twisty wrote:which ktm model is it for the replacement shims and how easy was it to strip the stepper. Did you break anything
Tom,
KTM shims for the 450 & 530 EXC models are identical...the smaller capacity motors use different sizes.
Kits for sale on ebay for £50 for 84 shims which makes em dead cheap but I reckon it'd be overkill and most of the sizes would most likely be irrelevant....
As for the stepper, I simply removed it from the TB assembly for cleaning...it's only held on by two screws. It looks like a sealed unit and unable to be stripped, but at leat it's replaceable if we can identify what type it is. In the Morini Worrkshop manual it states that the whole TB assembly must be replaced if the stepper fails
It is likely to be an off the shelf part, but as yet I've not identified it...
If you remove it , reconnect the electrics and hold it while you cycle the ignition you can feel/see the plunger cycle to ansure its working correctly....
the stepper appears to be held in place by a circlip. If you look dead on at the body that hold the stepper you can see a ring of dots which don't go past the "notch" in the cast body that its placed in, about 10mm down.
I think the notch in the body is for circlip pliers (may be wrong) It's a very small thin perimeter gap which only a pair of needles or very thin circlip pliers could catch the holes in the circlip. Assuming that's what it is.
twisty wrote:which ktm model is it for the replacement shims and how easy was it to strip the stepper. Did you break anything
Tom,
KTM shims for the 450 & 530 EXC models are identical...the smaller capacity motors use different sizes.
Kits for sale on ebay for £50 for 84 shims which makes em dead cheap but I reckon it'd be overkill and most of the sizes would most likely be irrelevant....
As for the stepper, I simply removed it from the TB assembly for cleaning...it's only held on by two screws. It looks like a sealed unit and unable to be stripped, but at leat it's replaceable if we can identify what type it is. In the Morini Worrkshop manual it states that the whole TB assembly must be replaced if the stepper fails
It is likely to be an off the shelf part, but as yet I've not identified it...
If you remove it , reconnect the electrics and hold it while you cycle the ignition you can feel/see the plunger cycle to ansure its working correctly....
found this on another forum, another source of shims and in more half sizes
11/20/07: I've had several emails regarding where to buy shims. The easiest is likely your local dealer, especially if you only need a shim or two. However if you need multiple shims or want to build up a mini shim bank, head down to your local Harley Davidson Dealer. The Harley Davidson V-rod and Buell 1125R both use 10mm shims, and since both are considered performance engines, the shims they use are of equal quality to those in your KTM. The shims they sell are available in half sizes which aren't even available from KTM (i.e. 2.425mm) The best part is the price, only $2.40 a shim, less than half of what KTM charges, meaning you can make a 20 shim mini kit for only $48. Here are the part numbers for the most common shims you will need...
I've swapped the coils to eliminate the fault codes. I'll need to take another reading once the laptop has recharged.
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Tom,
I have had chance to run mine up with the 'new' coil sticks today...the coil fault has gone.
Cut out after a short while though, but not the sudden death like before...almost like a blocked jet in a carb..would not rev cleanly of the bottom end then died.
Had got the tank tilted back against the rear seat unit and only a litre or two of fuel in so it may have been starvation.
Anyway, decided to whip the tank off to check for water etc in the fuel....no sign of any dirt or water. Ordered a new fuel filter though and have performed a pm on the old one...the paper element inside was filthy...bike has now done about 9k miles.....
Have posted a separate thread on the fuel filter details.
Thought I'd resurrect this thread as I've got the old girl sorted now.....it's only taken me 12 months, but in fairness that's because I haven't had the time due to other projects etc.
In summary, after the event last year I set about the bike to check it all over and fit a new dash unit as the old one was damaged when it got accidentally sprayed with petrol at the garage while filling up.
So here's a resume of the work.
Valve clearances checked - shims out of whack on both exhaust cams (clearance too tight) Cams out & re-shimmed.
Valve timing double checked - OK.
New plugs & replaced front coil stick as it kept throwing a DTC on the diagnostics - this could just be an anomaly as it seems to do it on all the bikes using both Ducatidaig and the OEM diagnostic package according to a tech at NLM. I Had one in stock so swapped it out anyway.
Checked all relays & electrical connctors
Replaced fuel filter
Replaced all exhaust coupling gaskets (£15 each !!!) after reading about the air bleed problem on some bikes. All joints done up nice & tight, especially those before the lamda.
Re set the throttle bodies after considering other causes for the intermittent stalling - the Ducati 1098 has a similar problem and it is caused by the stepper not flowing enough air.
Thinking back, my problem started happening after I had set up the synch according to the book - the bike cut out when hot after a high speed run.
So I have ignored the book and have synched the trottle bodies in the first instance "correctly" ie both bleed screws closed etc. I have then opened BOTH screws 1/4 turn to bleed additonal air at tickover. (The high speed sync is fixed so it only really affects the low speed running)
Reset CO
Took her out for the MOT yesterday and she is running sweeter than ever - result - I am one happy bunny and had forgotten just how much grunt & engine braking these bikes have.
Added bonus is I haven't had to resort to using the spare engine I bought off Tom so I'm keeping that for emergency spares if the Morini situation doesn't improve.
Next up is to remap the spare ECU with a Veloce map. Head tech at NLM reckons the map transforms any bike regardless of base spec.
