KTM 250 (SX F, EXC F, XCF W, XC F, SXS F) Engines - Repair, Service and Maintenance Manual

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KTM 250 (SX F, EXC F, XCF W, XC F, SXS F) ENGINES - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for KTM 250 (SX F, EXC F, XCF W, XC F, SXS F) Engines.
 

CONTENTS:

Service-Informations
General Information
- Bleeding The Cooling System
- Changing The Oil Filter
- Oil Circuit
- Bleeding Of The Hydraulic Clutch
- Adjusting The Throttle Cables
- Special Tools Engine
Removing And Refitting Engine
- Dismounting The Engine
- Mounting The Engine
Disassembling The Engine
- Preparatory Work
- Moving The Engine Into The Tdc Position
- Removing The Camshafts
- Removing The Cylinder Head And Piston
- Removing The Clutch Cover
- Dismantling The Clutch
- Removing The Chain Drive And Primary Gear
- Dismantling The Shift Mechanism
- Removing The Oil Pumps
- Separating The Casing Halves, Removing The Crankshaft And Transmission Shafts
Servicing Individual Components
- Left Casing Half
- Right Casing Half
- Bypass Valve
- Clutch Cover
- Crankshaft
- Measuring The Outside Dimension Of The Crankshaft Webs
- Crankshaft Bearings
- Axial Clearance Of The Crankshaft
- Cylinder
- Measuring The Piston And Cylinder, Mounting Clearance
- Piston
- Piston Ring End Gap
- Checking The Oil Pumps For Wear
- Lubricating System
- Camshaft Bearing
- Camshafts
- Automatic Decompression
- Camshaft Bearing Bridges
- Timing Chain Tensioner
- Timing Train
- Cylinder Head
- Clutch
- Kickstarter
- Pre-Mounting The Kickstarter Shaft
- Shift Mechanism
- Pre-Mounting The Shift Shaft
- General Information On Servicing The Transmission
- Assembling The Main Shaft
- Assembling The Countershaft
Assembling The Engine
- Installing The Transmission Shafts And Crankshaft, Assembling The Casing Halves
- Mounting The Oil Pumps
- Mounting The Shift Mechanism
- Mounting The Primary Pinion And The Chain Drive
- Mounting The Clutch
- Mounting The Clutch Cover
- Mounting The Piston And Cylinder Head
- Mounting The Camshafts
- Mounting The Chain Tensioner
- Checking The Valve Clearance
- Assembling The Engine
Electrical
- Cdi Unit
- Checking The Ignition Coil
- Troubleshooting In The Ignition System
- Ignition System
- Checking The Stator And Pulse Generator
- Replacing The Stator
- Main Fuse
- Checking The Starter
- Checking The Start Relay
- Dismounting And Mounting The Battery
- Charging The Battery
- Checking The Charging Voltage
- Checking For Loss Of Current
- Engine Characteristic (250 Exc-F Eu)
- Measuring With The Peak Voltage Adapter
- Static Ignition Values
- Static Generator Values
- Throttle Valve Sensor
- Adjusting
- Checking
Fuel System
- Dismounting And Installing The Carburetor
- Disassembling The Carburetor
- Choke Knob And Hot Start Slide
- Checking The Accelerator Pump
- Checking The Jet Needle
- Checking The Float Needle Valve
- Checking The Throttle Valve
- Assembling The Carburetor
- Adjusting The Position Of The Throttle Valve Sensor
- Checking The Throttle Valve Sensor
- Dismounting And Installing The Throttle Valve Sensor
- Carburetor Adjusting Idling
- Checking/Adjusting The Float Height
Trouble Shooting
Technical Specifications
- Engine 250 Sx-F Model 2005-07
- Engine 250 Sxs-F Model 2006-07
- Chassis 250 Sx-F Model 2005-06
- Chassis 250 Sxs-F Model 2006
- Chassis 250 Sx-F/Sxs-F Model 2007
- Engine 250 Xc-F, Xcf-W, Exc-F Model 2007
- Chassis 250 Xc-F, Xcf-W, Exc-F Model 2007
- Engine 250 Sx-F, Xc-F, Xcf-W, Exc-F Model 2008
- Chassis 250 Sx-F, Xc-F, Xcf-W, Exc-F Model 2008
- Mounting Clearances, Wear Limits
- Tightening Torques
- Engine
- Chassis
Periodic Maintenance Schedule
- Model 2005
- Model 2006
- Model 2007
- Model 2008
- 250 Sx-F, Xc-F
- 250 Xcf-W, Exc-F
Wiring Diagrams
- Model 2005
- 250 Sx-F
- 250 Exc-F Usa
- Model 2006
- 250 Sx-F
- 250 Exc-F Usa
- 250 Exc-F Eu
- Model 2007
- 250 Sx-F
- 250 Exc-F Eu
- 250 Xc-F, Xcf-W
- Model 2008
- 250 Sx-F
- 250 Xc-F, Xcf-W
- 250 Exc-F
- Cable Colors