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Old 03-07-2013, 10:03 PM   #1
rsuncloud OP
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04 only firing on one cylinder

I have an 03/4 S with 30,000 miles. Usual problems and changes:
KTMTwins slave cylinder
Clutch basket explosion and 60 day wait for parts
Oil pressure sending unit leak
NOISE.
Truth is I love this bike. It always brings me home, sometimes with an oily boot but. Last summer was N Dakota and she ran great.

Now, front cylinder is not firing. Coil pack is good but???? Anyone have this problem
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Old 03-08-2013, 12:41 AM   #2
gefr
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Maybe coil not seated properly?

Start with the simple stuff.
Cheers.
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Old 03-08-2013, 04:29 AM   #3
mccasksl
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For what's worth...

...my 04.5 950 Orange w/ 15,000+ miles had been running very rough and got progressively worse to where it would only run on one cylinder (rear) till about 3-4,000 rpm and then fairly smooth, finally only one cylinder no matter what. With a long to do list, I took the bike down and did major maintenance on everything short of taking the heads off / crankcase apart. Two years later it started on the first try, but only on the rear cylinder. The coils, TPS, spark, everything checked out OK. I could see the front carb slide plate not moving as much nor as much gas discharging. I had rebuilt the carbs but two more times I took the carbs down and carefully cleaned / reassembled. The third time I invested in an ultrasonic cleaner to clean everything. It started instantly and after careful carb balance, tinkering w/ the idle screw it runs so smooth, on both cylinders. I'm convinced some small passageways were blocked in the jets / carb. When I put bikes away for the winter, I'll be more carefull w/ fuel stabilizer or run dry and drain completely.

Cheers!
Steve
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Old 03-08-2013, 08:08 AM   #4
akarob
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Well, its probably either low compression or dirty pilot jets. I had a bike that would not fire #3 cylinder until I ran a wire through the holes in the pilot jets, then it ran perfectly.
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Old 03-08-2013, 10:40 PM   #5
rsuncloud OP
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Pissed New news

Oops
Pulled the carbs and neither valve moves on front cylinder....
Houston, we have a problem
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Old 03-09-2013, 11:06 AM   #6
pdxmotorhead
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OUCh... (Sympathy pains)

Dave
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Old 03-10-2013, 01:41 AM   #7
Leodis41
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The front cam chain drive sprocket is mounted on the Stator side of the engine and is integral to the balance shaft. Obviously the balance shaft is still receiving drive as the rear pot is firing. I would pull the cams out first and see if the cam chain is still tight and check the upper cam drive bearing hasn't collapsed letting the gear sag so it isn't driving the cams. After that your gonna have to pull the heads and balance shaft out to see what is going on.

Sorry cannot help further, have you got the services manual, there are good piccies in there.

Leodis41 screwed with this post 03-10-2013 at 01:48 AM
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Old 03-10-2013, 03:07 PM   #8
pdxmotorhead
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You should be able to at least isolate the fail by pulling the stator cover right? Can this engine shear the cam gear key or pin and spin? so the cam stops turning? I know youcan see the valves if you take the front head pipe off.. :)

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Old 03-11-2013, 12:19 PM   #9
Leodis41
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I think the gear for the drive gear for the front pot is integral to the shaft, the rear pot is a loose gear fixed by a woodruff key.
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Old 03-11-2013, 10:08 PM   #10
rsuncloud OP
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Looks like there are plenty of Learning Opps in my future. I appreciate all the advice. Going to pull head with engine still on bike for a look see.
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