KTM 250, 300, 380, SX, MXC, EXC Engines - Repair, Service and Maintenance Manual

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KTM 250, 300, 380, SX, MXC, EXC ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for KTM 250, 300, 380, SX, MXC, EXC Engines.
 

CONTENTS:

Service-Informations
General Information
- Operating Ranges Of The Carburetor
- Carburetor Adjustment
- Checking Of The Setting Of The Tvc System
- Bleeding Of The Hydraulic Clutch
- Special Tools - Engine
- Cleaning
- Storage
Removing And Refitting Engine
- Removing The Engine
- Refitting The Engine
Disassembling The Engine
- Draining Gear Oil
- Dismounting Of Sprocket And Shift Lever
- Dismounting Of Cylinder Head, Cylinder And Piston
- Dismounting Of Clutch Cover
- Dismounting Of Pressure Cap And Clutch Discs
- Dismounting Of The Primary Drive
- Dismounting Of Kickstarter
- Dismounting Of The Shift Lock
- Dismounting Of Ignition Cover
- Dismounting Of The Ignition (Kokusan)
- Dismounting Of The Ignition (Sem)
- Dismounting Of Intake Flange And Reed Valve Housing
- Parting Of Engine Housing Halves
- Dismounting Of Gearshift Mechanism And Transmission
- Dismounting Of The Crankshaft
Servicing On Individual Components
- Working On The Right-Hand Housing Half
- Working On The Left-Hand Housing Half
- Crankshaft
- Crankshaft Webs – Measure Outer Dimension
- Piston
- Piston Ring End Gap
- Checking Cylinder For Wear
- Recoated Cylinder
- Nikasil Coating Of Cylinder
- Cylinder Exhaust Control System
- Cylinder Preassembly
- Exhaust Control, Clutch Cover
- Preassembly Of Clutch Cover
- Reed Valve Housing, Intake Flange
- Clutch
- Replace Outer Clutch Hub
- Shift Mechanism
- Preassembly Of Shift Shaft
- Ignition (Kokusan)
- Spark Plug
- Check Stator And Pulse Generator (Kokusan)
- Ignition (Sem)
- Check Stator (Sem)
- Transmission
- Assembly Mainshaft
- Assembly Countershaft
- Kickstarter
- Assemble Of Kickstarter Shaft
Assembling The Engine
- Crankshaft
- Transmission
- Assembling The Engine Housing
- Mounting Shift Mechanism
- Mounting Kickstarter
- Mount Primary Drive And Clutch
- Mounting Clutch Discs And Pressure Cap
- Mounting Clutch Cover
- Mounting Piston And Cylinder
- Adjusting Dimension „X“
- Adjusting Control Flap (Dimension „Z“)
- Mounting Steering Covers
- Mounting Cylinder Head
- Mounting Reed Valve Housing And Intake Flange
- Mounting Engine Sprocket
- Mounting The Ignition (Kokusan)
- Mounting The Ignition (Sem)
- Adjusting Ignition Point (Sem)
- Mounting Ignition Cover
- Mounting Starting Lever And Shift Lever
Electrical
- Checking The Voltage Regulator-Rectifier (Shindengen)
- Checking The Voltage Regulator (Kokusan)
- Checking The Voltage Regulator (Tympanium)
- Checking The Capacitor
- Ignition Coil (Sem)
- Ignition Coil (Kokusan)
- Cdi Unit
- Checking The Voltage Regulator (Mod. 2000)
- Checking The Capacitor (Mod. 2000)
- Static Ignition Values 250 - 380 Sx, Exc
- Static Generator Values 250 - 380 Exc
- Static Ignition And Generator Values 250 Mxc, Exc (Usa)
Trouble Shooting
- Trouble Shooting 250 - 380
Technical Specifications
- Model 1999 Engine 250 - 380 Usa
- Model 1999 - Engine 250 - 380
- Model 1999 - Chassis 250 - 380
- Model 1999 - Carburetor Settings
- Model 2000 Engine 250 - 380 Usa
- Model 2000 - Engine 250 - 380
- Model 2000 - Chassis 250 - 380
- Model 2000 - Carburetor Settings
- Model 2001 Engine 250 - 380 Usa
- Model 2001 - Engine 250 - 380
- Model 2001 - Chassis 250 - 380
- Model 2001 - Carburetor Settings
- Model 2002 Engine 250 - 380 Usa
- Model 2002 - Engine 250 - 380
- Model 2002 - Chassis 250 - 380
- Model 2002 - Carburetor Settings
- Model 2003 - Engine 250 - 300
- Model 2003 - Chassis 250 - 300
- Model 2003 Carburetor Settings
Periodic Maintenance Schedule
- Model 1999
- Model 2000
- Model 2001/2002
- Model 2003
Wiring Diagrams
- Model 1999
- Model 2000
- Model 2001 / 2002
- Model 2003