Question about 2003 KTM SX 250

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2003 KTM SX 250 replace the shift drum

Can you install the shift drum wrong and cause neutral to be in between 3rd and 4th and it shifts fine through all gears. On 03 ktm 250 sx @

Posted by Mitch Warner on

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5 Related Answers

SOURCE: 03 330i transmission indicator lamp on

what was the problem?

Posted on Oct 04, 2008


tombones

  • 3567 Answers

SOURCE: 03 YZ 250 won't shift into 3rd

You have a bent shift fork. The repair means removing the engine from the frame then tearing it down into about 75 parts which will then allow the bent shift fork to be replaced. This is not a job for the amature mechanic. Wish I were there with you to guide the repair.

Posted on Mar 11, 2009

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Scott

  • 420 Answers

SOURCE: transmission will not upshift between 3rd and 4th gear

It sounds like the shifter pawl might not be centered. This is located behind the clutch basket and is a pretty big job to get to, easy adjustment just a pain to get to. You will need a manuel to do it yourself.

Posted on Mar 31, 2009

NOT ME

  • 2841 Answers

SOURCE: 92 Accord Automatic shifting

Has anyone change the transmission fluid and used anything other than Honda ATF-Z1. If so, have the fluid/filter changed in this car and use only Honda Fluid. This is the only fluid that you can use in a Honda. Even if you have used the correct fluid an fluid/filter change may help. If that is not the case then I suggest you seek out a trusted professional.

Posted on Aug 08, 2009

Anonymous

  • 167 Answers

SOURCE: how much oils should i put in my ktm 250 sx 2

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

Posted on Nov 30, 2009

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I have a 1998 ktm 65 sx I just bought it when we test rode it it ran good but we only took it to 3 rd gear then when rode it after getting it home the first time it went into 5th gear it got stuck there...


Thank you for contacting FixYa with your inquiry.
The first thing we need to do is eliminate the possibility that the shift lever is not interfering with anything limiting it's travel into the top three gear positions. It's possible that the lever is bent or has been incorrectly re-installed on the wrong spline position.
That being said, we more than likely have a problem with a bent shifting fork, a pall, or a shift rail, maybe even a broken gear.. There is also a good possibility the engine has been previously disassembled and not had parts replaced and the engine did not get re-assembled correctly. You will have to remove the engine and split the case to inspect the shafts, shifting forks, spacers, and shifting drum to correct the problem. This link will take you to the complete shop repair manual for this bike. Check the section 4 beginning on page 36-37.
http://www.scribd.com/doc/44875530/20355873-1998-03-KTM-60-65SX-Service-Manual
You may have to make some holding parts and/or rent some pullers but it's not to bad of a project. A good KTM Shop can always fix the problem but it's expensive. This is a great little bike. I'm sorry it's having problems.
Thanks again for contacting FixYa.
TF

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I have 2006 Honda cr125r that has developed a neutral between 3rd and 4th gears. What is the most likely cause of this?


There are a few possible causes. A slightly bent shift fork, the index wheel on the shifter not operating properly, and rider error are the usual causes. I doubt you are failing to lift the shift lever fully, so we can rule that one out. Since the other gears are indexing properly, I doubt the index wheel is bad. That leaves a slightly bent shift fork. If the shift lever is getting physically harder to move up and down when changing from a certain set of gears, i.e. 3rd to 4th or 4th to 3rd, it would tend to indicate a bad fork. This is an expensive repair and is not recommended for the novice mechanic.

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