KTM 250, 525, SX, MXC, EXC Engines- Repair, Service and Maintenance Manual

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KTM 250, 525, SX, MXC, EXC ENGINES - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for KTM 250, 525, SX, MXC, EXC Engines.
 

CONTENTS:

Service - Informations
- Deristriction
- Overheating At High Outside Temperatures
- Hotstart Behaviour
- Maintainance Recommendations For 4-Stroke Racing Engines Series 2001
- Over-Revving And Subsequently Engine Damages
- Automatic Decompression Stop-Screw
- Radiator Mounting Position
- Engine Smoking
- Carburetor Retrofit Action
General Information
- Oil Circuit
- Engine Oil
- Checking The Engine Oil Level
- Changing The Engine Oil
- Changing The Oil Filters
- Checking The Oil Level Of The Hydraulic Clutch
- Bleeding Of The Hydraulic Clutch
- Special Tools
- Cleaning, Storage Of Motorbike
Removing And Refitting Engine
- Dismounting The Engine
- Mounting The Engine
- Bleeding The Cooling System
- Checking The Adjustment Of The Hand Decompression Release Cable
- Adjusting The Throttle Calbes
Disassembling Engine
- Draining The Engine Oil
- Dismounting The Oil Filter
- Dismounting The Chain Wheel
- Disassembling The Clutch
- Dismounting The Ignition System (400/520 Models Until 2002)
- Dismounting The Ignition System And Loosening The Primary Gear (250 Exc Models From 2002, 450/525 Models From 2003)
- Removing The Flywheel
- Removing The Clutch Drive And The Outer Cluch Hub
- Dismounting The Oil Pump
- Dismounting The Upper Cylinder Head Portion
- Dismounting Cylinder Head, Cylinder And Piston
- Dismounting The Timing Chain And The Timing Gear
- Dismounting The E-Starter Drive Gear And Kickstarter
- Dismounting The Primary Gear And Freewheel
- Dismounting The Shift Mechanism And Transmission
- Dismounting The Balancer Shaft And Crankshaft
Servicing Individual Components
- Left Casing Half
- Right Casing Half
- Clutch Cover
- Crankshaft
- Crankshaft Webs - Measure Outer Dimension
- Driving Gear Of Balancer Shaft
- Compensating The Axial Clearance Of The Crankshaft
- Cylinder - Nicasil Coating
- Measuring Piston And Cylinder, Piston Fitting Clearance
- Piston
- Measuring Piston Ring End Gap
- Checking The Oil Pumps For Wear
- Lubrication System
- Upper Portion Of Cylinder Head
- Cylinder Head
- Camshaft
- Preassembling The Camshaft
- Timing Chain Tensioner
- Timing Train
- Checking The Clutch For Wear
- Checking The Kickstarter For Wear
- Preassembling The Kickstarter Shaft
- Shift Mechanism
- Preassembling The Shift Shaft
- Assembling The Main Shaft (4-Speed)
- Assembling The Main Shaft (6-Speed)
- Assembling The Countershaft
- Ignition
- Replacing The Stator
- E-Starter Drive Gear
- Checking The Free Wheel
- Replacing The Free Wheel Hub
Assembling Engine
- Mounting The Crankshaft And Balancer Shaft
- Mounting The Shift Mechansim And Transmission
- Assembling The Engine Case
- Mounting The Primary Gear And Free Wheel
- Mounting The Oil Pumps
- Mounting The Shift Arrester
- Mounting The E-Starter Drive Gear And Kickstarter
- Mounting The Outer Clutch Hub And The Driver
- Mounting The Primary Gear Nut (250 Exc And All Mod. From 2003)
- Mounting The Timing Gear
- Mounting The Piston And Cylinder
- Mounting The Cylinder Head
- Mounting The Cylinder Head Top Portion
- Mounting The Timing Chain Tensioner
- Adjusting The Valve Clearance
- Mounting The Flywheel
- Mounting The Pulse Generator And The Ignition Cover
- Mounting The Clutch
- Mounting The Oil Line And The Electric Starter
- Mounting The Oil Filter
- How To Fill In Engine Oil
Electrical
- Leakage Inspection
- Removing The Battery
- Charging The Battery
- Filling The Battery
- Checking The Capacitor
- Checking The Voltage Regulator-Rectifier
- Checking The Charging Voltage
- Cdi Unit
- Checking The Ignition Coil
- Troubleshooting In The Ignition System
- Main Fuse
- Checking The Electric Starter Motor
- Checking The Starter Relay
- Measurements With Peak Voltage Adapter
- Static Ignition Values 250-525 Sx, Mxc, Exc Racing
- Static Generator Values 250-525 Sx, Mxc, Exc Racing
- Dynamic Generator Values 250-525 Sx, Mxc, Exc Racing
- Throttle Valve Sensor
- Adjustment
- Check
Fuel System
- Dismounting And Installing The Carburetor
- Disassembling The Carburetor (Keihin Fcr 35/39)
- Disassembling The Carburetor (Keihin Fcr-Mx 37/39/41)
- Choke Slide And Hot Start Knob
- Checking The Accelerator Pump
- Checking The Jet Needle
- Checking The Float Needle Valve
- Checking The Throttle Valve
- Assembling The Carburetor (Keihin Fcr 35/39)
- Assembling The Carburetor (Keihin Fcr-Mx 37/39/41)
- Adjusting The Position Of The Throttle Valve Sensor
- Checking The Throttle Valve Sensor
- Dismounting And Installing The Throttle Valve Sensor
- Carburetor Adjusting Idling (Keihin Fcr 35/39)
- Checking/Adjusting The Float Height
- Carburetor Adjusting Idling (Keihin Fcr-Mx 37/39/41)
- Checking/Adjusting The Float Height
Technical Specifications
- Model 2000
- Technical Specifications - Engine
- Basic Carburetor Setting
- Tightening Torques - Engine
- Assembly Clearance, Wear Limit
- Technical Specifications - Chassis
- Standard Adjustment - Fork
- Standard Adjustment - Shock Absorber
- Tightening Torques - Chassis
- Model 2001
- Technical Specifications - Engine
- Basic Carburetor Setting
- Technical Specifications - Chassis
- Standard Adjustment - Fork
- Standard Adjustment - Shock Absorber
- Model 2002
- Technical Specifications - Engine
- Basic Carburetor Setting
- Mounting Clearances, Wear Limits For Models Up To 2002
- Technical Specifications - Chassis
- Standard Adjustment - Fork
- Standard Adjustment - Shock Absorber
- Model 2003
- Technical Specifications - Engine
- Basic Carburetor Setting
- Tightening Torques - Engine
- Mounting Clearances, Wear Limits For Models From 2003
- Technical Specifications - Chassis
- Standard Adjustment Fork / Shock Absorber
- Tightening Torques - Chassis
Periodic Maintenance Schedule
- Periodic Maintenance Schedule Model 2000
- Periodic Maintenance Schedule Model 2001
- Periodic Maintenance Schedule Model 2002
- Periodic Maintenance Schedule Model 2003
Wiring Diagrams
- Model 2000
- Wiring Diagram Usa
- Wiring Diagram Eu
- Model 2001
- Wiring Diagram Eu
- Wiring Diagram Usa
- Model 2002
- Wiring Diagram Usa
- Wiring Diagram Eu
- Model 2003
- Wiring Diagram Usa
- Wiring Diagram Eu