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250/300/380 SX,MXC,EXC
REPAIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at
Related Manuals for KTM EXC
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Motorcycle KTM 125 EXC, EXC SIX DAYS, 200 XC, XC-W, EXC, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, XC-W, EXC-E, EXC-E SIX DAYS Owner’s Manual
Ktm owner’s manual motorcycle 125 exc, exc six days 200 xc, xc-w, exc 250 xc, xc-w, exc, exc six days 300 xc, xc-w, exc-e, exc-e six days (74 pages)
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Summary of Contents for KTM EXC
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Page 1
250/300/380 SX,MXC,EXC REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.at… -
Page 3
250 — 380 SX,MXC,EXC REPAIR MANUAL ENGINE… -
Page 5: Table Of Contents
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…
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Page 7
5-13 to 5-14 10-1 11-1 KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -
Page 9
3.206.004-E Updating of Rep.Manual 3.205.63-E Modelyear 2003 (Engine number with first digit “3“) Modification / Updating: Technical Specification, Periodic Maintenance Schedule, Wiring Diagrams P D AT I N G 250 / 300 / 380 SX, MXC, EXC 11/1998 2/2000 3/2001 11/2002 Edition 11/2002… -
Page 11
„NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an on going total reengineered quality plan for a brighter tomorrow. -
Page 13
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 –… -
Page 14: Table Of Contents
2-1C GENERAL INFORMATION INDEX OPERATING RANGES OF THE CARBURETOR ….2-2 CARBURETOR ADJUSTMENT ……2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM .
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Page 16: Operating Ranges Of The Carburetor
OPERATING RANGES OF THE CARBURETOR mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve. This range is influenced by the position of the air control screw .
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Page 17: Carburetor Adjustment
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 –…
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Page 18: Bleeding Of The Hydraulic Clutch
Make sure that the oil does not overflow. CAUTION – H AVING COMPLETED THE BLEEDING PROCEDURE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT – KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS – A…
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Page 19: Special Tools — Engine
2-5C SPECIAL TOOLS – ENGINE Fig. 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 179 000 503.29.050.000 250 / 300 / 380 Description Universal engine work stand Clutch holder…
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Page 20: 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. EVER CLEAN YOUR MOTORCYCLE WITH A HIGH ELECTRICAL COMPONENTS CONNECTORS…
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Page 22: Removing And Refitting Engine
3-1C REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ……. . .3-2 REFITTING THE ENGINE .
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Page 24
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. – Drain coolant, and disconnect radiator hoses from engine. – Dismount engine strut –… -
Page 25
3-3C – Loosen the 3 screws, and remove intermediate flange chamber KTC system together with O-ring. – Remove engine fastening screw – 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. -
Page 26
Refitting the engine – To install the engine, reverse the steps for removing the engine. Filling in of transmission oil: – Remove the plug and top up with engine oil 15W-50 (i. e. MOTOREX TOP SPEED 4T). – In order to check the transmission oil level the control screw clutch cover is to be removed. -
Page 28: Disassembling The Engine
4-1C DISASSEMBLING THE ENGINE INDEX DRAINING GEAR OIL ……..4-2 DISMOUNTING OF SPROCKET AND SHIFT LEVER .
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Page 30
– 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. -
Page 31
4-3C – Undo the screws and remove the right control cover. – Remove the securing clip of the ball socket socket from the adjusting lever. – Remove gasket of the control cover. – Remove the 4 collar nuts – Cover the crankcase. –… -
Page 32
Dismounting of pressure cap and clutch discs – Loosen collar screws wedging of discs as springs expand. – Remove collar screws, springs and spring retainers. – Take pressure cap and disc package out of outer clutch hub. – Take thrust bearing off the drive shaft. -
Page 33
4-5C Dismounting of kickstarter – Remove circlip – Carefully release collar screw tension on kickstarter spring and unhook spring hanger. AREFULLY RELEASE THE KICKSTARTER SPRING – Take the complete kickstarter shaft out of the housing. – Take care of the stop disc, which could stay in the housing. Dismounting of the shift lock –… -
Page 34
Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel. – Undo the 3 screws and remove the stator together with the base plate. -
Page 35
4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws – Remove intake flange and reed valve housing. 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. –… -
Page 36
– 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 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. -
Page 37: Table Of Contents
SERVICING 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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Page 39
Working 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 Press old grooved ball-bearing inwards. Press in new ball bearing to the stop. -
Page 40
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. Crankshaft roller bearing Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside). -
Page 41: Crankshaft
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.
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Page 42: Checking Cylinder For Wear
5-5C 10mm 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. Engine Cylinder Ø 67,500 — 67,512 67,513 — 67,525 72,000 — 72,012 72,013 — 72,025 78,000 — 78,012…
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Page 43: Cylinder Preassembly
only 250 Cylinder exhaust control system Dismantle and clean all exhaust control components, check for signs of wear and damage. Control rollers – Check clearance of bearings. Remove oil-derived deposits. Check toothing of control rollers for signs of wear. Gear segments –…
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Page 44
5-7C – Mount and grease silicon O-rings (15×1,50 mm) – Slightly grease the bearing sleeves – Mount toothed segments (the toothed segment with the cylindrical pin has to be mounted on the right side). – On the right-hand side, mount bearing bushing spring with short leg on outside and spring sleeve –… -
Page 45: Exhaust Control, Clutch Cover
LOCTITE 243 LOCTITE 243 Exhaust control, clutch cover – Remove screws and take off the bearing support. – Take cup tappet , adjusting spring clutch cover. – Take off water pump cover, remove allen head screw water pump wheel – The centrifugal timer can be pulled out of the bearing.
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Page 46: Reed Valve Housing, Intake Flange
5-9C Reed valve housing, intake flange NOTE: Reed paddles gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced. If the reed sealing surfaces of the reed valve housing are also damaged, replace the complete reed valve housing. CAUTION 243.
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Page 47
5-10C 13,5 mm LOCTITE 242 Clutch Thrust bearing check for wear Push rod Check for wear. Minimum length: 199 mm (new: 199.80 mm) Clutch springs New spring length 42,5 mm / 1.7 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable. 9 Lining discs Minimum thickness 2.60 mm (0.102 in) / new disc 2.70 mm (0.106 in). -
Page 48: Replace Outer Clutch Hub
5-11C Replace outer clutch hub – Drill open the clutch rivets remove parts. – Check 8 absorbing elements replace all 8 where applicable. HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN THAT THE OUTER CLUTCH HUB ON THE PRIMARY GEAR CROWN TENSION WITH THE CLUTCH RIVETTING TOOL in area of retaining bracket for signs of mechanical damage,…
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Page 49: Shift Mechanism
LOCTITE 243 LOCTITE 243 0,40 — 0,80 mm LOCTITE 243 Shift mechanism Shift forks Check shift fork blades and shift roller driving pin Shift roller Check shift grooves for wear. Check position of shift roller in grooved ball bearings Slide plate Check slide plate at meshing points Check return surface for wear (renew, if strongly notched).
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Page 50: Ignition (Kokusan)
5-13C Kokusan 2K-1/2K-4 Kokusan 2K-2 Kokusan 2K-3 Ignition (Kokusan) 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.
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Page 51: Ignition (Sem)
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.
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Page 52: Assembly Mainshaft
5-15C Transmission 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 –…
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Page 53: Assembly Countershaft
Transmission 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 –…
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Page 54: Assemble Of Kickstarter Shaft
5-17C LOCTITE 243 LOCTITE 243 Kickstarter Starter gear Check clearance of starter gear. Starter intermediate gear Check clearance of starter intermediate gear. Locking pawl Check for signs of wear and damage. Kickstarter shaft Check for signs of wear and damage. For changing the locking pawl, press bearing needle kickstarter shaft.
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Page 55: Table Of Contents
6-1C ASSEMBLING THE ENGINE INDEX CRANKSHAFT ………6-2 TRANSMISSION .
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Page 57
– 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. HEN PUSHING IN CRANKSHAFT Transmission – Grease the driving pins of the shift forks and mount the shift rollers –… -
Page 58: Assembling The Engine Housing
6-3C M6 x … – Fix the 4 pressure springs 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. NOTE: It must now be possible to gently turn gear shafts.
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Page 59: Mounting Shift Mechanism
Mounting shift mechanism – Place locating spring with bent leg upwards into engine housing. – Insert collar sleeve into spring with collar upwards. – Coat collar screw – Insert locating lever screw. – Hook locking spring must abut the casing nose –…
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Page 60: Mount Primary Drive And Clutch
6-5C Mount primary drive and clutch – Grease crankshaft seal ring. – Put the oiled O-ring (25×1.50 mm) onto the crankshaft and mount the distance bushing with the chamfer facing the crank web. – Insert woodruff key into crankshaft. – Place primary gear –…
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Page 61: Mounting Clutch Discs And Pressure Cap
M6x … Mounting clutch discs and pressure cap – Oil the thrust bearing , and slide it over the drive shaft. – 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.
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Page 62: Mounting Piston And Cylinder
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).
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Page 63
control flap 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. 250 Model 1999 : 48,0 mm 250 Model 2000 : 50,5 mm 250 ab Model 2001 : 49,5 mm 300 : 46,0 mm… -
Page 64: Mounting Steering Covers
6-9C Mounting steering covers – Mount the right-hand control cover – Place gasket in position and fix left-hand steering cover 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. –…
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Page 65: Mounting Engine Sprocket
Mounting engine sprocket – Lubricate O-ring with oil and slide over counter shaft. – Slide distance bushing in position so that O-ring is in correct position. – Slide sprocket onto the countershaft with the collar facing inward, and fix it with the circlip (sharp edge facing outward).
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Page 66: Mounting The Ignition (Sem)
6-11C Mounting the ignition (SEM) – Insert woodruff key into crankshaft. – Apply Loctite 243 to the threads of the 3 screws – Mount base plate – Mount the cable guide – Mount the rotor. – Mount the detent edged ring and the nut. –…
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Page 67
CHECKING THE CAPACITOR (MOD. 2000) ….7-4 STATIC IGNITION VALUES 250 — 380 SX, EXC ….7-5 STATIC GENERATOR VALUES 250 — 380 EXC . -
Page 69
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. -
Page 70
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 –… -
Page 71
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. In the case of a significant deviation from the nominal value: –… -
Page 72
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 –… -
Page 73
7-6C 250-380 EXC 2000 S P O R T M O T O R C Y C L E S… -
Page 74
NOTE: – the black measuring lead applied to the ground. – 300/380 USA corresponds to 300/380 EXC Europe but with less accessories (blinkers, horn, no capacitor installed). Features no rectifi- cation, only an over-voltage regulation. (also see circuit diagram on opposite… -
Page 75
7-8C 250-380 EXC 2000 S P O R T M O T O R C Y C L E S… -
Page 76
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 –… -
Page 77
7-10C 250 EXC 2001… -
Page 79
8-1C TROUBLE SHOOTING INDEX TROUBLE SHOOTING 250 — 380 ……8-2… -
Page 81: 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. TROUBLE Engine fails to start Operating error…
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Page 82
8-3C TROUBLE Engine has not enough Reed paddles tensionless or dama- power ged, surface of reed valve housing damaged Wear Electronical ignition timing faulty Engine revs not high and Carburetor overflows if level adjust running with four stroke too high, float needle seating is cycle dirty or enlarged Loose carburetor jets… -
Page 83: Technical Specifications
9-1C TECHNICAL SPECIFICATIONS INDEX MODEL 1999 ENGINE 250 — 380 USA ……..9-2 ENGINE 250 — 380 .
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9-2C… -
Page 86
60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 100 Nm (74 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.08 mm (380) 380 SX, MXC, EXC Keihin PWK 38 070598 170(168,172,175) 48(45,50) NOZ H(NOZ G,NOZ I) 1,5 Umdr. -
Page 87
9-4C… -
Page 88
100 Nm (74 ft.lb) (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 380 EGS 380 SX, MXC, EXC AUSTRALIA Keihin PWK 38 Keihin PWK 38 070598 060598 170(168,172,175) 175(168,170,172) 48(45,50) 45(48,50) NOZ H(NOZ G,NOZ I) NOZ G(NOZ H,NOZ I) 1,5 Umdr. -
Page 89
TECHNICAL SPECIFICATIONS CHASSIS 250 / 300 / 380 SX / MXC / EXC / EGS ‘99 250/380SX Frame Fork Wheel travel front/rear Rear suspension Front brake Rear brake Front tires 80/100 — 21“ 51M – Air pressure offroad 1.0 bar (14 psi) Air press. -
Page 90
9-7C… -
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9-8C… -
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9-9C… -
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9-10C… -
Page 94
10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.06 mm (300) 0.08 mm (380) 300 MXC, EXC 380 SX, MXC, EXC Keihin PWK 38 AG Keihin PWK 38 AG 140499 150499 175 (172,178) 170 (168,172) 45 (48) -
Page 95
9-12C… -
Page 96
Loctite 648 19 Nm (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.08 mm (380) 250/300 EXC 380 SX, MXC, EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 150499 050799 170 (168,172) -
Page 97
Rebound adjuster Spring PDS3–250 Spring preload 5 mm (0.2 in) 250/300/380 SX, MXC, EXC 2000 250/300/380 MXC Central chrome-moly-steel frame White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø… -
Page 98
9-15C 21.06.99… -
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9-16C 21.06.99… -
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9-17C 21.06.99… -
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9-18C 21.06.99… -
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9-19C… -
Page 104
Loctite 648 19 Nm (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 300 MXC, EXC 380 SX, MXC, EXC Keihin PWK 38 AG Keihin PWK 38 AG 050300 070300 175 (172,178) 170 (168,172) 45 (48) 45 (48) -
Page 105
9-21C… -
Page 106
Ø 2.5 new = 43 mm, minimum length = 42 mm 0.5 mm 0.5 mm as required 0.2/0.4/ 0.5 / 0.75 mm O-rings 250 EXC AUS 300 EXC AUS throttled throttled Keihin PWK 38 AG Keihin PWK 38 AG 040300… -
Page 107
Rebound adjuster Spring PDS7–265 Spring preload 5 mm (0.2 in) 250/300/380 SX, MXC, EXC 2001 250/300/380 MXC Central chrome-moly-steel frame White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø… -
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9-24C… -
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9-25C… -
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9-26C… -
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9-27C… -
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9-28C… -
Page 113
35 Nm (25 ft.lb) 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 380 SX, MXC, EXC Keihin PWK 38 AG 050201 170 (168,172) 45 (48) NOZ G (NOZ H) – –… -
Page 114
9-30C… -
Page 115
NOZ E (NOZ F/D) Needle position from top Slide Air adjustment screw open Performance restrictor – Power jet jet – BASIC CARBURETOR SETTING 250 EXC USA Carburetor Keihin PWK 38 AG Carburetor setting number 030201 Main jet 178 (175,180) Idling jet 45 (48) -
Page 116
Rebound adjuster Spring PDS7–260 Spring preload 4 mm (0.16 in) 250/300/380 SX, MXC, EXC 2002 250/300/380 MXC Central chrome-moly-steel frame 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Disc brake with carbon-steel brake disc Ø… -
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9-33C… -
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9-34C… -
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9-35C… -
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9-36C… -
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9-37C… -
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(6 ft.lb) 100 Nm (74 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 300 EXC AUS 300 MXC / EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 130202 150202 175 (172,178) 175 (172,178) -
Page 123
5 mm (0.20in) Air chamber length 110 mm (4,3 in) Fork oil SAE 5 250/300 MXC, EXC 2003 250/300 MXC Central chrome-moly-steel frame White Power – Up Side Down 48 MA 300/335 mm (11.8/13.2 in) WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø… -
Page 124
9-40C Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, fork stubs Collar nut, rear wheel spindle Hexagon nut, swing arm bolt Hexagon collar screw, handlebar clamp Allan head screw, handlebar support Shock absorber, top Shock absorber, bottom… -
Page 125
9-41C… -
Page 126
9-42C… -
Page 127
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 . -
Page 129
PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE 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… -
Page 131
PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE 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… -
Page 132
NTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN AINTENANCE WORK DONE BY AINTENANCE ORK THAT CAN BE CARRIED OUT BY EXTRA ORDER AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER 250/300/380 SX/MXC/EXC 1. service after after after 10 hours… -
Page 133
10-5C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER 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… -
Page 134: Periodic Maintenance Schedule
NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN AINTENANCE WORK DONE BY AINTENANCE ORK THAT CAN BE CARRIED OUT BY EXTRA ORDER AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER 250/300 MXC/EXC 1st service after after after 10 hours…
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Page 135
10-7C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER 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… -
Page 136
Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED. 250/300 EXC ADDITIONAL ORDER FOR THE hours 250/300 EXC… -
Page 137: 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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Page 139: 250-380 Exc Wiring Diagram
11-2C…
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Page 140
11-3C… -
Page 141
11-4C… -
Page 142
11-5C… -
Page 143
11-6C… -
Page 144
11-7C S P O R T M O T O R C Y C L E S… -
Page 145
11-8C… -
Page 146: 380 Exc 2000 Wiring Diagram
11-9C…
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Page 147
11-10C… -
Page 148
11-11C… -
Page 149
11-12C… -
Page 150
11-13C… -
Page 151
11-14C 250-300 EXC 2003… -
Page 152
11-15C KTM 250-300 EXC 2003… -
Page 153
11-16C…
Сборник руководств (92 штуки) на английском языке по эксплуатации и техническому обслуживанию мотоциклов KTM 2000-2014 годов выпуска.
- Издательство: KTM-Sportmotocycle AG
- Год издания: 1999-2013
- Страниц: —
- Формат: PDF
- Размер: 341,5 Mb
Руководство на английском языке по эксплуатации и техническому обслуживанию квадроциклов KTM 450 XC/525 XC 2008 года выпуска.
- Издательство: KTM-Sportmotocycle AG
- Год издания: 2007
- Страниц: 103
- Формат: PDF
- Размер: 6,6 Mb
Руководство на английском языке по эксплуатации и техническому обслуживанию квадроциклов KTM 525 XC 2012 года выпуска.
- Издательство: KTM-Sportmotocycle AG
- Год издания: 2011
- Страниц: 207
- Формат: PDF
- Размер: 3,9 Mb
Руководство на английском и немецком языках по техническому обслуживанию и ремонту мотоциклов KTM 250 GS/250 MX/250 MXC.
- Издательство: KTM-Motor-Fahrzeugbau KG
- Год издания: 1983
- Страниц: 63
- Формат: PDF
- Размер: 178,0 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 60 SX/65 SX.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 92
- Формат: PDF
- Размер: 3,2 Mb
Руководство на английском языке по ремонту двигателя мотоциклов KTM 85 SX.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 89
- Формат: PDF
- Размер: 3,1 Mb
Руководство на английском языке по ремонту двигателей KTM 125/200.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 92
- Формат: PDF
- Размер: 158,0 Mb
Руководство на английском языке по ремонту двигателя мотоциклов KTM 250 SX.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 80
- Формат: PDF
- Размер: 2,7 Mb
Руководство на английском языке по ремонту двигателя мотоциклов KTM 250 SX-F 2005-2006 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 125
- Формат: PDF
- Размер: 7,3 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 250/300 SX/SXS/MXC/EXC/EXC Six Days/XC/XC-W 2004-2006 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 159
- Формат: PDF
- Размер: 11,3 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 250/300/380 EXC, MXC, SX.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 153
- Формат: PDF
- Размер: 5,3 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 250-525 SX, MXC, EXC Racing.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 167
- Формат: PDF
- Размер: 26,3 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 250 EXC Racing, 400/450 SX, MXC, XC, EXC, SMR, SXS Racing, 520/525 SX, MXC, XC, EXC, SMR Racing, 540 SXS, 560 SMR, 640 Crate 2000-2006 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 125
- Формат: PDF
- Размер: 12,2 Mb
Руководство на немецком языке по ремонту двигателей KTM 400/620 LC4/LC4e 1997 года выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 76
- Формат: PDF
- Размер: 10,2 Mb
Руководство на английском языке по ремонту двигателей KTM 400-660 LC4 2003 года выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 387
- Формат: PDF
- Размер: 18,4 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 950 Adventure 2003 года выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 185
- Формат: PDF
- Размер: 9,1 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 950 Adventure и 990 Super Duke 2003-2005 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 273
- Формат: PDF
- Размер: 18,0 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 950/990 Adventure, 950 Super Enduro, 950 Supermoto, 990 Super Duke 2003-2006 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 394
- Формат: PDF
- Размер: 24,4 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 950/990 Adventure, 950 Super Enduro, 950 Supermoto, 990 Super Duke 2003-2007 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 394
- Формат: PDF
- Размер: 25,8 Mb
Руководство на английском языке по ремонту амортизаторов WP Suspension моделей 5018 DCC/5018 SXS/5018 SMR 2005-2006 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 103
- Формат: PDF
- Размер: 5,1 Mb
Руководство на английском языке по ремонту амортизаторов WP Suspension Fork SXS/SMR 4860 MXMA 2005-2006 годов выпуска.
- Издательство: KTM Sportmotocycle AG
- Год издания: —
- Страниц: 123
- Формат: PDF
- Размер: 6,8 Mb
Руководство на английском языке по ремонту амортизаторов WP Suspension модели 4860 MXMA.
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- Страниц: 51
- Формат: PDF
- Размер: 1,5 Mb
Руководство на английском языке по ремонту амортизаторов WP Suspension модели 5018 PDS 2003 года выпуска.
- Издательство: —
- Год издания: —
- Страниц: 99
- Формат: PDF
- Размер: 4,9 Mb
В руководстве представлена информация об устройстве и работе всех узлов и агрегатов мотоцикла.
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Page 1
REPAIRMANUAL2007 450 / 505 SX-F 450 SXS-F REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN… -
Page 3
KTM Group Partner… -
Page 5: General Information
1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 DISMOUNTING AND MOUNTING THE ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS…
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Page 7
X P L A N A T I O N P D A T I N G 3.206.029-E Repair Manual 450/505 SX-F 10/2006 Basic version Model year 2007 Edition: 10/2006… -
Page 9
“NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. -
Page 11
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 manuals –… -
Page 13: Table Of Contents
GENERAL INFORMATION INDEX CHANGING THE COOLING LIQUID ……..2-2 CHECKING THE COOLING LIQUID LEVEL .
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Page 15: Changing The Cooling Liquid
Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). 5W/40 10W/50 KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F). Changing the engine oil CAUTION N ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE –…
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Page 16: Changing The Oil Filter
Changing the oil filter – Place a pan under the engine to drain the oil. Remove the 2 screws and take off the oil filter cover and O-ring. – Pull the oil filter insert out of the housing with circlip pliers 510.12.011.000.
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Page 17: Engine Oil Circuit
Engine oil circuit Engine oil circuit oil screen Pressure oil pump Bypass valve Oil filter insert Throttle to meter the oil for the timing chain tensioner Oil spraying nozzle for piston Jet to meter the oil to the lower conrod bearing Throttle to meter the oil to the clutch pushrod Oil duct for the cam lever support Oil spraying nozzle for the camshaft…
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Page 18: Checking The Oil Level Of The Hydraulic Clutch
Checking the oil level of the hydraulic clutch CAUTION SAE 10 NLY FILL BIODEGRADABLE HYDRAULIC OIL OTOREX YDRAULIC LUID INTO THE MASTER CYLINDER O NOT ADD BRAKE FLUID NOTE: remove the cover to check the oil level in the master cylinder of the clutch.
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Page 19: Changing The Front Brake Fluid
Changing the front brake fluid – Move the hand brake cylinder into a horizontal position. – Remove the screws and the cover together with the rubber boot – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
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Page 20: Changing The Rear Brake Fluid
Changing the rear brake fluid – Move the vehicle into a vertical position. – Disassemble the screw cap together with the rubber boot from the brake fluid reservoir. – Use a syringe to extract the used brake fluid and fill with fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
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Page 21: Special Tools — Engine
SPECIAL TOOLS — ENGINE 36 36…
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Page 22
SPECIAL TOOLS — ENGINE ITEM PART NO. DESCRIPTION 560.12.001.000 Universal engine work stand 773.29.002.000 Retaining arm, complete 600.29.012.000 Plastigauge measuring strips 510.12.011.000 Circlip pliers, inverted 590.29.033.000 Double jaw puller 600.29.015.000 Piston ring compressor 6899785 Loctite 243 blue 151.12.017.000 Bearing puller 151.12.018.000 Insert 12-16mm 151.12.018.100… -
Page 23
DISMOUNTING AND MOUNTING THE ENGINE INDEX DISMOUNTING THE ENGINE ……..3-2 MOUNTING THE ENGINE . -
Page 25: Dismounting The Engine
Dismounting the engine – Thoroughly clean the motorcycle and jack it up on a suitable assembly stand. Make sure it cannot tip over. – Remove the seat and tank with the spoiler. – Disconnect the battery. – Open the chain and remove. –…
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Page 26
– Loosen the hose clamp and remove the coolant hose – Disconnect the spark plug connector – Remove the vent hose – Unscrew the chain guard from the clutch slave cylinder and from the frame and remove. – Cut off the cable tie, unscrew the clutch slave cylinder and tilt aside. -
Page 27
– Push the carburetor back and remove the rubber sleeve from the cylinder head. – Dismount the carburetor towards the right and let it hang down. CAUTION O NOT PLACE THE CARBURETOR IN THE AIR FILTER BOX SINCE THE AIR FILTER WILL ABSORB ANY LEAKING FUEL –… -
Page 28: Mounting The Engine
Mounting the engine – Lift the engine into the frame from the left, position and screw in the lower and the front engine fixing screws (M10x123) but do not tighten them yet. – Mount the upper engine brace (all screws are M8x42), do not tighten yet.
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Page 29
– Screw the hot start actuator in the carburetor. – Connect the socket connectors on the throttle position sensor pulse generator and generator. Fasten the wiring harnesses with cable ties. – Mount the clutch slave cylinder , screw in both of the front screws (M6x25) and tighten to 10 Nm. -
Page 30
– Position the header pipe from the front of the motorcycle. – Attach the exhaust springs to the cylinder head with a suitable tool. – Mount the fixing screw (M6x25) for the header pipe with a washer and rubber sleeve and tighten to 10 Nm. –… -
Page 31
DISASSEMBLING THE ENGINE INDEX PREPARATION ……….4-2 DRAINING THE ENGINE OIL . -
Page 33: Preparation
Preparation – Thoroughly clean the outside of the engine and clamp in the universal work stand 560.12.001.000 with the engine holders 773.29.002.000. – Remove the shift lever. Draining the engine oil – Remove the oil drain plug together with the seal ring. –…
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Page 34: Removing The Sprocket
Removing the sprocket – Use holding wrench 510.12.012.000 to hold the sprocket while you remove the screw with the spring washer. – Remove the sprocket, distance bushing and O-ring. Removing the ignition cover – Remove the 7 screws on the ignition cover and take off the ignition cover –…
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Page 35: Moving The Engine To Ignition Tdc
Moving the engine to ignition TDC – Remove the 3 screws on the valve covers together with the rubber seal. – Remove the valve cover together with both gaskets. – Remove the spark plug. – Move the crankshaft to ignition TDC. Both cams point towards the outside in this position.
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Page 36: Removing The Clutch Cover
Removing the clutch cover – Remove the plug including the O-ring. – Insert the mounting pin 773.29.012.100. NOTE: you do not need to remove the water pump cover to remove the clutch cover. – Remove the screws and completely take off the clutch cover. –…
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Page 37: Removing The Timing Chain Tensioner
– Bend up the lock washer on the drive nut. – Hold the driver with the clutch holder 773.29.003.000 while you remove the drive nut together with the lock washer. – Remove the driver together with the stop disk mounted underneath. NOTE: the stop disk usually sticks to the driver.
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Page 38: Removing The Cylinder Head
Removing the cylinder head – Remove the screws and take off the retaining bracket. – Grasp the double gear and use a screw to pull the axle for the double gear out of the cylinder head. – Remove the timing chain from the double gear. –…
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Page 39: Removing The Cylinder / Piston
Removing the cylinder / piston – Remove the cylinder. – Remove the axles including the O-ring. – Take out the tensioning rail and guide rail. – Remove the lock ring – Gently push the piston bolt out of the piston and remove the piston. –…
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Page 40: Removing The Timing Chain
Removing the timing chain – Remove the screws and take off the retaining bracket. – Grasp the timing chain while you pull the axle for the balancer gear out of the engine case with a screw. – Simultaneously remove the timing chain, balancer gear, stop disk and both needle bearings.
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Page 41: Removing The Primary Gear
4-10 Removing the primary gear – Remove the nut with special socket wrench 773.29.021.000. – Remove the primary gear. – Remove the engine locking screw 773.29.010.000. Removing the oil pumps – Remove the screws – Remove the oil pump cover together with the gasket and oil pressure pump.
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Page 42: Removing The Shift Mechanism
4-11 – Remove the needle roller – Remove the screws on the oil pump cover and take off the oil pump cover. – Remove the suction oil pump together with the oil pump shaft and needle roller. Removing the shift mechanism –…
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Page 43: Separating The Engine Case Halves
4-12 Separating the engine case halves – Remove all screws from the housing. – Remove both nuts on the engine holder in the universal engine work stand. CAUTION O NOT PRY THE CASE HALVES APART WITH A SCREWDRIVER OR SIMILAR TOOL SINCE THIS WILL DAMAGE THE SEALING AREAS –…
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Page 45
SERVICING INDIVIDUAL COMPONENTS INDEX LEFT ENGINE CASE HALF ………5-2 RIGHT ENGINE CASE HALF . -
Page 47: Left Engine Case Half
Left engine case half – Pry out the shaft seal ring on the crankshaft , the shift shaft and the countershaft without damaging the case. – Remove the bearing bolt – Remove the throttle in the oil duct. – Remove the oil jet –…
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Page 48: Right Engine Case Half
Right engine case half – Pry out the shaft seal ring on the crankshaft without damaging the case. – Remove the screws from the bearing bolt and take off the bearing bolt together with the lock washer. – Remove the screw and washer from the locking lever and take off the locking lever together with the sleeve and locking lever spring.
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Page 49: Water Pump
Water pump – Remove the screws – Remove the water pump cover and the seal ring. – Remove the cap nut and take off the water pump wheel. Assemble in the reverse order, paying attention to the following items: – Inspect the parts for damage or wear. –…
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Page 50: Clutch Cover
– Degrease the thread on the screws for the retaining bracket, apply Loctite 243 and tighten to 6 Nm. – Align the mark on the balancer gear with the mounting pin Clutch cover – Remove the screws on the bearing retainer and the retaining bracket –…
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Page 51: Lubrication System
Lubrication system – Check the O-rings and gaskets for damage and replace if necessary. – Replace the oil filter every time you change the engine oil. – Clean the oil screen and replace if damaged. – Check the inner and outer rotor on the oil pump for damage and deposits.
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Page 52: Crankshaft
Crankshaft CAUTION EVER CLAMP THE CRANKSHAFT IN A VISE TOGETHER WITH THE CRANKPIN TO TRY TO EXTRACT THE INNER BEARING RING HIS WILL ONLY COMPRESS THE CRANKSHAFT WEBS AND MAKE THE CRANKSHAFT UNUSABLE – Clamp the crankshaft in a vise using protective jaws. –…
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Page 53: Axial Clearance Of The Crankshaft
– If you will continue to use the crankshaft, check the crankshaft journal for runout. Place the crankshaft on a roller stand or similar stand and measure the crankshaft journal runout with a gauge. Crankshaft journal runout: max. 0.15 mm –…
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Page 54: Piston / Cylinder
– Measure the diameter of the cylinder in the X and the Y-axis to detect any ovality. Cylinder diameter 450 SX-F / 450 SXS-F 505 SX-F size I: 97.000 — 97.012 mm size I: 100.000 — 100.012 mm size II: 97.012 — 97.025 mm…
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Page 55
5-10 – Insert the piston ring in the cylinder and align with the piston (approx. 10 mm under the upper edge of the cylinder). – Measure the end gap with a feeler gauge. Compression ring: max. 0.80 mm Oil scraper ring: max. 1.00 mm If the end gap is larger than indicated above, check the cylinder for wear. -
Page 56: Camshafts
5-11 Camshafts – Wrap some masking tape around the outer cam on the camshaft to protect it from being damaged in the vise. – Clamp the camshaft in a vise with aluminum protective jaws. Position the outer cam so that the camshaft will not rotate. –…
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Page 57: Radial Clearance Of The Camshaft Bearings
5-12 Radial clearance of the camshaft bearings – Insert the camshafts in the cylinder head without actuating the valves. – Position the plastigauge measuring strip 600.29.012.000 on the camshaft at the bearing positions Note: follow the instructions provided by the plastigauge measuring strip manufacturer.
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Page 58: Cylinder Head
5-13 Cylinder head – Fold up the cam lever. – Remove the shims (valve adjustment shims) from the spring retainer and mark the installed position. Note: if you mark the installed position you will only need to check the valve clearance when they are remounted. –…
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Page 59
5-14 – Pretension the valve springs and remove both valve keys – Remove the valve spring retainer and valve springs – Remove the valve. – Remove the valve stem gasket and spring washer Note: proceed in the same way for the remaining valves. Check: –… -
Page 60
5-15 Assemble in the reverse order, paying attention to the following items: – Replace any damaged or worn parts. – If the valves were removed, replace the valve stem gaskets. These must be oiled before they are mounted. – Oil the valve stems and insert the valves in the guides as marked when they were removed. -
Page 61: Timing Chain Tensioner
5-16 Timing chain tensioner CAUTION F YOU DO NOT FOLLOW THESE INSTRUCTIONS THE TIMING CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP RESULTING IN ENGINE DAMAGE NOTE: – The timing chain tensioner operates with spring force and with oil pressure.
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Page 62: Timing Train
5-17 Timing train – Check O-rings for damage and replace if necessary. – Inspect the parts for damage or wear. – Replace any damaged or worn parts. – Also check the timing chain for smooth operation of the chain links. NOTE: The smooth operation of the chain links can easily be checked by simply letting the timing chain hang down — the chain links should align in a row.
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Page 63: Clutch
5-18 LOCTITE 243 Clutch – Check the pressure piece for damage and smooth operation. – Check the axial bearing for damage and wear. – Lay the pushrod on a level surface and check for runout. – Check the length of the clutch springs .
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Page 64: Shift Mechanism
5-19 LOCTITE 243 LOCTITE 243 LOCTITE 243 Shift mechanism – Check the shift forks at the blade for damage and wear. New shift forks are 3.90 to 3.95 mm thick; the wear limit is 3.70 mm. – Check the shift grooves in the shift drum for damage and wear.
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Page 65
5-20 – Clamp the short end of the shift shaft in a vise (use protective jaws). – Mount the shift rail with guide bolt facing down and attach the guide bolt to the shift quadrant. – Mount the pressure spring –… -
Page 66: General Information On Servicing The Transmission
5-21 General information on servicing the transmission Clamp the main shaft or countershaft in the vise (use protective jaws). If continuing to use the shift ring and fixed gears, mark the installed position. Remove the gears and check the following parts for damage and wear: –…
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Page 67: Countershaft
5-22 Countershaft – Clamp the countershaft in a vise with the toothed end facing down (use protective jaws). – Carefully oil all parts before mounting. – Mount the split needle bearing – Mount the 2 gear idler gear with the shift dogs facing up. –…
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Page 68: Starter Drive
5-23 Starter drive Freewheel hub Take the freewheel out of the freewheel hub. Check the freewheel hub for damage and wear. Check the contact area pressure marks. Thoroughly clean the freewheel hub. Freewheel Thoroughly clean the freewheel. Check the freewheel segments for damage and wear. Oil the freewheel. Starter gear Check the starter gear for damage and wear.
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Page 69: Freewheel Hub
5-24 Freewheel hub – Lightly compress the spreader ring with circlip pliers and remove together with the freewheel Assemble in the reverse order, paying attention to the following items: – Inspect the parts for damage or wear. – Replace any damaged or worn parts. –…
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Page 71
ASSEMBLING THE ENGINE INDEX ASSEMBLING THE ENGINE CASE HALVES ……6-2 MOUNTING THE SHIFT MECHANISM ……. . .6-3 MOUNTING THE OIL PUMP . -
Page 73
Assembling the engine case halves – Fasten the right engine case half to the universal engine work stand. – Oil all bearing positions. – Mount the crankshaft. NOTE: the cone for the rotor must point towards the left engine case half. -
Page 74
– Mount the left engine case half, tapping lightly with a plastic hammer if necessary. – Fasten the engine to the universal engine work stand. – Insert the oiled case screws and tighten. M7x70 Tightening torques M6: 10Nm M7: 14Nm M6x70 –… -
Page 75
Mounting the oil pump – Mount the suction oil pump with the oil pump shaft and oiled needle roller. NOTE: – The rounded side of the suction oil pump should face the engine case. – The groove in the oil pump shaft should face the right side of the engine. -
Page 76
– Mount the oiled oil pressure pump. NOTE: the rounded side of the oil pressure pump should face the oil pump cover. – Degrease the thread on the screws and apply Loctite 243. Screw on the oil pump cover including the gasket and tighten to 10 Nm. Mounting the primary gear –… -
Page 77
Mounting the timing chain – Place the timing chain on the balancer gear. – Insert both oiled needle bearings in the balancer gear and mount the stop disk with the collar facing the balancer gear. – Simultaneously insert all parts in the timing chain compartment. –… -
Page 78: Mounting The Cylinder Head
– Lightly grease the outside surface of the cylinder. – Attach a cable tie to the timing chain and pull it through the timing chain compartment. – Mount the pre-assembled cylinder/piston unit and align the conrod with the piston. – Gently slide in the oiled piston bolt. –…
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Page 79: Mounting The Timing Chain Tensioner
– Insert both oiled needle bearings in the double gear. – Remove the cable tie and place the timing chain on the double gear. – Align the mark on the double gear with the mark on the cylinder head. Mount the axle double gear with the O-ring.
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Page 80
Mounting the camshafts NOTE: see Chapter 5 for camshaft reassembly / radial clearance of the camshaft bearing. – Place the pre-assembled camshafts in the oiled bearing positions and align with the flat sides facing up. NOTE: if the camshaft gears were not pressed off the camshafts, check the adjusting bearing bridge 773.29.050.000. -
Page 81
6-10 Checking the valve clearance – Remove the engine locking screw. – Switch on the engine several times. – Move the engine to the ignition TDC position (see Chapter 4) and insert the engine locking screw. – Check the valve clearance with feeler gauge 590.29.041.000: Intake valves: 0.10 — 0.15 mm Exhaust valves: 0.15 — 0.20 mm –… -
Page 82
6-11 Mounting the clutch – Mount the collar sleeve , oiled needle bearing and outer clutch NOTE: make sure the toothing engages in the oil pump idler gear. – Mount the stop disk and driver – Degrease the thread on the main shaft and apply Loctite 243. –… -
Page 83
6-12 Mounting the clutch cover – Insert the O-ring and the quad ring – Insert the rollers – Oil all bearing positions. – Pour approx. 30 ml of engine oil into the oil duct to the conrod bearing. – Degrease the sealing area and apply a thin coat of Three-Bond silicone sealant. -
Page 84
6-13 – Remove the engine locking screw – Insert the screw with the copper washer and tighten to 20 Nm. Mounting the pulse generator – Degrease the thread on the screws and apply Loctite 243. – Screw on the pre-assembled pulse generator and holder by hand. Do not tighten the screws yet. -
Page 85
6-14 Mounting the sprocket – Mount the O-ring, oiled distance bushing with the recess for the O- ring on the inside. – Mount the sprocket with the collar on the inside. – Degrease the thread on the screw , apply Loctite 243 and mount the spring washer. -
Page 86
6-15 Filling the engine with engine oil – Insert the oiled plug together with the oil screen and tighten to 30 Nm. – Insert the oil drain plug together with a new seal ring and tighten to 20 Nm. – Pour engine oil into the oil filter housing (approx. 1/3 full) and into the oil filter insert. -
Page 87
ELECTRICAL INDEX IGNITION SYSTEM TROUBLESHOOTING ……7-2 CDI UNIT ……….. .7-2 CHECKING THE IGNITION COIL . -
Page 89
Ignition system troubleshooting Before beginning the testing procedures on the ignition system, make sure: – the short circuit button is not actuated – the battery is fully charged – the main fuse is working Check whether there is an ignition spark upon starting, proceeding as follows: –… -
Page 90
Checking the pickup and stator Use an ohmmeter to take the following measurements (plug connectors disconnected): Pickup coil red — green setpoint value: 100 Ω ± 20 Ω Pickup coil red — ground setpoint value: ∞ Ω Stator coil yellow — yellow setpoint value: 1.8 Ω ± 0.3 Ω Stator coil yellow — ground setpoint value: ∞… -
Page 91
UICK CHARGES WITH HIGH VOLTAGE WILL IMPAIR THE SERVICE LIFE OF YOUR BATTERY – Connect KTM battery charger no. 584.29.074.000. The battery charger can also be used to test the offload voltage, the battery’s startability and the generator capacity. This battery charger cannot be overcharged. -
Page 92
Checking the charging voltage NOTE: : the following figures only apply to fully charged batteries (charging condition at least 90 %). – Connect a voltmeter to both battery terminals. – Start the engine. – Rev the engine up to 5000 rpm and read the voltage. Setpoint value: 14.0 –… -
Page 93
yellow-black blue-white brown yellow-black green blue blue yellow yellow black black red-white red-white white black-white black-white grey brown black yellow black yellow red-white red-white black-white… -
Page 94
Static ignition values Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs tightly connected – Battery fully charged – Gap between the rotor and the pickup: 0.7 mm –… -
Page 95
Static generator values Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs tightly connected – Battery fully charged – Actuate the starter at least 5 seconds for each measurement –… -
Page 97
FUEL SYSTEM INDEX DISMOUNTING AND MOUNTING THE CARBURETOR ….. .8-3 DISASSEMBLING THE CARBURETOR ……. . .8-5 CHECKING THE CHOKE SLIDE . -
Page 99
CARBURETOR — KEIHIN FCR-MX 4125 G… -
Page 100
Dismounting and mounting the carburetor NOTE: clean motorcycle thoroughly. – Remove the seat and tank with spoilers. – Take off the filter box cover and completely remove the air filter. – Loosen the carburetor clamp and remove the carburetor connection boot –… -
Page 101
– Pull the carburetor out of the rubber sleeve. – Unscrew the hot start actuator from the carburetor. – Remove the carburetor. Remount the carburetor in the reverse order, paying attention to the following points: – Check all parts for damage and wear. –… -
Page 102
Disassembling the carburetor NOTE: Before you start to disassemble the carburetor, make sure your workplace is clean and offers enough room to spread out the individual carburetor parts. – Dismount the carburetor and remove any coarse dirt. – Remove the 2 screws and disconnect all vent hoses from the carburetor. -
Page 103
– Remove the 3 screws from the accelerator pump cover and remove the accelerator pump cover. – Take the 2 seal rings , spring and diaphragm out of the accelerator pump housing. – Remove the remaining screws on the float chamber and take off the float chamber housing –… -
Page 104
– Remove the screw and pull the hose connection out of the carburetor. NOTE: only remove the throttle sensor if it is defective. If you loosen the screw , you will need to readjust the throttle sensor. – Remove the screw and take off the throttle sensor –… -
Page 105
Checking the choke slide The choke slide should operate smoothly. The choke slide piston should not have any deep score marks or deposits. Check the condition of the rubber boot and the choke lock. Checking the accelerator pump Check the membrane for cracks or brittleness. Check the gaskets for damage. -
Page 106
Checking the float needle valve Check the needle valve at the sealing area for indentations. Make sure no dirt has accumulated between the valve seat and float needle. Checking the throttle slide The rollers on the throttle slide must turn easily and should not have any flat areas. -
Page 107
8-10 Assembling the carburetor Assemble the carburetor in the reverse order, paying attention to the following points: – Lock the screw on the throttle sensor with Loctite 243 but do not tighten yet. – Lock the screws for the hose connection and the attachment of the throttle slide arm with Loctite 243. -
Page 108
8-11 Checking/adjusting the float height – Tilt the carburetor until the float rests against the float needle valve without compressing it. – The edge of the float should be parallel to the sealing area of the float chamber in this position (see photo). –… -
Page 109
8-12 Adjusting the position of the throttle sensor example NOTE: the following measurement must be made at a component temperature of approx. 20°C. The carburetor must be dismounted to take this measurement. The throttle slide must be in the starting position (1mm open). -
Page 110
8-13 Checking the throttle sensor NOTE: the following measurement must be made at a component temperature of approx. 20°C. The carburetor must be dismounted to take this measurement. The throttle slide must be in the starting position (1mm open). – Connect a multimeter (measuring range kΩ) to the blue (+) and black (-) cables on the throttle sensor and measure the total resistance of the throttle sensor (R ges ). -
Page 111
8-14 Adjusting the idle speed The carburetor idle speed strongly influences the starting performance, a stable idle and engine responsiveness when accelerating. An engine with a correct idle speed will be easier to start than one with an incorrect idle adjustment. The idle speed is adjusted with the adjusting screw and the idle mixture with the mixture control screw… -
Page 113
TROUBLE SHOOTING INDEX TROUBLE SHOOTING ……….9-2… -
Page 115
TROUBLE CAUSE REMEDY Engine doesn’t crank (E-starter). Blown fuse Dismount the filter box cover and replace the fuse in the starter relay. Discharged battery Recharge the battery and investigate the causes for discharging. Low outside temperature Use the 12 V / 4 Ah battery included in the scope of supply. -
Page 116
TROUBLE CAUSE REMEDY Engine does not rev up Carburetor fuel level too high because Dismount carburetor and check if worn out float needle valve is dirty or worn out Loose carburetor jets Tighten jets Electronic ignition timing faulty Check ignition system Engine will not reach full power Fuel supply partially interrupted or Clean and check fuel system as well as carburetor carburetor dirty… -
Page 117
10-1 TECHNICAL SPECIFICATIONS INDEX ENGINE ……….. . 10-2 CHASSIS . -
Page 119
10-2 TECHNICAL SPECIFICATIONS — ENGINE 2007 450 SX-F / 450 SXS-F 505 SX-F Design Liquid-cooled, 1-cylinder, 4-stroke Otto engine Displacement 449.3 ccm 477.5 ccm Bore / Stroke 97 / 60.8 mm 100 / 60.8 mm Compression ratio 12.5 : 1… -
Page 120
10-3 TECHNICAL SPECIFICATIONS – CHASSIS 2007 450 / 505 SX-F 450 SXS-F Frame Central tube chrome-molybdenum-steel frame Fork 4860 MXMA CC Fork offset (caster) adjustable 18mm/20mm adjustable 17.5mm/20.5mm Front/rear suspension travel 300/335 mm Rear suspension WP Progressive Damping System shock absorber, aluminum swing arm Front brake Disk brake with perforated Ø… -
Page 121
Conrod bearings Radial clearance max. 0.03 mm Axial clearance max. 0.80 mm Cylinder 450 SX-F / 450 SXS-F Bore diameter, size I 97.000 — 97.012 mm Bore diameter, size II 97.012 — 97.025 mm 505 SX-F Bore diameter, size I 100.000 — 100.012 mm… -
Page 122
10-5 TIGHTENING TORQUES — ENGINE Oil jet for piston Loctite 243 + 4 Nm Oil restrictor jet for crankshaft Loctite 243 Crankcase air jet Loctite 243 Oil jet for cam lever / camshaft Loctite 243 + 6 Nm Throttle oil supply clutch Loctite 243 + 6 Nm Screw on locking lever Loctite 243 + 6 Nm… -
Page 123
10-6 TIGHTENING TORQUES — CHASSIS Spoke nipple M4.5 / M5 5 Nm Screw on brake disk Loctite 243 + 14 Nm Screw on push rod ball joint 10 Nm Screw on brake caliper, front Loctite 243 + 25 Nm Screw on upper triple clamp 17 Nm Screw on lower triple clamp 12 Nm… -
Page 125
11-1 PERIODIC MAINTENANCE SCHEDULE INDEX 450/505 SX-F / 450 SXS-F ……..11-2… -
Page 127
IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. -
Page 128
Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Check tightness of screws, nuts and hose clamps regularly IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) every… -
Page 129
12-1 WIRING DIAGRAMS INDEX WIRING DIAGRAM ……….12-2 TERMS/TRANSLATIONS, CABLE COLORS . -
Page 131
12-2 yellow-black blue-white brown yellow-black green blue blue yellow yellow black black red-white red-white white black-white black-white grey brown black yellow black yellow red-white red-white black-white… -
Page 132
12-3…