'05 KTM 525 engine issue

Discussion in 'Thumpers' started by MKJ, May 10, 2013.

  1. MKJ

    MKJ Married w/ Children

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    Nuke it
    #1
  2. cross-country

    cross-country .

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    Is it possible that while the motor was apart someone went thought the carb? It sounds like a bike with its slide in backward. I would also look for an air leak and double check valve clearance.
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  3. MKJ

    MKJ Married w/ Children

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    The carb was rebuilt by Dave Hopkins. I have two of these bikes. I placed the stock carb from my other bike on it while I was waiting for Dave to rebuild the carb from this bike, and it behaved the exact same. Rechecking valve clearance was next on my trouble shooting list.
    #3
  4. anonny

    anonny What could go wrong?

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    Id make sure it wasn't off a tooth while checking the valves, also it's easy to be out 180 degrees while setting up the valves.
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  5. qkenf4u

    qkenf4u Been here awhile

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    one of the stupidest things ive ever seen is KTM's TDC setup..... freaking morons...

    make sure, then make sure you are in the slot, then make sure again..... i work at a all brands shop and we do a bit of KTM stuff.. even the boss whos very well informed about KTMs has a hell of a time getting that stupid TDC bolt/slot setup right the first time....

    oh and did i say freaking morons...:huh
    #5
  6. cross-country

    cross-country .

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    I don't get it, I've done a lot of top ends on RFS motors. The TDC procedure always seemed fairly simple to me. :dunno

    OP; you checked the timing with the chain adjuster engaged? The chain adjuster is functioning correctly? I've seen a couple of adjusters that had worn out the teeth on the pawl.

    While you are in the head (and if you have not already) inspect the rocker arm bearings, tappet feet, follower bearings, and the cam surface.

    If you can't find anything else, check that the flywheel hasn't sheered it's pin and spun on the crank, this could change the timing.
    #6
  7. anonny

    anonny What could go wrong?

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    And, make sure the adjuster nuts are tight! There's been a few disasters from them backing out.
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  8. gatorgrizz27

    gatorgrizz27 Been here awhile

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    Exhaust leak?
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  9. MKJ

    MKJ Married w/ Children

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    Are my symptoms indicative of timing off? Cam has new bearings and was checked for wear. Timing chain tensioner is something I have not considered. The bike ran great before the work was done. It feels strong on acceleration, just stumbles when backing off throttle. I will continue trouble shooting,
    #9
  10. qkenf4u

    qkenf4u Been here awhile

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    lol ok i guess i mis-read your post..... if its just popping on decel then look for an air leak (carb intake/airbox,exhaust-all joints)
    sounds like an air leak to me if its popping on decel....

    does it run well once warmed up ? if so then its lean at startup (cold)
    #10
  11. qkenf4u

    qkenf4u Been here awhile

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    its easy if ya lock it down while cylinder/head off.

    you must have a really skinny neck and really good eyes... :D
    #11
  12. MKJ

    MKJ Married w/ Children

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    Not it. Thanks though. It's the stumbling and flat power after backing off the throttle that is the real symptom. Not concerned with a a little backfiring. That should be corrected with a mixture adjustment.
    #12
  13. MattyG94

    MattyG94 n00b

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    Check the clutch side crank seal. I've road raced these bikes for years and when the crank seal pops the bike will run great on the bottom but will lose the top end. Not exactly what you're talking about but if everything else checks out (carb clean, etc), it sound like it could be a possibility.
    #13
  14. MKJ

    MKJ Married w/ Children

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    Spark plug gap was the culprit.
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  15. tundradirtbiker

    tundradirtbiker Been here awhile

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    Spark plugs can look perfect - and not work properly
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