99 KTM 200 tranny problems
jeb
first dirtbike so I'm helping her make sure things are kosher. I talked to the
former owner and he said he loved the bike but the tranny had gone out on it.
He traded it in on a RM125. Otherwise, the bike is in great shape and has a lot
of nice stuff (WER steering stabilizer, soft seat foam, Kstyle graphics, Cycra
ProBend BB's, disk guards, etc).
The dealership fixed the bike under warranty. I've heard of this problem on the
200's before. Any of you guys had this problem? Did the fix permanently fix it?
Are there any tell tale signs I can or should look for (noise, very notchy
shifting, etc)?
Thanks
jeb
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JIMSKTM250
got stuck in the shifting drum not allowing it to shift.7 long miles in 1'st
gear. It was fixed under warranty and I have a great relationship with the bike
shop.I saw the sliver of metal and they also replaced the shift drum cause of a
tiny scratch that I could barely see.They called ktm as they had this also
happen to a brand new 98 125exc.KTM told them to clean up all the gears and
check for burrs and such.Most bikes will have quite a bit of metal on the drain
plug as the gears wear in. Another reason to change that oil often.I just was
unlucky enough to have mine float into the shift drum and not to the magnet.
Haven't had any problems since(knock on wood as if it can happen it will happen
to me. Ride with alot of KTM"S and noone else has had any problems.
My clutch is starting to drag allitle,but only when stone cold.
Did the previous owner say what happened to the tranny?
Let us know what happens
JIM
KTM200EXC
David Jones
>I had mine get stuck in first gear at around 100 miles on it.A sliver of metal
>got stuck in the shifting drum not allowing it to shift.7 long miles in 1'st
>gear. It was fixed under warranty and I have a great relationship with the bike
>shop.I saw the sliver of metal and they also replaced the shift drum cause of a
>tiny scratch that I could barely see.They called ktm as they had this also
>happen to a brand new 98 125exc.KTM told them to clean up all the gears and
>check for burrs and such.Most bikes will have quite a bit of metal on the drain
>plug as the gears wear in.
I too had a sliver of metal, only mine was on the clutch side and got
wedged in the "intermediate" gear (idler) behind the clutch. Just
started bang, bang, banging about 1/2 way through a ride. Fortunately
it was just past a very gnarly, rocky sidehill section and about 2
miles down a fairly easy section to a two track. We towed it out and I
spent the next 8 hours sitting at a resturant/lodge in the beautiful
Stanley Basin while my partner rode the 35 miles back to the truck and
drove it back.
My dealer disassemble the entire engine looking for the source. It was
not to be found, everything inside looked "like new", and this was
with about 1750 miles on the bike. It too was covered under the 6
month warranty, by less than a week. Lucky me!
The sliver was about half the size of a piece of uncooked rice. I was
going pretty slow at the time it happened and I shut it down
immediately, there really wasn't enough damage to the gears to warrant
replacement, 10 minutes with a file and they have been fine since.
That was about 500 miles ago.
BTW, the piston (two very light scores in the exhaust port area) and
rings were still both in spec, the clutch basket and plates looked
like new as did the tranny internals......
>Ride with alot of KTM"S and noone else has had any problems.
Me too, but how the hell do you guard against this? Is the only answer
to tear it down when it's brand new and thoroughly flush it out? We
examined everything inside *very* closely, since it was such a
mystery, and there is no way that it came off any internal part, it
had to have been in there since initial assembly. AARRGGHH!
>Let us know what happens
>
>JIM
>KTM200EXC
David - 99 KTM 200EXC
Email: djo...@cyberhighway.net
Home of the "The Very Unofficial RMD Page"
http://www.cyberhighway.net/~djones/
HOSEHEAD
>
> Any of you guys had this problem? Did the fix permanently fix it?
My '91 250 EXC got stuck in second gear one time when it had less than
200 milkes on it. We were about 30 miles from nowhere and started to
head back to the trucks. About 10 miles later it became "unstuck."
Draining the tranny revealed several pieces of shrapnel that were 1/4"
wide and about 3/8" long stuck to the magnet on the drain plug.
The pieces didn't look like chunks of gears or anything. I never did
tear the bike apart and flushed it with fresh oil several times.
I kept riding it with no problems until I sold it in '96. A similiar
thing happened to a buddy of mine on his '94 300 EXC; It got stuck in
third gear and eventually freed itself after 15 or so miles. We pulled
several similar size pieces of shrapnel out of it.
Never had a problem with my '96 or '99 though....