KTM 250 300 380 SX MXC EXC Engine Repair Manual – PDF DOWNLOAD
DESCRIPTION:
KTM 250 300 380 SX MXC EXC Engine Repair Manual – PDF DOWNLOAD
INTRODUCTION:
- This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the
latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual. - A description of general working modes common in work shops has not been included. Safety rules
common in the work shop have also not been listed. We take it for granted that the repairs are made
by qualified profesionally trained mechanics. - Read through the repair manual before beginning with the repair work.
TABLE OF CONTENTS:
KTM 250 300 380 SX MXC EXC Engine Repair Manual – PDF DOWNLOAD
HOME…………………………………………………………. 0
NOTES AND PREFACE………………………………………….. 1
Titel page and file spine……………………………….. 1
Important information…………………………………… 7
Updating instructions…………………………………… 7
Explanation updating……………………………………. 9
Introduction ………………………………………….. 11
Replay fax for repair manuals……………………………. 13
TABLE OF CONTENTS………………………………………….. 5
SERVICE-INFORMATIONS …………………………………… 0
GENERAL INFORMATION…………………………………….. 14
OPERATING RANGES OF THE CARBURETOR……………………. 16
CARBURETOR ADJUSTMENT……………………………….. 17
CHECKING OF THE SETTING OF THE TVC SYSTEM……………… 18
BLEEDING OF THE HYDRAULIC CLUTCH……………………… 18
SPECIAL TOOLS – ENGINE………………………………. 19
CLEANING…………………………………………… 20
STORAGE……………………………………………. 20
REMOVING AND REFITTING ENGINE……………………………. 22
REMOVING THE ENGINE…………………………………. 24
REFITTING THE ENGINE………………………………… 26
DISASSEMBLING THE ENGINE………………………………… 28
DRAINING GEAR OIL…………………………………… 30
DISMOUNTING OF SPROCKET AND SHIFT LEVER……………….. 30
DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON………. 30
DISMOUNTING OF CLUTCH COVER………………………….. 31
DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS…………… 32
DISMOUNTING OF THE PRIMARY DRIVE……………………… 32
DISMOUNTING OF KICKSTARTER…………………………… 33
DISMOUNTING OF THE SHIFT LOCK………………………… 33
DISMOUNTING OF IGNITION COVER………………………… 33
DISMOUNTING OF THE IGNITION (KOKUSAN)…………………. 34
DISMOUNTING OF THE IGNITION (SEM)…………………….. 34
DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING…….. 35
PARTING OF ENGINE HOUSING HALVES……………………… 35
DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION…….. 35
DISMOUNTING OF THE CRANKSHAFT………………………… 36
SERVICING ON INDIVIDUAL COMPONENTS……………………….. 37
WORKING ON THE RIGHT-HAND HOUSING HALF………………… 39
WORKING ON THE LEFT-HAND HOUSING HALF…………………. 40
CRANKSHAFT…………………………………………. 41
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION……………… 41
PISTON…………………………………………….. 41
PISTON RING END GAP…………………………………. 41
CHECKING CYLINDER FOR WEAR…………………………… 42
RECOATED CYLINDER…………………………………… 42
NIKASIL COATING OF CYLINDER………………………….. 42
CYLINDER EXHAUST CONTROL SYSTEM………………………. 43
CYLINDER PREASSEMBLY………………………………… 43
EXHAUST CONTROL, CLUTCH COVER………………………… 45
PREASSEMBLY OF CLUTCH COVER………………………….. 45
REED VALVE HOUSING, INTAKE FLANGE…………………….. 46
CLUTCH…………………………………………….. 47
REPLACE OUTER CLUTCH HUB…………………………….. 48
SHIFT MECHANISM…………………………………….. 49
PREASSEMBLY OF SHIFT SHAFT…………………………… 49
IGNITION (KOKUSAN)………………………………….. 50
SPARK PLUG…………………………………………. 50
CHECK STATOR AND PULSE GENERATOR (KOKUSAN)…………….. 50
IGNITION (SEM)……………………………………… 51
CHECK STATOR (SEM)………………………………….. 51
TRANSMISSION……………………………………….. 52
ASSEMBLY MAINSHAFT………………………………….. 52
ASSEMBLY COUNTERSHAFT……………………………….. 53
KICKSTARTER………………………………………… 54
ASSEMBLE OF KICKSTARTER SHAFT………………………… 54
ASSEMBLING THE ENGINE…………………………………… 55
CRANKSHAFT…………………………………………. 57
TRANSMISSION……………………………………….. 57
ASSEMBLING THE ENGINE HOUSING………………………… 58
MOUNTING SHIFT MECHANISM…………………………….. 59
MOUNTING KICKSTARTER………………………………… 59
MOUNT PRIMARY DRIVE AND CLUTCH……………………….. 60
MOUNTING CLUTCH DISCS AND PRESSURE CAP………………… 61
MOUNTING CLUTCH COVER……………………………….. 61
MOUNTING PISTON AND CYLINDER…………………………. 62
ADJUSTING DIMENSION „X“……………………………… 62
ADJUSTING CONTROL FLAP (DIMENSION „Z“)………………… 63
MOUNTING STEERING COVERS…………………………….. 64
MOUNTING CYLINDER HEAD………………………………. 64
MOUNTING REED VALVE HOUSING AND INTAKE FLANGE………….. 64
MOUNTING ENGINE SPROCKET…………………………….. 65
MOUNTING THE IGNITION (KOKUSAN)………………………. 65
MOUNTING THE IGNITION (SEM)………………………….. 66
ADJUSTING IGNITION POINT (SEM)……………………….. 66
MOUNTING IGNITION COVER……………………………… 66
MOUNTING STARTING LEVER AND SHIFT LEVER……………….. 66
ELECTRICAL…………………………………………….. 67
CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN)…… 69
CHECKING THE VOLTAGE REGULATOR (KOKUSAN)………………. 69
CHECKING THE VOLTAGE REGULATOR (TYMPANIUM)…………….. 69
CHECKING THE CAPACITOR………………………………. 70
IGNITION COIL (SEM)…………………………………. 70
IGNITION COIL (KOKUSAN)……………………………… 70
CDI UNIT…………………………………………… 70
CHECKING THE VOLTAGE REGULATOR (MOD. 2000)…………….. 71
CHECKING THE CAPACITOR (MOD. 2000)……………………. 71
STATIC IGNITION VALUES 250 – 380 SX, EXC………………. 72
STATIC GENERATOR VALUES 250 – 380 EXC…………………. 74
STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC (USA)…. 76
TROUBLE SHOOTING……………………………………….. 79
TROUBLE SHOOTING 250 – 380…………………………… 81
TECHNICAL SPECIFICATIONS………………………………… 83
MODEL 1999 ENGINE 250 – 380 USA………………………. 85
MODEL 1999 – ENGINE 250 – 380………………………… 87
MODEL 1999 – CHASSIS 250 – 380……………………….. 89
MODEL 1999 – CARBURETOR SETTINGS……………………… 90
MODEL 2000 ENGINE 250 – 380 USA………………………. 93
MODEL 2000 – ENGINE 250 – 380………………………… 95
MODEL 2000 – CHASSIS 250 – 380……………………….. 97
MODEL 2000 – CARBURETOR SETTINGS……………………… 98
MODEL 2001 ENGINE 250 – 380 USA……………………….103
MODEL 2001 – ENGINE 250 – 380…………………………105
MODEL 2001 – CHASSIS 250 – 380………………………..107
MODEL 2001 – CARBURETOR SETTINGS………………………108
MODEL 2002 ENGINE 250 – 380 USA……………………….112
MODEL 2002 – ENGINE 250 – 380…………………………114
MODEL 2002 – CHASSIS 250 – 380………………………..116
MODEL 2002 – CARBURETOR SETTINGS………………………117
MODEL 2003 – ENGINE 250 – 300…………………………121
MODEL 2003 – CHASSIS 250 – 300………………………..123
MODEL 2003 CARBURETOR SETTINGS………………………..125
PERIODIC MAINTENANCE SCHEDULE…………………………….127
MODEL 1999………………………………………….129
MODEL 2000………………………………………….131
MODEL 2001/2002……………………………………..132
MODEL 2003………………………………………….134
WIRING DIAGRAMS…………………………………………137
MODEL 1999………………………………………….139
MODEL 2000………………………………………….143
MODEL 2001 / 2002……………………………………147
MODEL 2003………………………………………….151
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V