This Is Why You DON'T Buy a KTM Dirt Bike ($1300 KTM 450 Find)

I take the KTM400exc for the first test drive since buying it. #KTM, #Horrible,

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[betarider]

Definitely sounds like an ignition issue. Fuel delivery problems are seldom intermittent. Start with the simple stuff. Disconnect the stop/kill switch from the primary lead of the ignition coil and test ride the bike . If problem persists, unscrew the spark plug boot from the secondary ignition coil lead and check the resistance of the boot. It should be close to 5k ohms. 4.5 - 5.5k is fine. Then before re-installing the boot, trim the secondary coil lead back 1/2". Make sure the lead is long enough to do this. There have been thousands of perfectly good ignition coils replaced when the only problem was the spark plug boot or the connection between the boot and the secondary coil wire. Other than these checks, it's on to the stator, pick up coil and CDI unit.
Good luck!

[jozsef]

Dont be affraid of rejetting a carb! The stock jetting isnt always the answer. Even a couple degree change in the temperature can make it bog. If you feel like it needs a smaller one put one in it.

[madisimo]

Sounds exactly like what my bike was doing. And all I had to do was reset the ap timing and go down a size on my main jet, now she runs like a dream.

[Coastlylocal]

I have an 08 sxf and the jetting of the flat cr carb always gave me issues. Either around camp or at the top of the mountain. I’d always be swapping jets .
Once I switched to a lectron, “kinda felt like cheating “ I had instant power everywhere.
Lots of love bro, love the vids

[artiexr]

Another vote for stator electrical issues especially with it not registering above 14v charging.

[dariusfitch]

Had a very similar issue with my bike, turns out it was bad wire in the coil and a few other wires on the bike that had corroded over . Fixed all the wiring issues and it ran perfect

[nickbartolomeo]

I can’t justify saying that the stator isn’t an issue, but I had issues with my 2002 520 falling on its face like that. Checking that the throttle position sensor is rotated to the optimum position helped, because that adjust the spark timing as the throttle turns. The thing that seemed to help the most was dropping the needle in the throttle by raising the clip position two spots, reducing the flow of fuel as you open the throttle further. Really hope you figure it out, love the work you do, keep it up!

[keithcrampton]

a lot of times I go too far vintage guy and I forget to think about you because you are the main attraction here this is your channel you are the SUPERSTAR!

[cleighton]

Check valve clearances, and I would also pull the stator cover again and check the stator voltage output at the connector itself where it connects to the main harness. That bottom coil @ 17:00 mark in your last video looks very dark to me. It could be something simple as a bad electrical connection, someone was obviously messing with the electrical at one point based on the headlight wiring. Yes it does appear to slowly build up a charge, but that doesn't seem right. As soon as it starts up, if its charging properly, it should be reading high 13s - low 14s steadily, it shouldn't take a min or two to climb to 14. It should just read and maintain whatever it is outputting for voltage. From a quick google search, yours has symptoms of a dying stator, which can also cause engine running issues like yours is having. So I would find the stator resistance/output specs and start troubleshooting there. If none of that helps, then I would start looking at re-jetting the carburetor.

[beaublackford]

I had a 2002 EXC 300 2 stroke when I was a kid, I loved it! I was so comfortable riding it. I was racing my CR 85 before, when I switched to the KTM I noticed and felt a major improvement in my riding. I miss it, it looked exactly like yours.

[mikekubani]

If it truly is a 2002 400EXC then the exhaust is wrong. The 2002 400 had two pipes out of the cylinder all the way to mid pipe before it went to one and into the silencer. Also, the muffler does have a spark arrestor in it. I owned one since new and just recently sold it for a newer model.
A JD Jetting kit would wake that bike up, but I agree with others that the bogging issue is electrical.
That year carb was difficult to get the pump set correctly as you have to bend a tab. Took me many tries to get it right.
Good luck!

[kylelangdown]

Recheck your valve clearance. Could be as simple as your intake is too tight and not clearing all the fuel into the cylinder when it opens causing it to pile up and get more and more rich as it runs. Other than that the timing could be slightly off, maybe the woodruff key bent slightly when you were having those one way bearing issues.

[johnhicks]

Checkout the vented fuel tank gas cap to it maybe plugged in the tip nipple to by chance from dirt., or dust.packed inside of it to tom.

[rick]

20-year old bike. For a sanity check, try a quick leak down test just to verify there's no issue with valves or rings before getting too involved with carb adjustments or electrical system.

[MMKnight_]

The hole in the fuel tank on KTM bikes for the choke is just for the extra fuel capacity of the tank, not "over-engineering" in my opinion.

[gregdyer]

Hi had an EXC 520 - I converted it to a Supermoto with stiffer suspension, upgraded brakes, 17 inch wheels front an drear, road tyres and different sprocket ratios and it was AWSOME!!!!

[modelrc]

I had a failing stator and it produced the exact symptoms your dealing with. It would start up and run good in the low rpm’s but would break up at high rpm’s like seen in the video. The stator does seem to have an issue with it based off those charging voltages. Should immediately jump up in voltage, not a slow climb as seen on your bike

[johnhicks]

Also checkout the inline fuel filter for being plugged up with debris.&sludge build up. One more thing to checkout is the fuel tank line inlet port for fuel flow blockage to like from rust.& Etc.

[timothydeshotel]

I've had something similar happen before. Turns out when I replaced the diaphragm on the carb, i put the fuel needle through the retaining clip instead of under it. It caused the bike to bog under load. You can also see if you can adjust where the fuel needle sits on the clip and check for tears in the diaphragm.

[billyjames]

New Regular rectifier - Cheap as chips - (Voltage should higher than that), also voltage drops slightly if anything when you rev it up - Also compression doesn’t last very long on the EXC’s - New rings and yer good - Get yer money back on that sprag clutch bearing - Still a good buy though.