Shifting problems KTM 250SX 2016

JMX82
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JMX82
I have some problems with up shifting under load with my 2016 250SX. I tried filing shifter sliding plate "claws" but it didn't solve the issue. Does anyone have any suggestions what to do next?
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TheClayTurtle 9/18/2019 7:56am
9/18/2019 7:56am
Is your clutch lever pulling enough cable? If it’s not it won’t bring your clutch release crankshaft far enough forwards and won’t put enough pressure on your clutch to shift smoothly
paddyB745
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paddyB745 9/18/2019 8:27am
9/18/2019 8:27am
I know there was issues with the return spring that returns the “claws” have you tried stretching the spring a little bit to try and stiffen it up? Or finding a stiffer spring?
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T-Fish
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T-Fish 9/18/2019 8:38am
9/18/2019 8:38am
My 17.5 Factory Edition 250SXF was a pain in the ass to shift under a load.

My 18 350SXF is a pain in the ass to shift under a load.

My 17.5 Factory Edition 450SXF shifted like butter at all times.

My 18 150SX shifts like butter at all times.

The 18 250SX I picked up for a buddy shifts like butter at all times.

Kris Keefer mentioned his test 2020 250SXF had the same issue I had with mine.



T-Fish
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T-Fish 9/18/2019 8:39am
9/18/2019 8:39am
TheClayTurtle wrote:
Is your clutch lever pulling enough cable? If it’s not it won’t bring your clutch release crankshaft far enough forwards and won’t put enough pressure on...
Is your clutch lever pulling enough cable? If it’s not it won’t bring your clutch release crankshaft far enough forwards and won’t put enough pressure on your clutch to shift smoothly
I’m betting it’s not pulling any cable since it’s hydraulic.
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JMX82
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JMX82 9/19/2019 9:57pm
9/19/2019 9:57pm
I tried stretching the spring also but it didn't help. Anyone know where to get a stiffer spring?

And for your information TheClay Turtle KTM's have hydraulic clutches so that is not the problem and dirt bikes usually shifts fine even with out using the clutch
YZed250
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YZed250 9/22/2019 12:51pm
9/22/2019 12:51pm
try searching google "250sx shifting" and you will see a number of fixes. That 2016 generation motor was used for about 10 years with different internal gear ratios, but the same shift mech and forks.
JMX82
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JMX82 9/23/2019 12:38am
9/23/2019 12:38am
I just ordered new sliding plate, spring and "shift star". I was also instructed to polish the sliding plate. I hope changing these parts will cure the issues.
seth505
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seth505 9/23/2019 6:48am
9/23/2019 6:48am
I struggled with that on my 2013 250sx. I filed the pawls and stretched the spring and it got better.
daboza27
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daboza27 9/25/2019 2:30am
9/25/2019 2:30am
Make sure the bolt connecting the shift star to the shift drum is torqued properly.
Mine slowly loosened up and shifting kept getting worse until the bike would no longer up shift from the binding of the shift star. Others have mentioned the same problem.

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