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250/300/380 SX,MXC,EXC
REPAIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
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250 - 380 SX,MXC,EXC REPAIR MANUAL ENGINE
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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
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IMPORTANT INFORMATION/UPDATING 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: 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) 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 5-13 to 5-14 5-13C to 5-14C 7-1 7-1C 7-5C to 7-10C 9-1 9-1C 9-
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EXPLANATION - UPDATING 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 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 3.205.63-E Modelyear 2003 (Engine number with first digit “3“) 1
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INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profe
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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. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorre
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2-1C GENERAL INFORMATION 2 INDEX OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . .2-2 CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM . . . . . . . . . . . . . .2-4 BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . .2-4 SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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: not enough fuel in proportion to air 2 mixture too rich: too much fuel in proportion to air 1 Idling range A 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. To this end, slightly increase the idling speed of the
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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. Essential
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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). start of advance end of a
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2-5C SPECIAL TOOLS – ENGINE 250 / 300 / 380 13 10 17 6 5 14 16 1 4 19 18 26 7 25 8 11 3 9 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 8 544.12.012.000 Holding spanner for flywheel SEM 9 584.29.037.040 Mounting tool inner ring NJ 207 9 584.29.037.043 Mounting tool inner ring NJ 2
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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. THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARI
