Trouble Shooting - KTM 400 Owner's Handbook 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 (E-starter).
Engine will not start (Kick-
starter).
Engine fails to idle

TROUBLE SHOOTING

CAUSE
Operating errror
Blown fuse
Discharged battery.
Low outside temperatur
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
Short circuit cable scored in wiring
harness, emergency OFF switch or
short circuit button 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 emergency-OFF switch (Australia only)
Dismount the left paneling and the filter box cover and replace
the fuse in the starter relay.
Recharge the battery and investigate the causes for dischar-
ging; contact a KTM dealer.
Start engine with kickstarter
Open fuel tap, tank fuel, actuate choke. Pay attention to star-
ting information (see driving instructions).
The easily inflammable components of the new fuels evaporate
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.
Close fuel tap, loosen fuel hose at carburettor, lead into a basin
and open fuel tap
– if fuel leaks out, the carburetor might need cleaning
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
In order to "pump the engine free", pull the hand decompres-
sion lever, fully rev up the engine, actuate the kickstarter 5 to
10 times or actuate the E-starter 2 times for 5 seconds each.
Then, start the engine as described above.
If the engine fails to start, unscrew the spark plug and dry it.
Clean and dry the spark plug or exchange it, respectively
Adjust spark plug elektrode gap to 0,6 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
Dismount the fuel tank, disconnect the black/yellow cable from
the cable of the emergency-OFF switch and the short-circuit
button, respectively, and check the ignition spark.
If a spark is generated, look for the problem in the short-circuit
circuit.
Remove the seat 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
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