I have a 2003 KTM 525 EXC it stalls only sometimes when i'm going to stop. if i work the throttle a bit it will not stall. any thing

SOURCE: Front fork oil change.

Kenji,
be careful, the front forks are under a spring. Just keep going and BE CAREFUL.

SOURCE: KTM EXC 250F - Battery now holding its charge

is the battery charging by engine

gavin jones

• 1508 Answers
• Posted on Apr 28, 2010

SOURCE: have a 2005 ktm 525 exc,after 20 mins of riding it

sounds rich, especially if its a problem when it warms up, was the JD kit a much bigger main jet,might need to try standard main, is it standard exhaust, I assume the air cleaner is clean and good condition, the foam can deteriate over time.Not sure if you have a hot start button or lever, this leans the mixture, if you have one and it helps then its definately rich

as a non related hint I use moreys upper cylnder lube in my WR it starts easier, idles easier, doesnt stall as easy under hard braking, and doesnt seem to get as hot and ping when working hard in tight bush.

SOURCE: MY ELECRIC STARTER ON KTM

Thank you for contacting FixYa with your inquiry.
This is not an uncommon behavior and we need to locate the source of the problem and eliminate the things that are not effecting the issue.
Most probable causes: Battery, Starter Relay, Start Button, Starter.
Manually start the bike and take it for a good rip and see if the battery takes/holds a good charge for the rest of the day. If you don't have trouble starting through out the day then it's a good chance you may need to replace the battery. Recommend the use of a trickle charger to keep the charge up during the week when bikes in the garage. Part# 53 Frame Parts/Wiring Harness. http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx
If your battery is known to be new or has a good charge, do you often hear a clicking sound. It might indicate your starter relay is wearing out or you have a short. Trace the wire harness and confirm insulation wear.Check starter wire and confirm the nut's tight with a good star washer. If relay - replace it. Part Number #58 Frame/Wiring Harness http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx
If the battery is known good and the relay pulls in but the starter won't engage and you can hear it attempting you may have an issue with the starter being in a bind from some internal obstruction or just plain worn out. Pull it and check it. See if it engages off the frame. You may have to take it to an alternator shop and have it re-wound. New ones are spendy. http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx
Starter Control Button: Reseat the connection and confirm it's engaging the relay. Part Number #69 chassis/Handlebar Controls. http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx
Hope this helps you resolve your starting issue. If we can provide further assistance please advise,
Best regards,
TF

SOURCE: It's an 01 ktm 400

Thanks for contacting FixYa with your inquiry.
Check externally for the obvious things first like a bent shift lever or lever re-installed in a position interfering with frame or something preventing engagement into 1st gear. I'm never that lucky.
More than likely you have either bent a shifting fork or lost a tooth on a gear or something on the shift mechanism internally is bent, broken, or has lost a clip. Drain your oil and check the plug magnet to see if any metal shavings, fragments, or parts appear.
You will most likely have to pull the engine and split the case and replace parts. You can take it to a shop or if your handy do it your self. Take a look at the link to the parts fiche and determine your preference.
http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx
2001/400/Engine/Transmission II (Don't know if your bike is a SX or EXC Racing)
2001 > 400 SX RACING > ENGINE > SHIFTING MECHANISM
You can also order a repair manual from this site or ask your dealer

http://www.repairmanual.com/KTM.html

If we can provide other information or service please advise.

Kind regards,

TF