Instruction/ maintenance manual of the product 250 SX KTM
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 250/300/380 SX,MXC,EXC REP AIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www .ktm.
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REP AIR MANUAL ENGINE 250 - 380 SX,MXC,EXC.
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1 SER VICE-INFORMA TIONS 2 GENERAL INFORMA TION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SER VICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING.
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Remove page (s) Replace by page (s) Insert page (s) after page 2-1 to 2-4 2-1C to 2-6C 3-4 3-4C 4-1 to 4-9 4-1C to 4-8C 5-1 5-1C 5-4 5-4C / 5-5C 5-1.
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E XPLANA TION - U PDA TING Edition 11/2002 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 3.205.63-E Repair Manual 250 / 300 / 380 SX, MXC, EXC Basicversion Modelyear 1999 (Engine number with first digit “9“) 11/1998 3.205.87-E Updating of Rep.
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INTRODUCTION This repair manual of fers 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 curr ent issue of this manual.
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REPL Y F AX FOR REP AIR MANUALS We have made every effort to make our r epair manuals as accurate as possible but it is always possible for a mistake or two to creep in.
Repair manual 250 / 300 / 380 Art Nr 3206004 -E OPERA TING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . .2-2 CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control scr ew 1 and the idle adjusting screw 2 .
2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for of f-road use and central European premium-grade fuel (ROZ 95 MOZ).
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-4C Checking the setting of the TVC system The function of the TVC system is checked with the engine running. This test checks the start of advance and the end of advance. – For this, remove the left control cover .
2-5C Fig. Part no. Description 1 560.12.001.000 Universal engine work stand 3 546.29.003.000 Clutch holder 4 560.12.004.000 Gear wheel segment 5 546.29.009.044 Magneto extractor M 27x1 Kokusan 66 276 807 Magneto extractor M 26x1,5 SEM 7 510.12.011.000 Circlip plier 8 544.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-6C Should you wish to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil (old engine oil contains aggressive contaminants).
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Repair manual 250 / 300 / 380 Art No 3206004 -E REMOVING AND REFITTING ENGINE REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Dismounting the engine – Clean motorcycle thoroughly . –P r op up motorcycle on an appr opriate stand. – Remove seat, right side paneling, and tank with spoilers. – Dismount exhaust system. – Drain coolant, and disconnect radiator hoses from engine.
– Loosen the 3 screws, and remove intermediate flange chamber 1 of KTC system together with O-ring. – Remove engine fastening screw 2 . – Remove cable ties and loose the cable of ignition from frame. – Loosen both hose clamps, and pull caburetor out of carburetor connection boot and intake flange.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Refitting the engine –T o install the engine, reverse the steps for removing the engine. Filling in of transmission oil: – Remove the plug 1 and top up with engine oil 15W -50 (i. e. MOTOREX TOP SPEED 4T).
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Repair manual 250 / 300 / 380 Art No 3206004 -E DISASSEMBLING THE ENGINE DRAINING GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 DISMOUNTING OF SPROCKET AND SHIFT LEVER . . . . . . . . . . . . . . .4-2 DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON .
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4-2C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E – Cleaning the engine thoroughly . – Clamp the engine into the workstand. – Remove the kickstarter together with the distance bushing behind. Draining gear oil NOTE: The transmission oil should already be drained when the engine is dismounted.
4-3C – Undo the screws 1 and remove the right contr ol cover . – Remove the securing clip of the ball socket 2 and unhook the ball socket 3 from the adjusting lever . – Remove gasket of the control cover . – Remove the 4 collar nuts 4 on cylinder base and remove cylinder .
4-4C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Dismounting of pressure cap and clutch discs – Loosen collar screws 1 in diagonally opposite sequence to prevent wedging of discs as springs expand. – Remove collar screws, springs and spring retainers.
4-5C Dismounting of kickstarter – Remove circlip 1 and kickstarter intermediate gear . – Carefully release collar scr ew 2 kickstarter spring is tensioned, release tension on kickstarter spring and unhook spring hanger .
4-6C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner 1 and undo the collar nut. – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel.
4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws 1 . – Remove intake flange and reed valve housing. Parting of engine housing halves –T op ignition-gear upwards and remove all 11 housing scr ews. – Loosen the 2 engine fixtures on the engine work stand.
4-8C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E – Pull out the shift rails and swing the shift forks aside. – Pull the shift roller out of the bearing seat. – Remove the shift forks. NOTE: During disassembly , watch out for the shift rollers 1 on the driving pins of the shift forks.
Repair manual 250 / 300 / 380 Art No 3206004 -E SER VICING ON INDIVIDUAL COMPONENTS WORKING ON THE RIGHT -HAND HOUSING HALF . . . . . . . . . . . . . .5-2 WORKING ON THE LEFT -HAND HOUSING HALF . . . . . . . . . . . . . . . .5-3 CRANKSHAFT . . . . . .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E W orking on the right-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. Grooved ball bearing of crankshaft 1 Press old grooved ball-bearing inwar ds.
W orking on the left-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. Crankshaft roller bearing 1 Press old roller bearing inwar ds, press in new ball bearing to the stop with the open side of ball cage downwards (outside).
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be renewed. – Heat special tool 584.29.037.040 on a heating pad up to approx. 150°C and slip it on the inner ring immediately .
Checking cylinder for wear Measure diameter of cylinder approx. 10 mm (0.4 in.) below top of cylinder edge. Check diameter in several corresponding places to see if cylinder in worn oval. Recoated cylinder NOTE: If the cylinder diameter is larger than e.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Cylinder exhaust control system Dismantle and clean all exhaust control components, check for signs of wear and damage. Control rollers 1 – Check clearance of bearings. Remove oil-derived deposits.
– Place preassembled control flap in cylinder , engage gear segments in control rollers in such a manner that, when the contr ol flap is ,open (pivoted right to the top), the markings of the gear segments and the gear rollers coincide.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Exhaust control, clutch cover – Remove screws 1 and take off the bearing support. –T ake cup tappet 2 , adjusting spring 3 and auxiliary spring 4 out of clutch cover . –T ake off water pump cover , remove allen head screw 6 and take off water pump wheel 7 .
Reed valve housing, intake flange NOTE: Reed paddles 1 gradually lose tension through operation, r esulting in power loss. Damaged or worn reed paddles must be r eplaced. If the reed sealing surfaces 2 of the reed valve housing ar e also damaged, replace the complete reed valve housing.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Clutch Thrust bearing 1 check for wear Push rod 2 Check for wear . Minimum length: 199 mm (new: 199.80 mm) Clutch springs 3 New spring length 42,5 mm / 1.7 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable.
5-11C Replace outer clutch hub – Drill open the clutch rivets bl in area of retaining bracket bm and r emove parts. – Check 8 absorbing elements bn for signs of mechanical damage, r eplace all 8 where applicable. ! CAUTION ! T HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 5-12C Shift mechanism Shift forks 1 Check shift fork blades A and shift roller driving pin B for signs of wear . Shift roller 2 Check shift grooves for wear . Check position of shift roller in grooved ball bearings 3 .
Ignition (Kokusan) General information The measurements described below will only reveal sever e problems. Coil short circuits leading to weak ignition sparks or low generator output, r espectively , can only be detected with the help of an ignition test bench.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Ignition (SEM) General information The measurements described below will only reveal sever e problems. Coil short circuits leading to weak ignition sparks or low generator output, r espectively , can only be detected with the help of an ignition test bench.
5-15C Tr ansmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 5-16C T ransmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: – Needle .
Kickstarter Starter gear 1 Check clearance of starter gear . Starter intermediate gear 2 Check clearance of starter intermediate gear . Locking pawl 3 Check for signs of wear and damage. Kickstarter shaft 4 Check for signs of wear and damage. For changing the locking pawl, press bearing needle 9 out of the kickstarter shaft.
Repair manual 250 / 300 / 380 Art No 3206004 -E ASSEMBLING THE ENGINE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E – Secure the right-hand housing half in the engine work stand. Crankshaft – Insert crankshaft from above through gr ooved ball bearing and push carefully as far as stop. ! CAUTION ! W HEN PUSHING IN CRANKSHAFT , MAKE SURE CONROD IS F ACING CYLINDER .
– Fix the 4 pressure springs 1 with ample amounts of gr ease in the gearshift rails. – Oil gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft). Insert gearshift rails into the casing bores as far as they will go.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Mounting shift mechanism – Place locating spring with bent leg upwards into engine housing. – Insert collar sleeve into spring with collar upwards. – Coat collar screw 1 with Loctite 243. – Insert locating lever 2 with roll upwards and fix all parts with collar screw .
Mount primary drive and clutch –G r ease crankshaft seal ring. – Put the oiled O-ring (25x1.50 mm) onto the crankshaft and mount the distance bushing with the chamfer facing the crank web. – Insert woodruff key into crankshaft. – Place primary gear 1 onto crankshaft with collar downwards.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Mounting clutch discs and pressure cap –O il the thrust bearing 1 , and slide it over the drive shaft. – Oil lining discs before mounting. – Beginning with one lining disc, mount alternately 9 lining discs ( ≠ 2.
Mounting piston and cylinder – Before assembly , oil all parts thoroughly at the sliding points. – Insert needle bearing in conrod eye, mount piston (arrow on piston head shows direction for exhaust duct). – Mount piston pin and wire circlips with open side showing downwar ds (see sketch).
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Adjusting control flap (dimension “Z“) Note: Dimension “Z“ is the distance from the lower edge of the control flap to the upper edge of the cylinder , as measured in the centre of the exhaust port.
Mounting steering covers –M ount the right-hand control cover 1 , and fix it with 3 screws. – Place gasket in position and fix left-hand steering cover 2 on cylinder . Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O-rings in grooves.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 6-10C Mounting engine sprocket – Lubricate O-ring 1 with oil and slide over counter shaft. – Slide distance bushing 2 in position so that O-ring is in correct position.
Mounting the ignition (SEM) – Insert woodruff key into crankshaft. – Apply Loctite 243 to the threads of the 3 screws 2 . – Mount base plate 1 together with stator , and tighten the 3 screws. – Mount the cable guide 3 into the cutaway portion of the casing.
Repair manual 250 / 300 / 380 Art No 3206004 -E ELECTRICAL CHECKING THE VOL T AGE REGULA TOR-RECTIFIER (SHINDENGEN) . . .7-2 CHECKING THE VOL T AGE REGULA TOR (KOKUSAN) . . . . . . . . . . . . .7-2 CHECKING THE VOL T AGE REGULA TOR (TYMP ANIUM) . . . .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Checking the voltage regulator -rectifier (Shindengen) – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative).
Checking the capacitor – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor . The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 1 .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 7-4C Checking the voltage regulator – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor . – Accelerate the engine to a speed of 5000 r .p.
7-5C Static ignition values 250-380 SX, EXC (except 250 USA) Check the pulse generator for an output signal – two-pin connector 1 with green and red cable colors (also see cir cuit diagram on opposi.
7-6C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E SPORTMOTORCYCLES 1 2 3 4 5 250-380 EXC 2000.
7-7C Static generator values 250-380 EXC (except 250 USA) Check the generator output 6 (also see circuit diagram on opposite page) for voltage between the following cable colors: – between yellow an.
7-8C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E SPORTMOTORCYCLES 6 9 10 11 250-380 EXC 2000.
7-9C Static ignition values 250 MXC, EXC USA Check the pulse generator for an output signal – two one-pin connectors 1 with green and red cable colors (also see cir cuit diagram on opposite page): .
7-10C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 1 2 3 4 5 6 250 EXC 2001.
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Repair manual 250 / 300 / 380 Art No 3206004 -E TROUBLE SHOOTING TROUBLE SHOOTING 250 - 380 . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 INDEX 8-1C 8.
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 8-2C TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in or der to find the cause of error .
8-3C TROUBLE Engine has not enough power Engine revs not high and running with four stroke cycle High rpm misfiring Engine spluters into the carburetor Engine overheating Emission of white smoke (stea.
Repair manual 250 / 300 / 380 Art No 3206004 -E TECHNICAL SPECIFICA TIONS MODEL 1999 ENGINE 250 - 380 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 ENGINE 250 - 380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-2C Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 67.
9-3C Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .
Art No 3206004 -E 9-4C Repair manual KTM 250 / 300 / 380 Engine 250 SX 250 EXC, EGS 300 EXC, EGS 380 SX 380 EXC, EGS Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 67.
9-5C Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-6C 250/380SX 250/300/380 MXC 250/300/380 EXC 250/300/380 EGS Frame Central chrome-moly-steel frame Fork WP Extr eme Ø 50 mm Wheel travel front/rear 280 / 320 mm (11.
9-7C VERGASERREGULIERUNG KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38 CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-8C VERGASERREGULIERUNG KTM 250 SX EUROP A, USA ‘99 KEIHIN PWK 38 CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24.
9-9C VERGASERREGULIERUNG KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38 CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-10C Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.
9-11C TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-12C Engine 250 SX 250 EXC 300 EXC 380 SX 380 EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.
9-13C TIGHTENING TORQUES Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-14C * Dead-weight without fuel WP 1218U718 WP 1218U720 Compression adjuster 4 5 Rebound adjuster 18 20 Spring PDS3–250 PDS2-250 Spring preload 5 mm (0.
9-15C VERGASERREGULIERUNG KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-16C VERGASERREGULIERUNG KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis .
9-17C VERGASERREGULIERUNG KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-18C VERGASERREGULIERUNG KTM 380 SX / MXC / EXC EUR / USA 2000 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 1.
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-19C Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.
9-20C TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-21C Engine 250 SX 250 EXC 300 EXC 380 SX 380 EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.
9-22C TIGHTENING TORQUES Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-23C * Dead-weight without fuel WP 1218V730 WP 1218V731 Compression adjuster 5 5 Rebound adjuster 25 25 Spring PDS7–265 PDS2-250 Spring preload 5 mm (0.
9-24C VERGASERREGULIERUNG KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-25C VERGASERREGULIERUNG KTM 250 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis .
9-26C VERGASERREGULIERUNG KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-27C VERGASERREGULIERUNG KTM 380 SX / MXC / EXC EUR / USA 2001 KEIHIN PWK 38 A G CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C .
9-28C Engine 250 SX 250 MXC/EXC 300 MXC/EXC 380 SX 380 MXC/EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-29C TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .
9-30C Engine 250 SX 250 EXC 300 EXC 380 SX 380 EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.4 / 72 mm (2.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-31C TIGHTENING TORQUES Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .
9-32C * Dead-weight without fuel WP 1218V736 WP 1218V737 Compression adjuster 15 LS (low speed) 15 2 HS (high speed) Rebound adjuster 25 25 Spring PDS7–260 PDS6–260 Spring preload 4 mm (0.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-33C VERGASERREGULIERUNG KTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C .
9-34C VERGASERREGULIERUNG KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-35C VERGASERREGULIERUNG KTM 300 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis .
9-36C VERGASERREGULIERUNG KTM 380 SX / MXC / EXC EUR / USA 2002 KEIHIN PWK 38 A G CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°.
9-37C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Engine 250 MXC/EXC 300 MXC/EXC Desgin Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm Bore / stroke 66,4 / 72 mm (2.
9-38C TIGHTENING TORQUES Flange bolts - cylinder -head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .
9-39C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E WP 5018-MCC 1218X759 Compression adjuster 17 Rebound adjuster 26 Spring 71-90/260 Spring preload 7 mm (0.27 in) S T ANDARD A DJUSTMENT - S HOCK A BSORBER WP 4860 MXMA 1418X736 Compression adjuster 20 Rebound adjuster 20 Spring 4,0 N/mm Spring preload 5 mm (0.
9-40C Collar screw , front wheel spindle M 24x1,5 40 Nm Brake caliper , front M 8 Loctite 243 + 25 Nm Brake disk, front M 6 10.9 Loctite 243 + 15 Nm Brake disk, rear M 6 Loctite 243 + 15 Nm Clamping s.
9-41C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E VERGASERREGULIERUNG KTM 250 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis .
9-42C VERGASERREGULIERUNG KTM 300 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F.
Repair manual 250 / 300 / 380 Art No 3206004 -E LUBRICA TION AND MAINTENANCE SCHEDULE MODEL 1999 LUBRICA TION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-2 MODEL 2000 LUBRICA TION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-3 MODEL 2001/2002 LUBRICA TION AND MAINTENANCE SCHEDULE 250 - 380 .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 10-2C PERIODIC LUBRICA TION AND MAINTENANCE SCHEDULE Check transmission oil level ● Change transmission oil ●● ● Check spark plug and electr.
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 10-3C PERIODIC LUBRICA TION AND MAINTENANCE SCHEDULE Check transmission oil level ● Change transmission oil ●● ● Check spark plug and electr.
10-4C PERIODIC MAINTENANCE SCHEDULE 2001/02 after 20 hours or 2000 kilometer 1. service after 10 hours or 1000 kilometer after 4000 kilometer or once a year IF MOTORCYCLE IS USED FOR COMPETITION 4000K.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 10-5C I MPORT ANT C HECKS AND M AINTENANCE TO BE C ARRIED OUT BY THE R IDER Check gear box oil level ● Check brake fluid level ● Check brake pad.
10-6C PERIODIC MAINTENANCE SCHEDULE 2003 after 20 hours or 2000 kilometers 1st service after 10 hours or 1000 kilometers after 4000 kilometer or once a year IF MOTORCYCLE IS USED FOR COMPETITION 4000K.
10-7C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E I MPORT ANT C HECKS AND M AINTENANCE TO BE C ARRIED OUT BY THE R IDER Check gear box oil level ● Check brake fluid level ● Check brake pad.
10-8C R ECOMMENDED INSPECTION OF THE 250/300 EXC AND MXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ( ADDITIONAL ORDER FOR THE KTM WORKSHOP ) Check the reed-type intake valve for wear .
Repair manual 250 / 300 / 380 Art No 3206004 -E WIRING DIAGRAMS MODEL 1999 WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . . .11-2 WIRING DIAGRAM 250 - 380 EGS . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 WIRING DIAGRAM 250 - 380 EXC (USA) .
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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-2C.
11-3C.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-4C.
11-5C.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-6C SPORTMOTORCYCLES.
11-7C SPORTMOTORCYCLES.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-8C.
11-9C SPORTMOTORCYCLES.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-10C.
11-11C.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-12C.
11-13C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E.
11-14C 250-300 EXC 2003.
11-15C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E KTM 250-300 EXC 2003.
11-16C 250/300 EXC 2003.
An important point after buying a device KTM KTM250 SX (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM KTM250 SX yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM KTM250 SX - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM KTM250 SX you will learn all the available features of the product, as well as information on its operation. The information that you get KTM KTM250 SX will certainly help you make a decision on the purchase.
If you already are a holder of KTM KTM250 SX, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM KTM250 SX.
However, one of the most important roles played by the user manual is to help in solving problems with KTM KTM250 SX. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM KTM250 SX along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
