Question about 2004 KTM EXC 200

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Shifter wont return to nutrel

Shifter has no spring to it and shifts hard on my 04' KTM 200 exc

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  • cjfmx May 11, 2010

    YOUR SHIFTER FORK ARE BEND REPLACE THEM

  • hshshs1 May 11, 2010

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  • 342 Answers

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

Posted on May 07, 2010

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1 Answer

89 Yamaha Venture Royal 1300 shifting problems. stays in 3rd gear and wont shift up to 4th or 5th


Hi, Rick and the usual suspects are:
1. Clutch not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
No 4th or 5th gear on 1983 yamaha venture
KTM stuck in gear or wont shift repair
http://www.yamahaventure.nl/pdf/servicemanualxvz1300.pdf
OEM parts for Yamaha
http://www.yamahaventure.nl/pdf/ownersmanualxvz1300.pdf

Oct 01, 2017 | Yamaha Motorcycles

1 Answer

Hard shifting


sounds like you bent a selecter fork in gearbox ! need to strip engine and check all parts inc cogs and bearings !

Jan 06, 2014 | KTM Motorcycles

1 Answer

Fork oil capacity for KTM 200 EXC 2005


https://youtu.be/kUzEuHYjodo

Oct 06, 2012 | 2005 KTM EXC 200

1 Answer

I have lost the torque on my ktm exc 200 and its rpm is very high what could it be


Sounds like the clutch has gone out. Pick up a manual on this bike and see if it can be adjusted. I don't think it can though. You can look to spend around $150 on parts plus labor. Hope this helps. Good luck.

Mar 06, 2010 | 2006 KTM 200 EXC

1 Answer

When changing down the gear box im finding it very difficult to get into 2nd and 1st gears it feels like the gear shift is sticking and not returning properly. i have put in a new clutc kit springs plates...


Do the gears 'crash' when attempting a shift--that might signal that the clutch is not releasing fully. If it just won't go into the gears, the shift fork inside may be bent from the intensity of racing (stomping the shift lever). The engine case must be taken apart and the fork and gears examined--likely the fork will need replacement.

Aug 28, 2009 | 2005 KTM EXC 250 Racing

2 Answers

Ktm 125 sx 08 stuck in 1st gear


You have a bent shift fork and possibly something else going on. The engine will need to come out of the bike. Remove the top end, the flywheel and electrics, the clutch, the shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to get to the crankshaft, gears and shift forks.
You will need an impact driver, flywheel puller, case splitter, torque wrench and factory service manual, plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it". I often tell people to take it to the shop just so they don't get into such an involved project and they now have a knowing eye and experienced hands working on the problem.
The repair cost will probably be $800 or so.

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Jun 21, 2009 | 2008 KTM 200 EXC

1 Answer

04 exc 450 wont rev


Pull the slide and move the jet needle clip down 1 or 2 notches.

Apr 21, 2009 | 2004 KTM EXC 450 Racing

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