2015.5 ktm 250 sxf broken transmision (need help finding gears)

Dannyderasmo106
Edited Date/Time 5/26/2016 6:00pm
Has anyone had any similer problems like this. I belive its third gear that theres something wrong with. While riding today landed a jump and heard a clanking kind of noise then the back wheel started to lock up on and off. It was clanking while i rode back to the truck but the noise went away but now it wont shift past second gear. It its a false nuetral after second and wont go up at all after. Has anyone had this happen and will ktm warenty it. If not whos a good engine builder to send it to?
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Moto_Geek
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Moto_Geek 5/11/2016 2:27pm
5/11/2016 2:27pm Edited Date/Time 5/11/2016 2:33pm
There are spoon shaped levers in there that make the shifter push into gear. Sounds like you broke one.

My recommendation: Typically what I do was take it to the dealer I bought it from or previous owner bought it from and have them repair it and then they might deem it warranty once they review the broken part. See the process is for them to determine you bought it new and then they have to make a repair request to KTM to see if it will be covered. That is why important to take back to dealer you bought it from.

KTM is pretty good about certain things. They took care of me. I had a weird thing happen with my bike and had gopro video it happening to me and they covered all the parts ($700) but I paid the labor. So if you were recording when it happen to show you weren't riding off a cliff, this helps tremendously too to support your incident.You can just upload to youtube as a private video link and send to the manager of the service department.Private because you don't want it to cause negative PR for KTM and look like a jerk.

Hope that helps
CarlinoJoeVideo
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CarlinoJoeVideo 5/11/2016 3:58pm
5/11/2016 3:58pm
I've heard of some trannys going on the 250. I don't know any more details than that. Let us know what you find out!
ML512
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ML512 5/11/2016 4:44pm
5/11/2016 4:44pm
I've heard of a few going... Hinson has a clutch we're going to check out tomorrow that's supposed to relieve some of the strain on the transmission.
Underground 5/11/2016 4:59pm
5/11/2016 4:59pm
Check the bolt for the shifter detent arm hasn't come loose. They have no loctite and when they do, it allows the detent roller to come off the side and then the shift drum spins freely. Continued riding with this will allow it to select in and out at random and place impacts on the gears resulting in a box of scrap. Removing just the outer clutch cover and clutch assembly will allow access to check the bolt, remove, loctite and refit if yours hasn't turned to scrap yet.

The Shop

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Dannyderasmo106 5/11/2016 5:27pm
5/11/2016 5:27pm
Thanks for the info guys. I spoke to one of the guys at the dealer and they said they have warentied a few trannys. There going to let me know tommorow if they think they can.
3D
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3D 5/11/2016 5:40pm
5/11/2016 5:40pm
Underground wrote:
Check the bolt for the shifter detent arm hasn't come loose. They have no loctite and when they do, it allows the detent roller to come...
Check the bolt for the shifter detent arm hasn't come loose. They have no loctite and when they do, it allows the detent roller to come off the side and then the shift drum spins freely. Continued riding with this will allow it to select in and out at random and place impacts on the gears resulting in a box of scrap. Removing just the outer clutch cover and clutch assembly will allow access to check the bolt, remove, loctite and refit if yours hasn't turned to scrap yet.
This happened to my son's 65. Actually, the bolt didn't come loose. The arm itself wore on the shaft/bolt and became loose and cocked itself off the drum. It luckily didn't hurt anything. My son just couldn't find a neutral when he came off the track. It kept sliding past. I felt his shifter and knew something was wrong and dug into it.
pete24
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pete24 5/11/2016 6:56pm
5/11/2016 6:56pm
same thing happened to my buddys 150sx landed from a jump busted trans , need four gears and a fork, no parts available, any where , been apart for two months
mb
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mb 5/11/2016 9:14pm
5/11/2016 9:14pm
pete24 wrote:
same thing happened to my buddys 150sx landed from a jump busted trans , need four gears and a fork, no parts available, any where...
same thing happened to my buddys 150sx landed from a jump busted trans , need four gears and a fork, no parts available, any where , been apart for two months
Now that's crazy
Fearo
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Fearo 5/12/2016 1:57am
5/12/2016 1:57am
Yes, I've heard this story from a few people as well. Yesterday I heard someone was using Kawi parts in their transmission after it had blown twice. Don't know exactly which parts however.
22Ryann
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22Ryann 5/12/2016 4:29am
5/12/2016 4:29am Edited Date/Time 5/12/2016 4:30am
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end.



Dannyderasmo106 5/12/2016 9:43am
5/12/2016 9:43am
22Ryann wrote:
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end. [img]https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/e35/12534436_1084476684937700_1242143179_n.jpg[/img]
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end.



Yikes. Were those parts available and did ktm warenty it?
mx836
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mx836 5/12/2016 10:00am
5/12/2016 10:00am
Fearo wrote:
Yes, I've heard this story from a few people as well. Yesterday I heard someone was using Kawi parts in their transmission after it had blown...
Yes, I've heard this story from a few people as well. Yesterday I heard someone was using Kawi parts in their transmission after it had blown twice. Don't know exactly which parts however.
Laughing This makes me smile.

Good luck OP. With an issue like this that seems to be too common, I feel like they should definitely step up and help out. Let us know what you hear.
cwtoyota
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cwtoyota 5/12/2016 11:52am
5/12/2016 11:52am
Fearo wrote:
Yes, I've heard this story from a few people as well. Yesterday I heard someone was using Kawi parts in their transmission after it had blown...
Yes, I've heard this story from a few people as well. Yesterday I heard someone was using Kawi parts in their transmission after it had blown twice. Don't know exactly which parts however.
mx836 wrote:
:laugh: This makes me smile. Good luck OP. With an issue like this that seems to be too common, I feel like they should definitely step...
Laughing This makes me smile.

Good luck OP. With an issue like this that seems to be too common, I feel like they should definitely step up and help out. Let us know what you hear.
Other brands have bad trannies too. I spent the early part of this year making upgrade parts fit into both of my YZ250s.
I have considered switching to KTM for a better transmission, but then I see this kind of thing going on...

It actually sounds like KTM is pretty good about taking care of these kinds of problems... What happens when KTM warranties the bike and fixes the trans with the same parts? Does it fail again and they leave you high and dry because the bike is no longer "new"?
seth505
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seth505 5/12/2016 11:56am
5/12/2016 11:56am
This happened to my last yz250 and I needed 4 gears and other bearings/internal crap. I really hope it never happens to my KTM!
BobPA
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BobPA 5/12/2016 12:58pm
5/12/2016 12:58pm
pete24 wrote:
same thing happened to my buddys 150sx landed from a jump busted trans , need four gears and a fork, no parts available, any where...
same thing happened to my buddys 150sx landed from a jump busted trans , need four gears and a fork, no parts available, any where , been apart for two months
I will give him $2500 as it sits
Dannyderasmo106 5/12/2016 5:28pm
5/12/2016 5:28pm
Ok so spoke to the guy at the dealer that handles the warenty claims today. He said since the bike is just over a year old they dont think they can do it. He said i can try calling customer service myself but he doubts they will cover it. Any suggestions on an engine guy that can do this and rebuild my top end?
colintrax
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colintrax 5/12/2016 5:37pm
5/12/2016 5:37pm
cwtoyota wrote:
Other brands have bad trannies too. I spent the early part of this year making upgrade parts fit into both of my YZ250s. I have considered...
Other brands have bad trannies too. I spent the early part of this year making upgrade parts fit into both of my YZ250s.
I have considered switching to KTM for a better transmission, but then I see this kind of thing going on...

It actually sounds like KTM is pretty good about taking care of these kinds of problems... What happens when KTM warranties the bike and fixes the trans with the same parts? Does it fail again and they leave you high and dry because the bike is no longer "new"?
For what it's worth the transmission in my 2012 has been flawless. Can't say the same about the Kawsakis I've had.
Underground 5/13/2016 12:21am
5/13/2016 12:21am
Dannyderasmo106 wrote:
Ok so spoke to the guy at the dealer that handles the warenty claims today. He said since the bike is just over a year old...
Ok so spoke to the guy at the dealer that handles the warenty claims today. He said since the bike is just over a year old they dont think they can do it. He said i can try calling customer service myself but he doubts they will cover it. Any suggestions on an engine guy that can do this and rebuild my top end?
Well a year on you will be pushing the friendship as it's just untold what owners can do within that time frame and if you have never had the shop service or work on your bike......? I'd be as diplomatic as possible, mention that you know there have been issues and at least offer them the chance to strip and quote and to see what KTM might come to the party with. You owe the guys who are going into bat for you at least that, and a workshop will always push harder for a loyal customer.

Pit Row

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Underground 5/13/2016 12:23am
5/13/2016 12:23am
22Ryann wrote:
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end. [img]https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/e35/12534436_1084476684937700_1242143179_n.jpg[/img]
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end.



Did the rear sprocket break?
22Ryann
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22Ryann 5/13/2016 3:00am
5/13/2016 3:00am
22Ryann wrote:
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end. [img]https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/e35/12534436_1084476684937700_1242143179_n.jpg[/img]
a friends 2016 250sxf after he had a sprocket come loose and lock up the rear end.



Underground wrote:
Did the rear sprocket break?
He actually never rode a stock one, changed it to to pro taper rear sprocket. Rode on it and it came loose, ruined hub and also the tranny. Can really only put it down to owner error i would assume on this one
Underground 5/13/2016 3:21pm
5/13/2016 3:21pm
I've seen a 450 do a similar thing. Rear aftermarket sprocket was snapped in half, hub flanges bent and the chain all wound up in the cases. Not sure which happened first and caused it but it all happened when landing from a jump and the gearbox result was the same
Moto520
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Moto520 5/14/2016 9:11pm
5/14/2016 9:11pm
Yes.......Tom Zont Racing does excellent work. I use them for pretty much everything and they are extremely anal about their work. Tom also knows these transmissions very well since he runs the TZR arenacross team and they were KTM exclusive. It's so difficult to find a shop that is as anal as I am about my bikes. My 2 cents.
MX558
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MX558 5/15/2016 4:32am
5/15/2016 4:32am
TZR is a great shop . He's as honest as they come and does phenomenal work, he even answers all my stupid questions .
Crisp BRAAAP! 5/15/2016 7:26am
5/15/2016 7:26am
I know he's known more for suspension but Paul Bruno at RG3 in NJ is amazing. He used to wrench for Nicoletti for a few years and has a beautiful shop in NJ, less than an hour away from the City. I specifically asked him about motor work and he told me he does everything and I believe him. He's a good dude with a beautiful, clean shop doing nearly all the work himself so it'll be done right. I'd highly recommend him.
gharmon
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gharmon 5/15/2016 7:40am
5/15/2016 7:40am
Dannyderasmo106 wrote:
[img]https://p.vitalmx.com/photos/forums/2016/05/14/135180/s1200_image.jpg[/img] Think im going to send the motor to tom zont racing. Anyone ever use them.


Think im going to send the motor to tom zont racing. Anyone ever use them.
Hell if you can take that much of the bike apart you can buy a manual and do the rebuild yourself. You didn't need to do all that just to get the engine out did you? Laughing
Dannyderasmo106 5/15/2016 6:26pm
5/15/2016 6:26pm
Dannyderasmo106 wrote:
[img]https://p.vitalmx.com/photos/forums/2016/05/14/135180/s1200_image.jpg[/img] Think im going to send the motor to tom zont racing. Anyone ever use them.


Think im going to send the motor to tom zont racing. Anyone ever use them.
gharmon wrote:
Hell if you can take that much of the bike apart you can buy a manual and do the rebuild yourself. You didn't need to do...
Hell if you can take that much of the bike apart you can buy a manual and do the rebuild yourself. You didn't need to do all that just to get the engine out did you? Laughing
Everything besides the front wheel and forks. I took them off to put on another bike until i get the motor back.
h&m_cycle
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h&m_cycle 5/15/2016 6:38pm
5/15/2016 6:38pm Edited Date/Time 5/15/2016 6:38pm
That whole deal sucks... I read the whole thread... Man you are hard core, stripping the bike and putting on another to
ride till you get your engine back... good luck

http://www.tomzontracing.com/
Dannyderasmo106 5/26/2016 6:00pm
5/26/2016 6:00pm
Ok so the motor is at tzr. They have it apart. 3rd gear and 5th gear are broken and are on backorder. If anyone can point me in the direction for these gears it would be greatly apricciated. Thanks.

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