KTM Motorcycles - Page 3 - Recent Questions, Troubleshooting & Support

probably not from the manufacturer spares try after market bike spares or take the failed part to an engineering shop and get a stronger , modified unit made out of quality steel

Check the coils if it is fine change sparks plugs should solve the problem

the valve clearance is incorrect at .15mm ( .005") it should be at .010"inlet and .012" exhaust and is set on tdc but on compression stroke tdc decompression cams have a special grind that holds the valve open for starting revolutions and as the engine rpm picks up the cam follower doesn't follow the profile any more and closes the valve engines that utilize such a cam are motors that have a rating exceeding 3 hp on a rope pull otherwise , the piston cannot be pulled over compression past enough to get it started 5 hp lawn mowers , 10-20hp rope pull generators etc have this cam

don't bother as the kit and effort is worth more than a new pump

When you "give it gas" you are opening the throttle. At that point the fuel system is supposed to supply the engine with more fuel to maintain the air/fuel mixture. Check for anything that might be clogged like filters, hoses, fuel passages, etc. If it is still under warranty you could void your warranty if you work on it though in this case a warranty is meaningless if you have taken it in 6 times. I've seen models where you could replace everything and a week later it would refuse to run. Sometimes it's better to leave the thing at the junk yard and buy a new one but that doesn't happen often.

.010" inlet hot .012" exhaust hot if water cooled if air cooled add .002" to the measurements

go to this link might help you... how do you test the magneto Google Search

Worn out shift dogs.

Try disconnecting blk wire with yellow stripe from cdi. Check to fire again.

Yep, lube lube lube. Take your throttle grip off and lube up your cables. Check for quick return while it is apart. Now make sure the grip is not rubbing (common problem), and just move it out till it is free, lube and tighten it back up in this position. If that doesn't work check for worn out cables? Good luck.