2017 - 2019 KTM fixes. Starter Button, Broken Spokes, Sticky Gas Cap

2017 - 2019 KTM fixes. Starter Button, Broken Spokes, Sticky Gas Cap

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Starter Button Wiring. This past weekend at Round 11 of the Rocky Mountain Enduro Circuit race in Upton Wy, my son Bodie's race was temporarily halted due to a non functioning starter button after he had fallen and inadvertently killed the motor. Since KTM no longer has kick starters, this button is really important.

A post race inspection revealed that a wire located behind the number plate that connects the starter relay to the starter button had pulled loose from the connector. This was probably due to the constant turning of the bars and maybe it became hung up on something, not exactly sure but after finding the problem I realized a couple other wires in the same connector came out relatively easy.

This particular connector is a four prong connector even though the 250 only uses two of the prongs and being that the two prongs are not directly across from each other, KTM loops two black wires around to complete the connection. So instead of having only four connections this ends up being eight connections to connect the four wires and complete the circuit, essentially doubling the chance of a wiring failure. (see photo)

The 2017 through the 2019 KTM's use this same connector. This problem can easily be fixed by either buying a two prong connector, or in my case our small auto parts shop did not have a two prong connector so I improvised by using some all weather butt connectors that you melt around the wire then adding additional structural support with some electrical tape. Connections are now much more secure. Problem solved.

Breaking Rear Spokes. I own a 2018 450 xcw and my son Bodie races a 2019 250 xcf. Both bikes started losing rear wheel spokes. The first time it happened was on my sons bike, I noticed 3 spokes missing and simply replaced them. He went out for a one hour training ride and lost two more. I then looked at my bike and notice that I was also missing a couple. After consulting with my friend and KTM guru, Levi, he too had issues on the newer KTM's losing spokes and theorized that it was because they were leaving the factory way to tight.

I thought he may be correct, so I pulled off the rear wheels, loosened all the spokes then proceeded to systematically tighten them to spec. So far so good. Both bikes now have a few more hours on them and we haven't lost a spoke.

Gas Cap Sticks A few races ago, I came into the pits for fuel, I reached down to remove the gas cap. I had some arm pump and did not have all the feeling in my hands. The KTM gas caps are notorius for sticking and now combined with my hands being numb made it really difficult to remove.

KTM uses a really soft rubber in order to maintain a good seal between the cap and the tank but the tradeoff is that it sticks to the plastic tank especially when warm. The solution turned out to be very simple. Apply a thin layer of grease to the rubber, any grease will work. Try it, the cap will come right off. You may have to clean and re-apply every now and then but at least it will come off when you need it to.

Hope these tips help, if so, let me know and feel free to share any tips you may have.

Rob Swan
Swan Racing