KTM 250 SX - Recent Questions, Troubleshooting & Support

Hey Luke, make SURE you have the throttle cable routed correctly.. and there is some slack in the cable too...

the SX forks really should be taken to a suspension tech to get the inner chamber properly bleed out. You never just add a cc amount because there is usually some left inside. You bleed out the air and fill. once no more air is coming out you set the fluid level on the outter chamber 110mm to 120mm with the spring out and the fork collapsed.

water pump seal

Take the engine apart and you will find out. Quite possibly will need new piston kit and a thorough cleaning and you'll be fine. If you're unlucky, main bearings, and cylinder coating repair.

I would first check the compresion to see if you do it will need a propper tester.

bikes are not meant to lay on their side they have a float which shuts off fuel in normal up right position

dont recomend it if piston liner is going to fail as it could trash the crank and make you cry ! P...

i would remove the clutch assy and check all parts including rear bearings ! something is failing !

Hi and welcome to FixYa,

Offhand, the only factor to be checked that could foul a sparkplug for your bike would be the 2T oil injector/pump. There is too much 2T oil going to the combustion chamber. Either the injector would require restricting or for some reason, there is also 2T oil in the fuel tank (pre-mix).

Good luck and Thank you for using FixYa. Happy Holidays.

Mervin, I'm not a motorcycle mechanic, but just knowing engines as I do, I would say drain the fuel tank and replace with new fuel and either a water remover additive or a more complete fuel treatment (Lucas makes some great products for that); pull the plug(s) and check them for any corrosion or buildup, replace if necessary; change the oil and filter; check the air cleaner; and check tensioning on any belts. I'd also suggest either replacing the battery straight away or just putting it on a charger for a while so you know it has a full charge when you go to start it - if you need to replace it, that will eventually become evident, but you should at least be able to get the engine started and see what else -if anything- needs doing.

Is the oil in your engine emulsified? (creamy substance in the oil or around the oil filler) If so then it would seem as if you may have a leaking head gasket, or cylinder base gasket.

I assume you're talking about 250SXF?Check the carbie jets are not blocked, air filter clean, exhaust not blocked and valves are in specified clearance.At night the manifold will glow red, this is normal.You just can't see it during the day.

Has major air leak (running seriously lean). If it is hard to start I would check carburation and crank seals.

Thank you for contacting FixYa with your inquiry. I have been going over some of the older help requests that have been archived and trying to provide solutions for those that didn't get answered. Hope this information helps.Try these:

KTM Owners Manual

Start here

http://www.carlsalter.com/motorcycle-manuals.asp

http://www.ktmusa.com/download.php?dataID=8101G9_OM_EN.pdf

KTM Service Manual

http://www.ktmcyclehutt.com/ktm-parts/ktm-parts-search.php?ktm-motorcycle-parts=Repair-Manuals&year=2007&ktm-model=sxf-450&fitment=bigbikes-all

KTM Repair Manuals Order Site

http://www.repairmanual.com/KTM.html

http://www.tryvod.com/search/ktm-2008-450-xcf-owners-manual-download.html

http://www.pdf-manual.com/user-guide-instruction-owner-manual-ktm-450-exc-2008-17793.html

http://www.pdf-manual.com/telechargement2.php?id=17793

http://www.mydrive.ch/browse#/

Manuals General:

http://www.dansmc.com/shopmanual2.htm

Other Manuals Sites:

http://www.fixya.com/motorcycles/ktm

The starter pinion attached to the kick pedal has an ratchet pin that engages in the engine shaft - the role of the pin is to allow the engine to turn freely once started. This pin is pressed on the shaft with a simple spring that in your case either broke or went out of position.
You will need to open that side of the transmission, access the starter mechanism and refit or replace the pin and its spring - it's a delicate job, work very carefully or you can do a lot of damage if you try to start the engine with the parts misplaced.

For a kwik fix you can take the shift lever off and use a dental pick and pull the seal out and replace with a new one, don't worry about messing up the one you are taking out but don't mess up the shaft. to do it right you have to remove the case on the clutch side and pull the shaft out from that side and them replace the seal.

Sounds like it's time to drain and replace the transmission fluid.
The link below is for the owners manual. It should help with draining and filling the fluids. When the fluid gets too thick, it will make shifting impossible.
Alternately, you may need to take it to a service shop. Their web site also shows a dealer locator.

http://www.ktm.com/Owner-s-Manuals.246.4.html

good luck,
Mark

See Below: