I have a 2023 ktm 450 with about 60 hours on it. Last fall a friend of mine needed to borrow the wiring harness as they were back ordered and I wasn’t using the bike much so I let them use it. I ended up throwing the harness back in a couple months later and the bike hasn’t stopped acing problems. It will start and run fine, but randomly bog or cut out and shutoff. The problem has gotten worse to the point it doesn’t stay running on the stand anymore. I since replaced the wiring harness, reset the tps sensor, had the Gear position sensor indicator pop up on the hour meter so I replaced that, replaced the spark plug, replaced the tip over sensor. Bike still has the same issues. Was wondering if anybody else has ran into similar issues and possible solutions. Thank you!
Other than parts you replaced, have you made certain that all connections are solid and grounds are all tight/clean?
Stock ECU?
Your friend gave you the shitty harness he was trying to replace.
Yes stock ecu
The Shop
Yes.
I had similar issues with an aftermarket Vortex ECU , maybe try another ECU to at least eliminate that part. Fuel pump replaced?
I’d go over every connection to make sure you didn’t inadvertently push any pins backward out of their connector. Not hard to do while plugging them in, and would be a likely answer to why it worked before and not now.
I've heard of people suffering from that with water or dirt in their connectors. I've heard some guys will only wash their bikes if they have compressed air to blow everything out.
Fuel pump and/or fuel filters?
I replaced fuel pumps and the in line filter. Also swapped the regulator, ignition coil, a relay, and a condensator and no luck. Going to try another reset of the tps incase it may have gotten bumped or adjusted somehow.
Try another ECU, or possibly reset yours. Also they swapping fuel tank. Could be bad fuel pump, or a kink in the fuel lines, possibly a leak even.
Updated list of parts I’ve thrown at it that didn’t help
wiring Harness
Ecu
Throttle body
TPS
TPS re set
Ignition coil
Voltage Regulator
Tip over sensor
Condensator
Start/ kill switch
Spark plug
Gps sensor
Relay
Fuel pump
inline fuel filter
Anybody have any other ideas?
Like @captmoto said, are you sure your buddy isnt trying to fuck you over?
I would move the engine over to another bike or vice versa. Then you will know where to look depending on outcome.
Did you check the stator wiring? I think it is very possible a wire is nicked or broken and those can be rather hard to hunt down sometimes. Also is there any chance of a fuel line with a cut or pinch?
Try another spark plug boot and harness Mae sure battery has 12+volts
Just found it. And the kid I gave the harness too was my roommate and best friend. We swapped all parts together. Turns out the spark plug boot cracked under the seal. Didn’t notice it until I removed the seal today. Thank you for the help everyone.
Awesome! Was the plug cavity filled solid with mud like cement? I had a 350 do this…
Pit Row
Nothing crazy. I noticed it was a bit wet when I first took it off about a month ago but didn’t think much of it at the time for some reason. Just thought maybe it wasn’t fully pushed down, then today I had some more parts come in to try so was swapping stuff around. Swapped the water temp sensor and started the bike as I was still lower and next to it and noticed the sparks coming from the cap. 🤦🏼♂️
Glad you found the fix man!
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