20 Most Recent 2003 KTM 625 SXC Questions & Answers

the valve clearance is incorrect at .15mm ( .005") it should be at .010"inlet and .012" exhaust and is set on tdc but on compression stroke tdc decompression cams have a special grind that holds the valve open for starting revolutions and as the engine rpm picks up the cam follower doesn't follow the profile any more and closes the valve engines that utilize such a cam are motors that have a rating exceeding 3 hp on a rope pull otherwise , the piston cannot be pulled over compression past enough to get it started 5 hp lawn mowers , 10-20hp rope pull generators etc have this cam

Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to ensure your issue has been resolved.

No neutral light exists on a 2003 KTM 625C.

TF

Common problem to a lot of bikes , Test all earth wires first and make sure all connections and contacts are ok If you do not have a good earth , you will not have a spark . Check all connections and make sure they are clean and in good contact with each others . The last thing could be the CDI unit which command the power to the coil/contact. best of luck and let me know how you go .

.004" per inch of bore. So, .016"


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but when the bike's stood for over 4 hours it's flat Confused Even with the main switch off Any ideas?OK beg,borrow, or steal a multitester with current(amps) reading on it. 10 amps is more than ideal, but you will probably need less after initial tests. Ammeters need to be in series, not in parallel like volt testers, so disconnect one battery lead(either will do) and complete the circuit by putting the multimeter leads between the battery lead(disconnected) and the battery terminal. You are now gonna see on the meter, every amp pulled from the battery. turn the ign on and turn a light on, you will see the current rise, as amps are drawn, ok! Turn the ignition off and see what happens. Probably with it set on the 10amp scale youll see nowt, so go down the range on the meter into milliamps, and my guess is that you will see a reading. You shouldnt see anything at all with ign off, but Id guess you can see a few milliamps on the gauge. If this is the case, proceed as follows: One by one, remove the bikes fuses and replace them, if at any point the reading drops to zero you have found the circuit which is sucking the power. If that fails, try again, but one by one undo (every) multiplug on the bike, again one of em should cause the reading to drop. When you have found a fuse or a plug that causes the meter to read zero amps, check that circuit. Maybe there is a wire rubbing onto the frame, a switch corroded internally, or similar, but now you know the bit you need to fix. If you connect the meter as described and there is NO current drain, you are either special! or leaving the side light circuit on(muppet!) good luck.,,,

Hi.

The problem is usually the kickstand switch. Try bypassing the kickstand safety switch.

Regards.

Ginko

I"m not an expert on the problem but personally I would let the little guy ride the wheels off it first before tearing it down. Anything could happen. As long as its safe. I mean, they grow so fast. So what if it leaks a little. Let the little chap lay it over a couple times first before you make it right. Besides, when he's older I doubt he'll remember about the drips it left on the concrete. After all, thats what cardboard is for! Right?

That would be like riding a fixed wheel bike.Think about how you will stop and start. Only hydraulic fluid will leak. Bad idea!

Question edited for clarity. That sounds like it is just a bad connection somewhere or possibly a bad switch. Remove the battery leads and clean the lead contacts and battery posts with a wire brush. Smear with Vaseline and reconnect. Remove the starter leads and do the same. Then it could be the Starter Relay https://www.google.com/search?q=ktm+450+sx-f+starter+relay+location Or Starter Button https://www.google.com/search?q=ktm+450+sx-f+starter+button+replacement ..

personnaly I would replace cylinder with new OEM

All dirt bikes have a VIN. It is on the steering neck. https://www.google.com/search?q=vin+on+my+ktm+300 ..

Have you checked battery connections. Run switch in the correct position? Checked spark plug for debris? Just thinking out loud..

Drain oil. Use degreaser to clean area. Use JB Weld & allow to set up properly before adding oil.

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Hi, try to see this link and looking for the manual that you need. https://www.pdfmotomanual.com/manuales/ktm/eng I hope to give you an help. Luca

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Hi, most likely your cdi unit or ignition coil needs replacing.

took me a min or two of WTF-ing to see pic and realize you meant a 2-stroke motorcycle..

try replace spark plugs

It's a bad seal of the head gasket. You need a new head gasket and to scrape every particle of debris from the cylinder head and cylinder surfaces that mate with the head gasket. Use the factory specified gasket sealing compound and do a clean job - no blobs or pools of the stuff. The head gasket should lay flat on the surface of the top of the cylinder, and you have to make this surface free of grit, leftover sealant and any other foreign matter before you put the head in place and torque it down. Start with the head bolts just finger tight and then go by the manufacturer's specs for the pattern and amount of torque to be applied. Usually it is recommended that you get to the specified torque amount in stages, going around several times and repeating the torque pattern until you get that maximum rated amount. This will prevent the seal from shifting or warping and should make the gasket seal perfectly. This is the old school method of doing this job. and I have never seen this fail to produce good results. Take your time, be clean, and you will have the results you want.