KTM won't shift HELP!

Barnett117
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Barnett117
Edited Date/Time 8/6/2017 9:06pm
My buddies 2011 250SX will shift fine while using the clutch into first and second but if he wants to get to third he has to float shift it without the clutch. He has had a new shift drum put in and still no luck. Any ideas and help would be great. Thanks!
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xnationalwrench 8/24/2013 9:57pm
8/24/2013 9:57pm Edited Date/Time 8/24/2013 9:59pm
Barnett117 wrote:
My buddies 2011 250SX will shift fine while using the clutch into first and second but if he wants to get to third he has to...
My buddies 2011 250SX will shift fine while using the clutch into first and second but if he wants to get to third he has to float shift it without the clutch. He has had a new shift drum put in and still no luck. Any ideas and help would be great. Thanks!
Not sure what you mean about float shifting, but it sounds like something in the shift forks parts have fallen out or have a bad gear
pete24
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pete24 8/25/2013 3:14pm
8/25/2013 3:14pm
yesterday i was floating in the pool with some Shift shorts on and a beer in my hand
Barnett117
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Barnett117 8/26/2013 7:44am
8/26/2013 7:44am
pete24 wrote:
yesterday i was floating in the pool with some Shift shorts on and a beer in my hand
Damn. Sounds good but I was racing.
Barnett117
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Barnett117 8/26/2013 7:44am
8/26/2013 7:44am
Barnett117 wrote:
My buddies 2011 250SX will shift fine while using the clutch into first and second but if he wants to get to third he has to...
My buddies 2011 250SX will shift fine while using the clutch into first and second but if he wants to get to third he has to float shift it without the clutch. He has had a new shift drum put in and still no luck. Any ideas and help would be great. Thanks!
xnationalwrench wrote:
Not sure what you mean about float shifting, but it sounds like something in the shift forks parts have fallen out or have a bad gear
Float shifting or shifting without the clutch.

The Shop

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Digger29
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Digger29 8/27/2013 6:36am
8/27/2013 6:36am
I'm definitely trying this little trick today because the last 2 races & I kept getting hung in 3rd & it just wouldn't shift into 4th.
ktmpartsdirect.com 9/5/2013 9:27am
9/5/2013 9:27am
have seen this no a lot on the SX 250 here, this is how we fix the problem. You will need to replace these parts
54834015000 - Shift locating drum
54634008044 - Sliding Plate Complete
56534013100 - Tensioning Spring

Any questions please ask thanks !!
Digger29
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Digger29 9/5/2013 10:46am
9/5/2013 10:46am
eins4eins wrote:
do this and if it doesnt work, replace the part they show in the video ... every 2 stroke ktm has this problem, if replace it...
do this and if it doesnt work, replace the part they show in the video ... every 2 stroke ktm has this problem, if replace it every 15-20h

http://www.youtube.com/watch?v=Ruy7lxSf5CA
Had Ron (the Bushman) Bushey do this to my 13 250SX last wk & I raced the 21st Annual Vet/Vintage race at Englishtown last weekend & my bike shifted better than it ever has. I honestly never had a problem & I don't think I've ever even missed a shift on my bike until 2 wks ago when it started to hang in 3rd gear. I got 3 out of 4 holeshots too which was awesome & my bike shifted flawlessly all day. I do love hearing from the 450 guys just how fast my bike is :-)
ktmpartsdirect.com 9/5/2013 3:58pm
9/5/2013 3:58pm
Good to hear you got it fixed, we just put together a SX 250 for a customer here and he is in love with it. He came off a SXF 450 and says he will never go back to the four stroke again !!!
Kryan5
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Kryan5 6/24/2015 10:07am
6/24/2015 10:07am Edited Date/Time 6/24/2015 10:08am
So recently just started having this issue on my 2013 250sx. Did this really work for you guys. I am also having a problem with it hitting a false neutral. Does it fix that too? A rebuild shop(very highly reputable) wants 2g to completely go through the bottom end of the bike, which it is due for, but 2g on a bike that is only worth maybe $4500.... "fart noise"
JBernard_401
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JBernard_401 6/24/2015 2:53pm
6/24/2015 2:53pm
Kryan5 wrote:
So recently just started having this issue on my 2013 250sx. Did this really work for you guys. I am also having a problem with it...
So recently just started having this issue on my 2013 250sx. Did this really work for you guys. I am also having a problem with it hitting a false neutral. Does it fix that too? A rebuild shop(very highly reputable) wants 2g to completely go through the bottom end of the bike, which it is due for, but 2g on a bike that is only worth maybe $4500.... "fart noise"
try this video that the guy posted above..

https://www.youtube.com/watch?v=Ruy7lxSf5CA

mine didnt want to shift under high revs and this completely solved it. shifts awesome now.
there *could* be something wrong with a broken part in yours. but this is free and only takes a couple hrs. its a bit of a pain to get to, having to pull the clutch basket to get access, but after that it slides right out.
Kryan5
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Kryan5 6/24/2015 7:16pm
6/24/2015 7:16pm
This is during a bench test. Does this have anything to do with my false neutral issue. Seems like the slider isn't shiting up enough to completely "finish" the shift. Any opinions?


Fearo
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Fearo 6/25/2015 1:24am
6/25/2015 1:24am
It does work Kryan, I had the exact same problem on my 2013 a few months back. I ended up replacing the shift star, sliding plate, spring, roller and the roller tensioning spring. It set me back around 50 euros and it has shifted flawlessly since then.
Kryan5
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Kryan5 6/26/2015 7:14am
6/26/2015 7:14am
How much filing on a clutch basket is to much. Feeling like this bike is clapped out and needs a lot of **** replaced, but I plan on replacing it soon and tranny work, new crank, new clutch basket/hub, discs just seems like a ridiculous amount of money to put in it consider the bike is only worth $4500. My predicament is, is that i don't want a 2016 and big changes are coming for the 2017. So basically i have to have this bike last until this time next year...

Fearo
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Fearo 6/26/2015 8:31am
6/26/2015 8:31am
Kryan, I believe we are in the exact same spot. I have the '13 also and it feels clapped out. I have been having a rediculous amount of small annoying problems these last few months like leaking gaskets, brake hose failure, clutch pressure cap breaking (how does this even happen),...

I was incredibly disappointed when I saw that the 250 didn't get the upgrades for '16 but the longer I think about it, the less I feel bad. I'm going to buy a 2016 SX 250, ride it for 2 years, and then buy a 2018. I have had really bad experiences with first year models of a bike platform, so by its second year people will hopefully have figured out the quirks and jetting and so on.
Kryan5
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Kryan5 6/26/2015 8:52am
6/26/2015 8:52am
Fearo wrote:
Kryan, I believe we are in the exact same spot. I have the '13 also and it feels clapped out. I have been having a rediculous...
Kryan, I believe we are in the exact same spot. I have the '13 also and it feels clapped out. I have been having a rediculous amount of small annoying problems these last few months like leaking gaskets, brake hose failure, clutch pressure cap breaking (how does this even happen),...

I was incredibly disappointed when I saw that the 250 didn't get the upgrades for '16 but the longer I think about it, the less I feel bad. I'm going to buy a 2016 SX 250, ride it for 2 years, and then buy a 2018. I have had really bad experiences with first year models of a bike platform, so by its second year people will hopefully have figured out the quirks and jetting and so on.
Thats not a bad idea. The biggest thing that has me stuck is the amount of money I have wrapped up in my suspension and I can't put it on the 2016. Also, I feel very "eeehhh" about the 4cs.

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Fearo
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Fearo 6/26/2015 9:06am
6/26/2015 9:06am
In that case I would definitely consider buying a '16. I don't know the prices of US parts, but there is no way I would put in a new crank, clutch basket, etc on my 13 at this point, even though they are all worn. Maybe you could get a good deal on a leftover '15 somewhere? I considered doing that over here but they are sold out. It's really weird, for the last 2 months, you can not buy an SX250 around here. The '15s are gone, and the '16s aren't out yet.
PFitzG38
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PFitzG38 8/1/2017 10:40am
8/1/2017 10:40am Edited Date/Time 9/2/2017 9:08am
Brand new SXF450 7 hours and i have never had 4th or 5th gear unless i let off the gas, clutch it and hit zero bumps under no load. I will be doing this and hoping for the best. My bike is unraceable as is
EDIT
OK I tried the filing trick and I have 4th 70% of the time but still have issues grabbing 5th under load. I didnt pay close enough attention to the video and just kind of filed a sharper notch in the plate with square file. I can see I needed to use a round file and make a hook to match the bars profile in the shift drum. I have a 1/4" round file but it looks too big I'm going to get a smaller round file another $16 gasket, drain my oil, pull my clutch, remove my shift shaft and try it again. Why does KTM let these leave the factory like this? and how come all my KTM friends have never heard of this? I'm wishing I never sold my 06 CRF!! I have zero confidence in a brand new 2017 KTM 450. I used to go to the line on a 10 year old bike pretty much KNOWING I was going to get the holeshot with my bigbore 490 - Not anymore, now I come out mid pack (if I'm lucky) and get swallowed up while I fight my tranny. The bummer is i can't take it to the dealer and complain because if you test ride it on the street it works. Only under load do I not have 4th or 5th. WTF!!!
UPDATE
I actually had to take my brand new KTM back to he dealer for this, (dealer to remain unnamed at this point) they have been very good to me so far! (never had a dealer work on my bike in my life - I've always done all my own work - Honda probably would've laughed at me) it now has 10 hours on it and it's 5 mos out of warranty, so far my dealer has been very cooperative about getting me to call KTM US, and trying to fix it - they have never heard of the problem, and really can't test it at the shop without a dragstrip - they haven't said it's going to cost me - but they haven't said it won't, we'll see what happens next week. I'm so bummed a 2017 KTM I have 10K wrapped up in, has me missing my 2006 CRF - Thats NOT RIGHT! ......... to be continued
GoggleFiend904 4/26/2020 5:48pm
4/26/2020 5:48pm
Old thread bump. I’m about over the shifting issue on my 14. Multiple times I’ve replaced everything inside the clutch case as far as shifting goes, and every time it shifts fine for 5ish hours, then shifts like shit again. I’m going to rebuild the lower end soon and I’m curious what I should be looking for? Damage to shift forks?

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