Question about 2006 KTM 200 EXC

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My ktm 200 exc 04 model keeps on jumping from 5th to 4th gear. Any ideas on what this could be or what to check before splitting the engine? thanks

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Sounds like a worn shifter fork in the tranny.

Good luck.

Posted on Aug 02, 2009

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The transmission secondary gear cogs are worn. Replace primary and secondary gears

Posted on Apr 04, 2014

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Posted on Jan 02, 2017

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as with all bikes of this nature, check for runout in wheels, loose spokes, lighting working, suspension not leaking, brake discs for exsess wear, check coolant level , check engine oil for evedence of water, leaking water pump, radiator cap leaking past overflow pipe this could be pressure in system due to head gasket failure, fuel leaking, also check area around eng oil plug for evidence of repaire with cemical metal or similar, slightly noisy tappets is not uncommon,, normaly prety good bike, avoid bikes that smoke exsessive, check all gears are working correctly. dont jump out of gear ride in every gear and check for mechanical noise from gearbox, good gearbox normaly easy to select, doesnt jump out of gear, if u are looking at buying a bike of this nature they are fairly high maintenance, like to be cleaned , oiled and addjusted frequent oil changes, these are basic things i would check when buying a machine of this type, not nessasary a ktm, and these coments are not meant to harm your decision only help you chose the rite one.

Jan 05, 2011 | 2008 KTM 530 EXC-R

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My 525s 2nd gear is whineing what is wrong


Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to make sure your issue was resolved.

Usually 2nd gear whine is caused by bent shifting forks or dogs and the gear is wearing incorectly. The best solution is pulling the engine, splitting the cases and replacing the worn, bent, or broken parts.

TF

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Well you solved you own problem you need to replace the return spring.

May 01, 2010 | 2004 KTM EXC 200

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Ktm output shaft oil seal


if you are lucky there is a clip behind the front sprocket remove both then pop the seal out drain gear box oil first though. if not which i think is most probable the engine will need splitting if you are good with spanners it is quite easy being a 2 stroke .in brief remove engine remove bore and carb in one lump remove sprocket gear lever split g-box .seal up push old seal out, from outside in, fit new then reverse prosses. a good manual will help.

Feb 12, 2010 | 2005 KTM EXC 250

1 Answer

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i would change the clutch befor they go out and mess up more things

Nov 30, 2009 | 2008 KTM 200 XC-W

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Model types


which one would be the best?First of all there is no sxc it's sx exc mxc. The difference in the sx and exc is the sx is strickly a mottocross bike. It is not geared or setup suspension wise to ride in the woods. It is much more radical than an exc which is designed specifically for woods riding.,,,

Nov 10, 2008 | 2004 KTM SX 200

1 Answer

Model types


which one would be the best?First of all there is no sxc it's sx exc mxc. The difference in the sx and exc is the sx is strickly a mottocross bike. It is not geared or setup suspension wise to ride in the woods. It is much more radical than an exc which is designed specifically for woods riding.,,,

Nov 10, 2008 | 2002 KTM MXC 200

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