KTM Motorcycles - Recent Questions, Troubleshooting & Support


Hi, Mark and the usual suspects are:
1. Contaminated or faulty speed sensor.
2. Faulty turn signal module.
3. Corroded, broken or loose connector pins/sockets in the wire harness between the speedometer and the ECM or TSSM and the sensor.
4. The speedometer unit has failed.
5. Speedometer instrument fuse has blown.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=wiring+diagram+2006+ktm+525+exc-g&tbm=isch&source=univ&sa=X&ved=2ahUKEwjMsdPtpebkAhWxTt8KHUGQCWwQsAR6BAgIEAE&biw=1440&bih=757
https://www.ktmshop.se/documents/8103I9_WD_EN.pdf
http://www.keustermans.nl/KTM_RFS_Workshop_Manual.pdf
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/90436/Ktm-400-Exc.html#product-525%20EXC%20RACING%202006

2006 KTM 525 EXC... | Answered on Sep 23, 2019


Hi I have a KTM 65 and it's got oil residue coming out of the exhaust, could it be from too much oil in the fuel? Or too much oil in the oil pan as I just replaced the oil pan bolt and put about 250ml of oil in it, I'm thinking that might be a bit too much?

2010 KTM 65 SX | Answered on Aug 25, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/524139-uh-oh-shooting-coolant
https://www.supermotojunkie.com/showthread.php?110693-07-450-SX-f-Help!-Leaking-Coolant
https://www.supermotojunkie.com/showthread.php?110693-07-450-SX-f-Help!-Leaking-Coolant
https://www.manualslib.com/manual/802703/Ktm-450.html
https://www.partsfish.com/page/oem-parts-for-ktm
https://ownersmanuals2.com/ktm/450-sx-f-us-2009-owners-manual-60188

2009 KTM 450 SXF | Answered on Jul 18, 2019


Hi, Chaz_bruno before testing any electrical component in the Starter Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries. Depending on battery voltage starter relays and starter solenoids can make the same noise when you hit the starter button. You can easily determine which one is at fault by two simple tests:
STARTER RELAY- place your thumb and index finger on the starter relay and press the starter button, if you feel the click then the relay is faulty and needs to be replaced.
STARTER SOLENOID- bridge the positive and negative poles of the solenoid with a small screwdriver if you get a loud clunk then the solenoid needs to be rebuilt or replaced as necessary. If the engine turns over then replace the starter relay.
A motorcycle starter relay is an electronic mechanical switch that has a small coil winding around a piece of metal that requires low amperage and thin wires to be activated. When you turn on your ignition switch power 12 volts is sent to the relay coil which in turn becomes a magnetic contact point that pulls a spring-loaded contact point to itself completing an electrical circuit that allows more amperage necessary to be accessed by the starter solenoid which in turn acts in the same way as the relay but on a larger scale with its stronger heavier contacts making available the necessary amperage to turn the starter motor. If your battery has low voltage it, in turn, makes the magnetic contact point weak in trying to pull its counterpart to make a connection. These relays are usually encased in a plastic housing that is sealed, depending on the quality of the product. When activated they will produce a small amount of heat to their metal components which in turn can create the perfect environment for condensation to form depending on weather conditions and how careless you may be with a water hose or sprayer while washing your bike. After a period of time, several months to several years depending on the circumstances this condensation is the starter button for electrolysis and the slow build-up of corrosion which ends by preventing the magnetic contacts in making a solid connection and alerts you to this situation with the customary greeting "CLICK or BUZZ" if you get a single loud "CLUNK" then the starter solenoid is at fault and needs to be rebuilt or replaced as necessary. The relay is inexpensive and needs to be replaced however in a pinch they can be forcibly opened cleaned and resealed with silicone. In a nutshell, motorcycle starter relays take in low amperage and send out higher amperage when activated and for curious minds, the voltage remains constant at whatever your battery reads at the time.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/442515-e-start-just-clicks
https://advrider.com/f/threads/bike-doesnt-start-starter-relay-just-clicks.370941
KTM 450 SX Repair Manual
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/1164682/Ktm-450-Sxs-F.html

2007 KTM 450 SXF | Answered on Jul 18, 2019


Hi, Anonymous external oil deposits fall into 3 categories:
1. WEEPAGE is the oil that is sweated pass gaskets, seals, o-rings, and crankcase seams, it's covered by dry dust and is normal for older engines with lots of miles, no repair is necessary.
2. SEEPAGE is the same as weepage except the deposit is wet and confines itself to a specific area, the repair is optional depending on the owner's cleanliness criteria, the deposit location and the weight of his bag of "DRACHMA"
3. LEAKAGE is the same as seepage except it is enough to drop to the ground leaving a spot. Repair as necessary.
To find the source of your oil leak, start at the point where you see oil and trace its path going up and forward, blowing baby powder from the palm of your hand will help in those difficult to see areas if there is too much oil present then buy a spray can of engine degreaser apply it to the affected area then rinse off with a pressure wand or garden hose, use compressed air to blow off excess water or just let it drip dry, take your bike for a 15 minute ride and check for the leak.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://adbmag.com.au/editorial/replacing-a-two-stroke-crank-seal
https://www.google.com/search?q=Gear+oil+leaking+2004+KTM+SX+65&tbm=isch&source=univ&sa=X&ved=2ahUKEwjZqo7piavjAhXLrFkKHcaoD6sQsAR6BAgEEAE&biw=1440&bih=757
2009 KTM 65 SX XC Service Repair Manual pdf
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/829205/Ktm-65-Sx-2005.html

2004 KTM SX 65 | Answered on Jul 10, 2019


Hi, Anonymous and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Improper valve clearance (too tight)
17. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
18. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
19. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
20. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
21. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
22. Faulty neutral, clutch, kickstand safety switch.
23. Faulty fuel pump or fuse or relay.
24. Faulty or corroded run/stop switch.
25. Tilt sensor needs a reset.
26. Security system not disarming alarm needs a reset.
27. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://advrider.com/f/threads/2005-ktm-625smc-wont-start.955325
What To Do If Your Motorcycle Doesn Start
https://drive.google.com/file/d/0B2-8B_LViIenbnllQmZ5WUVndVE/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.ktmshop.se/documents/9703F4_OM_EN.pdf

2005 KTM 625 SMC | Answered on Jul 02, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Schwinn, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://touchupdirect.com/touch-up-paint/kawasaki/vulcan-1600-classic
https://www.colorrite.com/department/kawasaki-vulcan1600classic-motorcycle-paint-10843.cfm
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.vulcansabs.com/
http://kentuckyvulcanriders.us/Docs/Vulcan%201600%20Nomad%20Service%20Manual.pdf

KTM VN Vulcan... | Answered on Jul 01, 2019


Hi, Anonymous and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting/leaking, spark plug cable connections loose check for spark leakage in the dark.
6. A faulty ignition coil or electronic control module.
7. Faulty pulse coil.
8. Faulty CKP, CMP, or BAS sensor.
9. Faulty ignition switch.
10. Faulty run/off switch
11. Tilt sensor needs a reset.
12. Security alarm failing to disarm needs reset
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.ktmforums.com/forums/two-strokes/97898-ktm-sx85-2011-no-spark.html
How to Check for Spark
https://kristofsx.com/
https://www.partsfish.com/page/oem-parts-for-ktm
2012 KTM 125 150 250 SX 250 300 XC Users Manual pdf

2012 KTM SX 85 | Answered on Jul 01, 2019


Turn your ignition on and jump across your starter solenoid. If you cant find the solenoid and if you have a piece of reasonably heavy wire. Run the wire from the positive terminal of your battery to the post on the starter with the heavy red wire. It should start up. Get a new key asap.lol

2008 KTM 690 SMC | Answered on Jun 30, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=Secure+the+exhaust+system+2001+KTM+SX+125&tbm=isch&source=univ&sa=X&ved=2ahUKEwiB5r6b943jAhUliOAKHRKHDHkQsAR6BAgFEAE&biw=1440&bih=757
https://www.youtube.com/watch?v=Fz0O6vqLFVg
http://www.motogelnar.cz/manual/KTM/KTM125-200_1999-2003ServiceManual.pdf
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/90431/Ktm-125-Sx.html

2001 KTM SX 125 | Answered on Jun 29, 2019


Hi, Anonymous "absolutely" if you are experiencing excessive oil coming out of the crankcase breather or air filter please drain all engine oil and replace half of the same oil that comes out. Many riders are overfilling their oil system because they do not know how to properly read their oil site glass or dipstick. The following procedure works on nearly all 4 stroke engines but to be on the safe side you should refer to your owners manual. Use your center stand if you have one.
1. Bring the engine up to operating temperature or let idle for 5 minutes.
2. Turn off your engine and let it sit for 2 minutes, this will allow the oil from the top end to drain to the bottom.
3. Hold your bike straight up or on the center stand and wait 2 minutes for the oil in the bottom of the engine to be level in the sight glass or on the dipstick.
4. Your oil level should be between the top full mark and the bottom add oil mark.
5. Never overfill your oil system it will cause problems:
a. oil leaking out of exhaust pipes.
b. oil leaking out of breather pipe/hose.
c. oil carryover into the air cleaner.
6. Your oil site glass must "NEVER" be, completely full or empty drain or add oil as necessary.
7. Your oil dipstick must "NEVER" be over the full mark and should never be below the add mark drain or add oil as needed.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/53696-overfilling-oil
http://www.dirtbikeworld.net/forum/showthread.php?t=84665
http://www.motogelnar.cz/manual/KTM/KTM125-200_1999-2003ServiceManual.pdf
https://www.partsfish.com/page/oem-parts-for-ktm
KTM EXC 200 EXC Owner Manual

2005 KTM 200 EXC | Answered on Jun 29, 2019


Hi, Ben no matter how many times you try to bleed a brake system you can end up with a spongy lever/pedal because there is always a handful of air bubbles that absolutely refuse to be evicted from an airline, depending on the angle of the dangle, using conventional purging methods. You have 2 options:
1. Back bleed hook up a vacuum pump at the caliper and suck out the trapped air bubbles.
2. Pressure bleed this requires special equipment that most reputable shops will have and is guaranteed to get all air out.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/642784-front-brake-has-gone-all-soft-on-me-how-do-i-fix-it
https://www.youtube.com/watch?v=8Vb7PDlCWuE
KTM 250 SX 2006 Repair Manual
https://www.partsfish.com/page/oem-parts-for-ktm
http://pdfstream.manualsonline.com/4/44632692-b866-53f4-bd3d-50b1bc5c5f57.pdf

2006 KTM 250... | Answered on Jun 28, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=Kick+start+lever+bolt+torque+spec+KTM+250+SXF&tbm=isch&source=univ&sa=X&ved=2ahUKEwj7tpzPxIvjAhWFT98KHcy7Cm4QsAR6BAgHEAE&biw=1440&bih=757
https://www.manualslib.com/manual/90432/Ktm-250-Sx-F.html?page=45
KTM 250 SX 2006 Repair Manual
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.ktmshop.se/documents/7103F2_OM_EN.pdf

2007 KTM 250 SXF | Answered on Jun 28, 2019


Hi, Pl_teknik and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting/leaking, spark plug cable connections loose check for spark leakage in the dark.
6. A faulty ignition coil or electronic control module.
7. Faulty pulse coil.
8. Faulty CKP, CMP, or BAS sensor.
9. Faulty ignition switch.
10. Faulty run/off switch
11. Tilt sensor needs a reset.
12. Security alarm failing to disarm needs reset
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/1162844-2008-250-sxf-no-spark-help
How to Check for Spark
https://www.manualslib.com/manual/812364/Ktm-250-Sx-F-2005.html#product-250%20SX-F%202008
https://www.partsfish.com/page/oem-parts-for-ktm
https://ownersmanuals2.com/get/ktm-250-sx-f-2008-owners-manual-59906

2008 KTM 250... | Answered on Jun 28, 2019


Hi, Nikkistuart1 and the usual suspects are:
1. Throttle cables not properly adjusted.
2. Idle screw adjusted too low.
3. Air-fuel mixture screws not properly adjusted.
4. Pilot jet clogged.
5. Pilot jets too small.
6. Clogged air filter.
7. Faulty choke.
8. Multi carburetors not in sync.
9. Carburetor float needle valve stuck.
10. Fuel not getting to the carburetor.
11. Slide stuck in the carburetor.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/1120104-ktm-250sxf-2008-idling-issues
https://www.youtube.com/watch?v=C8Q6jINb0d0
https://www.manualslib.com/manual/812364/Ktm-250-Sx-F-2005.html#product-250%20SX-F%202008
https://www.partsfish.com/page/oem-parts-for-ktm
https://ownersmanuals2.com/get/ktm-250-sx-f-2008-owners-manual-59906

2008 KTM 250... | Answered on Jun 28, 2019


Hi, Rm_tokay for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=Cam+chain+installation+2011+KTM+250+SXF&tbm=isch&source=univ&sa=X&ved=2ahUKEwiXx-yHv4vjAhWEr1kKHY48CzoQsAR6BAgCEAE&biw=1440&bih=757
https://www.youtube.com/watch?v=56WhyUxGMhE
https://www.manualslib.com/manual/1201971/Ktm-250-Sxf-2016.html#product-250%20sx-f%202011
https://www.partsfish.com/page/oem-parts-for-ktm
https://ownersmanuals2.com/ktm/250-sx-f-us-2011-owners-manual-60157

2011 KTM 250 SXF | Answered on Jun 28, 2019


Hi, Wesley and the usual suspects are:
1. Throttle cables not properly adjusted.
2. Idle screw adjusted too low.
3. Air-fuel mixture screws not properly adjusted.
4. Pilot jet clogged.
5. Pilot jets too small.
6. Clogged air filter.
7. Faulty choke.
8. Multi carburetors not in sync.
9. Carburetor float needle valve stuck.
10. Fuel not getting to the carburetor.
11. Slide stuck in the carburetor.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/839245-08-ktm-250sxf-starting-and-idle-problems
Dirt bike won idle and backfires FIX
KTM 250 SX 2006 Repair Manual
https://www.partsfish.com/page/oem-parts-for-ktm
http://pdfstream.manualsonline.com/4/44632692-b866-53f4-bd3d-50b1bc5c5f57.pdf

2006 KTM 250... | Answered on Jun 28, 2019

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