2017 250SX idle gear case break?

jmtheo91 wrote:

[img]https://p.vitalmx.com/photos/forums/2018/12/18/311230/s1200_C061C759_CA69_48E6_9BB2_CAE3839C64FF.jpg[/img] 55 hours in in my Ktm just put a fresh top end in and I went to go ride at the local mx track and...

55 hours in in my Ktm just put a fresh top end in and I went to go ride at the local mx track and this happened after kicking it .. didn’t even get a lap in

BR8ES wrote:

that is horrible Alexi... is KTM taking care of this?

BR8ES wrote:

that is horrible Alexi... is KTM taking care of this?

alexl230 wrote:

KTM wanted to send new cases to have it rebuilt at the dealer. I said forget it, I want my money back, luckily I got the...

KTM wanted to send new cases to have it rebuilt at the dealer. I said forget it, I want my money back, luckily I got the dealer to give me a complete refund after some hassle.

seth505 wrote:

Is this the bolt on a 2017 that people are talking about changing to an 18mm length? [img]https://p.vitalmx.com/photos/forums/2019/01/08/316611/s1200_kickstart_bolt.jpg[/img]

Is this the bolt on a 2017 that people are talking about changing to an 18mm length?

jmtheo91 wrote:

@br8es that is smart ... praying I won’t have to pay out of pocket for mine
@seth505 yea that’s what holds the idle gear

YZed250 wrote:

What tap to use in the hole? Finishing M10 or M8 x ?

CSAR FE wrote:

There’s a million page thread on this issue on KTM Talk, and I believe there’s one on thumper Talk as well. KTM/Husky updated the cases in...

There’s a million page thread on this issue on KTM Talk, and I believe there’s one on thumper Talk as well. KTM/Husky updated the cases in 2018 because of this issue. See if KTM will warranty it since it’s a known issue.

Gravy wrote:

This is my 2016 KTM 150 SX. Does the idler gear have some kind of retainer? Because it looks like it just sits on this post...

This is my 2016 KTM 150 SX. Does the idler gear have some kind of retainer? Because it looks like it just sits on this post with a brass idler gear bushing. The post was chewed up and the new bronze bushing lasted 30 seconds.
Does the bronze bushing spin on the ID also or just the OD between itself and the ID of the idler gear?
Because I was thinking to stick the bronze idler gear bushing on with loc-tite 660.

Gravy wrote:

This is my 2016 KTM 150 SX. Does the idler gear have some kind of retainer? Because it looks like it just sits on this post...

This is my 2016 KTM 150 SX. Does the idler gear have some kind of retainer? Because it looks like it just sits on this post with a brass idler gear bushing. The post was chewed up and the new bronze bushing lasted 30 seconds.
Does the bronze bushing spin on the ID also or just the OD between itself and the ID of the idler gear?
Because I was thinking to stick the bronze idler gear bushing on with loc-tite 660.

project racer wrote:

looks like you are going to be buying some cases.

Gravy wrote:

The loc-tite 660 seemed to do the trick. It took up the gap between the Aluminum post boss and the ID of the brass idler bushing...

The loc-tite 660 seemed to do the trick.
It took up the gap between the Aluminum post boss and the ID of the brass idler bushing. I maybe put 20 more hours on the bike with no issues before sending it down the line with a work of caution to the new owner. He's either had no further problems or hasn't mentioned them to me (as he lives around the corner).

Bearuno wrote:

2 external pictures of the New case, 1 big, 1 small - the 'double bump' you can see on the case does not exist on the...

2 external pictures of the New case, 1 big, 1 small - the 'double bump' you can see on the case does not exist on the dodgy cases:





The inside of the new case showing the totally different landing, and the new steel post that uses a circlip to hold the idler gear on:


It's all a major change in design, over a demonstrably bad design . If you don't think so, well .........

Of course, a bloke on the site that seems upset with my describing the crap original cases as 'ticking time bombs', has put up a few posts / pictures of it still being OK, after a succession of hours. It seems that strange affliction -"pride of ownership", rules people even when faced with a genuine problem with 'their' bike. But, he notes he doesn't use the Kick Starter........ that appears to be the tactic most are using. SX owners, of course, don't have an ES. A friend of mine who bought a '17 EXC, that has had to leave it idle due to work commitments, when I saw he had it, I warned him about the problem. He called his dealer, to be told "they've never heard of it". Yet, there's an OZ bloke or two on the thread I put up, that have had failures. With, I think, no help coming from KTM Australia.

It's like the 250 4ts a few years back, that were doing conrods / big ends. It was shown on KTM Talk, for quite some time, but, there were "no problems in OZ", until all of a sudden, at a dealership I worked at, at least 5 250s we had, had to have the rods / big ends replaced. Luckily ( though on the warranty 'flat rate' for labour, we were far from lucky) 4 were still in stock. The one that had 'got away', we had in for a service, so did the rebuild. Unfortunately, the dreadful mechanic that did the job, buggered the job up, as when the owner came to pick it up, it pissed out oil at the case joint. In all my years in the industry, I don't think I came across a worse mechanic, continually effing up, yet he thought he was near god like. I think he's still out there, bullshitting his way up the stairway to the top.

Bearuno wrote:

2 external pictures of the New case, 1 big, 1 small - the 'double bump' you can see on the case does not exist on the...

2 external pictures of the New case, 1 big, 1 small - the 'double bump' you can see on the case does not exist on the dodgy cases:





The inside of the new case showing the totally different landing, and the new steel post that uses a circlip to hold the idler gear on:


It's all a major change in design, over a demonstrably bad design . If you don't think so, well .........

Of course, a bloke on the site that seems upset with my describing the crap original cases as 'ticking time bombs', has put up a few posts / pictures of it still being OK, after a succession of hours. It seems that strange affliction -"pride of ownership", rules people even when faced with a genuine problem with 'their' bike. But, he notes he doesn't use the Kick Starter........ that appears to be the tactic most are using. SX owners, of course, don't have an ES. A friend of mine who bought a '17 EXC, that has had to leave it idle due to work commitments, when I saw he had it, I warned him about the problem. He called his dealer, to be told "they've never heard of it". Yet, there's an OZ bloke or two on the thread I put up, that have had failures. With, I think, no help coming from KTM Australia.

It's like the 250 4ts a few years back, that were doing conrods / big ends. It was shown on KTM Talk, for quite some time, but, there were "no problems in OZ", until all of a sudden, at a dealership I worked at, at least 5 250s we had, had to have the rods / big ends replaced. Luckily ( though on the warranty 'flat rate' for labour, we were far from lucky) 4 were still in stock. The one that had 'got away', we had in for a service, so did the rebuild. Unfortunately, the dreadful mechanic that did the job, buggered the job up, as when the owner came to pick it up, it pissed out oil at the case joint. In all my years in the industry, I don't think I came across a worse mechanic, continually effing up, yet he thought he was near god like. I think he's still out there, bullshitting his way up the stairway to the top.

thomasdeese wrote:

Will the 18 case bolt up???

i have no idea what to do 

Tuplavee wrote:

Has anyone repaired 2017 idler gear mount with welding and machining? I did put broken ones to my "trophy wall" but have been wondering If I...

Has anyone repaired 2017 idler gear mount with welding and machining?

I did put broken ones to my "trophy wall" but have been wondering If I should try to make a fix someday