Have a 2006 ktm 250 sxf seized rod to the crank got it changed reinstalled put motor back together now can not even kick it like somthing is stuck. Toke the clutch basket out, timing gear and water pump gears turn easaly, kickstart gear and all other gears turn good until I put the clutch basket in. Bought new clutch put it in same problem any sugestions.

That's liquid-cooled? The problem sounds VERY much like water or coolant getting into a cylinder.

could be as simple as water in the fuel.
kick starter issue: need to remove side cover and inspect!

could be a faulty spark plug or the wrong one.

CLEAN CARB AND REPLACE FUEL FILTERS CHOKE ENGINE TAKE OFF AIR FILTER REMOVE SPARK PLUG AND RUN IT IDLE 5 MIN PLACE ALL COMPONITES ON IT AND DRIVE

If the bike has been seized up it's important to check out the piston and cylinder head. It's a good learning experience and not that hard a project. Remove the seat, tank, pipe and maybe the carburetor and you should be able to get at the head bolts. Pull the head and inspect the top of the piston and ring area. Rings usually get stuck to the piston so there is not any compression. Pull the jug and more than likely there will be alloy from the piston transfered to the cylinder heard.
Take it to a bike shop or automotive machine shop that can hone it to first over. Purchase new 1st over-sized piston and matching rings. Re-assembly and replace all gaskets.
Thanks for contacting FixYa,
TF

check inlet valve clearances. they close up making it hard to start exactly as you described. titanium valve coatings wear and ressesion happens quickly,a clean air filter must be maintained to prevent contaniments wearing valve coatings.

You can download an owner's manual for free here

http://www.ktm.co.uk/250-SX-F.28.19.html?&detailview=4&cHash=dcbf8829e1

Hi bengriffith1
You can download a copy of the engine manual from here
It has all the info you need. Any problems with the download just let me know
regards robotek