125/150/250/300 KTM/HUS/GG jetting thread

AJ565
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3/10/2020 5:09pm Edited Date/Time 3/10/2020 5:11pm
#434 wrote:
How do I do that? If I‘m going to do the slide mod I want to do it right so I would need a drawing or...
How do I do that? If I‘m going to do the slide mod I want to do it right so I would need a drawing or something similar. German engineer, can‘t help it...
From the top of the arch to go from a 4.0 slide to a 5.0 slide is 1.0mm higher. Then grind to that point and blend it into the sides. And polish it back out.

Also you’ll need a 42-74 needle and S-4 needle jet to match it instead of the S-7
1
#434
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3/11/2020 4:45am
#434 wrote:
How do I do that? If I‘m going to do the slide mod I want to do it right so I would need a drawing or...
How do I do that? If I‘m going to do the slide mod I want to do it right so I would need a drawing or something similar. German engineer, can‘t help it...
AJ565 wrote:
From the top of the arch to go from a 4.0 slide to a 5.0 slide is 1.0mm higher. Then grind to that point and blend...
From the top of the arch to go from a 4.0 slide to a 5.0 slide is 1.0mm higher. Then grind to that point and blend it into the sides. And polish it back out.

Also you’ll need a 42-74 needle and S-4 needle jet to match it instead of the S-7
Thanks.

Yeah, that's the standard Needle/Needle Jet combo of the 2018 150sx. However, the 125 and the 150 have quite different jetting. The 150 is quite a bit leaner all around.
#434
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3/11/2020 4:49am Edited Date/Time 3/11/2020 4:50am
I found a pic of the different slides on ktmtalk:


1
jeffoff
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3/11/2020 6:07am
I have slide, needle jet & needle for sale, located in belgium.

The Shop

digger
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3/11/2020 6:37am
#434 wrote:
Thanks. Yeah, that's the standard Needle/Needle Jet combo of the 2018 150sx. However, the 125 and the 150 have quite different jetting. The 150 is quite...
Thanks.

Yeah, that's the standard Needle/Needle Jet combo of the 2018 150sx. However, the 125 and the 150 have quite different jetting. The 150 is quite a bit leaner all around.
In reality though, the jetting specs for the 125's and 150's are not that different. The jetting specs that have been listed above, S-4 needle jet, 42-74, i'de start out in the 2nd clip position, a 490 main along with #5 slide, are all going to be very good starting points for either a 125 or 150. The biggest difference between the 2 engines is the pilot jet, and that's only slightly and it varies as to how large, or no notch you have on the front side of the slide. Opening up the front side of the slide makes the pilot circuit more efficient, which in turn will will cause it to run richer, so you will need to compensate for this by using a smaller/leaner pilot jet.
3
AJ565
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3/11/2020 7:11am
#434 wrote:
Thanks. Yeah, that's the standard Needle/Needle Jet combo of the 2018 150sx. However, the 125 and the 150 have quite different jetting. The 150 is quite...
Thanks.

Yeah, that's the standard Needle/Needle Jet combo of the 2018 150sx. However, the 125 and the 150 have quite different jetting. The 150 is quite a bit leaner all around.
digger wrote:
In reality though, the jetting specs for the 125's and 150's are not that different. The jetting specs that have been listed above, S-4 needle jet...
In reality though, the jetting specs for the 125's and 150's are not that different. The jetting specs that have been listed above, S-4 needle jet, 42-74, i'de start out in the 2nd clip position, a 490 main along with #5 slide, are all going to be very good starting points for either a 125 or 150. The biggest difference between the 2 engines is the pilot jet, and that's only slightly and it varies as to how large, or no notch you have on the front side of the slide. Opening up the front side of the slide makes the pilot circuit more efficient, which in turn will will cause it to run richer, so you will need to compensate for this by using a smaller/leaner pilot jet.
Listen to this guy, he's the reason we are where we are with this jetting thread.
2
Dexter
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3/28/2020 7:48am Edited Date/Time 3/28/2020 7:53am
I finally did all the mods on my TC 250 2018, Im an average C rider I think and not very sensible to carb tunning, I didn't have any problem with the TMX from factory except the massive pipe bang on deceleration.

First I did the "Jarvis" mod, truly no difference.
Then I filed the slide to a 5.25 roughly, transition low to mid was better but not night and day better
And at last the S4, 42-75 with 35 pilot and 470 main (my order was messed up, I didnt get the 480), pipe bang is well reduced but still there a little I need to try a 32.5 pilot, and above all the high range and overrev are far better and dont seem to hit a wall like before

Thanks for all the tips

Edit: straight 98 pump gas (93 US) and 55:1 fuel mix
BikePilot
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3/28/2020 7:57am
You may need head work to totally clean up pipe bang. I know that on my TX300 (which as a worse head than your bike to be sure) no amount of jetting would clean it up. I bolted on an RK Tek head and pipe bang went away (it also made way more power).
AJ565
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3/28/2020 7:08pm
Dexter wrote:
I finally did all the mods on my TC 250 2018, Im an average C rider I think and not very sensible to carb tunning, I...
I finally did all the mods on my TC 250 2018, Im an average C rider I think and not very sensible to carb tunning, I didn't have any problem with the TMX from factory except the massive pipe bang on deceleration.

First I did the "Jarvis" mod, truly no difference.
Then I filed the slide to a 5.25 roughly, transition low to mid was better but not night and day better
And at last the S4, 42-75 with 35 pilot and 470 main (my order was messed up, I didnt get the 480), pipe bang is well reduced but still there a little I need to try a 32.5 pilot, and above all the high range and overrev are far better and dont seem to hit a wall like before

Thanks for all the tips

Edit: straight 98 pump gas (93 US) and 55:1 fuel mix
Also get a 490 MJ and give it a try. I’ve been having good luck running a 500 MJ in mine, but it’s a tad rich.
mxstate
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3/29/2020 6:14am
Dexter wrote:
I finally did all the mods on my TC 250 2018, Im an average C rider I think and not very sensible to carb tunning, I...
I finally did all the mods on my TC 250 2018, Im an average C rider I think and not very sensible to carb tunning, I didn't have any problem with the TMX from factory except the massive pipe bang on deceleration.

First I did the "Jarvis" mod, truly no difference.
Then I filed the slide to a 5.25 roughly, transition low to mid was better but not night and day better
And at last the S4, 42-75 with 35 pilot and 470 main (my order was messed up, I didnt get the 480), pipe bang is well reduced but still there a little I need to try a 32.5 pilot, and above all the high range and overrev are far better and dont seem to hit a wall like before

Thanks for all the tips

Edit: straight 98 pump gas (93 US) and 55:1 fuel mix
AJ565 wrote:
Also get a 490 MJ and give it a try. I’ve been having good luck running a 500 MJ in mine, but it’s a tad rich.
+1 on AJ specs
19 TC250 with all his setup. I settled on 480 MJ/32.5 pilot/needles/slide mod etc.)
Rips!!!
1
jsippola
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3/29/2020 6:09pm Edited Date/Time 3/29/2020 6:10pm
Just picked up a 18 TC 125. I plan on running T2 in it. What are the jetting specs you all would recommend? Thank you.
AJ565
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3/29/2020 6:18pm
jsippola wrote:
Just picked up a 18 TC 125. I plan on running T2 in it. What are the jetting specs you all would recommend? Thank you.
MJ 500
PJ 35
AS 1.5
slide 5.0 (stock is 4.0)
Needle 42-75 on the 2nd clip (Yamaha part #284-14116-H5-00)
PV 1.75 turns in from all the way out.

This is a solid start for a 125 running T2. You’ll have to adjust from there. If it seems to load up off idle you’ll need to drop to a 32.5 PJ. If you’re ordering jets get a 35 and a 32.5 on the PJ side and a 490 and 500 on the MJ side.
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jsippola
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3/29/2020 6:25pm
jsippola wrote:
Just picked up a 18 TC 125. I plan on running T2 in it. What are the jetting specs you all would recommend? Thank you.
AJ565 wrote:
MJ 500 PJ 35 AS 1.5 slide 5.0 (stock is 4.0) Needle 42-75 on the 2nd clip (Yamaha part #284-14116-H5-00) PV 1.75 turns in from all...
MJ 500
PJ 35
AS 1.5
slide 5.0 (stock is 4.0)
Needle 42-75 on the 2nd clip (Yamaha part #284-14116-H5-00)
PV 1.75 turns in from all the way out.

This is a solid start for a 125 running T2. You’ll have to adjust from there. If it seems to load up off idle you’ll need to drop to a 32.5 PJ. If you’re ordering jets get a 35 and a 32.5 on the PJ side and a 490 and 500 on the MJ side.
Awesome thank you!
1
nornevrder
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4/5/2020 11:10am
Hello all!!! Holy shit from reading this thread there has been a lot of work going into this. Thank you much!!!!
Digger helped me get my 13 250 dialed back in the day when I lived in Alaska. Yesterday I picked up a 2020 and will start break in at the end of the week. I used to race the A class and Vet expert but am now 41 and am a bit washed up. I’m now back in Reno 4500’ and will mostly be doing trail riding in the hills. According to the manual stock jetting at 60:1 will work until it gets warmer. I have also read some good things about the JD kit and their support. Are these mods a must do for the type of riding that I will be doing? Is the stock jetting really that bad?
AJ565
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4/5/2020 1:52pm
nornevrder wrote:
Hello all!!! Holy shit from reading this thread there has been a lot of work going into this. Thank you much!!!! Digger helped me get my...
Hello all!!! Holy shit from reading this thread there has been a lot of work going into this. Thank you much!!!!
Digger helped me get my 13 250 dialed back in the day when I lived in Alaska. Yesterday I picked up a 2020 and will start break in at the end of the week. I used to race the A class and Vet expert but am now 41 and am a bit washed up. I’m now back in Reno 4500’ and will mostly be doing trail riding in the hills. According to the manual stock jetting at 60:1 will work until it gets warmer. I have also read some good things about the JD kit and their support. Are these mods a must do for the type of riding that I will be doing? Is the stock jetting really that bad?
The stock jetting is that bad and the JD kit is a band aid and doesn’t really make that good of improvement.
7/2/2020 9:42am
AJ565 wrote:
I get a lot of emails from here and at the track about jetting for the 2 strokes. Thanks to digger for pointing me in the...

I get a lot of emails from here and at the track about jetting for the 2 strokes. Thanks to digger for pointing me in the right direction this is the currant specs. I have for everything. Its easier to start a thread With all the jetting in it to keep track of everything. Your jetting might need tweaked based on your temps and elevation, but this is a good start for you.

**Updated 4/19/23**
'17+ 125/150 jetting (‘22 bikes have a known bog, there is no jetting or carb swap combo yet that takes care of that problem. If or when it gets figured out I’ll update)


MJ 510
PJ 32.5
AS 1.75
slide 5.0 from JD Jetting
Needle 42-74 on the 2nd clip (Yamaha 284-14116-H4-00)
Needle jet S4 (KTM part #55431021400)
PV 2.25 turns in from all the way out.
Fuel mix 40:1

(credit to FGR01 for continuing to refine the small bore jetting)


On the '17+ 250's **Updated 10/13/2020**
Pump gas/race gas or straight C12

This is my current jetting. Its more refined all around and crisp down low with better top end over rev.

Main jet 500
Pilot jet 32.5
Slide 5.75 (Kawasaki part#16025-0003)
Needle 43-75 (KTM part #55431134400)
Clip position #2
Needle jet S4 (KTM part #55431021400)
Air screw 1.5-2.0
Fuel 55:1

OR

Solid jetting if you're someone that doesn't live on top end. Crisp down low out of turns pull.
MJ 490
PJ 32.5
AS 1.5 turns out
Needle jet S4 (KTM part #55431021400) stock is S1
Needle 42-75 on the 2nd clip (Yamaha part #284-14116-H5-00)
Slide 5.5 (Kawasaki part 16025-0002)
PV 1.75 turns in from all the way out
Fuel mix 50:1

300sx jetting

Pilot jet 25 and main jet 460 to start.
Slide 5.5 (Kawasaki part 16025-0002)
Needle 42-75 on the 2nd clip (Yamaha part #284-14116-H5-00)
5/32” chainsaw file to notch the front of the slide.
A/S 1.5 to start, you’ll need to adjust as needed.
 

On the 2017 150,are you using the stock s1 needle jet ? Thanks.
1
digger
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7/2/2020 2:10pm Edited Date/Time 7/2/2020 2:11pm
On the 2017 150,are you using the stock s1 needle jet ? Thanks.
No, use the S-4 needle jet in the 150.
1
AJ565
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7/2/2020 3:24pm
Edited the original post to include the S4 with the 125/150's. I must have missed that part before.

digger, if you come back through here and see this can you email me? ameade565@ gmail . com
1
7/3/2020 7:27am
Anyone running 93 pump 50:1 in a 19 250? Looking for some settings to try.
7/3/2020 7:56am
Anyone running 93 pump 50:1 in a 19 250? Looking for some settings to try.
I’m running pump gas. Go with 60:1 and the settings on the first page. Working real good for me!
AJ565
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7/3/2020 9:41am
Anyone running 93 pump 50:1 in a 19 250? Looking for some settings to try.
Yes, I am. It’s on the first page of this thread.
Bruce372
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7/3/2020 11:19am
Does anyone have a part number for the S4 nozzle?
7/6/2020 6:24am Edited Date/Time 7/6/2020 6:28am
On the 2017 150,are you using the stock s1 needle jet ? Thanks.
digger wrote:
No, use the S-4 needle jet in the 150.
Digger, I sent you a private message, but it didn't give me a confirmation that it sent, not sure if it went through. I can send again if not... Thanks.
digger
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7/6/2020 6:51am
Digger, I sent you a private message, but it didn't give me a confirmation that it sent, not sure if it went through. I can send...
Digger, I sent you a private message, but it didn't give me a confirmation that it sent, not sure if it went through. I can send again if not... Thanks.
Sorry, These PM's ,Vital, go to my work email acct, and I sometimes will go days without looking at it. I just went through my work emails and I don't see one from you. You can try again, I'm at work now.
1
7/6/2020 8:44am
digger wrote:
Sorry, These PM's ,Vital, go to my work email acct, and I sometimes will go days without looking at it. I just went through my work...
Sorry, These PM's ,Vital, go to my work email acct, and I sometimes will go days without looking at it. I just went through my work emails and I don't see one from you. You can try again, I'm at work now.
Tried sending again but no dice Sad I will try from work later this evening where I have better service... Sorry for clogging up this thread...
dave_daum
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Encinitas, CA, USA
7/12/2020 1:55pm
I have a 2017 KTM 150 XCW that has been really hard to jet. The bike came equipped with a Mikuni TMX 38. Out of shear frustration I pulled out one of my Keihin PWK 38 Air Strikers and bolted it on. It has a #6 slide, 1469D needle, 182 main jet and a 40 pilot. While much better it is still not perfect. To get closer I'm looking for recommendrd settings for:
1. slide size?
2. needle?
3. main jet?
4. pilot?
Any tips are appreciated!
Dave
AJ565
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7/28/2020 3:51pm
Updated the original post to include a new jetting setup I've been testing with the 250 just to even more fine tune, plus I get bored and wonder if it could be better.
7/29/2020 5:31am
Thanks AJ and Digger for all the work you guys have done on fixing up the jetting.

First post to the group, but I’ve read through several posts these last few months, as I was looking for a 2018 250 SX. Picked one up, and changed out several things, but noticed I did one thing incorrect... When I ground my factory slide I added 1mm around the entire radius (not just the very top). Put it together and rode with it (about 30 minutes), and the bike was way better down low, but in reading through another thread I noticed I shouldn’t have widened the opening. Also, I only modified the air filter side of the slide (as that was the side that I’d seen discussed more in depth) and figured since the two slide mods should make it leaner, if I didn’t touch the smaller reeds side notch, it would only leave it slightly richer overall than a “total modification”.

So far I’ve completed the Jarvis Mods, float adjusted, s-4 needle jet, 35 pilot jet (1.75 turns), 470 main (to start... 100* out), and plan to order the leaner 42-75 needle (still 43-73 and clip at #3). I’m running 2/3 93 with 1/3 c12, at 50:1.

The BIG question... Did I trash my slide? Bike seems great down low (0-1/3), and just feels a bit more sluggish now up top, but I haven’t got the leaner needle yet, and I started out running a very large main (at ~600’ and 100*). Between the needle and the main size, and the heat, I think I can clean up the top, but I’m worried about overall efficiencies. Will this grenade my motor? Lol. How much power might be losing from the wider slide notch?.. Should I order a new one?

And FYI... The other mods to the bike are a Pro Circuit pipe, and 296 Silencer (neighbors). Figured I should be jumping one main jet size for the pipe alone, and when I first picked it up a month ago, it pulled really solid with the 440 main it had. I was never a jetting Waze, and just wanted to start with a set up it was very conservative. Between my minimal slide modification, the larger pilot jet (without the leaner needle), and the three steps up in the main jet, I think there should certainly be better response available. Just seemed you were always talking about huge main jets (even when not running oxygenated fuel), and wanted to start conservative.

I just need to make sure I get this right so my four year old doesn’t start out running me on his PW50.
:-P

Thanks again, and please advise!
AJ565
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7/29/2020 7:58am
Thanks AJ and Digger for all the work you guys have done on fixing up the jetting. First post to the group, but I’ve read through...
Thanks AJ and Digger for all the work you guys have done on fixing up the jetting.

First post to the group, but I’ve read through several posts these last few months, as I was looking for a 2018 250 SX. Picked one up, and changed out several things, but noticed I did one thing incorrect... When I ground my factory slide I added 1mm around the entire radius (not just the very top). Put it together and rode with it (about 30 minutes), and the bike was way better down low, but in reading through another thread I noticed I shouldn’t have widened the opening. Also, I only modified the air filter side of the slide (as that was the side that I’d seen discussed more in depth) and figured since the two slide mods should make it leaner, if I didn’t touch the smaller reeds side notch, it would only leave it slightly richer overall than a “total modification”.

So far I’ve completed the Jarvis Mods, float adjusted, s-4 needle jet, 35 pilot jet (1.75 turns), 470 main (to start... 100* out), and plan to order the leaner 42-75 needle (still 43-73 and clip at #3). I’m running 2/3 93 with 1/3 c12, at 50:1.

The BIG question... Did I trash my slide? Bike seems great down low (0-1/3), and just feels a bit more sluggish now up top, but I haven’t got the leaner needle yet, and I started out running a very large main (at ~600’ and 100*). Between the needle and the main size, and the heat, I think I can clean up the top, but I’m worried about overall efficiencies. Will this grenade my motor? Lol. How much power might be losing from the wider slide notch?.. Should I order a new one?

And FYI... The other mods to the bike are a Pro Circuit pipe, and 296 Silencer (neighbors). Figured I should be jumping one main jet size for the pipe alone, and when I first picked it up a month ago, it pulled really solid with the 440 main it had. I was never a jetting Waze, and just wanted to start with a set up it was very conservative. Between my minimal slide modification, the larger pilot jet (without the leaner needle), and the three steps up in the main jet, I think there should certainly be better response available. Just seemed you were always talking about huge main jets (even when not running oxygenated fuel), and wanted to start conservative.

I just need to make sure I get this right so my four year old doesn’t start out running me on his PW50.
:-P

Thanks again, and please advise!
I cut 1mm all the way around on my last slide and it was fine. I've notched the front and not notched the front before too and didn't notice a whole lot. So far my favorite modified slide has been 1mm in the middle blended to the sides and notched in the front.

It looks like your main is way to small and that could be the sluggish feel you have. Its been over 100 in the last few weeks here and I'm still running a 500 main. I'd drop your needle to #2 with the needle you have now, drop the pilot one size to 32.5 and put the big main in it and see how it runs. I'm about the same elevation as you are too, these bikes seem to like more fuel up top for sure. Its a very noticeable difference in my bike when I drop to a 490 and feels way lean. The other needle that I just updated the thread to running in the #2 position is like running your needle in the #2.5 position (credit to digger for that information). I felt in my bike that #3 was way to rich and had a lot of smoke and #2 was too lean. I tested with the needle spacer washer in the #2.5 position and it was perfect so I swapped out to the other needle in the #2 position.

And as always, this jetting information is what has worked for me and is just a guide for anyone else. Because of different air and elevations in different places you may need to adjust one way or the other, but this should get you really close.

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