2003 KTM SX 250 - Answered Questions & Fixed issues

always look for that one bolt they hid behind an idler pulley or something like that. or if there are tapped holes in the cases you may have to use a puller to get it to move. be gentle or it could get expensive!

HI. REMOVE THE POWERVALVE COVER ON THE SIDE OF THE CYLINDER. MAKE SURE THE ARM IS CLIPPED ON TO THE POWER VALVE ITSELF START YOUR ENGINE AND AS YOU REV YOUR MOTOR YOU SHOULD SEE THE ARM ON THE POWER VALVE MOVE. IF NO MOVEMENT YOU WILL HAVE TO REMOVE THAT SIDE ENGINE CASE AND CHECK CHECK VALVE FUNCTION....CHEERS

SOUNDS LIKE YOU MAY HAVE A DICKY KILL SWITCH . TRY TO FIND IT'S CONNECTOR( COULD BE UNDER THE TANK NEAR THE HEAD STOCK)UNPLUG THE CONNECTOR AND YOU SHOULD GET A SPARK. IF SO CHAGE THE SWITCH . MAKE SURE YOU CHECK TRY A NEW SPARKPLUG FIRST.....CHEERS.

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

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

Try these:

KTM Owners Manual

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

Is your power valve clean, and moves freely? And don't forget to make sure the air filter is squeaky clean. How does the plug color look?

drain your oil and try to run it with a 20w 40. Sounds like you may be having friction problem

Isn't the sx a two stroke? I don't know of any "sump pump!"

How is your clutch? Does it slip or drag when starting out? When you put it into 1st gear when starting out does the bike lunge forward? Hold it in first gear with the clutch in and rev the bike up. See if the bike wants to move forward with the clutch in.It sounds to me like your clutch isn't set right or getting worn out. Much easier to shift at low rpms on a clutch than high rpms. I hope this helps...

check the barrel for any even wear.

Yes. If you look around, you might be able to get a kit to eliminate the oil injection pump.

The bolt seems to be held on just with the nut, and should be able to remove with a soft hammer to get it started, and a soft rod such as brass or aluminum that is smaller than the size of the bolt to finish driving it out. If you need to use a steel hammer to get the bolt to start moving, you should put the nut back on several turns so the end of the bolt will not be damaged, causing the threads to be ruined. Of course, bolt removal will be easier if the weight of the tire is not on it. I assume you removed the rear wheel and also any bolts holding the shock to the swingarm. Sometimes if the swingarm is worked up and down while trying to push the bolt out it can be helpful. There is a chance of some wear on the bolt causing it to be hanging up on a bearing or other part. As the bolt is removed, be sure to note the position of all seals, spacers and bearings. This unit came with needle bearings surrounding the shaft of the bolt, and if they are loose, as in not contained in a metal cage, they can be very difficult to keep track of, and later to assemble. I wish you luck, and hope I have been able to help.

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

the best way to bleed them is with a syringe and a bit of rubber tube. take off the resavoir tops, crack the nipples. do one at a time. fit tube over the nipple, fit the syringe into the pipe,make sure it is a tight fit bothe ends of the tube. fill syringe with dot 4 brake fluid. gently push in the plunger, very gently untill all air bubbles come out of the brake resevoir. hope this helps.

Why 50:1?
All bikes should be 32:1, and then jet to match that.
Your oil is fine, and yes...go smaller on the pilot.

2 stroke Mx bikes generally have(one or more of) four different methods of checking gearbox oil level.
The most common way to know is it is usually stamped on the clutch cover near the oil filler plug. It will read in CC's. 1cc equils 1ml. Sometimes they have an oil dipstick attatched to the filler plug. They have two lines on them. The bottom line is the lower level, the upper line is the full level.
The third style is an oil window situated at the bottom rear of the clutch cover, again with a high & low mark.
The fourth style is a bolt or screw on the clutch cover(with a alloy/copper/fibre washer behind it. For this type you remove the screw & fill thec gearbox untill oil starts to leak out of it with the bike upright.
Your bike will have one or more of these oil level checking systems.
If your totally unsure, ask your KTM dealer.
Hope this helps
Regards Andrew Porrelli

this sounds like the selector fork has broken inside the gear box so its a strip down to sort this one out

what jets and needles do you need what size buddy also have you tried adjusting the air mixture screw on carb get back to me

Black Plugs are indicating that your bike is running too rich(too much fuel to air mixture) you need to have the carburator adjusted,more air.Good Luck.

hi bud on carb there are 2 screws the mixture screw is the one you need screw it in 1/2 of turns or more if required at the moment your fuel is too rich which is putting to much fuel too the plug so do what i said and try a br8es/br8eg sparky good luck bud