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KTM EXC User Manual
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Repair manual KTM 250 / 300 / 380
Art No 3206004 -E
250/300/380 SX,MXC,EXC
REP
AIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www
.ktm.at
2
Table of Contents
Table of Contents
5
Updating Instructions
7
Explanation - Updating
9
General Information
14
Operating Ranges of the Carburetor
16
Basic Information on a Change of the Carburetor Setting
17
Basic Information on the Original Carburetor Setting
17
Carburetor Adjustment
17
Bleeding of the Hydraulic Clutch
18
Checking the Setting of the TVC System
18
Special Tools - Engine 250/300/380
19
Cleaning
20
Conservartion for Winter Operation
20
Storage
20
Removing and Refitting Engine
22
Dismounting the Engine
24
Filling in of Cooling Liquid
26
Filling in of Transmission Oil
26
Refitting the Engine
26
Disassembling the Engine
28
Dismounting of Cylinder Head, Cylinder and Piston
30
Dismounting of Sprocket and Shift Lever
30
Draining Gear Oil
30
Dismounting of Clutch Cover
31
Dismounting of Pressure Cap and Clutch Discs
32
Dismounting of the Primary Drive
32
Dismounting of Ignition Cover
33
Dismounting of Kickstarter
33
Dismounting of the Shift Lock
33
Dismounting of the Ignition (Kokusan)
34
Dismounting of the Ignition (SEM)
34
Dismounting of Gearshift Mechanism and Transmission
35
Dismounting of Intake Flange and Reed Valve Housing
35
Parting of Engine Housing Halves
35
Dismounting the Crankshaft
36
Servicing of Individual Components
37
Working on the Right-Hand Housing Half
39
Working on the Left-Hand Housing Half
40
Crankshaft
41
Crankshaft Webs – Measure Outer Dimension
41
Piston
41
Piston Ring End Gap
41
Checking Cylinder for Wear
42
Nikasil Coating of Cylinder
42
Recoated Cylinder
42
Cylinder Exhaust Control System
43
Cylinder Preassembly
43
Exhaust Control, Clutch Cover
45
Preassembly of Clutch Cover
45
Reed Valve Housing, Intake Flange
46
Clutch
47
Replace Outer Clutch Hub
48
Preassembly of Shift Shaft
49
Shift Mechanism
49
Check Stator and Pulse Generator (Kokusan)
50
Ignition (Kokusan)
50
Kokusan Ignition & Spark Plug
50
Check Stator (SEM)
51
Ignition (SEM)
51
SEM Ignition & Spark Plug
51
Assembly Mainshaft
52
Transmission
52
Assembly Countershaft
53
Assemble of Kickstarter Shaft
54
Assembling the Engine
55
Assembling the Engine Housing
58
Mounting Kickstarter
59
Mounting Shift Mechanism
59
Mount Primary Drive and Clutch
60
Mounting Clutch Discs and Pressure Cap
61
Adjusting Dimension „X“
62
Mounting Piston and Cylinder
62
Adjusting Control Flap (Dimension “Z“)
63
Mounting Cylinder Head
64
Mounting Reed Valve Housing and Intake Flange
64
Mounting Steering Covers
64
Mounting Engine Sprocket
65
Mounting the Ignition (Kokusan)
65
Adjusting Ignition Point (SEM)
66
Mounting Starting Lever and Shift Lever
66
Mounting the Ignition (SEM)
66
Electrical
67
Checking the Voltage Regulator (Kokusan)
69
Checking the Voltage Regulator (Tympanium)
69
Checking the Voltage Regulator-Rectifier (Shindengen)
69
CDI Unit
70
Checking the Capacitor
70
Ignition Coil (Kokusan)
70
Ignition Coil (SEM)
70
Checking the Voltage Regulator
71
Static Ignition Values 250-380 SX, EXC (Kokusan 2K-1, 2K-3, 2K-4)
72
Static Generator Values 250-380 EXC (Kokusan 2K-3) (Except 250 USA)
74
Static Ignition Values 250 MXC, EXC USA (Kokusan 2K-2)
76
Troubleshooting
79
Trouble Shooting
81
Technical Specifications
83
Technical Specifications - Engine 250/300/380 SX/MXC/EXC ‘99 (Only for USA)
85
Basic Carburetor Setting
86
Gasket Thicknesses
86
Tightening Torques
86
Tolerances and Fitting Clearances
86
Technical Specifications - Engine 250/300/380 SX/EXC/EGS ‘99 (All Models out of USA)
87
Standard Adjustment - Fork
89
Standard Adjustment - Shock Absorber
89
Technical Specifications Chassis 250/300/380 SX/MXC/EXC/EGS ‘99
89
Carburetor Setting KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38
90
Carburetor Setting KTM 250 SX Europe, USA ‘99 KEIHIN PWK 38
91
Carburetor Setting KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38
92
Technical Data - Engine 250/300/380 SX/MXC/EXC 2000 (Only USA)
93
Technical Data - Engine 250/300/380 SX/EXC 2000 (All Models out of USA)
95
Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2000
97
Carburetor Setting G KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ
98
Carburetor Setting KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
99
Carburetor Setting KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
100
Carburetor Setting KTM 380 SX/MXC/ EXC/EUR/USA 2000 KEIHIN PWK 38 AG
101
Technical Data - Engine 250/300/380 SX/MXC EXC 2001 (Only USA)
103
Technical Data - Engine 250/300/380 SX / EXC 2001 (All Models out of USA)
105
Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2001
107
Carburetor Setting KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ
108
Carburetor Setting KTM 250 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
109
Carburetor Setting KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
110
Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2001 KEIHIN PWK 38 AG
111
Technical Data - Engine 250/300/380 SX / MXC / EXC 2002 (Only USA)
112
Technical Data - Engine 250/300/380 SX / EXC 2002 (All Models out of USA)
114
Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2002
116
Carburetor Setting KTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG
117
Carburetor Setting KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG
118
Carburetor Setting KTM 300 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG
119
Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2002 KEIHIN PWK 38 AG
120
Technical Data - Engine 250/300 MXC/EXC 2003
121
Periodic Lubrication and Maintenance Schedule
131
Periodic Maintenance Schedule 2001/02
132
Important Chacks and Maintenance to be Carried by the Rider
133
Periodic Maintenance Schedule 2003
134
Recommended Inspection of the 250/300 EXC and MXC Engine Used for Enduro Competitions by Your KTM Workshop
136
Recommended Inspection of the 250/300 EXC and MXC Engine Used for Hobby Enduro by Your KTM Workshop
136
Wiring Diagrams
137
250-380 EXC Wiring Diagram
139
25-38- EGS '98 Wiring Diagram
140
125/250/300 EXC '98, '99 Wiring Diagram
142
125/200/250/300/380 EXC 2000 Wiring Diagram
143
125-380 EXC 2000 Wiring Diagram
144
380 EXC 2000 Wiring Diagram
146
125/200/250 EXC 2001 Wiring Diagram
147
125-380 EXC 2001 Wiring Diagram
148
300/380 EXC 2001 Wiring Diagram
150
250-300 EXC 2003 Wiring Diagram
151
250/300 EXC 2003 Wiring Diagram
153
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KTM EXC Specifications
General
Ignition
Kokusan
Starter
Kickstarter
Transmission
6-speed
Engine Type
Single Cylinder, 2-Stroke
Cooling
Liquid Cooled
Lubrication
Premix
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