16 250sxf bike and motor rebuild

Ktm 5
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1/1/2017 10:49am




Ok I got a 2016 ktm 250sxf that is getting orange frame, of course and a complete motor rebuild. Bottom end has 72.4 and top end has 31.9 hours and clutch has 14 hrs. If anyone has any tips tricks or ideas please feel free I plan on rebuilding entire motor so we will see what it all looks like.
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Ktm 5
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1/1/2017 10:55am
So far pulled the oil screen filter and there's these flakes.

My son said they were there the last 2 or 3 oil changes also and we had just put in a Hinson clutch fibers and steels so maybe that? The clutch is 14 old
1/1/2017 11:20am
Ktm 5 wrote:
So far pulled the oil screen filter and there's these flakes. [img]https://p.vitalmx.com/photos/forums/2017/01/01/166537/s1200_1483296691265.jpg[/img] My son said they were there the last 2 or 3 oil changes also...
So far pulled the oil screen filter and there's these flakes.

My son said they were there the last 2 or 3 oil changes also and we had just put in a Hinson clutch fibers and steels so maybe that? The clutch is 14 old
I don't think it's unlikely to be clutch material, depends on the "abuse". nice though that there is an removable screen on KTM.
I had to split the cases on my Yz250f to see that the screen was totally packed with dirt. Good luck with the build, will look good in orange frame
Ktm 5
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1/1/2017 3:51pm


First time tearing down a four stroke motor besides my Chinese pitbike motor. Intake valves were both .005 and clutch side exhaust valve was a tight .005 but probably .0045 and ignition side was .006 Thats untouched since new
CarlinoJoeVideo
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1/1/2017 10:37pm
What is the one valve spec?

I often have little metal flakes in that screen. As long as it's not a ton, you should be OK. I got my tranny polished for smoothing shifting when my engine got rebuilt. Definitely inspect the gears while you have it apart.

The Shop

Ktm 5
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1/2/2017 6:22am Edited Date/Time 1/2/2017 10:55am
It is 4.5 thousandsth. It would fit the .005 shim but real tight and the .004 shim was a little loose so I figured it was .0045
Ktm 5
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1/2/2017 10:59am


Got the top end off. I notice there is a little more build up on one exhaust valve more than the other, any reason?
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Ktm 5
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1/2/2017 12:12pm


Piston on left is original piston with 40.5 hrs then we sucked in some sand and lost compression, son was riding took a break and then would not start because no comp. Ring gap is .013 on last piston and crank side to side is .016



Everything in the clutch looked good but I did notice a lot of slop in the water pump propeller. I think I'll replace that for safe measure

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CarlinoJoeVideo
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1/2/2017 1:21pm
I had to get new valve seats cut on mine at 75hours because it wa s burning some oil. I think your exhaust valves might be starting to leak. Maybe look into new valves and seats while it's a part?
Ktm 5
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1/2/2017 3:16pm
Oh definitely getting all redone
Sixeightone
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1/3/2017 4:49am
Definitely check all the plastic gears. CLEAN THE OIL PUMP, that's a big to do! I would also be sending that cylinder out with a new piston to match it for new nikasil. 80% of the time when I take an engine apart the ring end gap is ok but the cylinder is always out of spec, or dang close to it. The coatings they put in there do not last as long as people think! Also pull those valves out and take a look at those seats, lots of build up on that head, you might want to get those lapped or cut. Best of luck, bike is going to be awesome with an orange frame and fresh rebuild!
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Ktm 5
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1/3/2017 8:20am
Thank you for the advice I will definitely go through the oil pump. So far all of the plastic gears look good and I am definitely getting the cyl renickled especially since we had sucked in sand
Ktm 5
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1/6/2017 4:59pm
Definitely check all the plastic gears. CLEAN THE OIL PUMP, that's a big to do! I would also be sending that cylinder out with a new...
Definitely check all the plastic gears. CLEAN THE OIL PUMP, that's a big to do! I would also be sending that cylinder out with a new piston to match it for new nikasil. 80% of the time when I take an engine apart the ring end gap is ok but the cylinder is always out of spec, or dang close to it. The coatings they put in there do not last as long as people think! Also pull those valves out and take a look at those seats, lots of build up on that head, you might want to get those lapped or cut. Best of luck, bike is going to be awesome with an orange frame and fresh rebuild!
Is there any dos or donts when removing and cleaning the oil pump? I heard it Can be pain
Ktm 5
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1/7/2017 10:56am


Well that was pretty easy. Now just have to get some replacement parts...
Ktm 5
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1/7/2017 11:11am


Well I believe I found where the goldish flakes are coming from on the oil screen
Ktm 5
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1/7/2017 11:25am


You can see some wear on this shift fork.

Is it necessary to replace any bearings in the tranny while I'm there? 72 hrs
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