KTM EXC REPAIR MANUAL Pdf Download.

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KTM EXC Repair Manual

Related for KTM EXC

Motorcycle KTM 125 EXC, EXC SIX DAYS, 200 XC, XC-W, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, EXC-E, EXC-E SIX DAYS Manual (74 pages)

Ktm owner’s motorcycle 125 exc, exc six days 200 xc, exc 250 xc, xc-w, exc, exc six days 300 xc, exc-e, exc-e six days 9.08 MB

Motorcycle KTM 125 EXC Owner’s (69 pages)

Ktm owner’s manual 125 exc, exc 200 xc, exc 250 xc, xc-w, exc, exc 300 xc, exc Size: 5.12 MB

Page 1

SX,MXC,EXC REPAIR MANUAL KTM SPORTMOTORCYCLE AG 5230 Mattighofen www.ktm.at.

Page 3

250 — 380 REPAIR MANUAL ENGINE.

5

1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 AND REFITTING ENGINE 4 DISASSEMBLING THE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 THE ENGINE 7 ELECTRICAL 8 TROUBLE 9 TECHNICAL SPECIFICATIONS 10 PERIODIC SCHEDULE 11 WIRING DIAGRAMS.

7

5-13 to 5-14 10-1 KTM REPAIR MANUAL IN LOOSE-LEAF STORING THE REPAIR MANUAL IN THE #x2013; Put the index into the #x2013; Put the front page of the manual (210×297 mm) into the pocket provided for this on the outside of the binder.

Page 9

Updating of Rep.Manual 3.205.63-E 2003 (Engine number first digit #x201C;3#x201C;) / Updating: Technical Specification, Maintenance Schedule, Wiring P D AT I N G 250 / 300 / 380 SX, MXC, EXC 11/1998 2/2000 11/2002 Edition 11/2002.

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#x201E;NOTE#x201D; POINTS OUT USEFUL Use only ORIGINAL KTM SPARE when replacing parts. The KTM performance engine is only to meet user expectations if the work is performed regularly and

KTM Austria#x2019;s certificate of achievement for its system ISO 9001 is the beginning of an on total reengineered quality for a brighter tomorrow.

Page 13

FAX FOR REPAIR MANUALS We have every effort to make our manuals as accurate as possible but it is possible for a mistake or two to creep in. To improving the quality of our repair we request mechanics and shop to assist us as follows: If you find any or inaccuracies in one of our repair manual

Page 14: Table Of Contents

GENERAL INFORMATION INDEX RANGES OF THE CARBURETOR. 2-2 CARBURETOR 2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM .

16: Operating Ranges Of The Carburetor

RANGES OF THE CARBURETOR mixture too not enough fuel in proportion to air too rich: too much fuel in to air Idling range Operation closed throttle valve. range is influenced by the position of the air screw .

Page 17: Carburetor Adjustment

Carburetor adjustment Basic on the original carburetor setting The carburetor setting was adapted for an of approx. 500 meters (1600 above sea level, and the ambient of approx. 20#xB0; C (68#xB0; F), for off-road use and central European fuel (ROZ 95 MOZ).

ratio 2-… motor super fuel 1:40


Page 18

Make sure the oil does not overflow. CAUTION H AVING COMPLETED THE BLEEDING OIL LEVEL IN THE MASTER CYLINDER IS #x2013; KTM USES BIODEGRADABLE OIL FOR THE HYDRAULIC CLUTCH CONTROL MIX BIODEGRADABLE HYDRAULIC OILS MINERAL OILS #x2013; A.

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2-5C SPECIAL TOOLS ENGINE Fig. Part no. 546.29.003.000 560.12.004.000 546.29.009.044 6 276 807 544.12.012.000 584.29.037.040 584.29.037.043 546.29.012.100 501.12.013.000 501.12.030.000 6 899 785 151.12.018.100 151.12.018.000 151.12.018.200 0276 179 000 503.29.050.000 250 / 300 / 380 Description engine work stand holder.

Page 20

Clean motorcycle regularly in order to the beauty of its plastic surfaces. The manner would be to use warm that has been mixed a normal brand-name washing and a sponge. The hard dirt can be before washing with the of a soft water jet.

CLEAN YOUR MOTORCYCLE A HIGH ELECTRICAL COMPONENTS

Page 22

3-1C REMOVING AND ENGINE INDEX REMOVING THE 3-2 REFITTING THE ENGINE .

Page 24

Dismounting the engine #x2013; motorcycle thoroughly. #x2013; up motorcycle on an appropriate stand. Remove seat, right paneling, and tank with #x2013; Dismount exhaust #x2013; Drain coolant, and radiator hoses from #x2013; Dismount engine #x2013;.

Page 25

3-3C Loosen the 3 screws, and remove flange chamber KTC system with O-ring. #x2013; engine fastening screw Remove cable ties and the cable of ignition from #x2013; Loosen both clamps, and pull caburetor out of connection boot and intake

Page 26

Refitting the engine To install the engine, reverse the for removing the engine. Filling in of oil: #x2013; Remove the and top up with engine oil 15W-50 (i. e. TOP SPEED 4T). #x2013; In to check the transmission oil level the screw clutch cover is to be

Page 28

4-1C DISASSEMBLING THE INDEX DRAINING GEAR 4-2 DISMOUNTING OF SPROCKET AND SHIFT .

Page 30

#x2013; Cleaning the thoroughly. #x2013; Clamp the into the workstand. #x2013; the kickstarter together with the bushing behind. Draining oil NOTE: The transmission oil should be drained when the engine is Otherwise, the transmission oil will out of the drive shaft following the of the slave cylinder of the clutch.

31

4-3C #x2013; Undo the and remove the right control #x2013; Remove the securing of the ball socket socket the adjusting lever. #x2013; gasket of the control cover. Remove the 4 collar nuts Cover the crankcase. #x2013;.

32

Dismounting of pressure cap and clutch #x2013; Loosen collar wedging of discs as springs #x2013; Remove collar springs and spring retainers. Take pressure cap and disc out of outer clutch hub. Take thrust bearing off the shaft.

Page 33

4-5C of kickstarter #x2013; Remove #x2013; Carefully release screw tension on kickstarter and unhook spring hanger. RELEASE THE KICKSTARTER SPRING Take the complete kickstarter out of the housing. #x2013; Take of the stop disc, which stay in the housing. Dismounting of the lock #x2013;.

Page 34

of the ignition (Kokusan) #x2013; the flywheel with the holding #x2013; Put the protection cover on the thread, twist in the flywheel and remove the flywheel. #x2013; the 3 screws and remove the stator with the base plate.

35

4-7C Dismounting of intake and reed valve housing Remove the 5 collar screws Remove intake flange and valve housing. Parting of housing halves #x2013; Top upwards and remove all 11 housing #x2013; Loosen the 2 engine on the engine work stand.

Page 36

#x2013; Pull out the rails and swing the shift aside. #x2013; Pull the roller out of the bearing seat. Remove the shift forks. During disassembly, watch out for the rollers driving pins of the forks. They may remain in the roller.

Although the counter shift forks are identical should be refitted in the same as before if reused.

Page 37

ON INDIVIDUAL COMPONENTS WORKING ON THE HOUSING HALF. 5-2 WORKING ON THE HOUSING HALF. 5-3 CRANKSHAFT .

39

Working on the right-hand housing #x2013; Remove all shaft rings and use an oven to heat the half to approx. 150#xB0;C. ball bearing of crankshaft old grooved ball-bearing inwards.

Press in new ball bearing to the

Page 40

5-3C Working on the housing half #x2013; all shaft seal rings and use an to heat the casing half to 150#xB0;C. Crankshaft roller Press old roller bearing press in new ball bearing to the with the open side of cage downwards (outside).

41

Crankshaft #x2013; When the roller bearing, the inner ring must also be #x2013; Heat special 584.29.037.040 on a heating pad up to approx. and slip it on the inner ring Press the special tool tightly so as to obtain a good transfer and pull the inner off the crankshaft.

Page 42

5-5C Checking cylinder for wear diameter of cylinder approx. 10 mm in.) below top of cylinder Check diameter in several places to see if cylinder in worn

Engine Cylinder #xD8; — 67,512 67,513 67,525 72,000 — 72,013 — 72,025 — 78,012.

Page 43

250 Cylinder exhaust control Dismantle and clean all exhaust components, check for signs of and damage. Control rollers Check clearance of bearings. oil-derived deposits. Check of control rollers for signs of

Gear segments #x2013;.

44

5-7C #x2013; Mount and silicon O-rings (15×1,50 mm) Slightly grease the bearing #x2013; Mount toothed (the toothed segment the cylindrical pin has to be mounted on the right #x2013; On the right-hand side, bearing bushing spring short leg on outside and spring #x2013;.

Page 45

LOCTITE 243 243 Exhaust control, clutch #x2013; Remove screws and off the bearing support. #x2013; cup tappet. adjusting spring cover. #x2013; Take off pump cover, remove head screw water wheel #x2013; The centrifugal can be pulled out of the bearing.

Page 46

Reed valve housing, flange NOTE: Reed gradually lose tension operation, resulting in power Damaged or worn reed must be replaced. If the reed surfaces of the reed valve are also damaged, replace the reed valve housing.

243.

Page 47

5-10C mm LOCTITE 242 Clutch Thrust check for wear Push rod for wear. Minimum length: 199 mm 199.80 mm) Clutch springs New length 42,5 mm / 1.7 in (new 43 mm / in). Replace all 6 springs if

9 Lining discs Minimum 2.60 mm (0.102 in) / new disc mm (0.106 in).

Page 48

Replace outer clutch hub Drill open the clutch remove parts. #x2013; 8 absorbing elements replace all 8 applicable. HE ABSORBING ELEMENTS ARE THAN THE PRIMARY GEAR THAT THE OUTER CLUTCH HUB ON THE GEAR CROWN TENSION THE CLUTCH RIVETTING TOOL in of retaining bracket for signs of damage.

Page 49

LOCTITE 243 243 0,40 — 0,80 mm 243 Shift mechanism Shift Check shift fork and shift roller driving pin roller Check shift for wear. Check position of roller in grooved ball Slide plate Check plate at meshing points return surface for wear if strongly notched).

Page 50

Kokusan 2K-1/2K-4 Kokusan Kokusan 2K-3 Ignition General information The measurements below will only severe problems. Coil circuits leading to weak sparks or low generator output, can only be detected with the of an ignition test bench. In the of malfunction always check the and the plug and socket connections of the system first.

Page 51

(SEM) General information The described below will reveal severe problems. short circuits leading to ignition sparks or low generator respectively, can only be detected the help of an ignition test In the case of malfunction always the cables and the plug and socket of the ignition system first.

52

5-15C Transmission Secure or countershaft in the vice (using jaw-covers). Remove gears and the following for wear: #x2013; bearing #x2013; Mainshaft and pivot points including gears #x2013; Shift and gear wheels #x2013; faces of all gears #x2013;.

53

Transmission Secure mainshaft or in the vice (using soft Remove gears and check the for wear: #x2013; Needle #x2013; Mainshaft and countershaft points including idler #x2013; Shift dogs and wheels #x2013; Tooth of all gears #x2013;.

Page 54

LOCTITE 243 LOCTITE 243 Kickstarter gear Check clearance of gear. Starter intermediate Check clearance of starter gear. Locking pawl for signs of wear and damage. shaft Check for signs of and damage.

For changing the locking press bearing needle shaft.

Page 55

6-1C THE ENGINE INDEX CRANKSHAFT. 6-2 .

Page 57

#x2013; Secure the housing half in the engine stand. Crankshaft #x2013; crankshaft from above grooved ball bearing and carefully as far as stop. HEN PUSHING IN Transmission #x2013; Grease the pins of the shift forks and the shift rollers #x2013;.

Page 58

6-3C M6 x. #x2013; Fix the 4 springs gearshift rails. Oil gearshift rails and insert into the gearshift forks gearshift rail toward shaft). Insert gearshift into the casing bores as far as will go. NOTE: It must now be to gently turn gear

Page 59

Mounting shift #x2013; Place locating with bent leg upwards engine housing. #x2013; collar sleeve into with collar upwards. Coat collar screw Insert locating lever #x2013; Hook locking must abut the casing #x2013;.

Page 60

6-5C primary drive and clutch Grease crankshaft seal #x2013; Put the oiled O-ring mm) onto the crankshaft and mount the bushing with the chamfer the crank web. #x2013; woodruff key into crankshaft. Place primary gear

Page 61

M6x. Mounting discs and pressure cap #x2013; Oil the bearing. and slide it over the shaft. #x2013; Oil lining before mounting. #x2013; with one lining disc, alternately 9 lining discs ( mm / 0.10 in) and 8 intermediate discs ( mm / 0.047 in), with a disc forming the final upwards.

Page 62

6-7C piston and cylinder #x2013; assembly, oil all parts thoroughly at the points. #x2013; Insert bearing in conrod eye, piston (arrow on piston shows direction for exhaust #x2013; Mount piston pin and circlips with open showing downwards (see

Page 63

control flap control flap (dimension Note: Dimension #x201C;Z#x201C; is the from the lower edge of the flap to the upper edge of the as measured in the centre of the exhaust 250 Model 1999. 48,0 mm 250 2000.

50,5 mm 250 ab Model 49,5 mm 300. 46,0 mm.

64

6-9C Mounting steering #x2013; Mount the right-hand cover #x2013; Place in position and fix left-hand steering Mounting cylinder head Clean cylinder and cylinder sealing surface, place in grooves. #x2013; Mount head with water on the exhaust side. #x2013;.

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Mounting engine sprocket Lubricate O-ring with oil and over counter shaft. Slide distance bushing in so that O-ring is in correct #x2013; Slide sprocket the countershaft with the collar inward, and fix it with the circlip edge facing outward).

Page 66

6-11C Mounting the (SEM) #x2013; Insert key into crankshaft. #x2013; Loctite 243 to the threads of the 3 screws Mount base plate Mount the cable guide Mount the rotor. #x2013; the detent edged ring and the #x2013;.

Page 67

CHECKING THE (MOD. 2000). 7-4 STATIC VALUES 250 — 380 SX, EXC. 7-5 GENERATOR VALUES 250 — 380 EXC .

69

Checking the voltage regulator-rectifier #x2013; Start the engine and on the low beam. #x2013; Connect a to the two terminals of the capacitor (red/white = positive, brown cable = #x2013; Accelerate the engine to a of 5000 r.p.m. and read off the

Page 70

7-3C Checking the #x2013; Discharge the capacitor by the two terminals with a screwdriver and #x2013; Connect the negative of a 12V battery with the negative of the capacitor. The connection between the pole of the battery and the positive of the capacitor (marked +) is made a test lamp #x2013;.

71

Checking the voltage regulator Start the engine and switch on the low #x2013; Connect a voltmeter to the two of the capacitor. #x2013; Accelerate the to a speed of 5000 r.p.m. and off the voltage. In the case of a significant from the nominal value:

Page 72

7-5C STATIC VALUES 250-380 SX, EXC (KOKUSAN 2K-3, 2K-4) Measuring #x2013; cold engine seat and tank removed all connectors and the ground connection in a condition, connectors tightly #x2013; spark plug out and spark plug connector to ground #x2013;.

Page 73

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NOTE: #x2013; the black lead applied to the ground. 300/380 USA corresponds to 300/380 EXC but with less accessories horn, no capacitor installed). no rectifi- cation, only an regulation. (also see circuit on opposite.

KTM 125 EXC
KTM 125 EXC
KTM 125 EXC

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