Question about 2006 KTM 525 EXC Racing
Bike starts ok but when i put it into gear with the clutch still in its like its still in gear, back wheel is locked but bike dosent stall. checked master cylnder and slave, both work fine. plenty of fluid in there, was working fine one day then the next this. Tryed pumping the leaver loads still no joy
SOURCE: 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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Posted on Jun 21, 2009
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