KTM 250-525 SX MXC EXC RACING Repair Manual – PDF DOWNLOAD
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KTM 250-525 SX MXC EXC RACING Repair Manual – PDF DOWNLOAD
Language : English
Pages : 167
Downloadable : Yes
File Type : PDF
Size: 26.3 MB
TABLE OF CONTENTS:
KTM 250-525 SX MXC EXC RACING Repair Manual – PDF DOWNLOAD
HOME………………………………………………………………………………………………………………. 0
NOTES AND PREFACE……………………………………………………………………………………………….. 1
Title page and file spine…………………………………………………………………………………….. 1
Important information………………………………………………………………………………………… 7
Updating instruction…………………………………………………………………………………………. 7
Explanation update…………………………………………………………………………………………… 9
Introduction………………………………………………………………………………………………… 11
Reply fax for repair manuals………………………………………………………………………………….. 13
TABLE OF CONTENTS……………………………………………………………………………………………….. 5
SERVICE – INFORMATIONS……………………………………………………………………………………….. 5
Deristriction……………………………………………………………………………………………. 0
Overheating at high outside temperatures……………………………………………………………………. 0
Hotstart behaviour……………………………………………………………………………………….. 0
Maintainance recommendations for 4-stroke RACING engines series 2001…………………………………………… 0
Over-revving and subsequently engine damages………………………………………………………………… 0
automatic decompression stop-screw…………………………………………………………………………. 0
Radiator mounting position………………………………………………………………………………… 0
Engine smoking…………………………………………………………………………………………… 0
carburetor retrofit action………………………………………………………………………………… 0
GENERAL INFORMATION………………………………………………………………………………………….. 14
OIL CIRCUIT……………………………………………………………………………………………… 16
ENGINE OIL………………………………………………………………………………………………. 17
CHECKING THE ENGINE OIL LEVEL……………………………………………………………………………… 17
CHANGING THE ENGINE OIL…………………………………………………………………………………… 18
CHANGING THE OIL FILTERS………………………………………………………………………………….. 19
CHECKING THE OIL LEVEL OF THE HYDRAULIC CLUTCH………………………………………………………………. 20
BLEEDING OF THE HYDRAULIC CLUTCH…………………………………………………………………………… 20
SPECIAL TOOLS……………………………………………………………………………………………. 22
CLEANING, STORAGE OF MOTORBIKE…………………………………………………………………………….. 23
REMOVING AND REFITTING ENGINE…………………………………………………………………………………. 24
DISMOUNTING THE ENGINE……………………………………………………………………………………. 26
MOUNTING THE ENGINE………………………………………………………………………………………. 29
BLEEDING THE COOLING SYSTEM……………………………………………………………………………….. 29
CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION RELEASE CABLE……………………………………………….. 29
ADJUSTING THE THROTTLE CALBES……………………………………………………………………………… 29
DISASSEMBLING ENGINE…………………………………………………………………………………………. 30
DRAINING THE ENGINE OIL…………………………………………………………………………………… 32
DISMOUNTING THE OIL FILTER………………………………………………………………………………… 32
DISMOUNTING THE CHAIN WHEEL……………………………………………………………………………….. 32
DISASSEMBLING THE CLUTCH………………………………………………………………………………….. 33
DISMOUNTING THE IGNITION SYSTEM (400/520 MODELS UNTIL 2002)…………………………………………………… 33
DISMOUNTING THE IGNITION SYSTEM AND LOOSENING THE PRIMARY GEAR (250 EXC MODELS FROM 2002, 450/525 MODELS FROM 2003)…. 34
REMOVING THE FLYWHEEL…………………………………………………………………………………….. 35
REMOVING THE CLUTCH DRIVE AND THE OUTER CLUCH HUB……………………………………………………………. 35
DISMOUNTING THE OIL PUMP………………………………………………………………………………….. 36
DISMOUNTING THE UPPER CYLINDER HEAD PORTION…………………………………………………………………. 37
DISMOUNTING CYLINDER HEAD, CYLINDER AND PISTON………………………………………………………………. 37
DISMOUNTING THE TIMING CHAIN AND THE TIMING GEAR…………………………………………………………….. 39
DISMOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER…………………………………………………………. 40
DISMOUNTING THE PRIMARY GEAR AND FREEWHEEL………………………………………………………………….. 41
DISMOUNTING THE SHIFT MECHANISM AND TRANSMISSION…………………………………………………………….. 42
DISMOUNTING THE BALANCER SHAFT AND CRANKSHAFT……………………………………………………………….. 43
SERVICING INDIVIDUAL COMPONENTS……………………………………………………………………………….. 44
LEFT CASING HALF…………………………………………………………………………………………. 46
RIGHT CASING HALF………………………………………………………………………………………… 47
CLUTCH COVER…………………………………………………………………………………………….. 49
CRANKSHAFT………………………………………………………………………………………………. 50
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION…………………………………………………………………… 51
DRIVING GEAR OF BALANCER SHAFT…………………………………………………………………………….. 51
COMPENSATING THE AXIAL CLEARANCE OF THE CRANKSHAFT…………………………………………………………… 51
CYLINDER – NICASIL COATING………………………………………………………………………………… 52
MEASURING PISTON AND CYLINDER, PISTON FITTING CLEARANCE………………………………………………………. 52
PISTON………………………………………………………………………………………………….. 53
MEASURING PISTON RING END GAP……………………………………………………………………………… 53
CHECKING THE OIL PUMPS FOR WEAR……………………………………………………………………………. 53
LUBRICATION SYSTEM……………………………………………………………………………………….. 54
UPPER PORTION OF CYLINDER HEAD…………………………………………………………………………….. 55
CYLINDER HEAD……………………………………………………………………………………………. 56
CAMSHAFT………………………………………………………………………………………………… 58
PREASSEMBLING THE CAMSHAFT………………………………………………………………………………… 59
TIMING CHAIN TENSIONER……………………………………………………………………………………. 60
TIMING TRAIN…………………………………………………………………………………………….. 60
CHECKING THE CLUTCH FOR WEAR………………………………………………………………………………. 61
CHECKING THE KICKSTARTER FOR WEAR………………………………………………………………………….. 63
PREASSEMBLING THE KICKSTARTER SHAFT………………………………………………………………………… 63
SHIFT MECHANISM………………………………………………………………………………………….. 65
PREASSEMBLING THE SHIFT SHAFT……………………………………………………………………………… 65
ASSEMBLING THE MAIN SHAFT (4-SPEED)………………………………………………………………………… 66
ASSEMBLING THE MAIN SHAFT (6-SPEED)………………………………………………………………………… 67
ASSEMBLING THE COUNTERSHAFT……………………………………………………………………………….. 68
IGNITION ……………………………………………………………………………………………….. 69
REPLACING THE STATOR……………………………………………………………………………………… 69
E-STARTER DRIVE GEAR……………………………………………………………………………………… 70
CHECKING THE FREE WHEEL…………………………………………………………………………………… 71
REPLACING THE FREE WHEEL HUB………………………………………………………………………………. 71
ASSEMBLING ENGINE……………………………………………………………………………………………. 72
MOUNTING THE CRANKSHAFT AND BALANCER SHAFT………………………………………………………………….. 74
MOUNTING THE SHIFT MECHANSIM AND TRANSMISSION……………………………………………………………….. 74
ASSEMBLING THE ENGINE CASE………………………………………………………………………………… 76
MOUNTING THE PRIMARY GEAR AND FREE WHEEL……………………………………………………………………. 76
MOUNTING THE OIL PUMPS……………………………………………………………………………………. 77
MOUNTING THE SHIFT ARRESTER……………………………………………………………………………….. 78
MOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER……………………………………………………………. 78
MOUNTING THE OUTER CLUTCH HUB AND THE DRIVER………………………………………………………………… 79
MOUNTING THE PRIMARY GEAR NUT (250 EXC AND ALL MOD. FROM 2003)………………………………………………… 80
MOUNTING THE TIMING GEAR………………………………………………………………………………….. 81
MOUNTING THE PISTON AND CYLINDER…………………………………………………………………………… 82
MOUNTING THE CYLINDER HEAD………………………………………………………………………………… 82
MOUNTING THE CYLINDER HEAD TOP PORTION……………………………………………………………………… 84
MOUNTING THE TIMING CHAIN TENSIONER………………………………………………………………………… 85
ADJUSTING THE VALVE CLEARANCE……………………………………………………………………………… 85
MOUNTING THE FLYWHEEL…………………………………………………………………………………….. 86
MOUNTING THE PULSE GENERATOR AND THE IGNITION COVER………………………………………………………….. 86
MOUNTING THE CLUTCH………………………………………………………………………………………. 87
MOUNTING THE OIL LINE AND THE ELECTRIC STARTER………………………………………………………………. 88
MOUNTING THE OIL FILTER…………………………………………………………………………………… 89
HOW TO FILL IN ENGINE OIL…………………………………………………………………………………. 89
ELECTRICAL………………………………………………………………………………………………….. 90
LEAKAGE INSPECTION……………………………………………………………………………………….. 92
REMOVING THE BATTERY……………………………………………………………………………………… 92
CHARGING THE BATTERY……………………………………………………………………………………… 92
FILLING THE BATTERY………………………………………………………………………………………. 93
CHECKING THE CAPACITOR……………………………………………………………………………………. 93
CHECKING THE VOLTAGE REGULATOR-RECTIFIER……………………………………………………………………. 94
CHECKING THE CHARGING VOLTAGE……………………………………………………………………………… 94
CDI UNIT………………………………………………………………………………………………… 95
CHECKING THE IGNITION COIL………………………………………………………………………………… 95
TROUBLESHOOTING IN THE IGNITION SYSTEM……………………………………………………………………… 95
MAIN FUSE……………………………………………………………………………………………….. 96
CHECKING THE ELECTRIC STARTER MOTOR………………………………………………………………………… 96
CHECKING THE STARTER RELAY………………………………………………………………………………… 96
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER……………………………………………………………………… 97
STATIC IGNITION VALUES 250-525 SX, MXC, EXC RACING……………………………………………………….. 97
STATIC GENERATOR VALUES 250-525 SX, MXC, EXC RACING………………………………………………………. 99
DYNAMIC GENERATOR VALUES 250-525 SX, MXC, EXC RACING………………………………………………………101
THROTTLE VALVE SENSOR……………………………………………………………………………………..120
ADJUSTMENT……………………………………………………………………………………………120
CHECK………………………………………………………………………………………………..121
FUEL SYSTEM………………………………………………………………………………………………….102
DISMOUNTING AND INSTALLING THE CARBURETOR……………………………………………………………………106
DISASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39) ……………………………………………………………..107
DISASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41)…………………………………………………………110
CHOKE SLIDE AND HOT START KNOB……………………………………………………………………………..113
CHECKING THE ACCELERATOR PUMP………………………………………………………………………………113
CHECKING THE JET NEEDLE……………………………………………………………………………………113
CHECKING THE FLOAT NEEDLE VALVE…………………………………………………………………………….113
CHECKING THE THROTTLE VALVE………………………………………………………………………………..113
ASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39)…………………………………………………………………114
ASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41)……………………………………………………………117
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR…………………………………………………………..120
CHECKING THE THROTTLE VALVE SENSOR………………………………………………………………………….121
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR………………………………………………………….121
CARBURETOR ADJUSTING IDLING (KEIHIN FCR 35/39)……………………………………………………………….122
CHECKING/ADJUSTING THE FLOAT HEIGHT…………………………………………………………………………122
CARBURETOR ADJUSTING IDLING (KEIHIN FCR-MX 37/39/41)………………………………………………………….123
CHECKING/ADJUSTING THE FLOAT HEIGHT…………………………………………………………………………123
TECHNICAL SPECIFICATIONS………………………………………………………………………………………124
MODEL 2000……………………………………………………………………………………………….126
TECHNICAL SPECIFICATIONS – ENGINE……………………………………………………………………….126
BASIC CARBURETOR SETTING……………………………………………………………………………….126
TIGHTENING TORQUES – ENGINE……………………………………………………………………………127
ASSEMBLY CLEARANCE, WEAR LIMIT………………………………………………………………………….128
TECHNICAL SPECIFICATIONS – CHASSIS………………………………………………………………………129
STANDARD ADJUSTMENT – FORK……………………………………………………………………………..129
STANDARD ADJUSTMENT – SHOCK ABSORBER…………………………………………………………………….129
TIGHTENING TORQUES – CHASSIS……………………………………………………………………………129
MODEL 2001……………………………………………………………………………………………….130
TECHNICAL SPECIFICATIONS – ENGINE……………………………………………………………………….130
BASIC CARBURETOR SETTING……………………………………………………………………………….130
TECHNICAL SPECIFICATIONS – CHASSIS………………………………………………………………………131
STANDARD ADJUSTMENT – FORK……………………………………………………………………………..131
STANDARD ADJUSTMENT – SHOCK ABSORBER…………………………………………………………………….131
MODEL 2002……………………………………………………………………………………………….132
TECHNICAL SPECIFICATIONS – ENGINE……………………………………………………………………….132
BASIC CARBURETOR SETTING……………………………………………………………………………….133
MOUNTING CLEARANCES, WEAR LIMITS FOR MODELS UP TO 2002…………………………………………………….134
TECHNICAL SPECIFICATIONS – CHASSIS………………………………………………………………………135
STANDARD ADJUSTMENT – FORK……………………………………………………………………………..135
STANDARD ADJUSTMENT – SHOCK ABSORBER…………………………………………………………………….135
MODEL 2003……………………………………………………………………………………………….136
TECHNICAL SPECIFICATIONS – ENGINE……………………………………………………………………….136
BASIC CARBURETOR SETTING……………………………………………………………………………….137
TIGHTENING TORQUES – ENGINE……………………………………………………………………………138
MOUNTING CLEARANCES, WEAR LIMITS FOR MODELS FROM 2003……………………………………………………..139
TECHNICAL SPECIFICATIONS – CHASSIS………………………………………………………………………140
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER………………………………………………………………..140
TIGHTENING TORQUES – CHASSIS……………………………………………………………………………140
PERIODIC MAINTENANCE SCHEDULE………………………………………………………………………………….142
PERIODIC MAINTENANCE SCHEDULE MODEL 2000…………………………………………………………………….144
PERIODIC MAINTENANCE SCHEDULE MODEL 2001…………………………………………………………………….146
PERIODIC MAINTENANCE SCHEDULE MODEL 2002…………………………………………………………………….148
PERIODIC MAINTENANCE SCHEDULE MODEL 2003…………………………………………………………………….150
WIRING DIAGRAMS………………………………………………………………………………………………154
MODEL 2000……………………………………………………………………………………………….156
WIRING DIAGRAM USA…………………………………………………………………………………….156
WIRING DIAGRAM EU……………………………………………………………………………………..157
MODEL 2001……………………………………………………………………………………………….159
WIRING DIAGRAM EU……………………………………………………………………………………..159
WIRING DIAGRAM USA…………………………………………………………………………………….161
MODEL 2002……………………………………………………………………………………………….162
WIRING DIAGRAM USA…………………………………………………………………………………….162
WIRING DIAGRAM EU……………………………………………………………………………………..163
MODEL 2003……………………………………………………………………………………………….165
WIRING DIAGRAM USA…………………………………………………………………………………….165
WIRING DIAGRAM EU……………………………………………………………………………………..167
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