2003 KTM 525 sx stopped running. - KTM Forums: KTM Motorcycle Forum
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post #1 of 19 (permalink) Old 11-22-2016, 08:38 PM Thread Starter
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Arrow 2003 KTM 525 sx stopped running.

Hello KTM gurus! I have a 2003 KTM 525 sx that recently stopped running. Amazing bike Rode it over a month before any issues. The first thing I started to notice was losing my compression kick. It just started getting a lot easier to kick and would still start first or second kick every time. In its last week I could also tell a difference in its pitch of sound. No knocks or anything but somewhat of valve noise you might say. Last ride went half mile down the road and died on me. She hasn't talked to me since....

So now I began to trouble shoot

1. Order compression tester from ebay is my first step.

2.Check vavles.



Note. Whats the science behind the compression kick? Dose it have to do with vavles and could it effect it? Do we all think its piston and rings?

Thanks guys any info on the 525 would be greatly appreciated!
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post #2 of 19 (permalink) Old 11-22-2016, 10:24 PM
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Welcome to the forum fellow rfs owner.
It could be rings or valves or hopefully not a buggered bore.
I would first check your valve clearances. If your valves clearances are to tight and holding the valves open you will lose compression. Basically if the cylinder isn't sealed for the compression stroke you lose compression. So it could be a few things. Rings, bore, valves, valve timing, No 1 thing that usually goes
wrong is the valves. Was it blowing blue smoke when you were riding it?
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post #3 of 19 (permalink) Old 11-24-2016, 12:20 AM Thread Starter
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Welcome to the forum fellow rfs owner.
It could be rings or valves or hopefully not a buggered bore.
I would first check your valve clearances. If your valves clearances are to tight and holding the valves open you will lose compression. Basically if the cylinder isn't sealed for the compression stroke you lose compression. So it could be a few things. Rings, bore, valves, valve timing, No 1 thing that usually goes
wrong is the valves. Was it blowing blue smoke when you were riding it?


Right on man yeah I'm hoping it'll be easy as valves. Going to check them this weekend. For some reason my mind was pulling around the possibility of the valves had connection with the compression stroke Mostly because there is still so much compression in Kickstarter still I was hopping it to be one of the valves was off slightly which caused the less force behind the Kickstarter. Yeah I do remember some blue smoke in the last week. I've mostly build kx500 's 2 strokes first time with 4 stroke in awhile. Making the 525 my primary bike so need to gain all the knowledge out there haha.
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post #4 of 19 (permalink) Old 11-24-2016, 06:03 AM
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If its got blue under acceleration your rings will be shot as well. Fingers crossed its not the bore. If you need a hand or advice with pulling it down just yell out. A few very handy rfs guys on the forum. I will be putting a post on the forum of a full rfs rebuild, but not for another week probably.
I have one on the bench at the moment.
The only major tool out of the ordinary you will need to remove the head is a chain splitter. You have to split the timing chains on the rfs to be able to remove the cylinder head.
Check how tight your valves are first, but if its blowing blue when its warm your at least up for some rings.

If you need any top end repair work done, buzz miltech. He's the guru when it comes to that area.
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post #5 of 19 (permalink) Old 01-14-2017, 07:21 PM Thread Starter
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Cool She is cracked open<3

Well heres is my issue just found out today. About to do as much research as I can to changing out this problem. Any advice would be greatly appreciated thanks guys.
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post #6 of 19 (permalink) Old 01-15-2017, 03:48 AM
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Wow, I have never seen one crack the retainer. I would say the guide has grabbed the stem of the valve and possibly the valve is bashed back into the head.
You could definitely fit some good quality valve guides and stainless valves in, I personally like kibblewhite valve gear. The retainer you might have to order genuine, I'm not sure on that one.

current bikes
2002 ktm 520sx
2004 ktm 525exc
2005 yamaha fz1
1982 Honda xr500
1994 Yamaha dt200
1970 Yamaha dt250

Previous
2005 ktm 525exc
1996 ktm 360exc
1994 Honda cb400
2002 cbr954 Fireblade
2002 honda xr250
1998 honda xr250
1997 suzuki rmx250
1993 yamaha wr500
1993 suzuki dr350
1993 honda xr200
1978 honda mt250 elsinore
1982 honda xl185
1981 honda ct185
1985 yamaha dt100
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post #7 of 19 (permalink) Old 01-17-2017, 12:59 PM
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Quote:
Originally Posted by DW View Post
Wow, I have never seen one crack the retainer. I would say the guide has grabbed the stem of the valve and possibly the valve is bashed back into the head.
You could definitely fit some good quality valve guides and stainless valves in, I personally like kibblewhite valve gear. The retainer you might have to order genuine, I'm not sure on that one.
Give me a call and I can get that thing squared away for you. As DW said, not too often we see 'em break the retainers. We sell and use a ton of Kibblewhite valve train components. Good product.


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post #8 of 19 (permalink) Old 01-19-2017, 05:08 PM Thread Starter
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Right on thanks mill tech ive been needing to find a good shop to work bikes. What is all involved with putting on a new retainer? Dose the head need to come all the way off and if so is breaking the cam chain the only way on these 2003 ktm 525s?
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post #9 of 19 (permalink) Old 01-20-2017, 06:54 AM
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Quote:
Originally Posted by Calin Dyer View Post
Right on thanks mill tech ive been needing to find a good shop to work bikes. What is all involved with putting on a new retainer? Dose the head need to come all the way off and if so is breaking the cam chain the only way on these 2003 ktm 525s?
Yeah mate, you have to split the chains on the rfs to remove the head. I am a bit of a tight a*se and I will often just push the pin through with my chain splitter until it is just free of the roller link and still inside the side plate of the chain, that way you can just put it back together and press the pin back in.
I have a trick to removing the retainer from valves that doesn't involve removing heads. Engine must be at tdc and lock bolt in the crank. I then have a hose fitting I made up to screw into the plug hole and attach regulated compressed air to the cylinder around 30-60 psi. That will hold the valve up while you compress the spring, but give the top of the valve a little bit of a tap to free the collet from holding before you push the spring down.
To be honest though, you are best to rip the head off and have a look, to snap a retainer like that, I would say you may have another issue with that valve.
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current bikes
2002 ktm 520sx
2004 ktm 525exc
2005 yamaha fz1
1982 Honda xr500
1994 Yamaha dt200
1970 Yamaha dt250

Previous
2005 ktm 525exc
1996 ktm 360exc
1994 Honda cb400
2002 cbr954 Fireblade
2002 honda xr250
1998 honda xr250
1997 suzuki rmx250
1993 yamaha wr500
1993 suzuki dr350
1993 honda xr200
1978 honda mt250 elsinore
1982 honda xl185
1981 honda ct185
1985 yamaha dt100
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post #10 of 19 (permalink) Old 01-20-2017, 05:34 PM Thread Starter
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Time

What do you think of these magnetic retainers? Also replacing the piston with a wiseco. Cylinder wall didn't look to bad some lines but nothing to deep.
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Last edited by Calin Dyer; 01-20-2017 at 06:19 PM.
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