I've been at it for a while now... It's been a long haul and it still won't start. I have spark, the fuel pump turns on (and I have no kinked hoses) and the air filter is cleaned.
All connections have been double checked.
Story from the beginning (shortened):
(because the first thing will be to see what I've ruled out and what's the history)
About a month ago my bike died on me riding into work. As I was accelerating onto the highway. I pushed it home (uphill w/ a full tank). I took the tank off and checked all the fuel connections (since I know that a pinched breather hose will kill the engine). It was all good and I put back the tank. The bike fired up.
I sent it off to the dealership for a check-up just in case. Valve check, new plugs and see why it died. They found that the idiots from another shop put in the wrong plugs and didn't snap the plug caps down tight. I needed 2 more plug caps as they had worn and won't reliably contact the plug (the top of the plugs were burnt).
I picked up the bike and the next day it died on me coming home from work. I put the kickstand down and it fired back up. Ok, maybe the kickstand wasn't all the way up.
That saturday as I was trying to get into work: the bike died on the highway as I was accelerating up to speed.
The shop picked it up and played around with it for a day. They couldn't find anything wrong so they disconnected the PCIII
I put on 500km trouble free.
Monday rolled around and it wouldn't start after I had ridden it hard on Sunday.
I pull the tank off, check everything I can, and put it back together. It fires up.
I put on ~1000 trouble free kms.
Last weekend: same deal. I wanted to take a ride down to the KTM dealer to check out the 625SM and it wouldn't start.
Take the bike apart.
The #2 plug cap pulls off with a light touch. I order a new one, clean the air filter, check all the plugs and put it back together after checking that I have spark. All good.
Put fuel in the tank, turn it on and it'll just crank over. The fuel pump turns on, there are no error codes (even after I jumped the switch) and all the fuses are OK.