Hey guys, just recently bought a 2022 TC250, no issues for the first 5 hours until a couple weeks ago 2nd or 3rd lap I absolutely launched a jump into the up ramp of the next jump and collapsed the front wheel. I was positive I backed off and that the bike kept revving.
3 weeks later I got back on the bike today keeping my finger over the clutch at all times and sure enough the bike revved up again 2nd lap of the day.
The throttle and slide seem fine, I can’t see any sign of anything sticking or any issues with the throttle cable and the throttle returning but for whatever reason the problems occurring. Come to think of it I even held my finger on the kill switch and couldn’t turn it off which makes me think it’s some kind of air leak. I’ll be taking the bike back to Husqvarna tomorrow anyway but just looking for any advice or anyone that’s also had issues on 19-22 model 250 SX and TC250s.
Since buying the bike the only mods are DEP silencer and using vented airbox cover that came with the bike, besides that I haven’t touched any jetting or anything else on the bike.
Mixing Ipone oil @ 50:1 and 60:1 (husky/Ktm recommend 60:1)
Did you take apart the throttle assembly on the bars? The 21 and newer have the little blue pulley wheel in there and the cable can get frayed somewhat easily. The housing also has a torque setting of 5Nm stamped into it and it will crack if you overtighten it.
Hadn’t touched the throttle at all other than adjust the free play to my liking. I’ve since taken the throttle off after the crash and everything seems fine with it
is the cable routed correctly?
Cables routed the usual KTM way, doesn’t seem like it’s being crushed or pulled, I can twist the throttle 100 times and it snaps back every time, I can’t get the throttle or slide to stick at all but then once I get it on a track it happens 2nd lap 🤷🏽♂️
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I'm thinking maybe bent needle, etc. The tip of the needle can bend very easily on the Mikuni. Take the needle out and spin it between your fingers and you can feel pretty quick if the tip is bent. If it was me I'd take the carb completely apart and use it as an opportunity to put the S4 needle jet and all the other settings from the long thread in the carb.
Not sure if it’s the same setup as the 18’ throttle but I had the same issue. Couldn’t find anything wrong with anything until I looked very close at the throttle cable up to where it connects to the throttle cam. Where the cable housing ends it has the little metal cap and I could see it had the tiniest crack in the rubber part of the housing where they meet. Changed cables and everything works fine now
I took it apart again last night and towards the tip of the needle I spotted some scratches/scraps on it and you could definitely feel them with your fingers. I’m wondering if that’s enough to be hanging up the needle
Hmm interesting I’ll take another close look at the cable, I’ve got one on order anyway as I needed to buy the rubber cover for the adjuster which for some stupid reason you can’t buy on its own it comes with the cable so I figured let’s just order a cable anyway just to rule it out
It possibly could be a cause. I'd replace that needle for sure. Small scratches and gouges can affect the running of the bike since they alter the diameter and size of the needle.
One other thing to check with the cable routing is that there is nothing hanging up when the forks are fully compressed. Sort of hard to test in the shop, but look for any possible catches. I had an '02 250SX with a steering stabilizer 10 years ago, and I believe that grabbed my cable when the forks bottomed out and I had a stuck WOT in 5th gear down a hill. Brutal bailout, broken chest protector and ribs.
I also have a 22 TC250, and discovered you can substitute the older pre-pulley throttle housing and cable, and it's still cheaper than buying a new pulley cable. Works just as well in my view.
2 times I've had what appeared to be a uncontrolled rev on 2 stroke.
1) clutch side crank seal popped out while riding.
2) cracked a cylinder
The 2021+ housing and cable with the blue pulley are vastly superior to the 2017-2020 housing and cable with the plastic elbow and no pulley. The 2017 setup has horrible drag.
If you want the best setup, use the 2016-era domino housing and associated cable. You'll still come out cheaper than the 2021+ $75 cable.
Housing 51502010200 or Parts Unlimited 0632-0326
Cable from G2 (much cheaper than OEM) PU 0650-1691
Rubber cover (optional) 50302020000
I respectfully disagree here. I've had all 3 setups and haven't noticed much difference in feel if everything is set up properly. The condition of the slide and needle is a big factor too. The 2017-20 setup is cheaper and makes more sense since you already have an ODI throttle, and especially if you have spare ODI grip sets. All Balls makes good cables cheaper than oem.
Let me clarify my opinion, they can all feel good when new/fresh/clean, but the 17-21 without a pulley seems to get draggy quicker and worse.
You are definitely correct that the 17-21 housing and a cheap All balls cable will be cheaper than the setup I listed.
The ODI grips also fit the 2016 setup I mentioned.
This happened to me once, I always ride w/finger on the clutch so thank God no biggie, I opened the float bowl and the main jet had backed out and was sitting there 😃
I did have a guy insisting I needed to buy the 13ish - 2016 throttle assembly because he believed the 2022 assembly might be the cause, I don’t think it’s the actual cause of the problem I’m having but your not the first person to recommend that 2016 throttle setup
Scary stuff haha the carbs definitely going to be getting pulled apart fully.
I had a similar problem long, long, long time ago on an XL185 - basically the same bike, right? Anyway turned out the slide, while visually ok, was too dry and was locking up in the carb body. So maybe give it a little lube with some mix oil and see if that helps?
Pit Row
Sounds very similar to what I had with a 2012 KTM 150 10+ years ago. I had a thread on it (https://www.vitalmx.com/forums/Race-Shop,42/KTM-150sx-problem,1242023?p…)
KTM ended up having a recall for this problem shortly after. So it would be odd that is is still happening, but it is pretty spot on to what I had.
Thanks for sharing just had a read through. Really scary hearing all these stories about stuck throttles and cables popping out etc sounds like this has been an issue on KTMs for a long time.
I just sold a 2018 YZ250 I owned 4-5 years and 5hrs into Husky ownership my throttles Fukin stuck on almost sending me home in a helicopter 🤦♂️🤦♂️ My bikes at husky now and if/when I get it back I’m not sure I’ll ever get 100% of my confidence back until I sell it and move on to something else 😢 they’ve got a runout 2022 FC450 in the showroom maybe I should ask for a full refund and drop $500 extra needed to get the 450 at least it’s fuel injected and seem to have more reliable cables on the 4 strokes
Just wanted to post the cause of this as I eventually got to the bottom of it. After taking the bike back to Husqvarna they went through the carb and found a substantial amount of water in the bowl, most likely from contaminated fuel. The water was starving the jets and leaning the bike out making it lean rev on its own.
Just super unlucky that this happened on my 5hr old TC250 after getting 4-5 years out of my 2018 YZ250 with zero issues.
I have ridden the bike 3 times now and all seems well 😀😀
Good work finding the duff fuel and even better work updating the thread dude 👍
Super bad luck, like you say, but if it's all good now then onwards and upwards now! (hopefully not so onward and upward that you land in the face of the next jump again, of course)
Yep I can’t believe it, absolutely fell in love with my new bike and then that happened. About $700 worth of damage on a brand new bike, the last few times I rode it I’ve kept my finger on the clutch super paranoid about it happening again but I’ve finally been able to put my mind at ease now. I’ll definitely regularly drain my bowl from now on to try minimise the chances of it ever happening again.
This happened to me in 2015 on my 150SX. Turns out I did not seat the air filter cage and on the sand track during practice sand got into the carb and the slide hung up on moto1 first lap and I did a huge endo. Could not ride for 6 months and first lap of the next ride it stuck again. I took everything apart and discovered the sand in the boot and carb. Never happened again after that.
Yeh wow that’s crazy, when I got back on the bike the issue happened to me again too luckily had my finger on the clutch this time. I had drained my fuel and put fresh fuel in but unfortunately I didn’t think to drain my bowl so there was still water in there 😢.
in 1992 traded a 89 kx 500 for a 91 cr 250 everthing was fine for 6 months then after sevreal several stuck wide open incidents and finding nothing wrong anyware , went to the 60 year old pro at his shop told me to check the throttle spring in the carb ,as it tunrs out the previus owner who was a pro rider had cut the spring down for better throttle response after 6 monts the spring got weaker and would not push the slide down.
I had bent the bars on my 400mx but had a photo shoot the next day. My buddy replaced the bars and used Vaseline to install the grips. I was supposed to ride a lap then wheelie in front of the stands and camera flashing a one handed peace sign. Pretty standard stuff.
I lofted the front but the left grip came off in my hand...and slung straight at the camera. I whiskey throttled to the end of the straight and made the most perfect 90 degree right hander ever executed.
It was just a regional broadcast...I've tried to find it but no luck. My claim to fame.
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