20 Most Recent 2004 KTM EXC 450 Racing Questions & Answers

could be your small end bearings, notorious for whining and lack of power

Take the kill switch off and see if it starts. The killswitch may be permanently earthing the ignition.

bearings in wheel or arm to chassis?

Hi, if the big end bearing fitted within the con rod on the crankshaft fails it is accompanied by a knocking noise when the engine is running, when the engine is striped and the crankshaft is out, movment of the con rod in an up and down direction while grasping the conrod between finger and thumb indicates big end failure, youmay also notice while rotating the con rod that it locks up, more so in 1 direction. Visual damage bearing cage failure visible from within the oil cut out on the big end of the conrod, Crankshaft main bearing failure, the main bearings are fitted within the engine cases 1 left and 1 right, failure of this bearing would be movment of the crankshaft ends within the cases, accompanied by a rough vibrating sound.when running,Hope this helps paul

Thank you for contacting FixYa with your inquiry.
The Rubber Diaphragm by nature is usually somewhat collapsed and twisted looking. Unless it appears to be non functional it's probably OK. It's important to have fluid and make sure the air is out of the system. There is a bleeder screw to allow for evacuating the air out of the system.
http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx Go To: 2004 > 450 EXC-G RACING (USA) > CHASSIS > BRAKE CALIPER REAR
Also look at the repair kit Item #2 (50313081200)
You can purchase a complete repair manual from this site: http://store.payloadz.com/details/391226-eBooks-Technical-2003-2004-KTM-450-525-EXC-Racing-Owners-Manual.html
Make sure you have serviceable pads, proper KTM brake fluid, and the air is out of the system and the brake cylinder is functional and you will have brakes. There is also an accessory available the cools the fluid for the rear brakes and keeps them from fading if you ride the pedal or are constantly braking. Ask you dealer.
Let us know if we can be of further service.

Kind regards,
TF

the flat battery shouldnt cause the problem and you said it has spark at the plug, so that sort of eliminates electrical problems.
if the carb is clean and it has good fuel, its a bit tricky to diagnose.
perhaps a sheared flywheel key,
blocked fuel line( it might have a tiny filter in the tank on the ends of the fuel tap pick up tubes)
or short in the kill switch may let it spark sometimes)

You have replaced all the ignition components,
How do you determine weak spark?
If you can see or hear a spark, with the plug in the cap and it earthed against the head, its probably ok.
It can be hard to see in daylight
other problems could include a faulty kill switch or water or a short in the ignition switch

Hello,

I checked a few sites that have replacement stands for you bike. This site KTM has what you need. The replacement kickstand is a bit expensive, but it is the OEM part for your bike. Scroll down to the bottom of the page to see the options for your bike.

Regards,

Oz

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the shocks or dampers,as some call them are faulty answill need replacing

hi
1. stop the engine
2.open the engine oil filling cover
3.nw opne the drain of the oil tank. make sure all the oil has been drained off
4.nw flush the system wid new oil so thet the remaining old oil gets carried away with it.
5. now close the drain and fill gear case with the new oil through the top filing hole.
6.close the cap and DONOT start the engine with out closing the filling cover

Theres really not much to them and only a few things could be the case. Try bleeding the brake system first and check for leaks. Also make sure the fluid is changed. If that doesn't give pressure the master cylinder has gone bad and needs to be replaced..

Starter motor check for worn out carbon contacts.Also it's wiring and the starter relay.The regulator/rectifier is charging efficiently the battery?

Pull the slide and move the jet needle clip down 1 or 2 notches.

Put it up on your stand lossen the axel and remove the bolt on the bottom of the shock. Then tighten your chain and lift your swingarm up until its horizontal with the ground, then the chain should have almost no play. Not completely tight, but almost no play. Tighten the axel, and the bolt on the shock, and your set,,,

Thanks for contacting FixYa with your inquiry. More that likely this is an electrical problem caused by a shorting event. The usual culprit is the kill button. If you turn just right it shorts, if you hit the right sequence of whoop de do's something on the triple clamps pulls tension on the wire. Temporarily disconnect the wire from the kill button and go for a rip and try to duplicate the problem.

Second possiblility is the coil wire or wire to the kill button getting pinched by the tank, radiator, or even the exhaust pipe bracket shorting the bike out and killing the engine. If you've had the tank off receintly you may have disturned some of the wiring allowing it to get pinched.

Trace all electrical back to the source and tape any breaks or places where rubbing may have occured. Use wire ties to relocate and keep all wiring from future possiblily of shorting out engine.

Hope this gives you a few ideas,

TF

With a small brush, loosen off any sludge in the reservoir that you can get to. Extract as much fluid as you can from the reservoirs and refill with fresh fluid. Bleed the brakes in the normal manner until completely fresh and clean fluid only comes out of the bleeder pipe. Keep a close watch on the fluid level in the reservoir so that you do not introduce air into the brake systems and have to re-bleed them.

Hello,

The fuse box should be accessible by removing the seat. If I'm not mistaken, the air cleaner and battery are there too.

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Regards,

Oz

if its bogging that badly i think it may be the jets in ur carb take your carb off and blow through the fuel line and giv a proper clean it may help your problem

That would be like riding a fixed wheel bike.Think about how you will stop and start. Only hydraulic fluid will leak. Bad idea!