EXC 250 2 smoker with issues – OLD Bull Trailriders

This topic contains 14 replies, has 0 voices, and was last updated by TheBoss 15 years ago.

Viewing 15 posts - 1 through 15 (of 15 total)

Author

Posts
April 2, 2010 at 7:28 am #98270

michael Prott
Member

Just wondering if anyone can help me.

Last weekend at a Club Day my 09 EXC250 began running as rough as a bag of cement. I have done everything I can think of, fresh plug, fuel, air filter, drained carby, checked main jet etc. The thing is running ok off the bottom but anything more than half throttle and the thing just won’t sing.
I have just come back from a trailride and it was running like a dog out there too. I noticed that the digital display is really dull, so I am starting to guess there might be an electrical problem. I removed the mapping switch and kill switch and there has been no change.
If anyone has an idea, it would be greatly appreciated. I am supposed to be sweep riding the Four Day next week and the way the thing is running I am about to accept best offer and go buy something else….
regards
Busy.

April 2, 2010 at 7:36 am #175243

Fez
Member

Possibly could be a stuffed spark plug lead but it could be any number of things.

April 2, 2010 at 8:23 am #175246

Mick D
Member

Dunno Mick, seems as though you have checked everything that I would. We had a RM85 once that pulled that caper and it turned out to be a crank seal, not that it would effect your display lighting.

One of the 2T gurus on here may have an answer for you over the next day or so.

April 2, 2010 at 8:40 am #175247

Mal
Member

Have you hooked up any extra electrical gear to the bikes system? I fitted a trailtech computer to my 2 stroke and connected it to the 12v wire going to the old speedo and it dragged to much electrical power from the bike and wouldn’t go into the band. Shouldn’t be an issue with your as it has a battery. But sounds like what mine was doing and if your display is dull then something on your bike is chewing up eletricity and it’s not getting to the plug or CDI unit where it needs it.

Just my thoughts.

April 2, 2010 at 8:52 am #175244

Roy
Member

Not sure about the 250 but I’ve got an 09 300 and I thought the speedo ran off a watch type battery and was totally seperate to the rest of the bikes electrics which would mean that a dull display is not related to the bikes issues. If it’s not going into band properly then maybe it could be the pin on the power valve actuator has come off. Again not sure if the 250 has this issue but the 300 definitely does. The pin is a press fit and can come off and fall into the transmission. Has there been any issues with gear changes. If so this might be a sign the pin is floating around in the transmission.

If it sounds like it could be a possibility watch this to see the fix.

April 2, 2010 at 10:43 am #175249

michael Prott
Member

I changed the gearbox oil this morning before the ride and after pouring the spent oil into a container, found a “pin” in the bottom of the oil pan. Looks like I will be getting the welder out tomorrow to weld it back into the power valve! Last KTM I will own.
Thanks Bundyroy, your a champion and the video has been a great help too. Will update tomorrow if we have the answer.
Thanks to all who responded

April 2, 2010 at 12:08 pm #175257

Bruce Curtis
Member

excellent call Roy, KTMs have been doing this for years, you’d reckon word woulda got back to the factory and they’d do something about it by now.

BC

April 2, 2010 at 8:01 pm #175260

Mick D
Member

Well done Roy! Great call, the OBT knowledge pool amazes me at times.

Geez Busy223 you were lucky you got the pin back out of the case with out having to go right into it or it jamming your gears.

April 3, 2010 at 6:19 am #175264

michael Prott
Member

Ok, job done. Bundyroy, think I owe you a bottle. Can you believe that KTM would allow this to remain an issue. I have never heard of it, but something so simple could surely be sorted at the factory. The whole process took me about half an hour and once back together, the thing went like it use to. The young fella was thinking he had me on the last few rides but this arv showed him different (with a motor that works).

Tell anyone that you know who owns a KTM 2 Smoker they need to fix this issue. The expense of the pin dropping into the dreaded “hole” would be massive, I am thanking the dirt bike gods that my pin can out during an oil change.
And Bunyroy, don’t even know you but the dirt bike god sure sent you, thanks mate.
Might see you monday in Bago
Busy

April 3, 2010 at 7:36 am #175277

Roy
Member

Glad it helped Busy. I am in no way a mechanic, just keep an ear out for any problems associated with any bike I own or any bike I’m looking at. There’s been a lot of ktm’s with the pin attached to the magnetic sump plug. It happened to a mates 300 and by the time he got the pin out it looked very second hand from hitting the gears. Haven’t heard of ktm covering the issue under warranty either but haven’t really asked either.

Glad to here the bikes back to normal. Hopefully I get to meet you one day and we can swap bikes for a while. I’d really like to try the 250.

April 3, 2010 at 9:44 am #175245

Roy
Member

Just out of interest. How many km’s/hours did your bike have on it when the pin came unpressed.

April 3, 2010 at 10:35 am #175287

Mal
Member

Good to see you got it sorted Busy. I did check mine when it happened me but mine was a brain fade by me.

April 3, 2010 at 12:05 pm #175282

michael Prott
Member

1140km’s and 41 hours now, using elf oil and changing gearbox oil every 5 hours. I remember the old IT’s you didn’t change the oil and the spark plug you could get to without removing the seat and tank….. Anyone wanna buy a KTM 250?

April 6, 2010 at 12:46 am #175250

Anonymous

Bundyroy wrote:

Quote:

Not sure about the 250 but I’ve got an 09 300 and I thought the speedo ran off a watch type battery and was totally seperate to the rest of the bikes electrics which would mean that a dull display is not related to the bikes issues.

Good work on diagnosing the fault Roy.

Just for information, the speedo does have a watch type battery. The speedo unit uses the 12V bike battery and it’s own internal ‘watch’ type battery. Without the main battery connected you won’t have the “orange glow” backlighting on your odo, but you’ll have the dim, white backlighting of the LCD readout from the internal battery in the unit itself.

This is something to consider if anyone is thinking of ripping of the e-start and taking the battery out too.

April 6, 2010 at 5:31 am #175406

TheBoss
Member

Guys this is a tech help thread off topic posts have been deleted. It is the only forum we want serious input for people to get help and learn.
Author

Posts

Viewing 15 posts - 1 through 15 (of 15 total)

You must be logged in to reply to this topic.