2016 KTM250SXF Cranking Issues

Rick Amatuzio 12/21/2019 7:14am
12/21/2019 7:14am
Jg144 wrote:
[img]https://p.vitalmx.com/photos/forums/2019/12/20/393050/s1200_2017D25A_6BAC_4F7A_A571_C25450A9D8F0.jpg[/img]

I got ya, good to know. KTM has an intermediate clutch, good idea. I’ve had several starters broken due to the motor kicking backing trying to start, or hydro lock from a bad head gasket on vehicles.
Industry Moto
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Industry Moto 12/21/2019 11:30am
12/21/2019 11:30am
Underground wrote:
Starter clutch or freewheel. Same thing with the older models. look it up. Do your research. From memory there's a mod that can tighten it up...
Starter clutch or freewheel. Same thing with the older models. look it up. Do your research. From memory there's a mod that can tighten it up if you're tight.
damaged 450 video but this will get you going the right direction
Ive been in contact with a factory tech at KTM he wants me to try the torque limiter as a few others have suggested. Got one coming.
Rick Amatuzio 12/21/2019 11:55am
12/21/2019 11:55am
You should have someone else on here With the same bike pull the stator cover and rotate the motor with a torque wrench. If it’s similar, sounds like you have the right part coming.

This issue must have started slowly after time, not after a rebuild then? Curious to what you find
Industry Moto
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Industry Moto 12/21/2019 12:02pm
12/21/2019 12:02pm
Jg144 wrote:
The torque limiter is slipping causing it to turnover too slow to start. There isn’t a way to check it so you will have to buy...
The torque limiter is slipping causing it to turnover too slow to start. There isn’t a way to check it so you will have to buy a new one or try one out of another unit if you have access to one.
I spoke with a Factory Tech yesterday he also said to start with the torque limiter. Ive got one coming. Thanks for the help.

The Shop

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Rick Amatuzio 12/21/2019 12:32pm
12/21/2019 12:32pm
Jg144 wrote:
The torque limiter is slipping causing it to turnover too slow to start. There isn’t a way to check it so you will have to buy...
The torque limiter is slipping causing it to turnover too slow to start. There isn’t a way to check it so you will have to buy a new one or try one out of another unit if you have access to one.
Industry Moto wrote:
I spoke with a Factory Tech yesterday he also said to start with the torque limiter. Ive got one coming. Thanks for the help.
Just an FYI, not related to your problem but I had a 2016 350sx. They had a recall on the fuel pump. The corrugated hoses were too long, and they would kink. I bought the high pressure fittings and hose but KTM ended up replacing the pump for free. I have pictures of Vital somewhere. Kinda nice to have a board where you can share problems and solutions.
Look in your tank with a flashlight or bore scope since you are working on it anyway.
Industry Moto
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Industry Moto 12/30/2019 10:09pm
12/30/2019 10:09pm
Jg144 wrote:
I’ve dealt with this issue at work on the same year of 250 sxf. I didn’t think it was the issue either when I was talking...
I’ve dealt with this issue at work on the same year of 250 sxf. I didn’t think it was the issue either when I was talking with the guys at Ktm. The bike turns over too slow to start. When I replaced it it was immediately noticeable and the bike fired instantly.
Got it fixed and Yes it was the Torque Limiter!
3
Gunter_von Hagen 3/19/2022 2:18pm
3/19/2022 2:18pm
Hi everyone sorry to revive this old thread but...
I am trying to fix 2018 ktm xcf 250 100hours , very similar problem to this thread.
Very very slow crank, slower if cold start activated, new battery, new starter-no change.
all wiring 100% . Engine only cranks a few times before fully charged battery flat.
Its almost as though too much compression.
starter motor speed is proportional to crank shaft speed ie when crank shaft slow/stops starter motor slow/stops.
Valve timing checked out.
Valve clearance checked out.

Could this be the torque limiter even though starter motor does not keep turning when crank shaft stops turning?
Gunter_von Hagen 3/19/2022 2:26pm
3/19/2022 2:26pm
Jg144 wrote:
Industry moto I am a tech at a Ktm dealer. I was in the same boat as you tried a fuel pump, injector, battery valve inspection...
Industry moto I am a tech at a Ktm dealer. I was in the same boat as you tried a fuel pump, injector, battery valve inspection, leak down, compression check bunch of time with the xc2 a few calls to Ktm tech line and it was the torque limiter. The bike was almost impossible to get started. I had to crack the throttle the perfect amount to get it to fire up and once running it was totally fine you would never know it had an issue until you shit if off and tried to restart. I know it sounds crazy but it fixed it. I didn’t realize how much slower it turned over until I replaced the torque limiter. I’m surprised to see another unit with the same exact symptoms. Anyway good luck with it hope you get it fixed.
Hi , just trying to flag you about similar problem I have posted . Sorry if quoting you the wrong way to do it. Thanks Jack
Industry Moto
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Industry Moto 3/19/2022 3:02pm
3/19/2022 3:02pm
Jg144 wrote:
Industry moto I am a tech at a Ktm dealer. I was in the same boat as you tried a fuel pump, injector, battery valve inspection...
Industry moto I am a tech at a Ktm dealer. I was in the same boat as you tried a fuel pump, injector, battery valve inspection, leak down, compression check bunch of time with the xc2 a few calls to Ktm tech line and it was the torque limiter. The bike was almost impossible to get started. I had to crack the throttle the perfect amount to get it to fire up and once running it was totally fine you would never know it had an issue until you shit if off and tried to restart. I know it sounds crazy but it fixed it. I didn’t realize how much slower it turned over until I replaced the torque limiter. I’m surprised to see another unit with the same exact symptoms. Anyway good luck with it hope you get it fixed.
Gunter_von Hagen wrote:
Hi , just trying to flag you about similar problem I have posted . Sorry if quoting you the wrong way to do it. Thanks Jack
It ended up being the Torque limiter. I had never even heard of that so I wasn't searching for the right issue. Its between the starter gear and the flywheel. Apparently its a common issue. Try you tubing KTM Torque limiter and see if that resembles your issues.
1
Gunter_von Hagen 3/20/2022 12:05pm
3/20/2022 12:05pm
Jg144 wrote:
Industry moto I am a tech at a Ktm dealer. I was in the same boat as you tried a fuel pump, injector, battery valve inspection...
Industry moto I am a tech at a Ktm dealer. I was in the same boat as you tried a fuel pump, injector, battery valve inspection, leak down, compression check bunch of time with the xc2 a few calls to Ktm tech line and it was the torque limiter. The bike was almost impossible to get started. I had to crack the throttle the perfect amount to get it to fire up and once running it was totally fine you would never know it had an issue until you shit if off and tried to restart. I know it sounds crazy but it fixed it. I didn’t realize how much slower it turned over until I replaced the torque limiter. I’m surprised to see another unit with the same exact symptoms. Anyway good luck with it hope you get it fixed.
Gunter_von Hagen wrote:
Hi , just trying to flag you about similar problem I have posted . Sorry if quoting you the wrong way to do it. Thanks Jack
Industry Moto wrote:
It ended up being the Torque limiter. I had never even heard of that so I wasn't searching for the right issue. Its between the starter...
It ended up being the Torque limiter. I had never even heard of that so I wasn't searching for the right issue. Its between the starter gear and the flywheel. Apparently its a common issue. Try you tubing KTM Torque limiter and see if that resembles your issues.
Many thanks for adding to post.

I had looked at torque limiter problems and when faulty they appear to allow starter motor to spin but not crank motor.

motor cranks until on compression stroke then stops cranking , the starter also stops but continues drawing very large current.

If inlet air totally shut off engine cranks slowly.

Valve timing correct, valve clearances correct, no carbon build up on piston crown / combustion chamber. New genuine starter motor -no change.
Jumping directly to starter -no change.

Cams and bearing 100% engine turns well by hand / no binding.

This is a puzzle.

Best wishes

Jack
Industry Moto
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Industry Moto 3/20/2022 5:31pm
3/20/2022 5:31pm
Gunter_von Hagen wrote:
Hi , just trying to flag you about similar problem I have posted . Sorry if quoting you the wrong way to do it. Thanks Jack
Industry Moto wrote:
It ended up being the Torque limiter. I had never even heard of that so I wasn't searching for the right issue. Its between the starter...
It ended up being the Torque limiter. I had never even heard of that so I wasn't searching for the right issue. Its between the starter gear and the flywheel. Apparently its a common issue. Try you tubing KTM Torque limiter and see if that resembles your issues.
Gunter_von Hagen wrote:
Many thanks for adding to post. I had looked at torque limiter problems and when faulty they appear to allow starter motor to spin but not...
Many thanks for adding to post.

I had looked at torque limiter problems and when faulty they appear to allow starter motor to spin but not crank motor.

motor cranks until on compression stroke then stops cranking , the starter also stops but continues drawing very large current.

If inlet air totally shut off engine cranks slowly.

Valve timing correct, valve clearances correct, no carbon build up on piston crown / combustion chamber. New genuine starter motor -no change.
Jumping directly to starter -no change.

Cams and bearing 100% engine turns well by hand / no binding.

This is a puzzle.

Best wishes

Jack
Mine did the same covered intake and it would turn over slowly open intake and it would not turn over. Also huge amp draw on starter. The torque limiter is meant to absorb shock of a kick back and if that happens the dampers will let it spin the other way. So in essence its turning against it self when it fails. my starter would also stop turning. Id give it a shot. Its 10 min fix and if that doesn't do it send it back!!
1
Gunter_von Hagen 4/5/2022 8:59am
4/5/2022 8:59am
Industry Moto wrote:
Mine did the same covered intake and it would turn over slowly open intake and it would not turn over. Also huge amp draw on starter...
Mine did the same covered intake and it would turn over slowly open intake and it would not turn over. Also huge amp draw on starter. The torque limiter is meant to absorb shock of a kick back and if that happens the dampers will let it spin the other way. So in essence its turning against it self when it fails. my starter would also stop turning. Id give it a shot. Its 10 min fix and if that doesn't do it send it back!!
Just want to say a HUGE THANKS

Replacing the torque limiter has fixed the bike.

Two weeks to get the torque limiter from KTM Austria frustrating !!! Stupid politics of UK leaving European Union.

Best wishes Jack in England
Gunter_von Hagen 4/5/2022 9:02am
4/5/2022 9:02am
PS the part number has been recently superseded so fingers crossed improved part.
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Dampvan 3/28/2025 12:33am
3/28/2025 12:33am

I had the same problem, would not turn over with throttle open etc, replaced starter, battery etc no improvement. Read through other posts and discounted Torque Limiter.

In desperation replaced it, could not believe the difference starts first time cranks normally

Thanks 

Pit Row

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