Did you mess with the leak jet and accel pump adjustment? A friend and I got his WR running real well with the JD kit and these adjustments.
Also, I wonder what CDI they are using, as these have changed a bit.
If I had one, I'd buy another motor and build it up at my leisure with the best components. In fact the thing to do would be to buy a used one when it pops up on ebay and do just that.
KTMs run hard but if it goes boom its not worth fixing.
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