kit.

Plug check and some other debugging can still be done....

No 300 time till the tractor is running..... [emoji51][emoji51]


Sent from my iPhone using Tapatalk

 

Ok, without being able to get the feckin plug out it makes not much sense to keep trying. Take a break and wait till you get the bits

 

What would I need to hold the plug against to get it to fire, if I put the new plug in the cap?

Jammed it in against the other plug and the cylinder head.... but it wouldn't even turn. Obviously not completing the circuit.... would've worked on one of the two stroke bikes. [emoji51]


Sent from my iPhone using Tapatalk

 

Put the plug into the cap, then take the cap with inulated pliers and hold the hex or thread of the plug against metal (cylinder head), then crank the engine with the e-start. You should see healthy, strong blue-yellowish spraks jumping form the center electrode...

You could put a nail or cotter into the cap and hold close to metal while you crank. Will work too...

If the e-starter doesnt crank the engine you've another problem :burp:

 

I will beat this bike.....[emoji51][emoji51]


Sent from my iPhone using Tapatalk

 

Trade it for two camels

 

It's certainly drawing enough fuel through now.... exhaust stank of fuel after it wouldn't start. Advice from the KTM ATV forum is to check the TPS settings..... multimeter out time. Will do it after the track though, not before![emoji51][emoji1]


Sent from my iPhone using Tapatalk

 

This is more like it..... 15yr old, not moved on 4-5 months, stale fuel, 2-3 kicks..... [emoji1364][emoji100][emoji100][emoji100]

Sent from my iPhone using Tapatalk

 

So some progress tonight....

Got the plug out.... finally!

Old plug against rocker cover - faint crackly spark - something positive at least!

New plug - no spark!

Old plug again - no spark!

Held plug cap against head to ground - no spark!

Checked coil connections - corroded - cleaned and greased including bolts and frame connections.

No spark!

Cut end off plug lead - fried! Re-made connection.... no spark!

Stuck plug back in the head..... cranked a couple of times, battery dead!

Try again tomorrow.....

Throttle cable, TPS and cool to check now.... other suggestions greatly appreciated! [emoji51][emoji51]


Sent from my iPhone using Tapatalk

 

Strange, could be the power lead. I'd replace the lead and the cap, they're not expensive...

Sounds like a neverending story Miner. hope you'll get it sorted soon without suffering a heart attack

 

More news....

Battery fully charged and healthy... happy days.

Stator test - values ok. Black/black not shorted but not a steady resistance reading. Test to ground - infinity.

Pulser coil test - red/green not shorted but not a steady resistance reading. Test to ground - infinity.

Main coil 1 test - not shorted but not a steady resistance reading.

Main coil 2 test - not shorted but not a steady resistance reading.

Plug cap - not shorted but not a steady resistance reading.

Positive terminal to coil lead - 5.8V

Hmmm......

Open battery circuit, fresh off decent B&D multi battery charger & jump starter as fully charged - 5.8V

Multimeter probably needs a battery...... FML! Bedtime! Was at it late last night after messing about with the jetting on the 200.

So....

I've either cooked everything from the pulser to the plug cap cranking the bike with the jump starter on (but it was firing after that!).....

Or got a bad earth / connection somewhere....

Or my multimeter is shagged out (it's old and cheap) and I've not identified the problem.....

Disconnected the throttle cable and backed off the idle screw to max also btw, no spark.....

New multimeter tomorrow..... save me buying two coils and a CDI.... maybe!

Stay tuned for the next episode! No sparky, no likey![emoji85][emoji51]


Sent from my iPhone using Tapatalk

 

Ok - new fancy multimeter bought on way home.....

All gravy apart from the Coil 1 measurements..... I can get the actual reading range but struggling to get a consistent reading. Tiredness of operator or hardware?

Sent from my iPhone using Tapatalk