Question about 2003 KTM SX 200

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My 2003 KTM SX 200 lacking bottom end, top just rebuilt

My 2003 KTM SX 200 has very little bottom end, the top end was just done and has new spark plug,air filter,and silencer packing I did notice the oil was light Grey which usually is the water pump seal leaking into the gear box.I did change the oil since and have not yet drained it. the top end (powerband) seems to lack a bit as well, basically the engine doesn't seem to be as explosive as it was.

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  • tombones May 11, 2010

    The crank seals may need to be replaced.

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Isn't that a two-stroke? pull the jug off and check the piston/bore...if you can do that you're okay...Otherwise, call "Lazarus" at GT Thunder in Millersburg, FL and ask NICELY what to do.
P.S. he's a BUSY man be NICE to him!

Posted on Jun 15, 2009

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Posted on Jan 02, 2017

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Hi ave got a ktm 125sx 02 its just had a bottom and top end rebuild bike starts and runs great but there is still a rattle from the engine could anybody help thanks


Lots of engines make characteristic noises and air-cooled 2-strokes have lots of characteristic noises even when new and even when there is nothing wrong.

If you have just spent a parcel of money on it your first port of call should be to the person or dealer who carried out the work. Having a top and bottom overhaul means a world of different things to different people. If you don't know what has been done and what needed to be done you will be somewhat in the dark and at a disadvantage with perhaps unrealistic expectations.

Perhaps the engine hasn't had as much of an overhaul as you thought. A full bottom end overhaul is a good deal of cash and lots of work that would make it as good as a new engine again. Maybe the dealer decided for reasons of economy to refit some of the old parts instead of replacing everything.
I suggest you read your invoice and then go and ask some leading questions.

Apr 02, 2016 | KTM Motorcycles

1 Answer

I've got a KTM 125sx 2002 I've done a top end rebuild piston etc and put a new coil and plug on it and the bike won't start with the kicker, only with a bump start took the plug out and its got a weak


Hi, Ian and the usual suspects are:
1. Fouled spark plugs.
2. Discharged battery, check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Loose connection at ignition coil or plug between ignition sensor and module.
4. Spark plug cables in bad condition, shorting / leaking, spark plug cable connections loose.
5. Faulty ignition coil or ignition / electronic module
6. Failed CKP, CMP, or BAS sensor.
7. Faulty ignition switch.
8. Security alarm failing to disarm needs reset
For more information about your issue and valuable free downloads that you will need please visit the websites below. Good luck and have a nice day.
125sx won kick start please help me KTM 2 Stroke
ktm 85 sx no spark
1999 2003 KTM 125 200 SX MXC EXC Service Manual Moto Data Project

Feb 23, 2016 | KTM Motorcycles

1 Answer

Ave got a ktm 125sx 02 just done a top end rebuild piston air filter and plug but the bike still wont start with a kick only with bump any ideas thanks


Hi, Ian and the usual suspects are:
1. Fuel tank empty.
2. Fuel supply valve/petcock turned off.
3. Fouled spark plugs.
4. Engine flooded as a result of overuse of the enricher.
5. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
6. Fuel valve/petcock or filter clogged.
7. Discharged battery, check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
8. Loose or corroded wire connection at the coil, battery or plug between ignition sensor and module.
9. Spark plug cables in bad condition and shorting, cable connections loose, or connected to the wrong cylinders.
10. Ignition timing incorrect due to a faulty ignition coil, ignition module or sensors (MAP, CMP, CKP, O2 and/or BAS).
11. Security alarm needs a reset.
For more information about your issue and valuable free downloads that you will need please visit the websites below. Good luck and have a nice day.
1999 2003 KTM 125 200 SX MXC EXC Service Manual Moto Data Project
Dirt Rider Magazine
Thread Kick Starting Tricks

Feb 13, 2016 | KTM Motorcycles

1 Answer

KTM SX 125 bottom end locked


Hi, Anonymous you may have hydraulic lock caused by excessive liquid in the cylinder or you have squeaked your top end this is commonly known as "HEAT SEIZE" the piston heats up expands and becomes extremely tight in the cylinder bore and usually occurs mainly on 2 cycle engines right after a fresh top end rebuild, but it can also happen to brand new motorcycles, these are rare instances due to better quality control and education. Overheating failures that cause pistons to seize are many and each one should be carefully diagnosed to prevent future repeat offenders and the usual suspects are:
1. Lack of lubrication due to low or no oil.
2. Among the causes of lack of cylinder, lubrication is clogging of lubricator by dirt or waste, obstruction in oil pipes/lines, leaky check valves, leaky pump packing, broken oil pipe/line, oil too cold to feed.
3. Wrong type of oil used in premix or oil tank.
4. Improper premix ratio you should start with 32:1 as a baseline.
5. New rebuild piston to cylinder tolerances set up too tight.
6. Failure to follow proper break in procedures with a 16:1 premix ratio.
7. Loose fasteners causing intake, base, or head gaskets to leak or blown crankshaft seal, failure caused by age, overheating or walking. 8. Holes in the intake manifold bent or warped intake flange or reed cage any stray air coming into a cylinder will cause a super lean condition.
9. Improper assembly of reed valve gaskets.
10. Insufficient warm up time for temperature conditions before wide open throttle.
11. Broken, pinched or cracked fuel line.
12. Carburetor fuel passages clogged or restricted from stale fuel varnish, ethanol sludge, dirt, rust, or fuel level in float bowl too low.
13. Main jet size too small or partially clogged
14. Air filter improperly installed, missing or not sealing.
15. Faulty or improperly adjusted oil pump and or cable.
16. Failure to bleed oil pump after a rebuild/replacement or running oil tank dry.
17. Engine coolant level too low, too old, or improper mixture ratio.
18. Radiator clogged, fins damaged, or faulty cap.
19. No liquid circulation due to failed oil or water pump.
20. Cavitation due to air in oil or coolant system.
21. Water and oil mix due to blown head gasket.
22. Timing retarded due to faulty CKP sensor or CDI.
23. Improper spark plug heat range (too hot) and or gap.
24. Excessive engine load, brakes dragging, clutch slipping, transmission lubricant level too low or viscosity to high.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
2 stroke locked up
Motorcycle Bottom End Rebuild Part 1 of 3 Engine Teardown
1999 2010 KTM 125 200 SX EXC Service Repair Manual pdf pdf
http://www.partsfish.com/page/oem-parts-for-ktm
KTM 125 SX Owner Manual

Jun 09, 2017 | KTM SX 125 Motorcycles

1 Answer

Why doesn't my 2007 ktm 125 sx idle


Check inline fuel filter ( if you installed one) and the one on the top of the petcock in the tank. Then clean all of the carb and jets too. There is a special wire tool made by companies like k&l for cleaning inside of jets. Usefresh gas to and make sure the premix ratio is correct. Clean air filter while you are at it, and replace spark plug after checking the gap.

Jan 07, 2014 | 2007 KTM 125 SX

1 Answer

My 2007 ktm sx


Carburetor is dirty, idle circuit needs service.

Jan 07, 2014 | 2007 KTM 125 SX

1 Answer

I dont know where the spark plug is located on my 2003 KTM


follow the spark plug wire. one end will be the coil the other end is the spark plug

Aug 20, 2010 | 2008 KTM 450 SX-F

2 Answers

2003 KTM 250 SX won't start. When you kick it, it starts to fire but never turns over. I accidently put the wrong gas in it. It takes 60:1 but I didn't put enough oil in it. It died while I was riding it....


hi
If you have run the engine with too little oil then there is probably damage to the piston / rings & / or bore
Remove the exhaust to have a look

Ride Safe
Bike-Doc

Jun 03, 2010 | 2003 KTM SX 250

1 Answer

Ring burns up low compression


sounds like you are running to lean,whenever you alter your exhaust system you must rejet your carb. when you have jetted correctly your spark plug colour should be chocolate brown. white or gray is to lean black is to rich.Change your jet to a larger size,install new spark and take it on a short ride at full throttle stop and check plug colour. repeat this till plug colour is correct. hop this helps james

Mar 15, 2010 | 2003 KTM SX 250

1 Answer

KTM 250SX WITH WEAK SPARK. HAS SPARK WITHOUT CAP ONCE I PUT THE CAP BACK ON i GET NO SPARK. I'VE ALREADY TRIED A NEW CAP AND PLUG BUT STILL NO SPARK. dON'T HAVE THE MANUAL FOR THIS BIKE. HELP ME OUT.


try changing the HT leed the spark plug cap screws into this leed if its past its sell by date the plug cap dont make good contact with the carbon fibers inside the HT leed so just change it,,,

Feb 06, 2010 | 2004 KTM SX 200

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