Just about out ideas...

[KTMAndy]

I've had my gas gas for about 5 months and haven't been able to ride it properly yet...

The big end went bang in May, and I've replaced this, new piston, new crank and bearing set, rebuilt it and it runs like a dog.

So I've taken carbs off and cleaned them, same problem. Replaced the supressor cap and plug, same.

So now I'm looking at the stator for timing, I've read every post on here about it, but I can't see how I can change the timing?

I think is a 2k-3 by all the descriptions?

The bike starts fine, revs out fine, and sounds brilliant, until I put it in gear, it dips a little, which clears with a little reving, but then riding away it dives on revs, almost stalling, then splutters like its starving for fuel, which it isn't. As the carb is full. I think it might be firing a little too late?

Help...

 

[wasp4banger]

What jetting / needle are you running?

 

[KTMAndy]

To be honest, I'm not sure of the size, I have only cleaned them out, it did run before it went bang...

Just looking more at the stator, is it me or can they burn out? It looks very black and possibly burned out?

Having just put it back together, I now have no spark at all...

 

[gassergrant]

could be worth checking the coil it maybe buggered

 

[KTMAndy]

It doesn't look happy, how do I test it?

 

[Diggs345]

To be honest, I'm not sure of the size, I have only cleaned them out, it did run before it went bang...

Just looking more at the stator, is it me or can they burn out? It looks very black and possibly burned out?

Having just put it back together, I now have no spark at all...

That doesnt look good , does it smell of burned wires?

 

[gassergrant]

It doesn't look happy, how do I test it?

that i don't know, what i would do is look at a wiring diagram and see what wire coming out of the stator does what, with a side light bulb and some wire test to see is there is a spark, then check all the loom clean and has no brakes and WD the connectors. clean the earth on the coil and WD the bolts and connectors.
work your way up the loom testing it at the connectors for a spark, if you have another 2 stroke or a mate who has one try and swap the coil if it fits.
it does sound like feul but you saying the spark has gone changes it, i had my reeds brake away and it ran like a twat.
with out being able to see the bike its hard to say what it is, worst case i think there is a stator on ebay. buy it if its not that sell it on.

best of luck mate

grant

 

[KTMAndy]

Hmm, one of them is quite crispy Chris, didn't notice a smell though. When I do get this thing running, there won't be one thing I haven't dismantled and rebuilt on tho bike. I've had a huge learning experience... But I'd quite like a riding experience some time soon!

 

[KTMAndy]

Cheers for that grant, I'll give that a whizz, there is definitely some carbon deposit on 3 of the coils, I'll clean it up like you said with some WD. Is there a specific way the stator fly wheel goes on? I see the line at about the 4pm position on the coil, but can't see if that would specifically line up with anything on the fly wheel???

The reeds looked fine when I rebuilt the engine, but I'm learning not to dis-count anything. How was yours running when they broke?

I'm still thinking spark though, with the plug out and on the engine case, kicking it over gives me nothing, even with all the lights out in the garage...

 

[pscook]

There is a bolt with an oval shaped washer at 2:00 on the stator plate, right below the pickup. I believe the bolt hole is off center to allow two different timing points. You might try flipping it (if possible) to try another timing setting. Pull the bolt and washer, loosen the plate retaining bolts (it looks like one is missing at 10:00 on the plate), reinstall the washer/bolt 180* different, secure the stator plate, and have another go at it.

There is also a thread somewhere here, fairly recent, that discusses testing the coil resistance. Have a look and see if it applies to your stator. And I believe you do have a 2k3 stator, as it is much larger than my 2k2.

 

[gassergrant]

when my reeds went it would bog out big time would not hit the power bands at all, but i doubt its that.
the stator plate will only go on in one position, if it was out it would run but pop and bang like a car or just have no power.
there is a wood draft key on the crank just make sure it has not fallen out.
im the same as you my knowledge is limited with electrics its a process of elimination
try a old spark plug that you no works, also try a diffrent ht cap and lead.
im not working tomorrow i will have a look at my bike and a wiring diagram and figure out what to test and how i did it

 

[KTMAndy]

Ceres Phil, I'll try that as well, the plate did seem to be welded in place, but I didn't take much notice of the big oval shape at the top under the pick up, I kind of assumed it was all one peice. I hadn't put the bolt or washers in on the 10 and 5.00 positions when I took the picture.

 

[KTMAndy]

Cheers for that Grant, wudruff key was in place, good point, the fly wheel can only go in one way because of that! Think I'm getting tired, should have thought about that

 

[gassergrant]

there is a blue wire that goes to the coils connected with a spade type connection, this is the live, if you have a circuit tester or the bulb trick,pt one end in it and one to earth kick it over and see what happens if you get sign of life the stator should be ok if not you have a
red/white
black/red
red
green coming from the stator, im not sure if any are negitive but test these anyway
the feed from the cdi is black and yellow this will conect to the blue LT test it and clean again pull all the cdi connections and clean and wd
for now mate that all i can do

 

[gassergrant]

on the home page in the manaul section there is a basic wiring digram it would be worth a stdy

 

[pscook]

Check the reeds. Forgot about that, it always escapes my feeble mind. No gaps = good, any gap = bad. Big gap and missing chips = terrible.

 

[Cruiser]

Since your this deep into it.. test the excitor coil of the stator. The sinle black covered post. This has the connector that goes up to your ignition/cdi. The spec should be the same as the KTM, below 14 ohm resistance between the two wires going to the cdi/ign bad. if you have a good hairdryer and the specs are lower of close to the 14, 14.4-15.5 good, heat the excitor coil up with a hairdryer and retest. Does sound like reed or powervavle not connected correctly after reassemble tho. Good luck!

 

[KTMAndy]

Found the problem with the stator... A severed wire behind the plate!!!

One step closer, souldered it up, I have a big fat juicy spark... Now, all the dicking about with the jets and carbs, needs reverting, as it's drowning at the moment lol

 

[Diggs345]

Ill be home at dinnertime today if you need any help

 

[KTMAndy]

The s continues! At least, by the end of this, I'll pretty much have a brand new bike...

New fork seals
New big end bearing
New crank
New small end bearing
New wossner piston and rings
New clutch plates

I found the problem with the lack of spark, the wire on the back of the stator had snapped! So that's been replaced.

Still wouldn't fire.... Taken carbs apart, cleaned and levelled the float using the great instructions on this forum.
Still nothing!
So took the reed block out, that was ok when I rebuilt the bottom end and top end and found this.....,,

Don't know how or why it's smashed, maybe it got brittle??? So next question, I've got the part number, but only ones I can find are like ?60 or $100 plus P&P. Does anyone have a suggestion where to get a set from?

When I bought this bike, my knowledge stopped at changing the oil and spark plug and cleaning the air filter.... Jesus! What I don't know now about bloody 2-strokes lol!

Please help!!

Part number ME25616041