Trouble Shooting - KTM 625 SXC 2003 Owner's Manual

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error
occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
TROUBLE
Engine doesn't crank.
(E.-starter)
Engine cranks but doesn't
start.
46
Engine fails to idle

TROUBLE SHOOTING

CAUSE
Operating errror
Discharged battery.
Defect ignition lock or emergency
OFF switch
Blown fuse safe-starting system.
Blown main fuse.
Operating error
The motorcycle has been out of
operation for a longer period of
time. Therefore old fuel has accu-
mulated in the float chamber
Fuel supply interrupted
Flooded engine
Sooty or wet spark plug
Electrode gap too large
Spark plug connector or spark plug
faulty
The plug connection of the CDI-
unit, the pulse generator or the
ignition coil has oxydized
Water in carburetor or jets blocked
Glogged idling jet
Oncorrect adjustment of adjusting
screws on carburetor
Defective spark plug
Defective ignition system
REMEDY
Turn on the ignition
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer
Check ignition lock and emergency OFF switch, contact a
KTM dealer
Replace fuse (3)
Remove seat and replace the main fuse (1). If fuse blows
again contact a KTM dealer
Open fuel tap, tank fuel, you did not use choke i.e. the warm-
start device. Pay attention to starting off information (see
driving instructions
The easily inflammable components of the new fuels evapo-
rate during longer periods of standstill.
When the motorcycle has been out of operation for more
than a week, it is therefore recommended to drain the old fuel
from the float chamber. The engine will immediately start off
when the float chamber is filled with new fuel.
Place a vessel underneath, remove the drain plug from the
carburetor and open the fuel cock,
– if fuel leaks out, the carburetor might need cleaning
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
Fully open the throttle when starting or exchange the spark
plug, respectively
Clean and dry the spark plug or exchange it, respectively
Adjust spark plug elektrode gap to 0,9 mm
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate starter, a strong spark
must be produced at the spark plug
– If no spark is created exchange the spark plug.
– If the new spark plug doesn't produce a spark either, dis-
connect the spark plug connector from the ignition cable,
hold it a distance of approx. 5 mm from ground and start.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Remove the seat, the right side cover and the fuel tank. Clean
the plug connection and treat it with contact spray
Dismount and clean carburetor
Disassemble carburetor and clean jets
Have carburetor adjusted
Replace spark plug
Have ignition system checked