2016 KM 500 ETC backfires and pops with Vortex controller

[crowncokeandsoda]

The bike did not pop before. I installed a Vortex controller, FMF 4.1 slip on and removed the smog gear. The bike pops a lot when coming down the hill. It does this with any of the fuel maps. My dials were set on 5 5 5 running premium and 6 6 6 running 50/50 average gas. No difference.
It runs like a beast going uphill now.
Oh, I'm on a TS 137 (2013).
Any input appreciated.

Timbo.

 

[capulin overdrive]

Did you do the open/closed throttle procedure?

 

[mikew5945]

Must be the TS. LOL
All BS aside, this is happening with all the KTM 500s in our bunch. There must be a lot of fuel added to get this. I have changed the plug and the color is perfect. A buddy took off the head and the burn on the piston is really good. Just look at it as you are cool and all will be OK. I'm running on 555 and 7 for the low end grunt. Buddy runs on 3 for the RPM addition. If I run on 8 I get more popping. If you want to get rid of that popping Ill sell you my Power Commander (18-012) with the auto tune.

 

[007]

I have a 16 500 wcw with a raze Ecu. When I put it on it would do the very same thing pop, backfire and ran crappy. Got back from my trip called raze and they were head over heals more accommodating to get this problem resolved. They said they tried every map they had for it and non of them would work! They ended up welding in a afr Bung and writing a custom map and rips now. I wonder if some of the 16’s had something odd about them????

 

[crowncokeandsoda]

Must be the TS. LOL
All BS aside, this is happening with all the KTM 500s in our bunch. There must be a lot of fuel added to get this. I have changed the plug and the color is perfect. A buddy took off the head and the burn on the piston is really good. Just look at it as you are cool and all will be OK. I'm running on 555 and 7 for the low end grunt. Buddy runs on 3 for the RPM addition. If I run on 8 I get more popping. If you want to get rid of that popping Ill sell you my Power Commander (18-012) with the auto tune.

Maybe the TS. Lol! No, they buy beside me has the same bike and same mods. Exactly. Except he's on a Yeti.... and no popping.

 

[crowncokeandsoda]

Did you do the open/closed throttle procedure?

No, but I did see it on YouTube. I can't do it because my bike won't turn over with the kill switch off. Neither will my buddy's bike. Identicle bikes with identical mods. But he has no popping. I tied the old ecu and it still doesn't turn over with the kill off.

I have to confess, I saw the video where they adjusted the TPS by ear to make the bike run better. I didn't have the TPS positioning tool so I tried it by ear. I couldn't tell any difference in idle no matter where I set it. This was before the vortex or the FMF or the delete kit. I just re tightened it near center...

 

[assaultn]

High temp silicone all exhaust connections, it's amazing how the smallest reduction in back pressure can cause so much deceleration pop. I had a tiny hairline crack in my header pipe that would only really open up to be visible when hot. Had the same decel pop and farted around tuning and tuning. Found the crack and replaced header... Problem solved. Might not be ur issue but considering you have 2 bikes with same mods and only 1 is popping it could be as simple as that. Cheers.

 

[capulin overdrive]

No, but I did see it on YouTube. I can't do it because my bike won't turn over with the kill switch off. Neither will my buddy's bike. Identicle bikes with identical mods. But he has no popping. I tied the old ecu and it still doesn't turn over with the kill off.

I have to confess, I saw the video where they adjusted the TPS by ear to make the bike run better. I didn't have the TPS positioning tool so I tried it by ear. I couldn't tell any difference in idle no matter where I set it. This was before the vortex or the FMF or the delete kit. I just re tightened it near center...

Weird!

Was able to do the procedure with my 2016 500XCW, and it runs perfect. Starts great, runs great, just crazy how much better it is than stock ECU. FWIW my Vortex is from PR2 Racing.


Sounds like it might be worth finding why EXC wiring won't let it work like on the XCW.

 

[crowncokeandsoda]

High temp silicone all exhaust connections, it's amazing how the smallest reduction in back pressure can cause so much deceleration pop. I had a tiny hairline crack in my header pipe that would only really open up to be visible when hot. Had the same decel pop and farted around tuning and tuning. Found the crack and replaced header... Problem solved. Might not be ur issue but considering you have 2 bikes with same mods and only 1 is popping it could be as simple as that. Cheers.

all i did was slip the FMF onto the pipe. it never came with a clamp or silicone. ill start wirh that. thanks!!

 

[crowncokeandsoda]

Weird!

Was able to do the procedure with my 2016 500XCW, and it runs perfect. Starts great, runs great, just crazy how much better it is than stock ECU. FWIW my Vortex is from PR2 Racing.


Sounds like it might be worth finding why EXC wiring won't let it work like on the XCW.

I cant recall if it turned over with the kill off before. maybe ill try to set it with the kill off and kicking it over. i think its a combination of that and moving the TPS without measurinf the voltage.
i cant do anything with it for now because i got t boned last weekend and cracked the ignition (stator) cover. it wont hold oil. waiting on parts....

 

[crowncokeandsoda]

all i did was slip the FMF onto the pipe. it never came with a clamp or silicone. ill start wirh that. thanks!!

BTW, the silicone fixed the problem. thanks!!

 

[crowncokeandsoda]

High temp silicone all exhaust connections, it's amazing how the smallest reduction in back pressure can cause so much deceleration pop. I had a tiny hairline crack in my header pipe that would only really open up to be visible when hot. Had the same decel pop and farted around tuning and tuning. Found the crack and replaced header... Problem solved. Might not be ur issue but considering you have 2 bikes with same mods and only 1 is popping it could be as simple as that. Cheers.

yes, that fixed it. thanks!!