Top 20 2005 KTM 250 SX Questions & Answers


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.

2005 KTM 250 SX | 240 views | 0 helpful votes


water pump seal

2005 KTM 250 SX | 27 views | 0 helpful votes


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.

KTM 250 SX... | 176 views | 0 helpful votes


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.

KTM 250 SX... | 39 views | 0 helpful votes


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.

KTM 250 SX... | 24 views | 0 helpful votes


Drain oil. Use degreaser to clean area. Use JB Weld & allow to set up properly before adding oil.

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KTM Motorcycles | 84 views | 0 helpful votes


It's a bad seal of the head gasket. You need a new head gasket and to scrape every particle of debris from the cylinder head and cylinder surfaces that mate with the head gasket. Use the factory specified gasket sealing compound and do a clean job - no blobs or pools of the stuff. The head gasket should lay flat on the surface of the top of the cylinder, and you have to make this surface free of grit, leftover sealant and any other foreign matter before you put the head in place and torque it down. Start with the head bolts just finger tight and then go by the manufacturer's specs for the pattern and amount of torque to be applied. Usually it is recommended that you get to the specified torque amount in stages, going around several times and repeating the torque pattern until you get that maximum rated amount. This will prevent the seal from shifting or warping and should make the gasket seal perfectly. This is the old school method of doing this job. and I have never seen this fail to produce good results. Take your time, be clean, and you will have the results you want.

KTM Motorcycles | 116 views | 0 helpful votes


over full sump
fuel getting into sump
badly worn rings allowing excessive blow by

KTM Motorcycles | 77 views | 0 helpful votes


Have you tried an emissions test? That can tell you a lot about how the combustion is doing, and what you would need to adjust at the carburetor. Have you checked the spark plugs?

KTM Motorcycles | 929 views | 0 helpful votes


Make sure cables are working . Follow it down to clutch and make sure clutch lever is actually moving. It is does then pull clutch in and pushbike backwards. Should release If not , plates are probably frozen through excessive heat. Replace them. If lever does not move when clutch handle pulled, then adjust or broken cable. hope that' it, easier and cheaper!

KTM Motorcycles | 63 views | 0 helpful votes


Please contact KTM or a KTM dealer service dept. This site does not have access to this factory repair service data.

KTM Motorcycles | 24 views | 0 helpful votes

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