Question about 2008 KTM 200 EXC

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2006 250 xcw sputtering at high revs

I'm the second owner since last year and I've had this problem since I got it .I've tried different main jets and I took it to our local ktm dealer three times and got no results.If anyone has any ideas I'd appreciate it Thanks Rob

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Hi and welcome to FixYa,

Offhand, it appears that you have an air leak (not a vacuum leak). This could be caused by:

  • loose, detached rubber coupling from the airbox to the air intake;
  • torn, defective, loose air filter/cleaner;
  • improperly sealed cover of the airbox;
  • air filter was replaced with an aftermarket such as K&N and no rejetting, air/fuel mix adjustment and exhaust tuning done.
There are instances when the electrical has an issue and it affects the electronics, specifically the CDI at higher RPMs.

Would appreciate an update based on the above. Good luck and thank you for using FixYa.

Posted on Feb 23, 2009

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Bike spits and sputters at top end

Hi, Johnny and the usual suspects are:
1. Inlet system air leak.
2. Enrichener valve not seated or leaking.
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5. Dirty or damaged air cleaner element.
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I have a 2010 ktm 65sx ran like a top last year this spring got it out ran good all of a sudden bike starts good but it seems like it starves for fuel on the low end when it gets in the power band it takes...

Thank you for contacting FixYa with your inquiry.
Low power or stalling at start is usually air/fuel related. You have taken care of most of the things that effect the bottom end power band. Some other things you might consider:
  1. Check the air vent tube on top of the tank to make sure it's not pinched or restricted.
  2. Clean the fuel tap. May have sediment or debris. Some have a filter screen. Clean it.
  3. Clean the air filter and air box. Check the rubber boot for cracks or air leaks. Clamp??
  4. Exhaust system - Check for leaks or fiber fallen from the muffler.
  5. Check the diaphragm or reed valve for cracks or reed problems
  6. Check the timing or fault with the ignition system. Is something loose.
  7. Screw in the idle jet all the way and back it out to 1 1/2 turns.
Jetting: (Tons of options with a Mikuni) In general, the main jet is for high rpms and top speed running. Needle effects the mid range to about 3/4 throttle. Idle jet effects the bottom end. 3 sizes exist 20, 25, 30.
Drill down from this link for part numbers: 2010 > 65 SX > ENGINE > CARBURETOR
Let us know if we can provide further information.
Kind regards,

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I got a 2010 ktm 65 sx. Can't keep spark plugs in it. Always fouling them.Mixture is 60;1 What factory recomends. Any help wolud be appreaciated.

Thank you for contacting FixYa with your KTM Inquiry.
More than likely you have a jetting problem. My first thought would be to call the dealer service department and ask what jetting they suggest for the local area you are riding. May or may not be able to advise you and want you to bring it in. Check your user manual and see if any jetting suggestions exist. Pretty easy do it your self fix.
Start by cleaning your air cleaner so it's not drawing excessive fuel to air mixture. Replace fuel filter and confirm gas tank vent tube is not pinched or plugged.
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  2. Middle - Needle Jet and Tower. If it runs bad at half throttle to 3/4 this may be allowing over fueling. Simple fix is to lower the slide cir-clip holding the slide to a lower notch allowing the needle to project further down in to the pilot and leaning out the mixture bypassing the needle.
  3. Main Jet - Allows for optimum speed when you have the wire tight at high rpms. If it's fat and not running right go down a size on the main jet. Engine should have a smooth scream.
Jet's are comparatively inexpensive so experiment a bit until you get a cocoa brown spark plug color after a good run. As always make sure your float is working correctly and no shellac exists from winter storage with old gas.
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I would check the jetting by the color of the plug. If it's black, go smaller main. If it's white, go larger on the main. If jetting won't cure it, it probably has a crank seal out. My kid used to race these, and he blew out a crank seal trying to start it with the wash plug in the exhaust. Did the same thing as you're describing. Good luck!

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Black smoke indicates a too rich fuel mixture. Be sure the air cleaner is clean. Install a new spark plug. Check what size the main jet is. The prior owner may have installed a larger than stock main jet. There will be a number stamped on the side of the jet. Call the dealer and ask what the stock jet number is for your bike and then tell them what you have. Go back to stock.

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Hi, Mattpollack and the usual suspects are:
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2. Damaged or restricted fuel tank venting system.
3. Inlet system air leak.
4. Vacuum piston malfunction.
5. Accelerator pump leaking or no output.
6. Plugged bowl vent.
7. Fuel level in bowl too low.
8. Restricted fuel supply passages.
9. Plugged jets or passages.
10. Worn or damaged needle or needle jet.
12. The enricher valve not seated or leaking.
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