KTM 300EXC 1997 ! some problems please help! specialist needed!

[Kanadia]

hi

i have a KTM 300 EXC 1997, but it doesnt run! I think its because of the cylinder, because you cant kick the kickstarter !! So i wanted to have a look on the cylinder, but the cylinder is O.K. !!! So, what could it be ??

my situation : i mixed gas and oil ( 1:40 ) ! the best gas ( 93 octan ) and the best 2 stroke oil, its honda 2 stroke high performance oil (but what does premix ratio 32:1 mean??) ! So well ! i rode with it, and then it broke down and i couldnt kick the kickstarter ! Its enough liquid cooling inside ! the bike is all new, i bought it from a KTM specialist ! But i dont want to bring it to the KTM specialist, because its too expensive ! i can do it all alone ! but i have no clue, whats broken ?? today i built out the whole cylinder and the piston (i think its called piston) there were a lot of metal things on and in the crank shaft! it doesnt look really good! i think i have to build out the whole crank shaft! but that little or big metal things, i mentioned, werent from the piston ! but from what could they be! i have no idea!
Where can i buy a new cylinder and a new crank shaft? Does this **** (sorry ;) ) happened to anyone ?

please, i need help,

sorry, for the mistakes in the text, but i moved from germany, two weeks ago ! so my english is not that best !

ahhh by the way ! Does anybody know where i can get a dual sport kit for my bike? to legalize it ? Thanks !!

But i hope you can help me !!!!!!!

 

[TM-Frank]

... i can do it all alone ! but i have no clue,...

Well...
:think:

When piston and cylinder are undamaged the metal fragment could be fragments of the rod (Pleuel) or its bearings (Pleuellager und Kolbenbolzenlager). Another possibility could be that something entered the crankcase from the intake side, like some broken-off part of the reed stoppers (Anschlagbleche der Membranen im Einlass). Are the fragments steel or aluminium?
I suggest you remove the engine from the bike and disassemble as much as you can do on your own and bring it to the dealer then.

 

[Kanadia]

yes i removed the whole cylinder and the piston ! but the metal things are not from the cylinder or the piston! i think its from the bottom of the crank shaft ! but i'm not sure ! So today i have to have a look in it !
but whats wrong? i mixed it 1:40 ! I did nothing wrong !
so it can happen the next time once again!

 

[TM-Frank]

Crankshaft bearings and rod bearings are wear&tear parts and when you have bad luck they break and cause much more damage. But I would say that has nothing to do with 1:32 or 1:40. When there still was the first set of crank bearings in that engine then they had a pretty decent lifespan.
I don't know anything about Canadian warranty regulations but when that happened on the very first ride I would talk to the dealer who sold you the bike first before attempting any repairs. Maybe he pays for the parts or the labor or something.

 

[Kanadia]

oh ok ! today i will phone that guy who sold me the bike ! Why do you speak about canadian warranty ? its an american bike ! but thanks, before i will have a look in the crank shaft i will phone the KTM specialist!

thank you!!!! :cool:

 

[TM-Frank]

Was obviously confused because of your nickname. But I don't know anything about American warranty regulations either, so it doesn't matter. ;)

 

[Kanadia]

oh ok :laugh: ! but thanks anyway! :) ! i think the KTm specialist will help me ! i hope he's a nice guy :laugh: !

by the way i like the smilies in this community ! :moon:
but i think thats spam! i'm sorry!

now i have to call the ktm specialist!

 

[Layton]

A quick question on the oil mixture ratio. You did put one bottle of oil (16 oz) into 5 gallons of gas correct?

 

[Kanadia]

nono , i had a 2 gallons gas tank! and i have such a thing (sorry but i dont know the name of it :think: ) its for special oil gas mixture, its 1:40 on it, and 2 gallons, so you only have to fill it up ! up to 1:40 oil ! und then put it in the 2 gallon tank! sorry for that really bad example, but i dont even know the name of it! its hard to complain! :| !
but i can make photos of it, if you want ???

hope you can help me!!!!

 

[ScottS]

Ich glaube Layton fragt- - 40 mal benzin und 1 mal Ol- richtig ? 40 mal Ol und 1 mal Benzin geht nicht. Wenn Sie zum biespiel 1:32 schreiben, die erste Nummer ist Benzin und the Zweiten ist Ol . So fur Ihre Motorrad sollen sie 40:1 -

Entcheldigung, unsere Amerikansiche Computers hat keine Umlauten !

Maybe some photois owuld help- sounds like a piece came loose from somewhere and got sucked into the bottom end- the only way a 1997 is "all new " is if it blew up and was rebuilt- maybe a piece from the earlier incident was left in the cases to cause this problem

 

[ScottS]

By the way I just put a TRICK Dualsports lighting kit on my KTM and it is super easy to install.

After two weeks, you spell better than me anyway.

 

[Kanadia]

oh yes you're right ! 40:1 ! i'm sorry !!!!

was meinen sie mit: nach 2 wochen krieg ich es besser hin? Das versteh ich nich so ganz !

Thanks for the tipp with the trick dual sport! i will phone the guy ! So i hope i will have a dual sport kit soon! :) !

In ten minutes the pictures will be online!

ah to the trick dual sport kit! Does this kit come with an ignition??? because on the homepage i read that its only the lightning in this package! is it true ? Do you have the complete kit ?

 

[Kanadia]

mhhm i am looking for a function for the pictures, how can i show them to you??? i made them! !!!! And something "funny" :| happened to me, i tried, to get a really big metal thing out of the cran shaft, yes it was IN :yikes: the crank shaft! So i tried to get it out, and my big screwdriver broke in the middle! :yikes: !!!! But this metal thing is still inside the crank shaft! :think:

 

[ScottS]

I meant your english spelling is fine- mine needs work !

The trick dualsport includes the battery, handlebar switches, lights blinkers, flasher relay etc- your existing EXC ignition should handle it if you have a 2k-3 igniion ( 2 yellow wires come out for lighting)

The Trick kit is nice because all the electronics is in a box behind the headlight so you can take it off quick

Only have to connect a few wires and you are done ! I also picked it because it has an auxilary power port I use for a GPS

 

[ScottS]

Don't use quick reply- go to the "reply" button, then scroll down you will see "manage attachments"

I am curious to see what is in there :yikes:

 

[Kanadia]

i think i found the problem !!!!

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mhhm. whats that ? What did i wrong ? :|

Yes, its really frightened what happened to my crank shaft!
i dont think i will be better in spelling than you! i have to learn it ! but i will learn it ! I'm still 16 years old and i had "only" 5 years english lessons in school!!!! but you dont learn it in the school, you learn it here! but i dont think thats this thread about ;) ! So, does anybody know how to disable this function not to post attechments?????

 

[Timr]

Sorry, but you have to be a subscribing ($) member to post pics in the thread. If you have some web space through your Internet Service provider, you can post the pics there and then post a link to them in here. Welcome to the US. Does one of your parents work for Daimler Chrysler? In Vance?

 

[Kanadia]

oh thats sad! yes my father works for them! why ? what does it mean "vance"???? I haven't webspace ! :ugg: ! So there's no way to show them to you ???? :yikes:

what's a lifetime sponsor ???

 

[Timr]

E-mail them to me, and I will post them in this thread tonight. My e-mail Timr71 AT charter.net (replace AT with @ )

I was just curious about the Daimler thing. There's no other reason why one would move from Germany to Tuscaloosa, AL. Vance is where the plant is located. My Dad is retired from Daimler Chrysler and spent a lot of time in Germany and Switzerland.

What KTM person/Dealer are you talking to? I used to live down there (Tuscaloosa) when I was in college and I had a KTM then.

 

[Kanadia]

oh thank you i will email them as fast as i can!

no, my father doesnt work direct for daimler chrysler! He's a supplier ! but the headquarter is in germany, too!! I'm not talking to a local dealer! this KTm is from florida, my father "trailered" (i dont know if this is the right word, but i think you know what i mean) it to alabama! what KTM you had down here ?? Yes, i need it to get to the High School, too ! i rode this bike twice, and its really fun, in germany i drove a little scooter, it was fast, but it was nothing against a KTM ! my scooter ran about 60 mph, thats really fast for a 50ccm cylinder! but the police stopped me twice, so i had to give it up!

but you have no idea, what i did wrong ? I mixed it same as in the instructions! And now it seems that i have to rebuild the whole engine! Thats really sad :|

 

[Kanadia]

oh i'm sorry i forgot ! ScottS du you have the Mini Kit ??? I mean the dual sport Kit ! Because the standard kit comes with an special battery, i need it, too, is that right ? So i have to have this standard kit plus the trailtech computer! Do i need to know anything about that computer ? So it's about 500 dollar ??? Or do i have to have anything else ??? please help me once again !!

 

[ScottS]

Yes I have a standard kit, it was changed a liitle, talk to Trick they will basically make up what you need - I am bery impressed with the workmanship and the support. The battery is very small and is just to pass state requirements for a battery.

 

[Timr]

Here's the pics:

 

[Timr]

second set of pics:

 

[TM-Frank]

Kanadia,

you tried to remove the metal thing in the area where you painted the red rectangular on the photo, right? That is either a piece of the lower rod bearing or the washer that sits besides the bearing. Go to www.ktminfo.com , select your bike and take a look at the crankshaft picture.
I think you will need the repair kit (KTM Part #5463001504, Pos. 30 on the picture) for around 200$.
Problem is that you can not install that yourself because the crankshaft has to be disassembled and reassembled with a hydraulic press.
I don't think you did something wrong. It was just bad luck and can happen to anybody.