2001 KTM 250/300/380 SX,MXC,EXC ENGINE REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
2001 KTM 250/300/380 SX,MXC,EXC ENGINE REPAIR MANUAL – PDF DOWNLOAD
Language :English
Pages :153
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2001 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
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150×297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5 3 = chapter 3 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience.
The respective headings can be entered in the list of contents.
TABLE OF CONTENTS:
2001 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
S.M 13/3/2025
