2004-2006 KTM 250/300 SX,SXS,MXC EXC EXC SIX DAYS XC, XC-W Repair Manual – PDF DOWNLOAD
FILE DETAILS:
2004-2006 KTM 250/300 SX,SXS,MXC EXC EXC SIX DAYS XC, XC-W Repair Manual – PDF DOWNLOAD
Language :English
Pages :159
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2004-2006 KTM 250/300 SX,SXS,MXC EXC EXC SIX DAYS XC, XC-W Repair Manual – PDF DOWNLOAD
Repair manual KTM 250/300
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 at 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
For example: All pages with a page number that begins with the digit 3, 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:
2004-2006 KTM 250/300 SX SXS MXC EXC EXC SIX DAYS XC XC-W Repair Manual – PDF DOWNLOAD
HOME 0
NOTES AND PREFACE 1
Title page and file spine 1
Important information 7
Updating instructions 7
Explanation updating 9
Introduction 11
Reply fax for repair manuals 13
TABLE OF CONTENTS 5
GENERAL INFORMATION 15
SPECIAL TOOLS – ENGINE 17
CHECKING THE SETTING OF THE TVC SYSTEM 18
ENGINE CHARACTERISTIC 18
BLEEDING THE HYDRAULIC CLUTCH (UP TO MODEL 2005) 19
BLEEDING THE HYDRAULIC CLUTCH (AS OF MODEL 2006) 20
CHANGING THE FRONT BRAKE FLUID 21
CHANGING THE REAR BRAKE FLUID 22
CHECKING BRAKE PADS AND BRAKE DISCS 22
REMOVING AND REFITTING ENGINE 23
REMOVING THE ENGINE 25
REFITTING THE ENGINE 27
DISASSEMBLING THE ENGINE 31
PREPARATION 33
DRAINING THE GEAR OIL 33
DISMOUNTING THE SPROCKET AND SHIFT LEVER 33
DISMOUNTING THE CYLINDER HEAD, CYLINDER AND PISTON 33
DISMOUNTING THE CLUTCH COVER 34
DISMOUNTING THE PRESSURE CAP AND THE CLUTCH DISCS 35
DISMOUNTING THE PRIMARY DRIVE 35
DISMOUNTING THE KICKSTARTER SHAFT 36
DISMOUNTING THE SHIFT LOCK 36
DISMOUNTING THE IGNITION COVER 36
DISMOUNTING THE IGNITION 37
DISMOUNTING THE REED VALVE HOUSING 38
PARTING THE ENGINE HOUSING HALVES 38
DISMOUNTING THE GEARSHIFT MECHANISM AND TRANSMISSION 38
DISMOUNTING THE CRANKSHAFT 39
SERVICING INDIVIDUAL COMPONENTS 41
SERVICING THE RIGHT ENGINE HOUSING HALF 43
SERVICING THE LEFT ENGINE HOUSING HALF 44
CRANKSHAFT 45
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION 45
CHECK THE PISTON 45
PISTON RING END GAP 45
MEASURING PISTONS AND CYLINDERS – ESTABLISHING THE PISTON MOUNTING CLEARANCE 46
RECOATED CYLINDER 46
NIKASIL COATING OF CYLINDER 46
CYLINDER EXHAUST CONTROL SYSTEM 47
CYLINDER PREASSEMBLY 47
EXHAUST CONTROL, CLUTCH COVER 49
PREASSEMBLY OF CLUTCH COVER 49
REED VALVE HOUSING 50
CLUTCH 51
REPLACE OUTER CLUTCH HUB 52
SHIFT MECHANISM 53
PREASSEMBLY THE SHIFT SHAFT 53
ASSEMBLY MAINSHAFT 54
ASSEMBLY COUNTERSHAFT 55
CHECKING THE KICKSTARTER FOR WEAR 56
ASSEMBLING THE KICKSTARTER SHAFT 56
ASSEMBLING THE ENGINE 57
CRANKSHAFT 59
TRANSMISSION 59
ASSEMBLING THE ENGINE HOUSING 60
MOUNTING THE SHIFT MECHANISM 61
MOUNTING THE KICKSTARTER SHAFT 61
MOUNTING THE PRIMARY DRIVE AND CLUTCH 62
MOUNTING THE CLUTCH DISCS AND PRESSURE CAP 63
MOUNTING THE CLUTCH COVER 63
MOUNTING THE PISTON AND CYLINDER 64
ADJUSTING DIMENSION “X“ 64
ADJUSTING THE CONTROL FLAP (DIMENSION “Z“) 65
MOUNTING THE STEERING COVERS 66
MOUNTING THE CYLINDER HEAD 66
MOUNTING THE REED VALVE HOUSING 66
MOUNTING THE ENGINE SPROCKET 67
MOUNTING THE IGNITION 67
MOUNTING THE IGNITION COVER 68
MOUNTING THE STARTING LEVER AND SHIFT LEVER 68
FILLING UP THE TRANSMISSION OIL 68
CHECK THE TRANSMISSION OIL LEVEL 68
ELECTRICAL 69
IGNITION COIL 71
CDI UNIT 71
CHECKING THE VOLTAGE REGULATOR 71
CHECKING THE CAPACITOR 72
SPARK PLUG 72
IGNITION 73
CHECK THE STATOR AND PULSE GENERATOR (PICK UP) 73
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER 0
MODEL 2004 0
STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC 74
STATIC GENERATOR VALUES 250/300 MXC/EXC 76
STATIC IGNITION AND GENERATOR VALUES 250 EXC USA 78
MODEL 2005 0
STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC 80
STATIC GENERATOR VALUES 250/300 MXC/EXC 82
STATIC IGNITION AND GENERATOR VALUES 250 EXC USA 84
MODEL 2006 0
STATIC IGNITION VALUES 250 SX/SXS, 250/300 EXC/EXC SIX DAYS, 300 XC/XC-W 80
STATIC GENERATOR VALUES 250/300 EXC/EXC SIX DAYS, 300 XC-W 82
STATIC IGNITION AND GENERATOR VALUES 250 XC/XC-W 84
FUEL SYSTEM 87
OPERATING RANGES OF THE CARBURETOR 89
CARBURETOR ADJUSTMENT 90
DISMOUNTING AND INSTALLING THE CARBURETOR 92
DISASSEMBLING THE CARBURETOR 93
CHECKING THE JET NEEDLE AND THROTTLE SLIDE 94
CHECKING THE STARTING PISTON 94
CHECKING THE FLOAT NEEDLE VALVE 94
CHECKING THE CARBURETOR JETS AND GASKETS 94
ASSEMBLING THE CARBURETOR 95
DRAINING THE CARBURETOR FLOAT CHAMBER 96
CHECKING THE FLOAT LEVEL 96
TROUBLE SHOOTING 97
TROUBLE SHOOTING 250 / 300 99
TECHNICAL SPECIFICATIONS 101
MODEL 2004 0
ENGINE 103
CHASSIS 104
MODEL 2005 0
ENGINE 105
CHASSIS 106
MODEL 2006 0
ENGINE 250 107
ENGINE 300 108
CHASSIS SX / SXS / EXC / EXC SIX DAYS 109
CHASSIS XC / XC-W 110
TIGHTENING TORQUES – ENGINE 111
TOLERANCES AND FITTING CLEARANCES / GASKET THICKNESSES 111
TIGHTENING TORQUES – CHASSIS 112
CARBURATOR SPECIFICATION 0
MODEL 2004 113
MODEL 2005 115
MODEL 2006 117
PERIODIC MAINTENANCE SCHEDULE 121
MODEL 2004 / 2005 123
MODEL 2006 126
WIRING DIAGRAM 129
MODEL 2004 0
250/300 EXC 131
250/300 EXC-USA 137
250 SX 138
TERMS/TRANSLATIONS, CABLE COLORS 157
LIST OF SWITCHES 159
MODEL 2005 0
250/300 EXC/EXC SIX DAYS 139
250 EXC-USA 145
300 EXC-USA 146
250 SX 147
TERMS/TRANSLATIONS, CABLE COLORS 157
LIST OF SWITCHES 159
MODEL 2006 0
250/300 EXC 148
250/300 EXC SIX DAYS 139
250 XC-W 154
300 XC-W 155
250 SX/SXS/XC 156
300 XC 156
TERMS/TRANSLATIONS, CABLE COLORS 157
LIST OF SWITCHES 159
S.M 13/3/2025
