250/300/380 SX,MXC,EXC Repair manual KTM 250 / 300 / 380 Art No 3206004 -E REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.
250 - 380 SX,MXC,EXC REPAIR MANUAL ENGINE
1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS 12 13 14 15 16
I M P O RTA N T I N F O R M AT I O N /U P D AT I N G INSTRUCTIONS To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: Art No 3206004 -E 14-20, 26, 28-36, 37, 41, 42, 50, 51, 67, 72-77, 83, 121-126, 127, 134-136, 137, 151-153 Remove page (s) Replace by page (s) Insert page (s) 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 5-13 to 5-14 5-13C to 5-14
E X P L A N AT I O N - U P D AT I N G 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.Manual 3.205.63-E Modelyear 2000 (Engine number with first digit “0“) 2/2000 Art No 3206004 -E 3.210.02-E Updating of Rep.Manual 3.205.63-E Modelyear 2001/2002 (Engine number with first digit “1“) (Engine number with first digit “2“) 3/2001 3.206.004-E Updating of Rep.Manual 3.205.
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.
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in.
2-1C 2 GENERAL INFORMATION INDEX Repair manual 250 / 300 / 380 Art Nr 3206004 -E OPERATING RANGES OF THE CARBURETOR . . . . . CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . CHECKING OF THE SETTING OF THE TVC SYSTEM BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2C OPERATING RANGES OF THE CARBURETOR main jet jet needle jet needle idle jet throttle valve air control screw idle adjusting screw mixture too lean: Art No 3206004 -E not enough fuel in proportion to air 2 mixture too rich: too much fuel in proportion to air 1 Idling range A Repair manual KTM 250 / 300 / 380 Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2. Only make adjustments when the engine is hot.
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 off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of the carburetor setting Always start out from the original carburetor setting.
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. – Connect a rev counter (either to the ignition cable or to the blue/white cable in the electronics box, depending on the rev counter design). – Start engine, accelerate gently and observe when the TVC system starts to advance (tooth segment creeps upwards).
2-5C SPECIAL TOOLS – ENGINE 250 / 300 / 380 13 10 17 6 5 14 16 1 4 7 19 18 26 25 8 11 9 Fig. 1 3 4 5 6 7 8 9 9 10 11 13 14 16 17 18 18 18 19 25 26 Part no. 560.12.001.000 546.29.003.000 560.12.004.000 546.29.009.044 6 276 807 510.12.011.000 544.12.012.000 584.29.037.040 584.29.037.043 510.12.016.000 546.29.012.100 501.12.013.000 501.12.030.000 6 899 785 151.12.017.000 151.12.018.100 151.12.018.000 151.12.018.200 546.29.027.000 0276 179 000 503.29.050.
2-6C CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION ! ! NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET.
3-1C REMOVING AND REFITTING ENGINE INDEX Repair manual 250 / 300 / 380 Art No 3206004 -E REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2C Dismounting the engine – Clean motorcycle thoroughly. – Prop up motorcycle on an appropriate stand. – Remove seat, right side paneling, and tank with spoilers. – Dismount exhaust system. Art No 3206004 -E – Drain coolant, and disconnect radiator hoses from engine. – Dismount engine strut 1. – Disconnect plug-and-socket connector of ignition system and sparkplug connector. 1 – Remove sprocket cover 2 and chain. Repair manual KTM 250 / 300 / 380 2 – Remove footbrake cylinder cover 3.
3-3C – 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. 1 2 – Loosen both hose clamps, and pull caburetor out of carburetor connection boot and intake flange. – Remove transmission-oil drain plug 3 together with sealing ring, and drain the transmission oil. – Remove the 2 screws 4, and dismount clutch slave cylinder.
3-4C Refitting the engine – To 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). 1 Art No 3206004 -E – In order to check the transmission oil level the control screw 2 on the clutch cover is to be removed. Oil should just barely escape from the inspection opening when the motorcycle is in an upright position.
4-1C DISASSEMBLING THE ENGINE Repair manual 250 / 300 / 380 Art No 3206004 -E INDEX DRAINING GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISMOUNTING OF SPROCKET AND SHIFT LEVER . . . . . . . . . . . . . DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON . . . DISMOUNTING OF CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS . . . . . . . . DISMOUNTING OF THE PRIMARY DRIVE . . . . . . . . . . . . . . . . . . .
4-2C – 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. Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch. – Unscrew plug 1, allowing oil to drain.
4-3C – Undo the screws 1 and remove the right control cover. 1 – 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. 3 2 – Remove the 4 collar nuts 4 on cylinder base and remove cylinder. 4 – Cover the crankcase. – Place piston on wooden jig and remove both piston pin locking pins. – Expel piston pin from piston without exerting undue force. Use a suitable mandrel if necessary.
4-4C 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. 1 – Take pressure cap and disc package out of outer clutch hub. – Take thrust bearing 2 off the drive shaft. 2 Dismounting of the primary drive Art No 3206004 -E – Block the primary gear with the gear wheel segment 3 (see illustration).
4-5C Dismounting of kickstarter – Remove circlip 1 and kickstarter intermediate gear. – Carefully release collar screw 2 kickstarter spring is tensioned, release tension on kickstarter spring and unhook spring hanger. 2 ! CAREFULLY CAUTION DANGER RELEASE THE KICKSTARTER SPRING! ! OF INJURY! – Take the complete kickstarter shaft out of the housing. – Take care of the stop disc, which could stay in the housing.
4-6C Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner 1 and undo the collar nut. 1 – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel. Art No 3206004 -E – Undo the 3 screws 2 and remove the stator together with the base plate. 2 Dismounting of the ignition (SEM) Repair manual KTM 250 / 300 / 380 – Hold the flywheel with the special tool and undo the collar nut. – Place protective cap on crankshaft thread.
4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws 1. – Remove intake flange and reed valve housing. 1 Parting of engine housing halves – Top ignition-gear upwards and remove all 11 housing screws. – Loosen the 2 engine fixtures on the engine work stand. – Lift left-hand housing half with suitable tools by on the bosses provided, or part with a few light plastic mallet blows against the countershaft from the right-hand housing half.
4-8C – Pull out the shift rails and swing the shift forks aside. – Pull the shift roller out of the bearing seat. – Remove the shift forks. 1 NOTE: During disassembly, watch out for the shift rollers 1 on the driving pins of the shift forks. They may remain in the shift roller. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. Therefore mark accordingly upon removal. – Remove the 2 pressure springs 2 from the engine case.
5-1C SERVICING ON INDIVIDUAL COMPONENTS 5 Repair manual 250 / 300 / 380 Art No 3206004 -E INDEX WORKING ON THE RIGHT-HAND HOUSING HALF . . WORKING ON THE LEFT-HAND HOUSING HALF . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT WEBS – MEASURE OUTER DIMENSION PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . .
5-2C Working on the right-hand housing half 8 3 7 9 – 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 inwards. Press in new ball bearing to the stop. The open side of the ball cage must be towards the bottom (outside) of the case.
5-3C Working on the left-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. 7 Crankshaft roller bearing 1 Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside). The inner ring on the crankshaft must also be renewed (see paragraph about crankshaft).
5-4C 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. Press the special tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft. – To mount the new inner ring, heat the special tool again to approx. 150°C, engage the inner ring and slip it on the crankshaft journal immediately.
5-5C 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.
5-6C 7 6 5 1 14 13 12 only 250 11 7 10 2 4 3 6 1 9 5 8 9 3 17 2 Art No 3206004 -E 8 18 16 19 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. Check toothing of control rollers for signs of wear. Repair manual KTM 250 / 300 / 380 Gear segments 2 – Check toothing of gear segments and control rollers for signs of wear.
5-7C 14 13 12 11 10 2 3 9 4 9 3 2 8 17 16 – Mount and grease silicon O-rings (15x1,50 mm) 9 on control flap and grease. – Slightly grease the bearing sleeves 3 and plug them on the control flap. – Mount toothed segments 2 (the toothed segment with the cylindrical pin has to be mounted on the right side).
5-8C 6 7 LOCTITE 243 8 13 14 A 12 11 4 3 10 2 9 LOCTITE 243 LOCTITE 243 1 Exhaust control, clutch cover 1 Art No 3206004 -E – Remove screws 1 and take off the bearing support. – Take cup tappet 2, adjusting spring 3 and auxiliary spring 4 out of clutch cover. – Take off water pump cover, remove allen head screw 6 and take off water pump wheel 7. – The centrifugal timer 8 can be pulled out of the bearing. – Clean all parts and check for signs of wear.
5-9C Reed valve housing, intake flange NOTE: Reed paddles 1 gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced. If the reed sealing surfaces 2 of the reed valve housing are also damaged, replace the complete reed valve housing. ! SECURE CAUTION ALL SCREWS OF THE REED VALVE HOUSING WITH ! LOCTITE 243. Velocity insert 3 Check for firm mounting and for signs of damage. LOCTITE 243 Intake flange 4 Check for cracks and other signs of damage.
5-10C 4 3 13,5 mm 7 A 6 11 5 LOCTITE 242 13 14 12 B 8 Art No 3206004 -E 1 2 10 9 Clutch Repair manual KTM 250 / 300 / 380 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. 9 Lining discs 4 Minimum thickness 2.60 mm (0.102 in) / new disc 2.70 mm (0.106 in). Discs must be plane; there must be minimum spacing of 13.50 mm (0.
5-11C Replace outer clutch hub – Drill open the clutch rivets bl in area of retaining bracket bm and remove parts. – Check 8 absorbing elements bn for signs of mechanical damage, replace all 8 where applicable. CAUTION ! ! THE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN. TO ENSURE 11 12 THAT THE OUTER CLUTCH HUB 8 AND RETAINING BRACKET ARE POSITIONED DIRECTLY ON THE PRIMARY GEAR CROWN bo, THE PARTS MUST BE HELD IN POSITION UNDER TENSION WITH THE CLUTCH RIVETTING TOOL C WHILE RIVETING.
5-12C 5 E 6 D LOCTITE 243 4 C 7 8 10 LOCTITE 243 LOCTITE 243 1 A LOCTITE 243 3 1 2 3 B Art No 3206004 -E 1 Shift mechanism Shift forks 1 Check shift fork blades A and shift roller driving pin B for signs of wear. 0,40 0,80 mm Shift roller 2 Check shift grooves for wear. Check position of shift roller in grooved ball bearings 3. Slide plate 4 Check slide plate at meshing points C for wear. Check return surface D for wear (renew, if strongly notched).
5-13C Ignition (Kokusan) 2K-1 General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Make sure to select the correct measuring range when performing measurements. Spark plug – Set the electrode distance.
5-14C Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Make sure to select the correct measuring range when performing measurements. Spark plug 110 mm – Set the electrode distance.
5-15C Transmission 11 10 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 including idler gears – Shift dogs and gear wheels – Tooth faces of all gears – Tooth profile of mainshaft and countershaft and correspondending gears – Easy operation of gear-change Carefully clean components and replace damaged components.
5-16C Transmission 13 12 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 including idler gears – Shift dogs and gear wheels – Tooth faces of all gears – Tooth profile of mainshaft and countershaft and correspondending gears – Easy operation of gear-change Carefully clean components and replace damaged components.
5-17C LOCTITE 243 7 8 1 LOCTITE 243 9 6 3 5 4 10 2 LOCTITE 648 Kickstarter A 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. 3 Kickstarter shaft 4 Check for signs of wear and damage. 5 For changing the locking pawl, press bearing needle 9 out of the kickstarter shaft.
6-1C 6 ASSEMBLING THE ENGINE Repair manual 250 / 300 / 380 Art No 3206004 -E INDEX CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE ENGINE HOUSING . . . . . . . . . . . . . . . MOUNTING SHIFT MECHANISM . . . . . . . . . . . . . . . . . . MOUNTING KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . MOUNT PRIMARY DRIVE AND CLUTCH . . . . . . . . . . . . .
6-2C – Secure the right-hand housing half in the engine work stand. Crankshaft – Insert crankshaft from above through grooved ball bearing and push carefully as far as stop. ! WHEN CAUTION ! PUSHING IN CRANKSHAFT, MAKE SURE CONROD IS FACING CYLINDER. Transmission – Grease the driving pins of the shift forks and mount the shift rollers 1. – Fix the lower stop disc on the countershaft with a small amount of grease.
6-3C – Fix the 4 pressure springs 1 with ample amounts of grease in the gearshift rails. 1 – 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. NOTE: It must now be possible to gently turn gear shafts. 2 – Slide stop disc 2 (20.2x 33x1.5 mm) on the drive shaft, and stop disc 3 (25.7x40 x1.5 mm) on the countershaft.
6-4C Mounting shift mechanism 1 – – – – 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. – Hook locking spring 3 to lever. The other end of the retaining spring must abut the casing nose B. 2 B 3 LOCTITE 243 4 6 – Mount roller locking device 4 (plastic part) to shift roller.
6-5C Mount primary drive and clutch 1 – Grease 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. – Put the inner ring onto the main shaft with the collar facing downwards, then mount the oiled needle cage 2. 2 – Mount outer clutch hub and stop disc 3. 3 – Apply Loctite 243 to the thread of the main shaft.
6-6C Mounting clutch discs and pressure cap – Oil the thrust bearing 1, and slide it over the drive shaft. 1 – Oil lining discs before mounting. – Beginning with one lining disc, mount alternately 9 lining discs (≠ 2.70 mm / 0.10 in) and 8 intermediate discs (≠ 1.20 mm / 0.047 in), with a lining disc forming the final layer upwards. – Place pressure cap into position; fit clutch springs, spring retainer and collar screws. – Tighten the collar screws crosswise. Do not apply more than 6 Nm (4.5 ft.lb.
6-7C 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 downwards (see sketch). – Mount cylinder base gaskets. – Place piston on selfmade wooden stand and position piston ring. – Place on preassembled cylinder, remove wooden stand and tighten cylinder down crosswise, using two nuts.
6-8C Adjusting control flap (dimension “Z“) control flap 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.
6-9C Mounting steering covers – Mount the right-hand control cover 1, and fix it with 3 screws. 1 – Place gasket in position and fix left-hand steering cover 2 on cylinder. 2 Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O-rings in grooves. – Mount cylinder head with water nozzle on the exhaust side. – Oil the collar nuts at threads and contact faces.
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. 1 2 – Slide sprocket onto the countershaft with the collar facing inward, and fix it with the circlip 3 (sharp edge facing outward). 3 Mounting the ignition (Kokusan) Art No 3206004 -E – Insert the woodruff key into the crankshaft. – Apply Loctite 243 to 3 screws 4 and fix the stator (do not yet tighten the 3 screws all the way).
6-11C Mounting the ignition (SEM) 1 2 3 – – – – – – – 4 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. Mount the rotor. Mount the detent edged ring and the nut. Hold the rotor with the holding spanner and tighten the nut with 60 Nm (45 ft.lb.).
7-1C 7 ELECTRICAL INDEX Repair manual 250 / 300 / 380 Art No 3206004 -E CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN) CHECKING THE VOLTAGE REGULATOR (KOKUSAN) . . . . . . . . . . CHECKING THE VOLTAGE REGULATOR (TYMPANIUM) . . . . . . . . CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION COIL (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION COIL (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI UNIT . . . . . . .
7-2C 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). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage. Nominal value: 14.0 – 15.
7-3C 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. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease.
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.m. and read off the voltage. Nominal value: 14.0 - 15.0 V In the case of a significant deviation from the nominal value: – Check the capacitor – Check the connector between the stator and the voltage regulatorrectifier and between the voltage regulator and the cable tree. – Check the stator.
7-5C STATIC IGNITION VALUES 250-380 SX, EXC (KOKUSAN 2K-1, 2K-3, 2K-4) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground – light switch turned off – the gap between the rotor and pulse generator must be set to 0.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 7-6C SPORTMOTORCYCLES 5 2 250-380 EXC 2000 4 1 3
7-7C STATIC GENERATOR VALUES 250-380 EXC (KOKUSAN 2K-3) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off – kick the kick starter forcefully at least 5 times for each measurement 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 and
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 7-8C SPORTMOTORCYCLES 10 250-380 EXC 2000 6 9 11
7-9C STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC USA (KOKUSAN 2K-2) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground – light switch turned off – the gap between the rotor and pulse generator must be set to 0.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 7-10C 250 EXC 2001 5 4 3 2 1 6
8-1C TROUBLE SHOOTING INDEX Repair manual 250 / 300 / 380 Art No 3206004 -E TROUBLE SHOOTING 250 - 380 . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 order to find the cause of error.
8-3C TROUBLE CAUSE Engine has not enough power Reed paddles tensionless or damaged, surface of reed valve housing damaged Replace reed paddles or reed valve housing Wear Overhaul engine Electronical ignition timing faulty Check ignition system Carburetor overflows if level adjust too high, float needle seating is dirty or enlarged Clean carburetor, if necessary replace float needle and adjust level Loose carburetor jets Tighten jets Incorrect heat range spark plug or low quality spark plug Ref
9-1C 9 TECHNICAL SPECIFICATIONS Repair manual 250 / 300 / 380 Art No 3206004 -E INDEX MODEL 1999 ENGINE 250 - 380 USA . ENGINE 250 - 380 . . . . . CHASSIS 250 - 380 . . . . CARBURETOR SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Gear lubrication Available chain sprockets Coolant Ignition system Generator output Carburetor Air-filter TVC start open TVC fully open Primary drive Clutch Transmission Design Piston displacement Bore / stroke Fuel Oil / gasolin ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring (upper edge piston Dimension "X" upper edge cylinder) Ignition timing Spark plug Electrode gap of the Dimension "Z" (height control flap)
9-3C TIGHTENING TORQUES Flange bolts - cylinder-head M8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and cover bolts M6 60 Nm (44 ft.lb) 8 Nm Swingarm pivot M 14 Flat head bolt release plate kickstarter M 6x16 Other bolts M6 M8 M 10 (6 ft.lb) 100 Nm (74 ft.lb) Loctite 648 19 Nm (14 ft.
300 EXC, EGS 380 SX 249 ccm 297 ccm 368 ccm 78 / 77 mm (3 / 2.98 in) 15:29 17:27 19.25 21:23 23:21 no generator Generator output Carburetor Air-filter KOKUSAN 2K-1 Ignition system Coolant ailable chain sprockets Gear lubrication Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Transmission Clutch NGK BR 8 ECM 5300/min 7750/min 46 mm (1.7 in) 0.6 mm (0.
9-5C TIGHTENING TORQUES Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Swingarm pivot Flat head bolt release plate kickstarter Other bolts M M M M M M M M M M M 8 10 12x1 18x1.5 18x1.5 6 14 6x16 6 8 10 35 35 60 Loctite 243 150 Loctite 243 100 8 100 Loctite 648 19 10 25 45 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm (25 (25 (44 (110 (74 (6 (74 (14 (7 (19 (33 ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.
9-6C TECHNICAL SPECIFICATIONS CHASSIS 250/380SX 250 / 300 / 380 SX / MXC / EXC / EGS 250/300/380 MXC Frame WP Extreme Ø 50 mm Wheel travel front/rear 280 / 320 mm (11.0 / 12.6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated Front tires Air pressure offroad Air press.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004 -E 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Gear lubrication Available chain sprockets Coolant Ignition system Generator output Carburetor Air-filter TVC start open TVC fully open Primary drive Clutch Transmission Engine Design Piston displacement Bore / stroke Fuel Oil / gasolin ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring edge piston Dimension "X" (upper upper edge cylinder) Ignition timing Spark plug Electrode gap of the Dimension "Z" (height control
9-11C TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head M8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and cover bolts M6 Swingarm pivot M 14 Flat head bolt release plate kickstarter M 6x16 Other bolts M6 M8 M 10 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 100 Nm (74 ft.lb) Loctite 648 19 Nm (14 ft.
Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Gear lubrication ailable chain sprockets Coolant Ignition system Generator output Carburetor Air-filter TVC start open TVC fully open Primary drive Clutch Transmission Engine Design Piston displacement Bore / stroke Fuel Oil / gasoline ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring edge piston Dimension "X" (upper upper edge cylinder) Ignition timing Spark plug Electrode gap of the Dimension "Z" (height control
9-13C TIGHTENING TORQUES Flange bolts - cylinder-head M8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and cover bolts M6 Swingarm pivot M 14 Flat head bolt release plate kickstarter M 6x16 Other bolts M6 M8 M 10 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 100 Nm (74 ft.lb) Loctite 648 19 Nm (14 ft.
9-14C TECHNICAL SPECIFICATIONS CHASSIS 250/380 SX 250/300/380 MXC Frame White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm (11,3/12,6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004 -E 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft LSCHR LD POS HD = = = = AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ Luftregulierschraube offen Leerlaufdüse Clip Position von oben Hauptdüse Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004 -E 5. 3. 1.
Available chain sprockets Coolant Ignition system Generator output Carburetor Air-filter Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Gear lubrication TVC start open TVC fully open Primary drive Clutch Transmission Engine Design Piston displacement Bore / stroke Fuel Oil / gasolin ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring edge piston Dimension "X" (upper upper edge cylinder) Ignition timing Spark plug Electrode gap of the Dimension "Z" (height contro
9-20C TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Swingarm pivot Flat head bolt release plate kickstarter Other bolts M8 M 10 M 12x1 M 18x1.5 M 18x1.5 M6 M 14 M 6x16 M6 M8 M 10 35 35 60 Loctite 243 150 Loctite 243 100 8 100 Loctite 648 19 10 25 45 Nm (25 ft.lb) Nm (25 ft.lb) Nm (44 ft.lb) Nm (110 ft.lb) Nm (74 ft.lb) Nm (6 ft.lb) Nm (74 ft.lb) Nm (14 ft.lb) Nm (7 ft.
Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Gear lubrication ailable chain sprockets Coolant Ignition system Generator output Carburetor Air-filter TVC start open TVC fully open Primary drive Clutch Transmission Engine Design Piston displacement Bore / stroke Fuel Oil / gasoline ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring edge piston Dimension "X" (upper upper edge cylinder) Ignition timing Spark plug Electrode gap of the Dimension "Z" (height control
9-22C TIGHTENING TORQUES Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Swingarm pivot Flat head bolt release plate kickstarter Other bolts M8 M 10 M 12x1 M 18x1.5 M 18x1.5 M6 M 14 M 6x16 M6 M8 M 10 35 35 60 Loctite 243 150 Loctite 243 100 8 100 Loctite 648 19 10 25 45 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm (25 (25 (44 (110 (74 (6 (74 (14 (7 (19 (33 ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.
9-23C TECHNICAL SPECIFICATIONS CHASSIS 250/380 SX 250/300/380 MXC Frame Fork White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 7 Zerstäuber= 6 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 6 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 6 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 6 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004
Available chain sprockets Coolant Ignition system Generator output Carburetor Air-filter Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Gear lubrication TVC start open TVC fully open Primary drive Clutch Transmission Engine Design Piston displacement Bore / stroke Fuel Oil / gasolin ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring edge piston Dimension "X" (upper upper edge cylinder) Ignition timing Spark plug Electrode gap of the Dimension "Z" (height contro
9-29C TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head M8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and cover bolts M6 Swingarm pivot M 14 Flat head bolt release plate kickstarter M 6x16 Other bolts M6 M8 M 10 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 100 Nm (74 ft.lb) Loctite 648 19 Nm (14 ft.
KOKUSAN 2K-1 no generator 15:29 17:27 19.25 21:23 23:21 0,8 l engine oil 20W-40 (Shell Advance VSX4) 15:29 18:26 19:24 21:23 23:21 0,8 l engine oil 20W-40 (Shell Advance VSX4) 13t / 14t / 15t for chain 5/8 x 1/4" 1.
9-31C TIGHTENING TORQUES Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Swingarm pivot Flat head bolt release plate kickstarter Other bolts M8 M 10 M 12x1 M 18x1.5 M 18x1.5 M6 M 14 M 6x16 M6 M8 M 10 35 35 60 Loctite 243 150 Loctite 243 100 8 100 Loctite 648 19 10 25 45 Nm (25 Nm (25 Nm (44 Nm (110 Nm (74 Nm (6 Nm (74 Nm (14 Nm (7 Nm (19 Nm (33 ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.
9-32C TECHNICAL SPECIFICATIONS CHASSIS 250/380 SX 250/300/380 SX, MXC, EXC 2002 250/300/380 MXC Frame 250/300/380 EXC Central chrome-moly-steel frame Fork White Power – Up Side Down 48 MA Wheel travel front/rear White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 5 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 5 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 5 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber =5 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear Gear lubrication ailable chain sprockets Coolant Ignition system Generator output Ignition system USA (MXC) Generator output Carburetor Air- filter TVC start open TVC fully open Primary drive Clutch Transmission Engine Desgin Piston displacement Bore / stroke Fuel Oil / gasolino ratio Crankshaft bearing Connecting rod bearing Piston pin bearing Piston Piston ring (upper edge piston Dimension “X“ upper edge cylinder) Ingition timing Spark plug Electro
9-38C TIGHTENING TORQUES Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Flat head screw release plate kickstarter Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Swingarm pivot Other screws M8 M 10 M 12x1 M 6x16 M 18x1.5 M 18x1.5 M6 M 14 M6 M8 M 10 35 35 60 Loctite 648 19 Loctite 243 150 Loctite 243 100 8 100 10 25 45 Nm (25 Nm (25 Nm (44 Nm (14 Nm (110 Nm (74 Nm (6 Nm (74 Nm (7 Nm (19 Nm (33 ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.
9-39C TECHNICAL SPECIFICATIONS CHASSIS 250/300 MXC, EXC 2003 250/300 MXC Frame Fork White Power – Up Side Down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.
9-40C TIGHTENING TORQUES Collar screw, front wheel spindle Brake caliper, front CHASSIS M 24x1,5 M8 40 Nm Loctite 243 + 25 Nm Brake disk, front M 6 10.
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 5 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD Art No 3206004
LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD LSCHR LD NADEL POS HD 2300 m 7500 ft 1500 m 5000 ft 750 m 2500 ft 300 m 1000 ft AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ AS IJ NEEDLE POS MJ LSCHR = Luftregulierschraube offen LD = Leerlaufdüse POS = Clip Position von oben HD = Hauptdüse Schieber= 6,5 Zerstäuber= 5 mm Meeresniveau Sea level 301 m 1001 ft 751 m 2501 ft 1501 m 5001 ft 2301 m 7501 ft LSCHR LD NADEL POS HD 5. 3. 1.
10-1C LUBRICATION AND MAINTENANCE SCHEDULE INDEX MODEL 1999 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-2 MODEL 2000 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-3 MODEL 2001/2002 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-4 Repair manual 250 / 300 / 380 Art No 3206004 -E MODEL 2003 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 300 . . . . . . .
10-2C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E ● ● ● ● at least once a year after 4000 km (2500 miles) or once a year Check transmission oil level Change transmission oil Check spark plug and electrode gap Change spark plug Functional testing of the exhaust control system Check intake manifold for leaks and cracks Drain and clean carburetor float chamber Adjust idling Check breather hoses of engine case and gas tank for correct position without buckles Clean and check airfilter element, bo
10-3C after 4000 km (2500 miles) or once a year at least once a year Check transmission oil level after washing AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE before each start 125-380 6.
10-4C PERIODIC MAINTENANCE SCHEDULE 2001/02 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Check gear box oil level Change gear box oil Check spark plugs, adjust distance between electrodes Renew spark plugs Check the carburettor connection boot for cracks and leaks Check idle speed setting Check that vent hoses are not damaged or bent Check cooling system for leaks, check quantity of anti freeze Check exhaust system for leaks
10-5C CARRIED OUT BY THE Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean fork dust bellows regulary Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Drain and cl
10-6C PERIODIC MAINTENANCE SCHEDULE 2003 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A clean motorcycle can be checked more quickly which saves money! Check gear box oil level Change gear box oil Check spark plugs, adjust distance between electrodes Renew spark plugs Check the carburetor connection boot for cracks and leaks Check idle speed setting Check that vent hoses are not damaged or bent Check cooling system for leaks, check quantity of antifreeze Check exhaust system for leaks and fi
10-7C CARRIED OUT BY THE Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Empty and clean
10-8C RECOMMENDED USED 250/300 EXC AND MXC ENGINE FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) INSPECTION OF THE Check the reed-type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the pist
11-1C WIRING DIAGRAMS INDEX MODEL 1999 WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . . .11-2 WIRING DIAGRAM 250 - 380 EGS . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 WIRING DIAGRAM 250 - 380 EXC (USA) . . . . . . . . . . . . . . . . . . . .11-5 Repair manual 250 / 300 / 380 Art No 3206004 -E MODEL 2000 WIRING DIAGRAM 250 - 300 EXC USA . . . . . . . . . . . . . . . . . . . . .11-6 WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . . .
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
SPORTMOTORCYCLES Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-6C
11-7C SPORTMOTORCYCLES
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-8C
SPORTMOTORCYCLES 11-9C
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
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-13C
11-14C 250-300 EXC 2003
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-15C KTM 250-300 EXC 2003
250/300 EXC 2003 11-16C
