20 Most Recent 2003 KTM SX 525 Racing Questions & Answers

then i stripped the hex bolt for oil screen.for overheating issue i was told to rejet to 185 @ 45 and change out pipe for restriction! after doing this the bike was still getting hot.so then i changed stockk coolant to cycle logics engine ice and gutted the thermostat for a free flowing system!after doing all this the bike needs a lot more abuse than before to over heat but it STILL DOES-very frustrating!! my only option left is to install the engine fan which is still on back order for at least another monthand was also recomended to run waterless coolan(evans)!im 260 pounds which doesnt help the situationi know. but if anyone else has any suggestions im all ears!dont get me wrong i love the bikeit HAS cooled down a lot! but im looking for news maybee to incress the lb rating on radiator cap to possibly 4lbs from the three lbs ktm supplies for this bike! if anybody has heard news with this problem please respond! thank you,ve got a 2006 450 exc that used to over heat also. I installed a JD Jetting kit aand it seems much better. Also installed a coolant recovery system for those real hot days. No problems since.,,,

Hi ridge,

good move will be have the recoil replaced and have the seals around the stator cleaned / investigated / repaired.

here is a good section from Supermoto Junkies on SX525

http://www.supermotojunkie.com/forumdisplay.php?f=43&order=desc&page=58

regards,

voodoo

You say the end gap is fine. To be sure put the new ring in the cylinder and check the gap before trying again. If you have and it is ok. Seeing you have broken 2 previous rings check the piston grove for some damage. Now looking at the parts for your model I find two type of ring setups. One has an outer ring with a coil spring inner, the other has two small rings and a spring middle. In the first type, you set the inner spring first in the grove, it may have a pin that will stick inside itself to hold the expander together. Once in the grove, turn the piston around with the pin or the gap to the back then install the outer ring with its grove 180 degs away. One ring end facing away, one facing you. Be sure that the inner expander ends do not catch on one of the oil holes in the oil ring grove. If using the 3 piece ring set up. Install the expander in the grove, next install the bottom ring into the grove made by the expander and the piston, These have an over lap but still put the ends in different locations. If this is not to clear. Tell me more of what you have done, so I know the steps you have taken.

set the mix screw back to standard and if you dont know the standard setting do it 2 turns out from fully in (dont tighten it, just feel for the stop) then finely adjust from there.

bent a shifter arm , estimate 1-200 if you do it , try it its basically an easy motor to work on and you can doit

That would be like riding a fixed wheel bike.Think about how you will stop and start. Only hydraulic fluid will leak. Bad idea!

Question edited for clarity. That sounds like it is just a bad connection somewhere or possibly a bad switch. Remove the battery leads and clean the lead contacts and battery posts with a wire brush. Smear with Vaseline and reconnect. Remove the starter leads and do the same. Then it could be the Starter Relay https://www.google.com/search?q=ktm+450+sx-f+starter+relay+location Or Starter Button https://www.google.com/search?q=ktm+450+sx-f+starter+button+replacement ..

personnaly I would replace cylinder with new OEM

All dirt bikes have a VIN. It is on the steering neck. https://www.google.com/search?q=vin+on+my+ktm+300 ..

Have you checked battery connections. Run switch in the correct position? Checked spark plug for debris? Just thinking out loud..

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

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Hi, try to see this link and looking for the manual that you need. https://www.pdfmotomanual.com/manuales/ktm/eng I hope to give you an help. Luca

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Hi, most likely your cdi unit or ignition coil needs replacing.

took me a min or two of WTF-ing to see pic and realize you meant a 2-stroke motorcycle..

try replace spark plugs

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.

Check the clutch, adjust, clean, or replace

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

Worn out shift dogs.