96 Ktm 250 sx rebuild questions?

96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
Hi guys I have a 96 Ktm 250sx it hasn't ran right since I got it. I took it to the dunes with a bunch of new jets and pilots knowing that the carb was jetted wrong. I'm currently running 172 main, 42 pilot, 2 turns out. But the bike won't hit power band? I took the reeds off and they were bent so I bent them back to see if that was the issue for a short term fix out at the dunes. Still no powerband. So when I got home I did a compression check and it's running 120psi is that to low to get powerband? I'm gunna tear the head and cylinder apart and replace gaskets, o'rings, piston, rings and wrist pin. Hopefully I'm within spec and don't have to have it coated. Any suggestions on brand? And anyone think that that compression should still hit powerband?
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Cygnus
Posts
14845
Joined
8/15/2006
Location
Hanover, CO, USA
9/28/2016 8:22am
Sounds like a stuck power valve.
96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
9/28/2016 8:33am
I took the tvc system cover off and cleaned it... not sure how else to unstick it?
96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
9/28/2016 12:39pm
I did some research I'm gonna replace my reeds and take a look at my power valve. There is a lot of spluge coming out my exhaust my power band is probably sticking. I have no problem starting my bike just get it to hit power band.
96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
10/18/2016 7:10pm
Bringing the thread back to life! Rebuilt my whole top end ! Power valve was indeed stuck, bearings were siezed. Rings were out .027. Cylinder was in spec. Ordered boysen dual stage power reeds, forged wiesco piston kit, very hard to find power valve parts for this engine. Next build will be 300 big bore kit simply to update the power valve system. When I do that I'll rebuild bottom end and upgrade plastics and what not. Ground up build would be fun we will see when funds come available. Here's some pics had to take side cover off to drill and tap it the original owner stripped oil level plug.











The Shop

sandman768
Posts
8150
Joined
3/21/2014
Location
Saratoga Springs, NY, USA
10/19/2016 12:42pm
Looks like a clean bike to start with...I rode a friends back in 96 or 97, they have some good quality parts on them... Keep us updated!
96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
10/20/2016 6:56am
Yeah it's pretty clean after I tore it all down and cleaned it . And bought a bunch of new parts
96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
10/20/2016 8:39am
Just got my adjustable housing from newer model bike and my aggressive spring!


Kidkawie
Posts
1186
Joined
8/31/2012
Location
ქუთაისი, GE
10/21/2016 4:23am
Cool bike, dont see them often.
96sx
Posts
25
Joined
9/14/2016
Location
Gresham, OR, USA
10/21/2016 7:28pm
Thanks everyone I know rides hondas! I like my bike not a big fan of the plastic design. But looking into putting on newer style plastics.

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