2022 KTM 125/150 SX/XC CDI recall?

NSP139
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NSP139 3/17/2022 5:02am
3/17/2022 5:02am
digger wrote:
Damn, This would explain a lot. I just spent 2 weekends, in Florida and Georgia trying to jet a 22' Husky 125. It simply would not...
Damn, This would explain a lot. I just spent 2 weekends, in Florida and Georgia trying to jet a 22' Husky 125. It simply would not respond to any of the jetting changes we made. I thought possibly it was fuel or spark plug related, but no matter what changes we made to it, it always ran pretty much the same. I also had access to a 20' Husky 125 and that bike would respond to jetting changes, just like I would expect it too, But his 22' race bike and 22' practice bike ran pretty much the same no matter what was done to them. Jetting wise, I had my hands on almost every tuning option in that carb. Regardless, the kid went out and won the XC3 class at the GA round of the GNCC's on a bike that I don't consider acceptable.
So you're thinking the CDI is faulty and affecting the tune ability of the carburetor?
digger
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digger 3/17/2022 5:43am
3/17/2022 5:43am
NSP139 wrote:
So you're thinking the CDI is faulty and affecting the tune ability of the carburetor?
We even went so far as to put a 38mm Keihin PWK on it, with what I would consider to be a super rich setup for a 125/150, and it did the same thing as the Mikuni. The entire time I was working on the bike, I was thinking something is just not right about this bike. Everything that we could see mechanically, appeared to be working fine. The bike just would not react to any carb tuning. we did switch the stock power valve spring out to a 250/300 red spring, and he really liked that.
NSP139
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NSP139 3/17/2022 6:01am
3/17/2022 6:01am
That's very interesting everything I've heard about these bikes is that they're very temperamental and sensitive to jetting.
sandman768
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sandman768 3/17/2022 6:13am
3/17/2022 6:13am Edited Date/Time 3/17/2022 6:14am
quiknic wrote:
You can use the below link and check your VIN# to confirm if there is a recall on your bike. I sadly looked my 22 KTM150SX...
You can use the below link and check your VIN# to confirm if there is a recall on your bike.

I sadly looked my 22 KTM150SX, and yes it has a recall as well. I am going to speak with my dealer and see if they can look into confirmed issues, I had a strange seizure at 14.4 hours that caused damage to the cylinder. Bike ran excellent up until it didn't... Jetting has been spot-on, rings gap and squish looked good. Just blows that at 14hrs I had to replace the entire top end, luckily was able to find a full 150kit in time to make my next race while I get the original cylinder repaired.

KTM Service & Safety Check
Thanks for posting this… it states mine is one for the recall… makes sense, I have had mine since early September. Luckily my main bike is a 350sfx, so I have only put 10hrs on this bike….have not received any letter in the mail yet..
2

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NSP139
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NSP139 3/17/2022 6:13am
3/17/2022 6:13am
NSP139 wrote:
So you're thinking the CDI is faulty and affecting the tune ability of the carburetor?
digger wrote:
We even went so far as to put a 38mm Keihin PWK on it, with what I would consider to be a super rich setup for...
We even went so far as to put a 38mm Keihin PWK on it, with what I would consider to be a super rich setup for a 125/150, and it did the same thing as the Mikuni. The entire time I was working on the bike, I was thinking something is just not right about this bike. Everything that we could see mechanically, appeared to be working fine. The bike just would not react to any carb tuning. we did switch the stock power valve spring out to a 250/300 red spring, and he really liked that.
Definitely sounds like an ignition issue
NSP139
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NSP139 3/17/2022 6:25am
3/17/2022 6:25am
NSP139 wrote:
So you're thinking the CDI is faulty and affecting the tune ability of the carburetor?
digger wrote:
We even went so far as to put a 38mm Keihin PWK on it, with what I would consider to be a super rich setup for...
We even went so far as to put a 38mm Keihin PWK on it, with what I would consider to be a super rich setup for a 125/150, and it did the same thing as the Mikuni. The entire time I was working on the bike, I was thinking something is just not right about this bike. Everything that we could see mechanically, appeared to be working fine. The bike just would not react to any carb tuning. we did switch the stock power valve spring out to a 250/300 red spring, and he really liked that.
NSP139 wrote:
Definitely sounds like an ignition issue
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for a bad cranks on these bikes
zac_k3
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zac_k3 3/17/2022 7:01am
3/17/2022 7:01am
I typed me and my friends v.i.n into the link provided and it said they do have a recall, called the local dealership and was told it was just on the EU models but he would check with the ktm mechanic and make sure and that he’ll get back to me. Called Mountain Motorsports and the guy in service said neither of the bikes had a recall. Not really sure what to do, didn’t have any plans to ride until April but really don’t wanna add hours to the bike if people are blowing up at only 14 hours.
digger
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digger 3/17/2022 7:14am
3/17/2022 7:14am
NSP139 wrote:
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for...
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for a bad cranks on these bikes
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has less than 15hrs on it, and I'm not sure how many hrs his practice 125 bike has on it.
It doesn't seem to matter what we do to it, it has a lean bog off idle, and will then run like crap through middle whenever there is a consistent load on the engine. The idle also seems to want to change all the time as well. We can get the bike to run great on the stand, but when you put a load on it, and ride it around, it's noticeably lean off idle. I wonder if that lean area in the carburation has anything to do with crank failures. I really don't know.
The Husky tech's at the GNCC's were pushing for 50-1 gas/oil ratio, and I was pushing for 32-1, we settled at 40-1. I was more concerned about the crank than the Husky' tech's.
1
NSP139
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NSP139 3/17/2022 7:40am
3/17/2022 7:40am Edited Date/Time 3/17/2022 8:02am
NSP139 wrote:
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for...
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for a bad cranks on these bikes
digger wrote:
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has...
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has less than 15hrs on it, and I'm not sure how many hrs his practice 125 bike has on it.
It doesn't seem to matter what we do to it, it has a lean bog off idle, and will then run like crap through middle whenever there is a consistent load on the engine. The idle also seems to want to change all the time as well. We can get the bike to run great on the stand, but when you put a load on it, and ride it around, it's noticeably lean off idle. I wonder if that lean area in the carburation has anything to do with crank failures. I really don't know.
The Husky tech's at the GNCC's were pushing for 50-1 gas/oil ratio, and I was pushing for 32-1, we settled at 40-1. I was more concerned about the crank than the Husky' tech's.
Maybe a tight crank is making the jetting on the bottom unpredictable . I had a very similar situation with a bike after a complete rebuild had a bog off bottom rough in the middle ran great on the top end. Went through all the electrical thinking that was the problem ended up tearing it back down it was a defective OEM crank rebuilt it with a another new crank problem went away. This bike was a Honda though not a KTM. And I definitely agree with you 32.1 is the way to go I'm a little leery running 40 to 1 in our 250 SX.
1
Rickyisms 3/17/2022 1:01pm
3/17/2022 1:01pm
NSP139 wrote:
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for...
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for a bad cranks on these bikes
digger wrote:
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has...
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has less than 15hrs on it, and I'm not sure how many hrs his practice 125 bike has on it.
It doesn't seem to matter what we do to it, it has a lean bog off idle, and will then run like crap through middle whenever there is a consistent load on the engine. The idle also seems to want to change all the time as well. We can get the bike to run great on the stand, but when you put a load on it, and ride it around, it's noticeably lean off idle. I wonder if that lean area in the carburation has anything to do with crank failures. I really don't know.
The Husky tech's at the GNCC's were pushing for 50-1 gas/oil ratio, and I was pushing for 32-1, we settled at 40-1. I was more concerned about the crank than the Husky' tech's.
I had the same problem on my 16 when the ignition plug wire snapped. After about five minutes of riding it would develop a lean bog when whacking the throttle under load or on the stand.
Rickyisms 3/17/2022 1:06pm
3/17/2022 1:06pm
NSP139 wrote:
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for...
Your rider sounds very fast how many hours does he have on his 2022s I'm worried that KTM is using to CDI to cover up for a bad cranks on these bikes
digger wrote:
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has...
He is one of the top 125cc based, offroad riders on the east coast currently, and yes, he's pretty fast. I think his race bike has less than 15hrs on it, and I'm not sure how many hrs his practice 125 bike has on it.
It doesn't seem to matter what we do to it, it has a lean bog off idle, and will then run like crap through middle whenever there is a consistent load on the engine. The idle also seems to want to change all the time as well. We can get the bike to run great on the stand, but when you put a load on it, and ride it around, it's noticeably lean off idle. I wonder if that lean area in the carburation has anything to do with crank failures. I really don't know.
The Husky tech's at the GNCC's were pushing for 50-1 gas/oil ratio, and I was pushing for 32-1, we settled at 40-1. I was more concerned about the crank than the Husky' tech's.
NSP139 wrote:
Maybe a tight crank is making the jetting on the bottom unpredictable . I had a very similar situation with a bike after a complete rebuild...
Maybe a tight crank is making the jetting on the bottom unpredictable . I had a very similar situation with a bike after a complete rebuild had a bog off bottom rough in the middle ran great on the top end. Went through all the electrical thinking that was the problem ended up tearing it back down it was a defective OEM crank rebuilt it with a another new crank problem went away. This bike was a Honda though not a KTM. And I definitely agree with you 32.1 is the way to go I'm a little leery running 40 to 1 in our 250 SX.
I ran 32:1 for years in my KTM 125 and 150. I just recently upped it to 28:1 and went a little richer on jetting since I’m a bit harder on the bike now and a little heavier than I was 5 years ago when I was 16.
Dirtysmile56 3/18/2022 11:13am
3/18/2022 11:13am
sandman768 wrote:
Just XC in USA?
NSP139 wrote:
No SX and the huskys also
NSP139 wrote:
Haven't looked up gas gas
I just put a deposit on a GasGas and they have it too. Kind of bummed they are slowing the bikes down instead of fixing the faulty cranks. I'm not sure if I want it now.
AgileMike
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AgileMike 3/22/2022 6:10pm
3/22/2022 6:10pm
New information is coming out hourly on this issue.
I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal, except that there are no cranks available nationwide due to the many failures on model year 2022 cranks. Just heard from a dealer this afternoon:
1. Crank part number "50430018000" is the 2021 and prior crank.
2. Part number "50530018000" is the 2022 crank.
3. KTM is calling back all the 2022 cranks from all dealers. They also won't let dealers repair any 2022 crank issue warranty bikes until they get the 2021 cranks back in stock.
4. They are seeing crank failures on 2022 models with as few as two hours.

This really sucks for because my son's 2022 SX125 just seized at about 12 hours (I haven't torn into it yet, so not positive it's the crank, but my guess is that's the problem). We do have a 2022 SX150 for my other son that has been running great up to 36.7 hours with no problems.

We run Motorex Cross Power T2 at 32:1 and VP110 50/50 with premium non-ethanol pump gas. I think the extra oil and lead in the VP110 should help out the cranks. We are also religious about changing air filters.

It's going to be interesting to see how KTM handles this issue. Not too hot on the idea of both of my sons racing motocross with large jumps on bikes with a bad crank.
1
Bruce372
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Bruce372 3/22/2022 6:20pm
3/22/2022 6:20pm
AgileMike wrote:
New information is coming out hourly on this issue. I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal...
New information is coming out hourly on this issue.
I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal, except that there are no cranks available nationwide due to the many failures on model year 2022 cranks. Just heard from a dealer this afternoon:
1. Crank part number "50430018000" is the 2021 and prior crank.
2. Part number "50530018000" is the 2022 crank.
3. KTM is calling back all the 2022 cranks from all dealers. They also won't let dealers repair any 2022 crank issue warranty bikes until they get the 2021 cranks back in stock.
4. They are seeing crank failures on 2022 models with as few as two hours.

This really sucks for because my son's 2022 SX125 just seized at about 12 hours (I haven't torn into it yet, so not positive it's the crank, but my guess is that's the problem). We do have a 2022 SX150 for my other son that has been running great up to 36.7 hours with no problems.

We run Motorex Cross Power T2 at 32:1 and VP110 50/50 with premium non-ethanol pump gas. I think the extra oil and lead in the VP110 should help out the cranks. We are also religious about changing air filters.

It's going to be interesting to see how KTM handles this issue. Not too hot on the idea of both of my sons racing motocross with large jumps on bikes with a bad crank.
With a failure at 12 hours. No way should you open it up. Just take it back to the dealer
2
AgileMike
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AgileMike 3/22/2022 6:58pm
3/22/2022 6:58pm
Tore into my son's 2022 SX125 with 12 hours. It's not seized but crank bearings are gone. There is about 2mm of up/down free play in the connecting rod. Going to submit a claim to KTM through my dealer in the morning.
1
AgileMike
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AgileMike 3/22/2022 7:08pm
3/22/2022 7:08pm
I know the dealer so I don't think it will be a problem to take the cylinder off. I'm not splitting the cases or anything. I will ask them in the morning if I need to reassemble it or not.
GingerSnapRacing 3/22/2022 9:16pm
3/22/2022 9:16pm
AgileMike wrote:
New information is coming out hourly on this issue. I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal...
New information is coming out hourly on this issue.
I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal, except that there are no cranks available nationwide due to the many failures on model year 2022 cranks. Just heard from a dealer this afternoon:
1. Crank part number "50430018000" is the 2021 and prior crank.
2. Part number "50530018000" is the 2022 crank.
3. KTM is calling back all the 2022 cranks from all dealers. They also won't let dealers repair any 2022 crank issue warranty bikes until they get the 2021 cranks back in stock.
4. They are seeing crank failures on 2022 models with as few as two hours.

This really sucks for because my son's 2022 SX125 just seized at about 12 hours (I haven't torn into it yet, so not positive it's the crank, but my guess is that's the problem). We do have a 2022 SX150 for my other son that has been running great up to 36.7 hours with no problems.

We run Motorex Cross Power T2 at 32:1 and VP110 50/50 with premium non-ethanol pump gas. I think the extra oil and lead in the VP110 should help out the cranks. We are also religious about changing air filters.

It's going to be interesting to see how KTM handles this issue. Not too hot on the idea of both of my sons racing motocross with large jumps on bikes with a bad crank.
For the 2019 just get the crank rebuilt. I wouldn’t buy a whole new crank if you don’t need to. Just a proX rod kit and have a competent builder do the work. That’s what I did with my spare crank.

On the 22 hopefully the shop helps you get it fixed on their dime.
2
Dirtdemon 3/23/2022 4:01am
3/23/2022 4:01am
So lowering RPM saves the crank...
Dont want to have less power on my sons 125

Regarding failure, noise or just total lockup ??

Maybe I´ll torn down and repress, anyone know if they have tighter tolerances or is it bad bearings ?

Sorry for my bad english..

Pit Row

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sandman768
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sandman768 3/23/2022 6:56am
3/23/2022 6:56am
This is a bummer, I bought my 22 to have some fun on a 125 again after a long time of not riding one. After 10 hrs, I was just starting to get in the groove on it….I have faith in KTM but looks like it will take some time.. Back in 2015 I had a new XC300 with around 40hrs, the crank bearings exploded and were sucked up into the cylinder, ruining just about everything…. I tore it apart and figured it was my mess… I contacted KTM and after some negotiations we agreed they would cover parts & I would cover labor, which I though was fair, considering it had 40hrs GNCC hrs on it…
Dirtysmile56 3/23/2022 9:51am
3/23/2022 9:51am
I just picked up our new 22 MC125 yesterday from Bills Motorcycles in Salem, Or. Awesome shop btw No mark ups whatsoever MSRP period! They put a new CDI box in from KTM. The fix is called something along the lines of "the crank update". But it's just a CDI box being changed. We are taking it to NorCal in the morning to break it in and see how it runs(I'll probably bring the YZ just incase). It sounds like 32:1 is the mixture. I've been running 40:1 Super M 92 non eth in our YZ's and haven't had any problems. It looks like I'm going to go 32:1 after reading this thread. on this one. Do you guys have any recommendations on fork pressure for a 120lb junior rider on this?
The kid is stoked!!!!
8
AgileMike
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AgileMike 3/23/2022 5:05pm
3/23/2022 5:05pm
AgileMike wrote:
New information is coming out hourly on this issue. I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal...
New information is coming out hourly on this issue.
I had a 2019 SX150 that just seized the crank at 170 hours. Not a big deal, except that there are no cranks available nationwide due to the many failures on model year 2022 cranks. Just heard from a dealer this afternoon:
1. Crank part number "50430018000" is the 2021 and prior crank.
2. Part number "50530018000" is the 2022 crank.
3. KTM is calling back all the 2022 cranks from all dealers. They also won't let dealers repair any 2022 crank issue warranty bikes until they get the 2021 cranks back in stock.
4. They are seeing crank failures on 2022 models with as few as two hours.

This really sucks for because my son's 2022 SX125 just seized at about 12 hours (I haven't torn into it yet, so not positive it's the crank, but my guess is that's the problem). We do have a 2022 SX150 for my other son that has been running great up to 36.7 hours with no problems.

We run Motorex Cross Power T2 at 32:1 and VP110 50/50 with premium non-ethanol pump gas. I think the extra oil and lead in the VP110 should help out the cranks. We are also religious about changing air filters.

It's going to be interesting to see how KTM handles this issue. Not too hot on the idea of both of my sons racing motocross with large jumps on bikes with a bad crank.
GingerSnapRacing wrote:
For the 2019 just get the crank rebuilt. I wouldn’t buy a whole new crank if you don’t need to. Just a proX rod kit and...
For the 2019 just get the crank rebuilt. I wouldn’t buy a whole new crank if you don’t need to. Just a proX rod kit and have a competent builder do the work. That’s what I did with my spare crank.

On the 22 hopefully the shop helps you get it fixed on their dime.
I will have to try the crank rebuild route. I've always been in a time crunch when I had lower end issues, so getting a crank rebuilt wasn't an option. I now have three bikes running the exact same cranks, so it will be pretty easy to purchase one new one, and just rebuild the cranks when we have an issue, and always have one available in the toolbox at home.

We put a lot of hours on our bikes, so it's nice to save some money now and again.
JTM5427
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JTM5427 3/23/2022 5:18pm
3/23/2022 5:18pm
Amateur I know had a brand new 2022 that he was getting ready to break in before RCSX, ran 4 heat cycles on it, and then went out for a slow easy moto and it locked up on the landing of a jump a few laps in. .3 hours on it and that was from heat cycles. Definitely something wrong with these bikes. The big issue is there are no parts to repair them.
NSP139
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NSP139 3/23/2022 6:03pm
3/23/2022 6:03pm
JTM5427 wrote:
Amateur I know had a brand new 2022 that he was getting ready to break in before RCSX, ran 4 heat cycles on it, and then...
Amateur I know had a brand new 2022 that he was getting ready to break in before RCSX, ran 4 heat cycles on it, and then went out for a slow easy moto and it locked up on the landing of a jump a few laps in. .3 hours on it and that was from heat cycles. Definitely something wrong with these bikes. The big issue is there are no parts to repair them.
Lucky it locked up on the down side not the face of the jump KTM needs to fix the issue not the CDI you can't get a crank for these bikes for a reason!
Ellgrand
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Ellgrand 3/23/2022 6:08pm
3/23/2022 6:08pm
sandman768 wrote:
I just turned over 10 hrs on my 22 125SX., wrung it’s neck yesterday in the deep sand down in Florida… if it was going to...
I just turned over 10 hrs on my 22 125SX., wrung it’s neck yesterday in the deep sand down in Florida… if it was going to blow, it would have been yesterday!
Mesa Mx
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sandman768
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sandman768 3/23/2022 6:46pm
3/23/2022 6:46pm
Ellgrand wrote:
Mesa Mx
Love Mesa👍
XC706 3/23/2022 8:28pm
3/23/2022 8:28pm
Dirtysmile56 wrote:
I just picked up our new 22 MC125 yesterday from Bills Motorcycles in Salem, Or. Awesome shop btw No mark ups whatsoever MSRP period! They put...
I just picked up our new 22 MC125 yesterday from Bills Motorcycles in Salem, Or. Awesome shop btw No mark ups whatsoever MSRP period! They put a new CDI box in from KTM. The fix is called something along the lines of "the crank update". But it's just a CDI box being changed. We are taking it to NorCal in the morning to break it in and see how it runs(I'll probably bring the YZ just incase). It sounds like 32:1 is the mixture. I've been running 40:1 Super M 92 non eth in our YZ's and haven't had any problems. It looks like I'm going to go 32:1 after reading this thread. on this one. Do you guys have any recommendations on fork pressure for a 120lb junior rider on this?
The kid is stoked!!!!
I would start with 108 psi in the forks. Set rear shock sag at 105mm, however you will not be able to get close to the 35mm static sag with the stock 39nm spring, he will need a 36 nm spring.
1
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IanMac138
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IanMac138 3/24/2022 12:36pm
3/24/2022 12:36pm
Side topic, but wanted to know what gearing anyone who owns a 150sx is running? I'm currently running 13/49 but looking for a new combo to get a little more out of 2nd-4th generally...
Here's my '19...love her.

1
SmokinJoe439 3/24/2022 1:03pm
3/24/2022 1:03pm Edited Date/Time 3/24/2022 1:11pm
I'm running on my 21 13/46 which is like equal to putting a 14t on it. You need to gear it taller in order to use 2nd 3rd 4th for longer periods.

I've seen you around at washougal man I'm #90 with Yellow backgrounds black numbers. Otmx colors. You can try it out if you doubt me. Makes it whole lot better. Normally I'm on my 21 250sx hopefully mt view next weekend
Bruce372
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Bruce372 3/24/2022 1:20pm
3/24/2022 1:20pm
IanMac138 wrote:
Side topic, but wanted to know what gearing anyone who owns a 150sx is running? I'm currently running 13/49 but looking for a new combo to...
Side topic, but wanted to know what gearing anyone who owns a 150sx is running? I'm currently running 13/49 but looking for a new combo to get a little more out of 2nd-4th generally...
Here's my '19...love her.

I use stock 13,48. I was thinking of going to 49 back, only because I've got two other bikes running that and I could setup my spare wheel the same for all bikes.

Smoking Joe's might work better to widen the gears, mine will already pull 3rd in corners so maybe with the 49 I could run 4th and 5th on the straights more often, but maybe it would mean a lot more shifting
IanMac138
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West Linn, OR US
IanMac138 3/24/2022 1:35pm
3/24/2022 1:35pm
Bruce372 wrote:
I use stock 13,48. I was thinking of going to 49 back, only because I've got two other bikes running that and I could setup my...
I use stock 13,48. I was thinking of going to 49 back, only because I've got two other bikes running that and I could setup my spare wheel the same for all bikes.

Smoking Joe's might work better to widen the gears, mine will already pull 3rd in corners so maybe with the 49 I could run 4th and 5th on the straights more often, but maybe it would mean a lot more shifting
The 13/49 I can easily pull corners in 3rd but from 3rd -5th especially I'm tap-dancing like a mofo and sometimes it gets sketchy on the face of a jump praying that you don't run out of gear or risk shifting up off a lip of a big booter. Bitten me a few times.
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