For KTM pre 07 riders

[Revv Up]

It's fairly well documented that the pre 07's have a locking lever that contacts the shift drum that is faulty. Save yourself from some headaches buy laying your bike on the right side and take off the clutch cover off.

In the photo below... if the forward lever contacting your shift drum has a ball bearing on the tip it needs to be changed, the outer race breaks and you end up with large shrapnel in you oil.

Here's mine with only the inner race is left (very undesirable), in 08 they upgraded the part to have a bushing instead of a bearing. The new part is $12 and well worth not having to split the cases and sit out the best snow of the winter.

 

[Ausm7499]

I had this very thing happen to me on my 06 525 in the middle of a race, I couldn't figure out why it was randomly popping out of gear and then re-engaging all by it's self. Luckily when I pulled my drain plug all the ball bearings were on the magnet. Pretty easy fix, if I had know it was a common problem I would have fixed it before it failed.

 

[off road rider]

Good Post..
Check it out now. Had mine fail on an 06 525 and also do damage to the tranny..

 

[Revv Up]

I'm waiting for some gears and gaskets.

 

[shoobear]

any part numbers for the 08 parts?

 

[Ausm7499]

All you should need is the locking lever and a new clutch cover gasket. The gasket costs more than the part. Here is a link to the 525 schematic it's part #20 and only cost $7.71 without shipping. Partspitstop is where I buy all my parts they have the best prices and if you call them before placing an online order they usually have a decent coupon code to give you.

http://www.partspitstop.com/pages/O...-_2006/Shifting_Mechanism/1M06500005/06500023

This is the clutch cover gasket for part #41 for $11.94

http://www.partspitstop.com/pages/O...Engine_-_2006/Engine_Case/1M06500005/06500005