2022 KTM 125/150 SX/XC CDI recall?

NSP139
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NSP139
Edited Date/Time 8/26/2022 10:22pm
Anybody have any information on this ? It is the same CDI from 2020 to 2022 now they want to lower rpm to prevent crank failure! Is this a bad batch of CDI'S that allows to much rpm for 2022 since they are not recalling 2020/2021? Or bad cranks for 2022? Any body experience any failure on there 2022?
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Rickyisms
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Rickyisms 3/16/2022 10:58am
3/16/2022 10:58am
From what I heard they switched the crank supplier for the 2022 bikes, same crank 16-22, but the ones the 22s came fitted with are pressed too tight apparently, also heard something about being Taiwanese too.

I’ve heard and seen some weird failures with the 2022 batch of cranks. Patrick Evans seized two in a week on his SX bike, a local engine builder that’s highly knowledgeable with KTM two strokes had two seize during heat cycles. When I rebuilt my 16 last year with a brand new OEM crank I did notice the crank stuffers were different upon first glance than the 2 other cranks I had pulled out of my 16s originally.
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NSP139
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NSP139 3/16/2022 11:14am
3/16/2022 11:14am
Rickyisms wrote:
From what I heard they switched the crank supplier for the 2022 bikes, same crank 16-22, but the ones the 22s came fitted with are pressed...
From what I heard they switched the crank supplier for the 2022 bikes, same crank 16-22, but the ones the 22s came fitted with are pressed too tight apparently, also heard something about being Taiwanese too.

I’ve heard and seen some weird failures with the 2022 batch of cranks. Patrick Evans seized two in a week on his SX bike, a local engine builder that’s highly knowledgeable with KTM two strokes had two seize during heat cycles. When I rebuilt my 16 last year with a brand new OEM crank I did notice the crank stuffers were different upon first glance than the 2 other cranks I had pulled out of my 16s originally.
That's pretty much what I expected since they superseded the crank part number for these bikes! Sounds like they should be recalling the crank not the CDI unit to mask the problem!
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Rickyisms
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Rickyisms 3/16/2022 11:23am
3/16/2022 11:23am Edited Date/Time 3/16/2022 11:23am
Rickyisms wrote:
From what I heard they switched the crank supplier for the 2022 bikes, same crank 16-22, but the ones the 22s came fitted with are pressed...
From what I heard they switched the crank supplier for the 2022 bikes, same crank 16-22, but the ones the 22s came fitted with are pressed too tight apparently, also heard something about being Taiwanese too.

I’ve heard and seen some weird failures with the 2022 batch of cranks. Patrick Evans seized two in a week on his SX bike, a local engine builder that’s highly knowledgeable with KTM two strokes had two seize during heat cycles. When I rebuilt my 16 last year with a brand new OEM crank I did notice the crank stuffers were different upon first glance than the 2 other cranks I had pulled out of my 16s originally.
NSP139 wrote:
That's pretty much what I expected since they superseded the crank part number for these bikes! Sounds like they should be recalling the crank not the...
That's pretty much what I expected since they superseded the crank part number for these bikes! Sounds like they should be recalling the crank not the CDI unit to mask the problem!
IIRC the 16s had a problem with transmission gears chipping and KTMs recall fix was to put softer clutch springs in to lessen to load on the gears.

To my knowledge they have never done anything about the case issue on 17-18 (maybe 16s too) idler gear problem that requires you to buy a new set of cases.

I’ve had some personal experiences with KTM and seen lots of unexplained failures that have swayed my decision to not go for an Austrian bike the next time around. I love my 2016 125 and 150 but they have left a sour taste in my mouth many times from the corporate side.
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NSP139
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NSP139 3/16/2022 12:01pm
3/16/2022 12:01pm
This is definitely not good news I have a deposit on one I can't even buy but I don't think I want a bike with an inferior crank and slower than last year so I would have to buy a complete motor rebuild and a new ignition just to get it back to stock. This doesn't even sound legal on their side
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Rickyisms
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Rickyisms 3/16/2022 1:06pm
3/16/2022 1:06pm
NSP139 wrote:
This is definitely not good news I have a deposit on one I can't even buy but I don't think I want a bike with an...
This is definitely not good news I have a deposit on one I can't even buy but I don't think I want a bike with an inferior crank and slower than last year so I would have to buy a complete motor rebuild and a new ignition just to get it back to stock. This doesn't even sound legal on their side
Like anything else on the internet take it with a grain of salt, even though I’ve seen a fair amount of failures online, there’s probably so many more 2022 KTM smokers out there running around that are just fine.

Where did you hear this CDI recall? I did a little searching but couldn’t find anything.
NSP139
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NSP139 3/16/2022 1:22pm
3/16/2022 1:22pm Edited Date/Time 3/16/2022 2:26pm
Rickyisms wrote:
Just found it on a Facebook group. [img]https://p.vitalmx.com/photos/forums/2022/03/16/538427/s1200_A2918507_A5C9_4175_8F7E_B3C2C94B5D8D.jpg[/img]
Just found it on a Facebook group.
Yep that's it and the dealerships down here can't even sell any of them until they get it fixed with no ETA! Weird that they're admitting they're slowing the engine down to save the crank
NSP139
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NSP139 3/16/2022 2:57pm
3/16/2022 2:57pm
sandman768 wrote:
Just XC in USA?
NSP139 wrote:
No SX and the huskys also
Haven't looked up gas gas
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dedi684 3/16/2022 3:05pm
3/16/2022 3:05pm
Damn I was going to the dealer tomorrow
sandman768
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sandman768 3/16/2022 3:49pm
3/16/2022 3:49pm
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!
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NSP139
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NSP139 3/16/2022 3:54pm
3/16/2022 3:54pm
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!
That's awesome to hear!
NSP139
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NSP139 3/16/2022 3:56pm
3/16/2022 3:56pm
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!
NSP139 wrote:
That's awesome to hear!
I just talked to Twisted development where I was going to take the motor they haven't heard of any massive failures but they also do recommend running at 32 to 1
NSP139
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NSP139 3/16/2022 4:03pm
3/16/2022 4:03pm
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!
NSP139 wrote:
That's awesome to hear!
NSP139 wrote:
I just talked to Twisted development where I was going to take the motor they haven't heard of any massive failures but they also do recommend...
I just talked to Twisted development where I was going to take the motor they haven't heard of any massive failures but they also do recommend running at 32 to 1
Just trying to figure out why KTM pulled their bikes off the market to change the CDI to save the crank! Nice bike!👍
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Atkinson 3/16/2022 4:08pm
3/16/2022 4:08pm
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!
How are you liking that pipe and exhaust combo? Ive got the same setup ordered for a MC125 and was curious what your thoughts are.
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ben5020 3/16/2022 4:13pm
3/16/2022 4:13pm
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!
I wouldn’t hold my breath on that thing staying together, a young ripper grenaded his 22 and ktm is paying to replace the entire engine but now this recall so they don’t want to release the bike…
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Rickyisms
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Rickyisms 3/16/2022 4:28pm
3/16/2022 4:28pm
To add, my 16 has (what I believe) is the same crank as 22s. Just turned over 19 hours at day in the dirt this weekend. Had an odd crank bearing failure at just over 18 hours but crank itself has been fine

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sandman768
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sandman768 3/16/2022 4:32pm
3/16/2022 4:32pm
ben5020 wrote:
I wouldn’t hold my breath on that thing staying together, a young ripper grenaded his 22 and ktm is paying to replace the entire engine but...
I wouldn’t hold my breath on that thing staying together, a young ripper grenaded his 22 and ktm is paying to replace the entire engine but now this recall so they don’t want to release the bike…
That sucks… but at least Ktm is making it right. I will stop into WMR in Stuart Fla. they are a high level KtM shop, see what they have to say… maybe they just remap the stock ECU? I have only ever had 1 issue with a KTM failure, And KTM stepped up and covered it when they bike had over 40 hrs on it.
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sandman768 3/16/2022 4:40pm
3/16/2022 4:40pm
Atkinson wrote:
How are you liking that pipe and exhaust combo? Ive got the same setup ordered for a MC125 and was curious what your thoughts are.
First ride with it was yesterday, perked up the power slightly across the board, added a slight amount of overrev, which the bike needed IMO..nothing earth shattering… The stock KtM system is very good, this is mostly so I can keep the stock pipe & silencer mint for when I sell the bike. Always a good idea to have a spare pipe for a 2 stroke on hand.
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NSP139
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NSP139 3/16/2022 4:49pm
3/16/2022 4:49pm
ben5020 wrote:
I wouldn’t hold my breath on that thing staying together, a young ripper grenaded his 22 and ktm is paying to replace the entire engine but...
I wouldn’t hold my breath on that thing staying together, a young ripper grenaded his 22 and ktm is paying to replace the entire engine but now this recall so they don’t want to release the bike…
sandman768 wrote:
That sucks… but at least Ktm is making it right. I will stop into WMR in Stuart Fla. they are a high level KtM shop, see...
That sucks… but at least Ktm is making it right. I will stop into WMR in Stuart Fla. they are a high level KtM shop, see what they have to say… maybe they just remap the stock ECU? I have only ever had 1 issue with a KTM failure, And KTM stepped up and covered it when they bike had over 40 hrs on it.
These bikes don't have a ECU they have a CDI I already asked Twisted development if they can reflash it to get the RPMs back they said no. The dealerships here in California still don't know what KTM plans on doing for the CDI
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NSP139
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NSP139 3/16/2022 4:53pm
3/16/2022 4:53pm
I don't want a motor grenading off the face of the jump or any situation it's just not safe I know we can't control that but a brand new bike should give you some sort of security! I also plan on doing motor work( only Port polish and head work) so there's no way KTM would give me any kind of warranty that's a hard pill to swallow if a bike blows up at 10 hours!
NSP139
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NSP139 3/16/2022 5:06pm
3/16/2022 5:06pm
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!
NSP139 wrote:
That's awesome to hear!
What ratio are you running for the sand?
NSP139
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NSP139 3/16/2022 5:17pm
3/16/2022 5:17pm
Rickyisms wrote:
To add, my 16 has (what I believe) is the same crank as 22s. Just turned over 19 hours at day in the dirt this weekend...
To add, my 16 has (what I believe) is the same crank as 22s. Just turned over 19 hours at day in the dirt this weekend. Had an odd crank bearing failure at just over 18 hours but crank itself has been fine
Just curious when did you put this crank in?
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sandman768 3/16/2022 5:27pm
3/16/2022 5:27pm Edited Date/Time 3/16/2022 5:34pm
NSP139 wrote:
What ratio are you running for the sand?
40:1, think I will go to 32:1 after reading this😂 25-33% 110 Sunoco leaded with 90 non ethanol. Jetting as per The jetting thread in here from Digger & RJ. I did richen my needle clip position to #3 as the track was deep, heavy sand that had just been bulldozed smooth…. So WFO until it got a little rougher later in the day. That was the first time I have had to adjust my jetting since using the thread settings. I have been on clip #2 in almost every temp & conditions with no issues but I played it safe going richer, the bike still ran great, but would slightly load up on the idling to enter the track, cleaned out on first straight.
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liver
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liver 3/16/2022 8:02pm
3/16/2022 8:02pm
My son has had 2-3 new KTM 85-105 bikes each year since 2019, each bike had 60-170hrs with no crank issues, I’m lucky. This fall he moved up to 125s, 2022 125SX and a 2022 125XC. The SX bike lost the crank seal at 70hrs, while replacing the seal alone I noticed a tiny thermal stress near the crank rod where the thrust washer is, but no other damage, 20 hrs later that washer exploded and locked up the crank. Not a huge deal, that’s moto. Regardless, it’s still the best 125 made.
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liver
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liver 3/16/2022 8:19pm
3/16/2022 8:19pm Edited Date/Time 3/16/2022 8:19pm
In addition, if this letter and/or issue is only related to the 2022 CDI. I’ve had to aggressively zip tie my wiring harness to the CDI because it kept high rev bogging, others I know have had to do this and it’s not limited to the 2022 model, but is limited to the 125. The only thing I could figure out is how reverse tight the connection is, it’s like spring loaded, but pushes the connector away from the CDI box, not a good design, and the 125 does not use a rubber boot like the KTM 4 strokes do, weird, I dunno
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zac_k3
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zac_k3 3/16/2022 9:27pm
3/16/2022 9:27pm
Guess me and my friend will be calling the local shop tomorrow, we’ve only got 9 hours on them but can’t tell it. Tongue
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quiknic 3/16/2022 10:37pm
3/16/2022 10:37pm
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
digger
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digger 3/17/2022 4:21am
3/17/2022 4:21am
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.

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