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KTM EXC Automobile Parts User Manual

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2. MOUNTING IGNITION COVER MOUNTING STARTING LEVER AND SHIFT LEVER Art No 3206004 E Repair manual KTM 250 300 380 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 CAUTION WHEN PUSHING IN CRANKSHAFT SURE CONROD IS FACING CYLINDER Transmission Grease the driving pins of the shift forks and mount the shift rollers Fix the lower stop disc on the countershaft with a small amount of grease Mount drive shaft together with countershaft and insert them into the bearings as far as they will go Shift fork with driving in the middle belongs to the mainshaft Mount the two other shift forks at the countershaft using the marks applied before disassembly for better orientation CAUTION USED SHIFT FORKS SHOULD BE MOUNTED IN THE SAME SLIDING GEAR AS BEFORE WATCH AT THE MARKINGS FROM DISMANTLING Attach the shift forks to the sliding gears and insert shift roller into the grooved ball bearing Attach the shift forks to the shift roller CAUTION ATTACHING THE SHIFT FORKS MAKE SURE THAT THE SHIFT DRUMS DO NOT SLIDE OFF THE SHIFT FORKS 6 3C Fix the 4 pressure springs with ample amounts of grease in the gearshift rails Oil gearshift rails and insert them into the gearshift forks
3. poi Sua SULIB9Q 13 01 Suueaq jeq 2 18 3Jeus ue17 y UO 0 XIU pp esn 10 JORJUOD aseajd Idnop uayM 9 gt 01IS 8 YSIY SUISN 09 4 Or L 5 9 x aus 2011s OM apeJS uSiu OU SUBIDO ant YJdNS papeajun U 86 C ZZ 8L Ul 88 C WU El CL Ul v8 c CZ 799 920415 9104 Jaquey W1 pue 5 45 OJJUO IAEA UML WLY 8 34015 oM Jopuri A2 9 Surs pajoo9 pinbr7 BIS vsn LOOT IX3 DXW XS 08 00 8 0ST 3NIDN3 VIVA 1V2INHO3L 3 70090TE ON HV 00 OST WL 9 20C TIGHTENING TORQUES ENGINE 35 Nm 05 ft lb 35 Nm 05 ft lb 60 Nm _ 44 ft b Loctite 243 150 110 ft Ib Loctite 243 100 Nm 74 ft b M 8 Nm 6 ft Ib Swingarm pivot 100 Nm 74 ft Ib Flat head bolt release plate kickstarter M 6x16 Loctite 648 19 Nm 14 ft Ib Other bolts M 10 Nm 7 ft lb M8 25 19 ft lb M 10 45 Nm 33 ft lb 8 6 6 TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 0 06 mm 250 0 06 mm 300 0 08 mm 380 Clutch springs length BASIC CARBURETOR SETTING Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 3
4. 10 au qoq 0 5ua22D p 01404 1102 uo y u 7 dois naj ous4JJ Ip 14504 146 1d0 5 1421 11 4ydS swaug UOXD A 4052012 uJoy 0 sua Ip 10634 Jay m JazuabBaqsbunuubds dois ap 4204 09 sod 0 58 0 1 J yozims 96118 015 Iu y95 y91 5wa g 9045 1201 02 juD 0 58220 1 ju 1 1 5 yy jdoys wyasyys jswauyg 1 3 42315 jpuiquo2 0 J8j Du2s quoy unz 55 dwod 410193 420 2 1 3461 Jayawopaads u ouwa 1 vids J4031021 pu woaq uBiu 8110431u0 31U2 1uJ8 4 0 10 1uB 1ppau ayas op o NM LO N LO N LO CO CN MA LO CO 425 150210 uosiua 103 425 163 y3syna 0X3 OBE SZI u A10 8222 000 9L0 11 686 86 NJ 2X3 088 052 3M 86 LO LO 002 SLO 11 auon e 8 4 O A C 0 O C d 0 E 2 3 q LU 5313420010818045 1151 pup ss unJapuy 2 137 un3D 1151 aqoy 118poy 3 ON HV 08 00 OST WL 11 3C Kin Modell Kabelstrangnummer Land Kabelstrangbez S R B 546 11 475 300 f 250 380 EGS 98
5. 54 DoOC anLvasIdW l OV 8 AMd NIHIDI E007 VSN AN XIXW 00 W 54 DGC ONILI3S YOLIANAAVI 10 1C LUBRICATION AND MAINTENANCE SCHEDULE 10 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 MODEL 2003 LUBRICATION AND MAINTENANCE SCHEDULE 250 300 10 6 Art No 3206004 E Repair manual 250 300 380 Art No 3206004 E Repair manual KTM 250 300 380 10 2C PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE 125 380 6 98 SPORTMOTORCYCLES AT A REGULAR COMPETITION USE OF THE BIKE THE 4000 KM 2500 MILES SERVICE IS TO BE DONE AFTER EVERY RACE Sie eS a Be Check transmission oil level Change transmission oil o lei Check spark plug and electrode gap pe Change spark plug Y e Functional testing of the exhaust control system O B e 2 N N s 8 O gt Eu O N O O E ESE O LO N efore each start 600 miles or 10 hours after washing Ec x o gt REIS O Check intake manifold for leaks and cracks Drain and clean carburetor float chamber Adjust idling Check breathe
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7. ee L GOG T IT L Z do EL Do GZ 1529 1 09 2 ue Op samt EL X8 10 1bL 1El p Ob MOL 8 0 DXI DXW XSA 92ueA py 1 5 OP AAOC 8 0 XS payenjoe mejo paads q GLI JH 19 5 payesado oineap u yyeq io osip 21 67 Arewud sueas nds 4nd 14312135 ulu 08S 7 utul 0007 utul 006S 0 ut ZL 9p Ul G6 L U CO0 9 0 U 600 U 80 0 bel U 400 wu 6 U OOO 0 0 0 jndino Joyesauay wajs s uous sje pouds a qe reAy uoneouqn IPD Je9D Ap 1890 pE EID put Ones UOISSILISUBA UI uado DAL uado UES DAL 98 7 UO SUOW G des opou129 3 W23 8 ADN eds Suju uoniu fo apa hold laddn UOISUIWIG sgun uoissaJduuoo ure d OM 8 uoissaJduuoo ure d suo SUL UOJSId SULIB9Q 13 01 JapuljAd Suueaq jeq 8 ayes ay UO 0 XIU esn 10 JORJUOD aseajd Idnop uayM 2013s 8 usiu SUISN 09 Op L x o ueApy 5
8. NOZ NOZ G H Needle position from top IV Slide 6 5 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 1 5 Performance restrictor Power jet jet 9 30C ad Jom Ja AIy 9 09 295 Sunjes 2 apl s Jey Jong MOLL AZL JOyeJaua3 OU MOLL AZL 8 ou jndino 1 EIC 5 EAC EAC NVSNION L AZ NVSNDIODI ua3s s uoniu do EL Do GZ 1589 Je Yayem 9509 Z nue SAYI EL 3ugoo Rat UNYI 10 GL pL sje pouds y Ob MOL 8 8 0 pxsA 90UEAPY 996 Ob MOZ 8 0 p 245 Ob MOL 80 PXSA eoueApy JUS Ob MOZ 10 auigua 80 uoneouqn ean Je9D Ap JID 1290 1890 put 1299 Ones payenjoe mejo paads UOISSILUSU J GLI JH 1945 oineap u yyeq io u inp osip 21 97 Arewud seag Inds 34312135 21 67 Arewud seag unds 4nd 1431235 utu 00cZ UW OGZZ utul 0007 dey 940 DAL 00 UILU Q06S 0 yodo Hejs DAL ut 66 U ZL 9p ut p6 1 2 9 ul 200 90 de3 W23 8 ADN eds 3019
9. Wheel base Seat height unloaded 1481 10 mm 58 3 0 4 in 925 mm 36 5 in Ground clearance unloaded 385 mm 15 2 in Dead weight Dead weight USA Dead weight without fuel Art No 3206004 E STANDARD ADJUSTMENT FORK woswos wr ostev7oa 101 kg 223 lbs 101 kg 223 lbs 12 12 102 5 kg 226 3 lbs Brake caliper front 109 kg 240 6 lbs 103 7 kg 229 lbs TIGHENING TORQUES CHASSIS Collar nut front wheel spindle M 16x1 5 40 Nm 30 ft Ib 25 Nm 19 ft Ib Loctite 243 Rebound adjuster Spring Spring preload 4 0 N mm 4 0 N mm 5 mm 0 20in 5 mm 0 20in 130 mm 5 1in 150 mm 5 9in Clamping screws upper fork bridge Clamping bolts lower fork bridge 20 Nm 15 16 11 16 Clamping bolts fork stubs M 8 M 8 8 8 7 ft Ib Air chamber length Fork oil Compression adjuster Rebound adjuster SAE 5 SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER WP 1218V730 2 25 WP 1218V731 5 25 Collar nut rear wheel spindle Hexagon nut swing arm bolt 59 ft Ib 74 ft Ib M M 20x1 5 M 14x1 5 100 Nm Collar bolt handlebar clamp M 8 20 Nm 15 16 Allen head bolt handlebar support M 10 40 Nm 30 ft Ib Loctite 243 Shock absorber top M 12 60 Nm 44 ft Ib Shock absorber bottom Screw adjusting ring spring preload M 12 60 Nm 44 16 6 ft Ib Other bolts on chassis Spring Spr
10. e Check brake lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs Check swing arm bearings CHASSIS Check adjust steering head bearings Check tightness of all chassis screws triple clamps fork leg axle passage axle nuts and screws swing arm bearings shock absorber Check spoke tension and rim joint Check tyres and air pressure Check chain rear sprockets and chain guides for wear fitment and tension WHEELS Lubricate chain Check clearance of wheel bearings at least every 2 years once a year or 20000 km Check function of exhaust control Complete maintenance of shock absorber Complete maintenance of fork Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Change hydraulic clutch fluid Change break fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALLS SHOULD NEVER EXCEED BY MORE THAN 5 HOURS OR kml MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER Art No 3206004 E Repair manual KTM 250 300 380 10 5C IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check gear box oil
11. 000 uedo DAL 0069 0005 uado Yes DAL ut ZU 9p 7Z0 O sj loo 7 UOISUILUIG 488 oponpor S3 Z ADN eds LO JOA 6 L LO JOA uoniSu U OOO 0 ww LO O dapuy o a3pa din Uojsid 8 uoissaJduuoo OM SUL UOJSId Zuueag uid uojsig Suueoq Sunosuuo SULIB9Q 19 01 Suueaq jeq 2 19 3Jeus ue17 5 uo xiu 0 aen Jo 312e1u00 aseajd ul USYAN 230145 OM apeg ySIY SUISN UUM 09 390135 APeIS YSIY ou auepo yaseasal YAdNS pepeejun Ul 88 C red WU El CZ U v8 c ZZ 799 940445 9108 anbi01 W1 pue 5 5 1sneuxe ALA WLY euigue 2 8 5 po ooo pinbr ESOS 2X3 2XW 00 2X3 2XW Les 00C 2X3 DXW OOE OSC ANIDNG RK PER 3 70090TE ON HV 00 OST WL 9 38C 35 Q5 35 Nm 25 60 Nm 44 ftlb Loctite 648 19 Nm 14 ftlb Loctite 243 150 Nm 110 ft Ib Loctite 243 100 74 ft 1b 8Nm 6ftlb 100 74 ft lb Other screws M6 10 Nm 7 ft lb M 8 25 Nm
12. Place needle cage in position push starter gear over it pressing locking pawl inwards so that starter gear passes smoothly over it Hook legs of the starter spring into driving hub push both together on the starter shaft hook starter spring leg into kickstarter shaft bore Release Kickstarter shaft and fix stop disc with a small amount of grease on the kickstarter shaft Art No 3206004 E Repair manual 250 300 380 ASSEMBLING THE ENGINE INDEX CRANKSHAFT see ee ee Rae ee oe eee eee a TRANSMISSION e x ASSEMBLING THE ENGINE HOUSING MOUNTING SHIFT MECHANISM MOUNTING KICKSTARTER MOUNT PRIMARY DRIVE AND CLUTCH MOUNTING CLUTCH DISCS AND PRESSURE CAP MOUNTING CLUTCH MOUNTING PISTON AND CYLINDER ADJUSTING DIMENSION X ADJUSTING CONTROL FLAP DIMENSION Z MOUNTING STEERING COVERS MOUNTING CYLINDER HEAD MOUNTING REED VALVE HOUSING AND INTAKE FLANGE MOUNTING ENGINE SPROCKET MOUNTING THE IGNITION KOKUSAN MOUNTING THE IGNITION SEM ADJUSTING IGNITION POINT SEM
13. QOO ee 6 m 29 m 4q ys unas Mc m 11 9 1 J ou 43A 51 16 aunor unJq najq 1 oJau 05504 3U0 I UP JO 015116 011016 a3u0JJ0u nig a 3 ym 13019 pau a6unu0 uaau halb 6 eng 1q 118 0 2 25 yOu unu 16 NUSNYOY B p s d y nw 109 340333409 24 6019 d yjnu 4343315 109 ZI s nduw p Jnay0Jauab 15 1102 a285jnd Jaqabs ndw 8j un 102 0101085 1 13 01 j un Q9 1 13 103 Ol a1d13 nu 109 6 g 6019 d yjnu 109 6 310 Q 1509 9 146 1081 9 2119 1 25 8 41005 azJaxpun7 a6pun p au qoq 9 Du qOq 9 1103 uo J u 9 5 7 9 a6 s d p Owoulp 2040 sus Ip 106534 y Jay w y Jazuau bagsbunuundg y i E E aan u gt y ms 14611 483110u251u2 E Ei E T JE 3 20 2 0 112 120 02 7 j n34 2 j420UuS 2 J81s
14. Ul 86 21 8L Ul 88 C v8 C El CZ U c9 c ZZ 99 940445 9104 Jaquey anbi01 W1 pue WaISAs 1sneuxe UML WLY aulsua 5 pajoo9 pinb17 Usa ysn 0007 DXW XS 08 00 0SC 3NIDN3 VIVG IWDINHDIL 3 70090TE ON HV 00 OST WL 9 11C TIGHTENING TORQUES ENGINE 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 6 Other bolts 10 7 ftlb M 8 25 Nm 19 ft lb M 10 45 Nm 33 ft lb TOLERANCES AND FITTING CLEARANCES GASKET THICKNESSES BASIC CARBURETOR SETTING 250 5 250 300 380 5 Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 110499 130499 140499 150499 Main jet 172 170 175 180 178 182 175 172 178 170 168 172 Idling jet 48 45 50 45 48 45 48 45 48 Starting jet 85 85 85 85 Jet needle NOZ E NOZ F NOZ NOZ NOZ NOZ NOZ Needle position from top Slide 7 6 6 6 Air adjustment screw open 1 5 Performance restrictor Power jet jet 55 9 12C 941 adA LUPO Jom 9 qe1 295 195 2 2 5
15. SPORTMOTORCYCLES V 2 5 3 8 0 E b 9 503 11 076 000 E UPO 02 07 97 KE 125 380 EGS 98 ge bl AHH 14 IC gt ge ra ge e p 9 LL i ge m Ho SEM K11 60 EG 05 12V 1300 5 5 59 5 CC L HH Dre ES Fe Sge 16 rw TA gw sl 28 y LIT es 30 gt 310 2054 a SN Blinkerstrang vo 503 11 080 000 Blinkerstrang hi 503 11 081 000 Art No 3206004 E Repair manual KTM 250 300 380 11 4C Scheinwerfer headlight faro phare Standlicht parking light luce di posizione feu de position Blinker l vo turn indic left fr lampegg ant sn clignoteur av gauche turn richt Tr lampegg ant dx clignoteur av droit luce di tachimetro ecla r comp vitesse spia abbagliante spia lampegg ator connettore a 4 poli accensione Blinker re vo 1998 speedometer light high beam indicator turn indicator mult p cont plug 4 Tachobeleuchtung Fernlichtkontrolle Blinkerkontrolle 4 pol Stecker temo n feu route temo n de cl gnoteur 4 N A 0 gt 0 connect multiple 4 contact d allum commodo contact de stop av ZUndech Lol Ignition lock C O zum Kombischalter to combinat switch mult
16. do EL Do GZ 1589 12 9509 9299 950t Sam EL 106000 x 8 10 1bL 1EL 519520195 o qe reAv SIUBAPY 0 80 Jean JID Ap JID 1890 pE 1290 ul Ones payenjoe mejo paads q UOISSIUISU J GLI JH 11 5 oineap u yyeq io u inp osip 21 97 suevas Inds 1431635 21 67 Arewud seag unds 3n9 1481635 UW OOTZ UW OGZZ UILU QOGZ uado DAL uluJ 00cG UILU QOES 000 uado HES DAL U ee U GOG U ee S OS ee 7 LOISUAWIA ul 200 9 0 de3 W23 8 ADN eds o ZL ut 6070 o ZL ut 20 0 O Z uoniu U OOO 0 L 0 0 SC UOISUALUIG sgun uoissaJduuoo 8 uoissaJduuoo ure d ouo SUL UOJSId ig por 5 SULIB9Q 19 01 JapuljAD jeq 2 18 Yeysyuelo y UO XIU pp esn 10 19310duui 124 aseajd Idnop uayM 2013s 8 usiu SUISN 09 Op L 8 WO x SUIDPY e ueApy 5 OM 2 8 ui ou auejoo yaJeasal Ian YIdNS pepeejun
17. Check the generator output also see circuit diagram on opposite page for voltage between the following cable colors between yellow and brown ground connector disconnected Multimeter display 250 19 volts 2 volts 300 380 15 volts 1 volt between white and brown ground connector disconnected Multimeter display 250 24 volts 2 volts 300 380 19 volts 1 volt Repeat both measurements with connector and connected The measured values should be the same NOTE the black measuring lead of the peak voltage adapter must be applied to the ground Check regulator rectifier output voltage O also see circuit diagram on opposite page cable colors yellow red regulator rectifier connected capacitor disconnected between yellow red and brown ground Multimeter display 14 volts 1 volt NOTE the black measuring lead of the peak voltage adapter must be 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 Art No 3206004 E Repair manual KTM 250 300 380 7 8C M Kabelstrangnummer vorne 503 11 075 600 Land SERVICE 250 380 EXC 2000 Blinker vorne 503 11 080 100 MN k 11 SPORTMOTORCYCLES Buc nd 503 11 081 000 Europa 07 04 99 Hei gt I X9 amp g 2 St ILL E bl
18. LOEC 1 00001 000 JHOHS333W ONILI3S YOLIANAAVI 5 9 35C G6 ZOY papeajun sadns 01n3 Jan 1821001 e G9 5 21 7 G6 1914194 190AS 01N3 4015945 do uon sod SCH Ce uaqo uonisog dl SOd da3lld8NaiSSVHls 403 LHOIN Sui p H gt 5 uado Mans SV uayo HOST rw Jana eas SOd 5 31033N Y 0001 SV 00 W SOd 41d44N fl SV W SOd 41d44N fl SV IW SOd 41d44N fl SV W 4 1094 SOd LOEC 41d44N fl 1 00001 SV 000 01 466 186 01 464 184 01 419 109 dolt Jolt 461 0 doc IGNGILIV 26 54 DLE 54 DGC 54 DIL 9 54 29 9 54 9 54 DoOC anLvasIdWw l JHOHS3 33W DV 8 NIHIF TOOT WSN YNA IXI DXW 00 WLY ureegen 3 ON HV 00 OST WL 9 36C G6 ZOW papeajun ISN AVMHDIH LON G6 ZOU sadns 01n3 Yolsye y 83113 55 7315 403 LHOIN 5 uado 25 JoOCL 01 466 186 01 464 18 4 01 419 109 dolt J06 54 DLE 2e8t 54 DGC 54 DIL 9 54 29 DV 8 NIHIDI WSN UNA do
19. uon sod 9 jal urew 504 ja sup fl SV Jolt OF 4 6L 304 SIG 9 1 06 01 doc Jal s q ww G 19qne1 5S19 7 9 1949 425 uaqo uonisog dil SOd oasnpjne i92 951 W SOd 41d44N fl SV W SOd 371993 fl SV W SOd 41d44N fl SV W SOd 41d44N fl SV W SOd 31033N fl SV 295 4 0001 ul 0 4 1094 LOEC 1 00001 000 JHOHS333W JX3 DON XS 08 W ONILI3S YOLIANAAVI INNYINNOIVAISVIHIA 9 37C ad Jam 193 Aly 2991 995 5 2 10 9 NQ4e9 3PI S 1P 4 Enge ACL jndino soyesauay NVSMION OXW VSN Waisds uoniu MOLL ACL EAT NVSNAODI 5 5 uous do EL Do GZ 1589 12 238M 9609 9 9 54911 EL OOD 10 ZGL ZVL ZEL 549520195 Ob MOL 110 aulsua 80 uone uqn IPD 1298 1298 1298 4 Jean jndino payenjoe mejo paads UOISSILUSUBA GLI 4H 1945 payerado Ajjes jneipAy yyeq io ur osip ad nus 21 67 Arewud sivas 1195 112 14816235
20. 2405 OM APRIS YSIY OU JUDO YJANS pepeejun Ul 86 C ZZ 8L Jaquiey W1 pue ua3sAs 1sneuxo SALA UIML WL 2 8 5 pajoo9 pinbr7 2X3 08 XS 08 Ul 88 C v8 C WW El ZZ u 78 C 9 2X3 00 2X3 09 uojsid 1522 Suueoq SUI99UUOD uojsid a8pa addn SUL UOJSId Suueaq uid uojsig uoissaJduuoo auo 3Jeus ue17 euiose 920445 9404 CZ 99 WSN 10 sjapow 0007 XS 08 00 097 3NIDN3 VIVO IVIINHIIL 3 70090TE ON HV 00 OST WL 9 13C Flange bolts cylinder head Other bolts M6 10 7 ftlb 25 Nm 19 ft Ib 45 Nm 33 ft lb Piston fitting clearance 0 05 mm 250 0 06 mm 300 0 08 mm 380 Piston ring end gap BASIC CARBURETOR SETTING 250 SX 250 MXC EXC 300 MXC EXC 380 SX MXC EXC 22 EXE throttled Carburetor Keihin PWK 38 AG PJ Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 110499 130499 140499 150499 050799 172 170 175 180 178 182 175 172 178 170 168 172 175 48 45 50 45 48 45 48 45 48 33 85 85 85 85 85 NOZ E NOZ F NOZ G NOZ NOZ H NOZ I NOZ H NOZ
21. de A E oS Pe 020 ay um iam 19 0 g m 5 38101 0333101 01 Jiou Ouau 49019 zJomu2s 05504 pau 10 aBunuo BU0 I DUDUD aBunuo aBunuo M 19 y 13A uaaJb unub 9 51 16 016146 6 fiauD 6 6 A Bunpf 011016 56 mo 1 4186 ung umoJg Aq Aq ns19 nig 14 eng 19 19 y a81d13 nu 1100 8J0318Uuu02 y 1 d y nw 2 15 100 Z s ndw 115 1102 Jas nd Jaga s ndwf ay1un 1 0 0 03035 1 y1un 10 1 8auu 3 01 81d 31nu 1109 84033auu02 3uo2 di31nu 109 6 ab Q 8J0148350d 81000 g 45174034 0 421 1971 426 0 m a nog 1 42085 azJa pun7 p 9 sua22D0 9 1102 uo 3 uB 9 a ndspunz 9 El 30 5 4 Pp Jnayouauab owoulp J03104auaD 4031048ua89 Jna301nBa4J sua Ip 106584 p Jay w Jazuau ags unuundg m 4 E adn ysy ms 34611 E 11042534217 ZT ALARN jaJJo 2 0 112 11203 09 Juayul 2 yIn9419 IJ0Y5 2 J33503gn u495zZu4Ny 2 i T aJoyd oun 18925 D 73 25150210 14 1 1 1
22. 2405 OM apeJS uSiu OU JUDO nl YJANS pepeejun Ul 86 C ZZ 84 Ul 88 7 v8 C El CZ U PEC CZ 99 Jaquiey W1 pue 5 5 sneyxa SALA UIML WI 301IS 0M 2 8 5 pa ooo pinbr 08 5 08 IXI IXW 00 IXI IXW WSN juo COOC IX3 DXW XS O8E 00E OSC ANIDNA TVDINHD3L Suueaq uid uojsig 3Jeus ue1 uijoses A 1 920115 9 09 Art No 3206004 E Repair manual KTM 250 300 380 9 29C 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 M6 10Nm 7 ft lb M8 25 19 ft Ib M 10 45 Nm 33 ft lb TOLERANCES AND FITTING CLEARANCES GASKET THICKNESSES BASIC CARBURETOR SETTING 250 5 250 300 380 5 Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 061200 030201 040201 050201 Main jet 170 168 172 178 175 180 175 172 178 170 168 172 Idling jet 48 45 50 45 48 45 48 45 48 Starting jet 85 85 85 85 Jet needle NOZ E NOZ F D NOZ E NOZ F
23. 400 8L uonius u UL O wu O Lat r X UOISUAWIC sgun 1 55 4 SUL UOJSId Suueaq uid uojsig o poau Suueaq pol SULIB9Q 13 01 1epuri Ao Suueaq jeq 2 18 3Jeus ue17 9pis uo 0 one XIU 0 L aen 10 Jayodw 32e1u00 aseajd uayM IO 2013s OM 8 UaU 09 06 1 ome uljoses WO x J9YS IO 23045 OM 8 8 ou auepo 5 YAdNS Ul 86 C 21 84 U 88 C 78 0 WW El CZ Ul pZ c 99 C G69 9 9 940445 9104 Jaquey anbioy W1 pu ua3sAs 1sneuxe UML WLY aulsua 5 pa ooo pinbr Usa WS N 103 JUO Po 472 T3 ZE SNOILWDISIDAdS TVIINHI3L 3 70090TE ON HV 00 OST WL 9 3C TIGHTENING TORQUES Flange bolts cylinder head 35 Nm 25 ftlb 60 Nm 44 ft Loctite 243 150 Nm 110 ft M6 Other bolts 10Nm 7 ftlb 25 Nm 19 ft Ib 45 Nm 33 ft lb BASIC CARBURETOR SETTING Carburetor Keihin PWK 38 Keihin PWK 38 Keihin PWK 38 Carburetor setting number 090598 100598 070598 Main jet 172 168 170 175 175 170 172 178 170 168 172 175 Idling jet 45
24. Q au goq 9 JnajoJauaD 1109 3404 3UU09 20 912 51 0101085 1 1 840338uu02 101 18 509 p 19 di31nu 1102 Jas nd y 1un 09 6019 d i31nu 146 1 4034 12095 1102 uo y u Ja31W11 4349339 109 Jagabs1ndu 3 109 10d E yy311gn1y35 7 andspunz J031048ua89 Jazua J6aqsBunuuodco O puiqoq Owoulp 105631 ab m m sua Ip MY CO CO ON TWN CO CO CO uayu 1 JJayul 423 5 14611 48310u253u21 c F 19110 0 1ND419034409 JJ83u 9 j n234012 340us J83503 Jn1u5szany EI E E 020 146 JajJamu layos id D 5 u3sisozuna 425 1101 425 1603 y3s3na 86 3X3 092 921 00700 86 USN IX 52 451 puo spuy 1513 aupuiajo J 000 9 0 11 Uejuru 000 SLO 116058 auson 2351 112424010 14045 3911435 MADE USNIXE 3Y 86 90 22 auoN WN3D OST pun 004 JAJ 054 00 9 JusBunuy3 187 3 ON HV 00 OST WL 11 11C Modell Kabelstra
25. U 8070 wu 3019 U G 0 0 WU 6 3019 U Z0 0 el Suu uous U OOO 0 0 TE reddy sgun uoissaJduuoo urejd auo SUL UOJSId Suueaq 5 JapuljAd Suueaq jeq 2 18 Yeysyuelo olyes 0528 x IIUBAPY aus OM DPRIS YSIY ee OU papeajun U 86z E ZZ 8L U 88 7 v8 c WW El ZZ Ul Y8 Z Z9 Z ZZ 99 W1 pue 5 5 sneyxa SALA UIML WLA 301IS OM 2 8 5 p2 002 p nb 7 Ti VSN 10 1no sj pow je ZOOT 2X3 XS 08 00 0SC ANIDNA VLVG IVDINHDIL y UO XIU 0 aen 10 Jayodu 32e1u00 aseajd Idnop USYAN 2013s 8 YSIY SUISN 09 4 Op L Art No 3206004 E Repair manual KTM 250 300 380 9 31C TIGHTENING TORQUES M M 10 6 Other bolts M 10Nm 7 ft lb M 8 25 Nm 19 ft Ib M 10 45 Nm 33 ft Ib TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 0 06 mm 250 0 06 mm 300 0 08 mm 380 Piston ring end gap GASKET THICKNESSES BASIC CARBURETOR SETTING 250 SX 380 SX 250 300 EXC 380 SX USA throttled
26. 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 75 mm kick the kick starter forcefully at least 5 times for each measurement Static ignition values 250 380 SX EXC except 250 USA Check the pulse generator for an output signal two pin connector with green and red cable colors also see circuit diagram on opposite page Apply the red measuring lead of the peak voltage adapter to the green cable and the black measuring lead to the red cable disconnect both connectors to disconnect the CDI unit Multimeter display 6 volts 1 volt 250 SX model 2000 2001 5 volts 1 volt Same measurement with CDI unit connected Multimeter display 3 volts 1 volt 250 SX model 2000 2001 9 volts 1 volt Check the generator charging coil for ignition capacitor charge for out put voltage two pin connector with black red and red white cable colors also see circuit diagram on opposite page Apply the red measuring lead of the peak voltage adapter to the black red cable and the black measuring lead to the red white cable disconnect connector to disconnect the CDI unit Multimeter display 35 volts 5 volts Same measurement with connectors CDI unit connected Multimeter display 200 v
27. comando gt Bremslichtsch vo stoplight switch int luce arresto ant Bremslichtsch hi stoplight switch r Horn horn Bl nkgeber turn indicator Diode diode Z ndkerze spark plug ndspule Ignition coil N N N contact Harr de stop klaxon int luce arresto pos clacson trasmett di lampeg diodo candela w Qo CO A gt centrale cl gnot d ode bougie bobine d allumage generateur O2 I bobina d accens Generator generator dinamo co co condensatore condensateur regol di tens batteria 1 2Ah fusibile 108 connettore a 9 poli Kondensator capacitor Spannungsreg ler voltage regulator Batterie 1 2Ah battery 1 2Ah Stecksicherung 108 fuse 108 b pol Stecker mult p cont plug 9 NO KN O N regulateur batterie 1 2Ah fusible 10A connect multiple 9 clign arr gauche clign arr droite feu arr et de stop KIM 250 380 EGS NO No N No NO No No N N NO NO No Ww N A N A NO me Blinker li hi blinker left rear Blinker re hi blinker right rear Brems Sch lu l cht rear stopl ght Bl nkerschalter blink switch lampegg post sn lampegg post dx fanal post di freno int Llampeggiatori parallelo composto N N N N O N OD N NO N J N contact d cl gnoteur N NO NO Para
28. s ME 71 L ei 0 4 5 o s ge RRE 4 g u 17 bl w STW KOKUSAN 2 K3 Su o bl u Ce pa PO AAA r fr br b brXo br 84 6140 61 Y 3 5 ge 10 ge r o ohne Funktion oO C QJ U t o O 1 Y 19 55h 294 3 6 o gt ul 310054 26 Blinkerstrong f r Wettbewerbse nsatz demontierbar Stecker 29 7 9 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 75 mm kick the kick starter forcefully at least 5 times for each measurement Static ignition values 250 MXC EXC USA Check the pulse generator for an output signal two one pin connectors with green and red cable colors also see circuit diagram on opposite page Apply the red measuring lead of the peak voltage adapter to the green cable and the black measuring lead to the red cable disconnect both connectors to disconnect the CDI unit O Multimeter display 3 5 volts 1 volt Same measure
29. 00 OST WL 9 19C ad Jom JOY I IV 295 195 JORNE MOLL AZL JoyeJauas OU Mov ACL 9 8 ou jndino JoyesaUayH EIC NVSNAION EIC NVSNIXON CIC 5 V c NVSNAOA ua3s s uoniu Jo EL Do GZ 1599 12 9 09 nue 59 EL a UIEUD 10 GL 1bL IEL sje pouds 4899 9US MOS 1893 8 0 IXI IXW 5 2 945 8 0 XS 1 Je9D 4G 1290 JID EI pz payenjoe mejo paads UOISSILISU J GLI JH 1945 pe1e1edo yyeq osip ejdninuu 21 97 one Arewud seag Inds 3n9 1431635 21 67 Arewud sueas unds 3n9 1481635 utu 00cZ UW OGZZ 0004 uado DAL 0 UILU Q06S 000 uado UES DAL 66 L GOG ut ZL WW 9p Ul 9671 2 ul 0 0 90 de3 W23 8 ADN eds DAL U LO wu 9 Z DAL U 960 0 DAL 660 0 7 20 0 64 uoniu U OOO 0 0 0 id 39093900 X UO SUOW G sgun uoissaJduuoo 8 uoissaJduuoo ure d ouo SUL UOJSId A apa
30. 19 ft Ib M 10 45 Nm 33 Piston ring end gap Connecting rod bearing radial clearance Transmission shafts end float Clutch springs length Crankshaft webs outer dimension Runout Crankshaft journal Crankshaft GASKET THICKNESSES BASIC CARBURETOR SETTING 250 300 EXC 250 EXC USA 300 EXC AUS 300 MXC EXC throttled throttled USA Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 120202 140202 130202 150202 Main jet 175 182 185 182 185 175 172 178 175 172 178 Idling jet 35 48 48 35 45 48 45 48 85 85 85 85 1475 J N3CH N3CW 1475 H NOZ NOZ NOZ Needle position from top N3CH N3CW IV Slide 6 5 6 5 Air adjustment screw open 6 5 L 6 5 Performance restrictor 1 5 1 5 Power jet nozzle slide stop 34mm e slide stop 34mm Art No 3206004 E Repair manual KTM 250 300 380 9 39C TECHNICAL SPECIFICATIONS CHASSIS 250 300 MXC EXC 2003 250 300 MXC 250 300 EXC Frame Central chrome moly steel frame Fork White Power Up Side Down 48 Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension WP PDS 5018 Progressive Damping System shock absorber aluminium swingarm Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Wear limit max 0 4 mm 0 016 in Front tires 90 90 21 548 Front tires USA 80 100 21 51M 80 100 21 51M Air pre
31. 48 50 45 42 48 48 45 50 Starting jet 85 85 85 Jet needle NOZ G NOZ H NOZ N85 C N85 D NOZ H NOZ G NOZ Needle position from top Throttle valve 6 6 Air adjustment screw open 1 5 TABLE 3 941 adA Jom 298 995 Sunjes 2 32 AC LLA WAS L AIC NVSNION LLA WAS L AC do EL Do GZ 15991 1 09 2 QU Op San EL UYD 10 361 1bL 1EL 5 SIUBAPY 945 8 0 payenjoe mejo paads GLJ 4H 1945 pe1e1edo oineap u yyeq io osip 21 97 one Arewud s ea8 Inds 143812135 21 67 Arewud seag unds 3n9 1481635 uluJ 00cZ UW OGZZ UILU OGGZ ulu 00cGS utu 00 GS ulul 00vG ee GOG ut ZL WW 9p ut 61 gy U CO0 9 0 W238 AIN PL ut 9070 t y 3019 o ZL U 8070 2018 o GEL ut 070 wu CL 2 18 o SEL ut GOO wu EL 2918 o 41 ut 200 wu el U 000 0 ww O 1231 3nd3no 103e 2uaD 545 von Ius 5192 0105 jqejre uoneougqn 1290 1299 EID IID pul UOISSILWISUBAL UI uado DAL uado 11945 DAL y Jo 14819 2 VOISUOWIC des opou129 3 eds Suu uoniu apu A2
32. 8 25 Nm 19 ft Ib Loctite 243 Rebound adjuster Spring Spring preload Air chamber length 4 2 N mm 5 mm 0 20in 100 mm 4 0 in 4 0 N mm 5 mm 0 20in 140 mm 5 9in Clamping bolts upper fork bridge Clamping bolts lower fork bridge M 8 M 8 20 Nm 15 16 11 16 Clamping bolts fork stubs M8 7 ft 1b Fork oil STANDARD ADJUSTMENT SHOCK ABSORBER Compression adjuster SAE 5 SAE 5 15 LS low speed 15 2 HS high speed Collar nut rear wheel spindle Hexagon nut swing arm bolt M 20x1 5 14x1 5 59 ft Ib 100 Nm 74 ft Ib Collar bolt handlebar clamp M 8 20 Nm 15 16 Allen head bolt handlebar support M 10 40 Nm 30 ft Ib Loctite 243 Shock absorber top M 12 60 Nm 44 ft lb Shock absorber bottom Rebound adjuster Spring PDS7 260 PDS6 260 Spring preload 25 25 4 mm 0 16 in 5 mm 0 19 in Screw adjusting ring spring preload M 12 60 Nm 44 ft lb 6 ft Ib Other bolts on chassis 7 ft Ib 19 ft Ib 33 ft lb 9 33C G6 ZOM sadns oinz jony 19Z 199 845197 99 PIS 4 9 19491425 G6 ZOU 1944199 194NS 01N3 JOS do LUOJJ uomnisod A UOA uonisod dijo SOd 1 55 15 UNA LHIIN fl IL A SV uajjo eqneJusieirnsan7 rw Jana 295
33. Adjust and Check electrical system Check adjustment Apply contact spray to ight switches eier switches and emergency au EN Check all bolts nuts screws and clamps for proper tightness Clean and lubricate control lever pivot points 60 Eon 2 Wei q 10 4C PERIODIC MAINTENANCE SCHEDULE 2001 02 250 300 380 sx mxc exc 1 service after after after 10 hours 20 hours 4000 kilometer or 1000 kilometer 2000 kilometer once a year SPORTMOTORCYCLES 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 CARBURETOR Check cooling system for leaks check quantity of anti freeze Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check oil level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting ADD ON PARTS o Check function of electric systems low high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness break lining O
34. Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 061200 050201 061200 Main jet 170 168 172 170 168 172 175 172 178 180 Idling jet 48 45 50 45 48 35 45 48 Starting jet 85 85 85 Jet needle NOZ E NOZ F D NOZ G NOZ H R 1475 J NOZ E H Needle position from top Slide 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 Performance restrictor slide stop 34mm Power jet jet BASIC CARBURETOR SETTING 250 EXC USA 300 EXC AUS 300 MXC EXC throttled USA Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 030201 070201 040201 Main jet 178 175 180 170 172 168 175 178 172 Idling jet 45 48 45 48 45 48 85 85 85 NOZ E NOZ NOZ NOZ NOZ NOZ Needle position from top IV Il Slide 6 5 6 5 6 5 Air adjustment screw open 15 13 1 5 Performance restrictor slide stop Power jet jet 9 32C TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 SX MXC EXC 2002 250 380 SX 250 300 380 MXC 250 300 380 EXC Frame Fork White Power Up Side Down 48 MA Central chrome moly steel frame White Power Up Side Down 43 MA Wheel travel front rear 295 320 mm 11 3 12 6 in Rear suspension Front brake WP Progressive Damping System shock absorber aluminium swingarm Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake
35. E 110425342 7 EI o GE 2 j O3 n2401203J409 4J83U 7 j n241 2 3J0U5 Z 50 4052 JN 2 ES E gJoud 0401 346 1 0 3 51592 0 14 u2siua 103 25 11 u2sina 31124240010W1H0dS jJlAdd5 MADE 86 3X3 086 00 U 00700 86 USN 002 OA 351 pubyspuy LUSNBEDE awu aod 000 9 0 11 206 000 SLO LI EZG 51 USNIXO8E 34 00 v0 O OST puo JX3 00 04 JusBunuu2187 unjio
36. L SV G44 SLL 081 CSL CSL IW E e SOd MIEN MOEN HOEN HOEN HOEN 41d44N GV Gy 81 fl ul 081 281 rw Y LOSZ c SOd LOEZ MOER fl 4 00001 SV 000 01 466 186 01 464 184 01 419 109 dolt Jolt 461 0 0 doc IGNGILIV 26 54 DLE S DGC 54 DIL DGL 54 29 9 54 9 54 DoOC univi3dWil JHOHS3 33W DV Md NIHIDI E007 VSN ANI IXI IXW OST WLM 3 ON HV 00 OST WL G6 ZOY papeajun Jadns 01n3 J NJ 1921 0 5197 ISN AVMHDIH LON 9 15 G 9 19491425 jal uew T G6 ZOY 99 Jadns ong yolsye y do uon sod SOd v uaqo uonisod di SOd 8319 19 55 7915 403 LHOIN 191 7 1 d1 5 uado Mans SV IW SOd 31033N fl SV W SOd 41d44N fl SV W SOd 31033N fl SV W SOd 31033N fl SV W SOd 41d44N fl SV 295 4 0001 ul 0 4 1094 LOEC 1 00001 000 9 42C 01 466 186 464 184 01 419 109 dolt Jolt 0 461 0 doc IGNGILIV JHOHS3333W D e 26 54 DLE IVC 54 DIL 9 54 29 54 9
37. Retaining bracket O When replacing the retaining bracket the two collar screws are to be secured with Loctite 243 Finally check clear passage of the crankshaft ball bearing lubrication bore O 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 Crankshaft roller bearing O 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 Needle bearing of drive shaft Press old grooved ball bearing inward press new grooved ball bearing from the inside up to the stop Grooved ball bearing of countershaft O Press old ball bearing inwards press in new ball bearing to the stop from inside Grooved ball bearing of shift roller Ball bearing falls out of its seat of its own accord when housing half has been heated to approx 150 C If necessary knock housing half on a plane piece of wood Press in new grooved ball bearing to the stop Needle bushing of shift shaft O Remove shaft seal ring and press old needle bushing inwards Press in new needle bushing from the outside to the collar Crankshaft seal ring O Press in new crankshaft seal ring from the outside with sealing lip facing inwards The seal ring is 1 mm 0 04 in lower than the upper edge ot the collar see sketch Counter s
38. SOd ss 577 1990 504 415 SOd G6 ZOY 91J19 q Jedns oJn3 404Sye y M 5 991 d1 AIIULIANISSVWALS LHIIN 5 Uado Mans SV W 295 NL AUSIII IW SOd 41044N fl SV IW SOd fl SV IW SOd 41044N fl SV IW SOd 41044N fl SV IW SOd 41044N 0001 0 H LOOL wu LOE 14 0052 067 14 LOSC 154 1 0009 009 1 1009 LOGL 1 0092 14 1094 LOEC Y 00001 SV 000 JOCL 01 1 66 186 01 464 184 0 419 109 dolt Jolt 0 461 Je0 doc JIUNAILIV JHOHS333W AA 26 54 DLE 54 De6SC anLvaIdWw il DV 8 NIHID 0007 VWSN AN IX3 IXW OSC WL 00 OST WL IVC 54 2 91 9 54 29 SIG 9 54 Io0C ONILI3S 1 3 70090TE ON HV 9 17C G6 ZO papeajun Jadns 01m3 Jon jal urew TW e asnpdneH E ISN AVMHDIH LON do uogisod di SOd 577 1990 UOnisog 445 SOd z G6 ZOY 24le q Jedns o4n3 HO SYLIY pol SUPLI g d1 AIIULIANISSVALS UNA LHDIN 5 Mans SY rw
39. SPECIAL TOOLS ENGINE 250 300 380 Fig Part no Description Universal engine work stand Clutch holder Gear wheel segment Magneto extractor M 27x1 Kokusan Magneto extractor M 26x1 5 SEM Circlip plier Holding spanner for flywheel SEM Mounting tool inner ring NJ 207 Mounting tool inner ring NJ 207 Protection cap Holding spanner for flywheel Kokusan Dial gauge 0 10 mm Dial gauge support Loctite 243 blue 6 ccm Bearing puller Internal bearing puller 18 23 mm Internal bearing puller 12 16 mm Internal bearing puller 5 7 mm Clutch rivetting tool Extractor primary gear Vent springe for hydraulic clutch LO CO O1 AI 0 5 0 Art No 3206004 E Repair manual KTM 250 300 380 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 HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS Before cleaning with water plug the exhaust pipe to prevent water ingress You should use normal brand name detergents to clean t
40. Sun Kee q1 43181 38 55 7415 LHDIN uado Mans Sy ru c HOST OZL CLL GLL SZL 081 CHL W 29 9 295 L 4 SOd 5 1 11Q33N GV 8v 09 CG 1 0001 CH PALL L cl SV OOE 891 GLL SZL 081 W SOd IZON H J1G33N Gy 0G CG D L L SV GOL 891 04 CLL GLL SLL W SOd J10JIN Gp er ev er OG fl C C V GAN L SV COL GOL 991 04 CAL G L W SOd J10JIN CV Gp Gp Gp er OG CIV c V L D L SV COL COL GOL 891 041 CEL W J 1094 L L L SOd LOEC H H H CV CV fl 4 00001 v Cc V LC C C L SV 000 166 1086 O 4062 484 19 109 dolt 161 1 0 del lt a ANnIVAidWil JHOHS3 133W J06 54 DLE 2e8t 54 DGC JVC 54 DIL 9 54 DI 54 9 54 De0cC 8 66 VSN 2X3 2XW XS 08 WLM ZE 9 10C 941 adA LUPO Jom 9 qe1 995 8011395 JOJAINGUeD VOJasnques 32 ONA MOLL AZL JOyeJaua3 ou Mor AZL 9 8 ou jndino 1 EIC NVSNION LIT NVSNION CIC y AL NVSNAOA ua3s s uoniu
41. THE MAINSHAFT Grooved ball bearing of countershaft O Press in new grooved ball bearing from downward to the stop The open side of the ball cage must be face inwards Grooved ball bearing of the shift roller O Remove retaining screws and press bearing inwards Press in new ball bearing from inside to the stop and secure retaining screws with Loctite 243 Needle bushing of the shift shaft O Press old needle bushing inwards press in new needle bushing flush from the outside Grooved ball bearing of centrifugal timer The bearings usually fall out of their seat of their own accord by knocking the housing half on a plane piece of wood when the housing has a temperature of 150 If necessary use a 6 mm internal bearing extractor and guide hammer see illustration Press in new grooved ball bearing to the stop Bearing bolt kickstarter intermediate gear O Experience has shown that it is never necessary to replace the bearing bolt It is not recommended to mount a used bearing bolt in a new housing half as it is practically impossible to remove it without causing damage Kickstarter release plate When replacing the release plate secure the flat head screws with Loctite 243 Crankshaft seal ring Press in new shaft seal ring from the outside with sealing lip facing inward until flush Stop screw kickstarter When mounting the stop screw it must be secured with Loctite 243 Do not forget new copper seal ring
42. U ee U GOG U A7 U p6 L Get 7 ul 0 0 90 de3 W23 8 ADN eds ZL ut LO ww 9 7 DAL U 960 0 DAL 660 0 7 0 0 64 uoniu U OOO 0 ww 0 Du E Jaddn UOISUAWIG sgun uoissaJduuoo ure d Sul urejd auo SUL UOJSId Rg pa poi So SULIB9Q 19 01 Suueaq jeq 2 18 3Jeus ue17 y UO 0 XIU pp esn 10 Jayodu JORJUOD aseajd Idnop uayM 9 gt 01IS OM 8 usiu SUISN 09 4 Op L 8 x Suey adUeAPY 9us Io 2013s OM apeIS USIY OU SUBIO ont YIdNS papeajun U 86 C ZZ 8L Ul 88 C WU El CL Ul v8 c CZ 799 920415 9108 Jaquiey W1 pue 5 45 OJJUO IAEA UIML WLY euigua 34015 oM 8 pajoo9 pinbr7 BISA YSN yo 1no sj pow je LOOT IX3 XS 08 00 0SC ANIONS VIVO 1VOINHO3L 3 70090TE ON HV 08 00 OST WL 9 22C TIGHTENING TORQUES M6 Other bolts 10Nm 7 ft lb M 8 25 Nm 19 M 10 45 Nm 33 TOLERANCES AND FITTING CLEARANCES 0 06 mm 250 Piston ring end gap 0 3 0 4 mm
43. a3pa Jaddn uojsid saddn X UOISUQuIg sgun uoissaJduuoo o poau SULIB9Q 19 01 1epuri Ao Suueaq jeq 2 18 opis Alps UO 0 one XIU 95 12e1uo0 aseajd ul uauM io 230145 OM apeJ8 YSIY SUISN uauM 09 OG L x Sui ey o ueApy US Io OM BpPeIS YSIY ou SUBIO 2 95 Ian HANS Ul 86 C UW ZZ 84 Ul 88C 78 0 UU El CZ 99 G69 9 Jaquiey W1 pue 5 5 sneyxa SALA UIML WL 2 8 5 pe ooo pinbr 503 2X3 08 XS 08 503 2X3 00 503 2X3 097 XS OGZ UOJSId Suueaq uid uojsig Suueaq pol Yeys ues 0528 920445 9404 YSN JO JNO sjapow jie 66 503 2 3 5 08E 00 0ST SNOILWDISIDAdS TWOINHDAL 3 70090TE ON HV 08 00 OST WL 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 18x1 5 Loctite 243 150 Nm 18x1 5 Loctite 243 100 Nm 35 Nm 35 Nm 60 Nm 25 ft
44. in service then the following should be checked 1 Piston running surface Check for pressure marks seizing marks minor friction marks can be removed with a fine abrasive stick 2 Piston ring grooves The piston rings must not get jammed in the grooves For cleaning the grooves use an old piston ring or abrasive paper grain size 400 3 The piston ring locating pins must be firmly seated in the piston and must not be worn out 4 Check piston rings for wear and check end gap Piston ring end gap Insert piston ring into the cylinder and adjust Piston ring must be approx 10 mm 1 2 inch from top of cylinder The end gap can now be checked with a feeler gauge Piston ring end gap max 0 40 mm 0 015 in NOTE If the end gap is greater check piston and cylinder for wear If piston and cylinder wear are within the permitted tolerance limits replace the piston ring 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 67 500 67 512 67 513 67 525 72 000 72 012 72 013 72 025 N ii 78 000 78 012 78 013 78 025 66 340 66 350 Zon the 2000 mod 66 351 66 360 71 940 71 950 i Recoated cylinder NOTE If the cylinder diameter is larger than e g 66 360 mm the cylinder must be regenerated or replaced For reconditioning of the old
45. level Before each After every cleaning For cross country use Once a year 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 clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regular 10 6C PERIODIC MAINTENANCE SCHEDULE 2003 250 300 MXC EXC 1st service after after after 10 hours 20 hours 4000 kilometer or 1000 kilometers 2000 kilometers once a year SPORTMOTORCYCLES 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 CARBURETOR Check cooling system f
46. secure flat head screws with Loctite 243 5 6C Mount silicon O rings 16x2 mm on control rollers and grease Place control rollers in cylinder and mount retaining brackets 6 5 7C Mount and grease silicon O rings 15x1 50 mm on control and grease Slightly grease the bearing sleeves and plug them on the control flap 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 with collar outside adjusting lever with ball head on outside overload spring with short leg on outside and spring sleeve to control flap Coat allan head screw with Loctite 243 and screw up about 5 revolutions hook the short leg of the overload spring on to the cylinder pin see illustration and tighten the allan head screw On the left side mount the stop plate Apply Loctite 243 to the threads of the two screws and mount them Turn control rollers in cylinder in such a way that ports are completely open and no edges protrude Place preassembled control flap in cylinder engage gear segments in control rollers in such a manner that when the control flap is open pivoted right to the top the markings of the gear segments and the gear rollers coincide Please check that the two control rollers do not block the cross section of the port when the control flap is open Coat sealin
47. 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 Slide stop disc 20 2x 33x1 5 mm on the drive shaft and stop disc 25 7x40 x1 5 mm on the countershaft AS EMISE the engine housing Remove engine fastener from engine work stand Check that both dowels are in proper place in right hand housing and that transmission shaft stop discs have been mounted Apply light coat of grease to sealing surfaces of the housing and position new gasket Grease shaft seal rings in left hand half and place left hand half in position Position screws and tighten with 8 Nm 6 ft Ib Gently knock crankshaft with plastic hammer and check easy running of shafts Fix engine in work stand Art No 3206004 E Repair manual KTM 250 300 380 6 4C Mounting shift mechanism Place locating spring with bent leg upwards into engine housing Insert collar sleeve into spring with collar upwards Coat collar screw with Loctite 243 Insert locating lever with roll upwards and fix all parts with collar screw Hook locking spring to lever The other end of the retaining spring must abut the casing nose LOCTITE 243 Ga Mount roller locking device plastic part to shift roller Ensure that the flat parts are not in the middle Pull locking lever from shift roller
48. with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Front tires Front tires USA Air pressure offroad Air pressure road driver only 80 100 21 51M 80 100 21 51M 1 0 bar 14psi Wear limit max 0 4 mm 0 016 in 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi 90 90 21 54R 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi Rear tires Rear tires USA Air pressure offroad Air pressure road driver only 100 90 19 62M 100 90 19 62M 1 0 bar 14psi 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi 140 80 18 708 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi Fuel tank capacity Final drive ratio Final drive ratio USA 7 5 liter 2 US Gallons 11 liter 2 9 US Gallons 14 52t 8 5 11 liter 2 2 2 9 US Gallons 15 48t 14 50t 14 52t Chain Available final sprockets 5 8 x 1 4 38t 40t 42t 45t 48t 50t 521 Steering head angle 63 5 Wheel base Seat height unloaded 1481 10 mm 58 3 0 4 in 925 mm 36 5 in Ground clearance unloaded 385 mm 15 2 in Dead weight Dead weight USA Dead weight without fuel STANDARD ADJUSTMENT FORK 101 kg 223 lbs 101 kg 223 lbs WP 1418W709 WP 0518W711 16 12 102 5 kg 226 3 lbs 109 kg 240 6 lbs 103 7 kg 229 lbs TIGHENING TORQUES CHASSIS Collar nut front wheel spindle M 16 20x1 5 40 30 ft Ib Brake caliper front M
49. 0 3006 Jka 00 095 004 9 jJlAdd5 DI puojssbunaapug JUSBUNUYI 137 awoy 11apoy 3 ON HV 08 00 OST WL 11 7C Ki Modell Kabe lst rangnummer vorne gt 5 Bi E Land Datum Nane hinten AAA SERVICE 125 380 EXC 2000 nm Europa ose C GN O amp BSH amp gt Ui MEM q 4 3 Y 3 d bri br Y o p ge r IE E 9 9 ZI blob b I Ka bl bl ge Jy ge AAA AAA EEE EE en 04 5 ge 5 ge ll ge bl lt ge 16 _ d bl w STW KOKUSAN SES GU o bl u AAA A AA AA Sg NN j 1114 SFP 3 ll AAA E y 18 S ge a OY U eee E D W ge gt na IL d IT o 29 8 ohne Funktion Dar La Oe eu O O AS 3 5 19 DEAD 95 30 br 310 Q Q54 a Qe C C O Blinkerstrong f r Wettbeuerbseinsatz O D demontierbor Stecker 29 11 8C Scheinwerfer headl ght l faro l phare 2 Standlicht 2 parking light 2 luce di posizione 2 feu de position CO 3 Blinker Li vo 3 turn indie left fr 3 lampegg ant sn 3 clignoteur av gauche CO 4 Blinker re vo 4 turn indic right fr 4 lampegg ant dx 4 clignoteur av droit 5 Tachobeleuchtung 5 speedometer light 5 luce di tachimetro 5 eclair comp vitesse 6 Fernlichtkontrolle 6 high beam indicator 6 spia abbagl ante 6 tem
50. 0 4251 1603 u3sina 86 3X3 08 00 00001 Puoi1spug HSN 000 9 0 11 205 uayu y SITIAIHOLOMIIOSS 96 USN 2 3 002 o LUSNBEOE A mann 000 SLO iV EZS J X U 0 0 2 J N j 5 MDI 11 2 2 51 JauunuBunJ351aqo q 190 7 190 puo 151 90 3 ON HV 08 00 OST WL 11 14 Modell Kabelstrangnummer vorne gt e Ae Land Datum Name Dateiname hinten SERV LUE 250 300 EXC 2003 ec 0 11 ET EU RUS one e 5 5 Q qu o Ex s E n gt u ojo ur ELE qp 23 E V 9 g E U W a a bl w Sw SEN EA 5 a 5300 m II LH KOKUSAN 2 K3 Co 5 gt 4 4 B UR Art No 3206004 E Scheinuerfe Standl cht Blinker Bl nker re Tacho Bl nkerkont 2 pol Steck pol Steck zum Kombisc WM Bremslichts Bremslichts Horn Bl inkgeber CDI ndkerze ndspule Generator Kondensator Spannungsre Impulsgeber r vo vo Fernlichtkontrolle rolle er er halter ch vo ch hi gler Bl nkerschalter b pol Steck Blinker Bl nker re er hi h 1 Brems Schlu l cht bl blau alienisch bl n bl braun br gelb ge blue broun br yellow ge KIM 250 300 EXC 200
51. 001 varna A USA 22 06 se SPORTMOTORCYCLES hinten 503 11 076 000 o ge 2 br A br c w b IA 2 dico d ge o r4o r a 4 I KOKUSAN 9 9 9 2K2 br co U g CO 8 1C TROUBLE SHOOTING 8 INDEX TROUBLE SHOOTING 250 380 8 2 Art No 3206004 E Repair manual 250 300 380 8 2C TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out disturbances can 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 CAUSE REMEDY Engine fails to start Operating error Open fuel tap switch o ignition replenish fuel do not use choke Fuel supply interrupted Close fuel tap loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out clean carburettor if no fuel leaks out check tank ventilation i e clean fuel tap Electrode distance too great Reduce electrode distance 0 60 mm Plug fouled by oil wet or bridged Clean spark plug or renew Ignition wire or spark plug connector Dismount spark plug connect ignition cable hold to ground damaged blank place on engine and actuate kickstarter a strong spark must be produced at the spark plug If no spark is produced loosen spark plug cap from ignition cable hold about 5 mm from ground and actuate kickstart
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53. 243 to the threads Then mount both screws but do not tighten them yet Set preselected value on depth gauge and fix Swifel control upwards and hold depth gauge into cylinder as shown in the illustration Control must rest against depth gauge Allow bump plate O to rest against retaining bracket O Secure bump plate fastening screws and Remove depth gauge Having tightened the screws you have to check the dimension Z again and correct it if necessary Press linkage of control flap down wards as far as stop and press ball socket onto ball of adjusting lever Keck pressing ball socket do not e pull the linkage too far up max 1 mm 0 04 in e swivel control flap upwards Adjust linkage length if necessary To so loosen counter nut and turn ball socket accordingly Retighten counter nut Once adjustments are completed remove ball socket once again and fit gasket for control cover Refit ball socket and fit safety device 6 9 Mounting steering covers Mount the right hand control cover and fix it with 3 screws Place gasket in position and fix left hand steering cover on cylinder 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 Mount the collar sc
54. 250 300 380 SX MXC EXC REPAIR MANUAL ENGINE SPORTMOTORCYCLES KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www ktm at REPAIR MANUAL ENGINE SPORTMOTORCYCLES 10 11 12 13 14 15 16 SERVICE INFORMATIONS GENERAL INFORMATION REMOVING AND REFITTING ENGINE DISASSEMBLING THE ENGINE SERVICING ON INDIVIDUAL COMPONENTS ASSEMBLING THE ENGINE ELECTRICAL TROUBLE SHOOTING TECHNICAL SPECIFICATIONS PERIODIC MAINTENANCE SCHEDULE WIRING DIAGRAMS Art No 3206004 E Repair manual KTM 250 300 380 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 aen rer 034 o o o mose e TT 05 Les on Le 11 1C 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 210x297 mm into the transparent pocket provided for this purpose on the outside of the binder Put the spine label 170x45 mm into the transparent pocket provided for this purpose on the spine of the binder Put the summary list of contents 150x297 mm into the transparent pocket provided for this purpose on the in
55. 2t 9 5 12 liter 2 5 3 2 US Gallons 15 48t 14 50t 14 52t Chain Available final sprockets 5 8 x 1 4 38t 40t 42t 45t 48t 50t 521 Steering head angle 63 5 Wheel base Seat height unloaded 1481 10 mm 58 3 0 4 in 925 mm 36 5 in Ground clearance unloaded 385 mm 15 2 in Dead weight Dead weight USA Dead weight without fuel STANDARD ADJUSTMENT FORK Compression adjuster 101 kg 223 lbs 101 kg 223 lbs 102 5 kg 226 3 lbs TIGHENING TORQUES Brake caliper front Rebound adjuster 14 14 12 12 109 kg 240 6 lbs 103 7 kg 229 lbs CHASSIS Collar nut front wheel spindle M 16x1 5 40 Nm 30 ft Ib 25 Nm 19 ft Ib Loctite 243 4 0 N mm 4 0 N mm Clamping bolts upper fork bridge 20 Nm 15 ft lb Spring Repair manual KTM 250 300 380 Spring preload Air chamber length 6 mm 0 24in 140 mm 5 5in 6 5 mm 0 26in 150 mm 5 9in Clamping bolts lower fork bridge 11 16 Clamping bolts fork stubs M 8 M 8 8 7 ft Ib Capacity per fork leg Fork oil approx 840 ccm SAE 5 SAE 5 approx 830 ccm STANDARD ADJUSTMENT SHOCK ABSORBER Compression adjuster Rebound adjuster WP 1218U718 4 18 WP 1218U720 5 20 Collar nut rear wheel spindle Hexagon nut swing arm bolt M M 20x1 5 59 ft Ib 14x1 5 74 ft 1b Collar bolt handlebar clamp M8 15 ft Ib Allen h
56. 3 On WM blu marrone giallo headlight position turn indic Light left fr turn indice right Tr speedometer high beam indicator turn indicator multip cont plug 2 multip cont plug 3 to combinat switch stoplight switch f stoplight switch r horn turn Indicator CDI spark plug Ignition coil generator capacitor voltage regulator pulser coil blink switch multip cont plug 6 blinker left rear blinker right rear rear stopl ght bleu brun jaune gt WM 10 12 13 14 ES 16 17 18 19 20 2 44 LS 24 29 26 bl bl faro luce di posizione lampegg ant sn lampegg ant dx tachimetro sp a abbagl ante spia lampeggiatori connettore a 2 poli connettore a 3 poli multicomando luce arresto ant luce arresto post int int clacson trasmett lampeg bobina 4 5 dinamo condensatore regol di tens trasmett d impulsi int lampeggiatori connettore a 6 poli lampegg post sn lampegg post dx fanal post di freno azul marron amarillo faro 19 wN 11 15C phare feu de position clignoteur av gauche clignoteur av droit compteur temoin feu route temoin de clignoteur multiple 2 multiple 3 connect connect commodo contact de stop av contact Harr de stop klaxon centrale clignot CDI bougie bobine d allumage generateur condensateur regulateur generateur d m
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59. 8 AG Keihin PWK 38 AG Carburetor setting number 010300 030300 050300 070300 Main jet 172 170 175 178 175 180 175 172 178 170 168 172 Idling jet 48 45 50 45 48 45 48 45 48 Starting jet 85 85 85 85 Jet needle NOZ E NOZ F NOZ G NOZ H NOZ H NOZ I NOZ G NOZ I NOZ H Needle position from top IV Slide 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 Performance restrictor Power jet jet 9 21C Ja Jom JOY Ay 918 295 Sunjes JOJaINGUed Jong MOLL AZL JoyeJauas OU MOLL AZL JOye 3uas ou jndino Joyesauay NVSMION NVSMION EIC NVSNAOA 5 5 uoniu do EL Do GZ 1529 Ye 230M 9609 9299 nue 594 EL 206000 jet 3v V EL 3920 5 08 d3 1290 1945 MOS 2295 8 0 XSA eoueApy 1995 Ob MOZ aulgua 8 0 08 d3 1290 1945 MO8 1298 80 PXSA 945 Ob MOZ 10 8 0 uone uqn 1490 Je9D 4G 1290 JID EI pz Ones payenjoe mejo paads UOISSIUISU J GLJ 4H 11 5 pe1e1edo oineap u yyeq io u inp osip ejdninuu Uu 21 97 Oel Arewud seag Inds 14312135 21 67 Arewud seag unds 112 1481635 UW OGZZ utul 0007 uado DAL 0 00 uado 31835 DAL
60. ARBURETOR 2 2 CARBURETOR ADJUSTMENT 2 3 CHECKING OF THE SETTING OF THE TVC SYSTEM 2 4 BLEEDING OF THE HYDRAULIC CLUTCH 2 4 SPECIAL FOOLS ENGINE 2 5 CLEANING asesora 2 6 STORAGE E 2 6 Art No 3206004 E Repair manual KTM 250 300 380 2 2C OPERATING RANGES OF THE CARBURETOR main jet jet needle idle jet throttle valve air control screw idle adjusting screw 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 and the idle adjusting screw Only make adjustments when the engine is hot To this end slightly increase the idling speed of the engine by means of the idle adjusting screw Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed Create a round and stable engine speed using the air control screw basic position of the air control screw open by 1 5 turns Then adjust to the normal idling speed by means of the idle adjusting screw Opening up B Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle setting the e
61. Connecting rod bearing radial clearance 0 021 0 032 mm Transmission shafts end float 0 1 0 2 mm Clutch springs length O 2 5 new 43 mm minimum length 42 mm Piston fitting clearance 0 06 mm 300 0 08 mm 380 GASKET THICKNESSES 0 5 mm Clutch cover 0 5 mm Cylinder bottom gasket Available cylinder bottom gaskets Cylinder head gasket as required 0 2 0 4 0 5 0 75 mm O rings BASIC CARBURETOR SETTING 250 EXC AUS throttled 300 EXC AUS throttled 380 EXC throttled Keihin PWK 38 AG 080300 170 168 172 45 48 85 85 85 Keihin PWK 38 AG 060300 175 172 178 45 48 Keihin PWK 38 AG 040300 178 175 180 45 48 Carburetor Carburetor setting number Main jet Idling jet NOZ G NOZ H NOZ H NOZ I NOZ G NOZ I NOZ H Needle position from top IV Il Slide 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 Performance restrictor slide stop 36mm slide stop 34mm slide stop 34mm Power jet jet BASIC CARBURETOR SETTING 250 300 EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 070300 020300 Main jet 172 170 175 170 168 172 175 172 178 180 Idling jet 48 45 50 45 48 35 Starting jet 85 85 85 NOZ E NOZ F NOZ G NOZ 2 R 1475 J Needle position from top Il Throttle valve 7 6 5 6 5 Air adjustment screw open 15 1 5 1 5 Keihin PWK 38 AG PJ 010300 Carburetor Carburetor setting number Jet needle Performance restrictor slide stop 34mm 55 Power j
62. ECTED IN ACCORDANCE WITH THEIR MARKINGS CONNECT RED WHITE CABLE TO TERMINAL Ignition coil SEM As this ignition coil uses electronic components you are advised not to use conventional measuring instruments An accurate function test can only be carried out on an ignition test bench Ignition coil Kokusan Disconnect all cables and remove the spark plug connector Use an ohmmeter to measure the following values NOTE The indicated setpoint values correspond to a temperature of 20 Replace the ignition coil if the measured values deviate significantly from the setpoint values Measurement Cable colours Resistance Primary coil blue white ground 0 425 0 575 Q Secondary coil blue white ignition wire 10 8 16 2 kQ CDI unit Check the cables and plug and socket connections of the CDI unit The CDI unit function can only be checked on an ignition test bench CAUTION 1 NEVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE CDI UNIT COMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS Art No 3206004 E Repair manual KTM 250 300 380 Pom 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 v
63. G THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST USE AFTER A PERIOD OF STORAGE Fill up the tank with fresh fuel Check the motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season 3 1C REMOVING AND REFITTING ENGINE 3 INDEX REMOVING THE ENGINE 3 2 REFITTING THE ENGINE 3 4 Art No 3206004 E Repair manual 250 300 380 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 Disconnect plug and socket connector of ignition system and spark plug connector Art No 3206004 E Remove sprocket cover and chain Remove footbrake cylinder cover Disengage and remove spring O Repair manual KTM 250 300 380 3 3C Loosen the 3 screws and remove interme
64. I 1475 J Needle position from top Throttle valve 7 6 6 6 6 Air adjustment screw open 1 5 1 5 Performance restrictor slide stop 34mm Power jet jet 53 Art No 3206004 E 9 14C TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 SX MXC EXC 2000 250 380 SX 250 300 380 MXC 250 300 380 EXC Frame Fork Central chrome moly steel frame White Power Up Side Down 43 Wheel travel front rear 295 320 mm 11 3 12 6 in Rear suspension Front brake WP Progressive Damping System shock absorber aluminium swingarm Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Front tires Front tires USA Air pressure offroad Air pressure road driver only 80 100 21 51M 80 100 21 51M 1 0 bar 14psi Wear limit max 0 4 mm 0 016 in 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi 90 90 21 54R 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi Rear tires Rear tires USA Air pressure offroad Air pressure road driver only 100 90 19 62M 100 90 19 62M 1 0 bar 14psi 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi 140 80 18 708 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi Fuel tank capacity Final drive ratio Final drive ratio USA 7 5 liter 2 US Gallons 12 liter 3 2 US Gallons 14 5
65. Ib 25 ft Ib 44 ft Ib 110 ft Ib 74 ft Ib 6 ft Ib 74 ft Ib 14 ft 1b 7 ft Ib 19 ft Ib 33 ft Ib 8 Nm 100 Nm Loctite 648 19 Nm 10 25 45 GASKET THICKNESSES Cylinder bottom gasket Clutch cover Available cylinder bottom gaskets 0 2 0 4 0 5 0 7 mm Cylinder head gasket BASIC CARBURETOR SETTING 250 MXC EXC 250 300 EGS 380 EGS 250 SX 300 MXC EXC AUSTRALIA 380 5 MXC EXC AUSTRALIA Keihin PWK 38 090598 Carburetor Carburetor setting number Main jet 172 168 170 175 Idling jet 45 48 50 Starting jet 85 NOZ G NOZ H NOZ TABLE 4 Jet needle Needle position from top Throttle valve Air adjustment screw open Performance restrictor Keihin PWK 38 100598 175 170 172 178 45 42 48 85 N85 C N85 D IH 6 1 5 Umar Keihin PWK 38 060598 175 168 170 172 45 48 50 Keihin PWK 38 070598 170 168 172 175 48 45 50 Keihin PWK 38 100598 1750170 172 178 45 42 48 85 N85 C N85 D 6 1 5 Umar 1 5 Umar slide stop 31mm H NOZ G NOZ G NOZ H NOZ 1 5 Umdr slide stop 36mm Art No 3206004 E Repair manual KTM 250 300 380 9 6C TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 SX MXC EXC EGS 99 250 3805X 250 300 380 MXC 250 300 380 EXC 250 300 380 EGS Frame Central chrome moly steel frame Fork WP Extreme 50 mm Wheel travel front rear 280 320 mm 11 0 12 6 in Rear suspension WP Progressive Damping Syste
66. J0 e auas OU NVSMION do EL Do MOLL ACL NVSMION UAX 8 4 URUD 10 PXSA MOLL ACL EIC NVSNAOA 15291 1 OEM 09 2 1 qu 950p 59411 EL GL TEL 945 8 0 pajenpe paads GLI 4H 1 5 pareado ejdninuu 21 97 one seag Inds 14316135 uUW OOTZ 0 66 L 21 87 saeas 1195 310 148 UW OGZZ UIW OOES ut ZL WW 9p U CO0 9 0 ul 66 000 1231 10 e 9u983 OU 3nd3no 1oye1ausn v Xc NVSNAON uo1s s uoniu 39420145 a qe re uoneougqn IPD 1090 Ap JID 1890 pE 1290 ul Ones UOISSIUISU J UI uado DAL uado UES DAL d o 104 des opou129 3 1245 Op W23 8 ADN eds 2018 o ZL U 800 3019 o ZL U 400 uiu U 00 0 0 0 Suu uoniu sgun uoissaJduuoo uojsid SULIB9Q 19 01 2 Suueaq jeq 2 18 y UO XIU pp esn 10 Japrodu 124 aseajd Idnop uayM 8 usiu SUISN 09 Op L x SDUPAPY 5
67. Mount driver for shift roller Coat allan head screw Q with Loctite 243 and mount NOTE From model 2002 on driver for roller and locking piece are made of aluminium Grease assembled shift shaft and push into bearings together with stop disc until slide plate contacts driver for shaft roller Now squeeze and push shift shaft in to the stop Check that legs of return spring surround both left and right side of housing nose Q Mount the foot shift lever and shift through all gears When shifting through the gears turn the countershaft Then remove the foot shift lever Mounting kickstarter Place spacing washer on the stop face an place preassembled kickstarter shaft in bearing bore in such a way that the locking pawl is outside the release plate NOTE If the kickstarter shaft is mounted correctly the visible end of the starter spring must point forward see photo Hook spring hanger to starter spring coat screw with Loctite 243 tighten starter spring approx 90 clock wise and fix spring pawl with allan head screw Adjust starter spring so that the distance to the Kickstarter shaft is the same all around Place starter intermediate gear amp with the high collar see sketch showing towards the engine casing on to the bearing Slip on stop disc 17 2x25x1 mm and mount circlip with the sharp edge showing upwards 6 5 Mount primary drive and clutch Grease crankshaft sea
68. N SEM 4 6 DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING 4 7 PARTING OF ENGINE HOUSING 5 4 7 DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION 4 7 DISMOUNTING OF THE CRANKSHAFT 4 8 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 O allowing oil to drain Dismounting of sprocket and shift lever Remove circlip from countershaft using circlip pliers Slide off engine sprocket distance bushing and O ring Undo the screw and remove the shift lever Pull out the clutch push rod O from drive shaft Art No 3206004 E Dismounting of cylinder head cylinder and piston Unscrew the 6 collar screws and remove cylinder head and the two O rings Undo the screws and remove the left control cover together with the gasket Repair manual KTM 250 300 380 4 3C Undo the screws and remove the right control cover Remove the securing clip of the ball socket and unhook the ball socket O from the adjusting lever Remove gasket of the control cover Remove t
69. NG POWER CAUTION AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL STORAGE Should you wish to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil old engine oil contains aggressive contaminants Check antifreeze and amount of cooling liquid Let the engine warm up again close fuel cock and wait until the engine dies off by itself In this way the carburetor jets are prevented from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate bearing points of the control levers footrests etc as well as the chain The storage place should be dry and not be subjected to too big temperature fluctuations Cover the motorcycle with an air permeated tarp or blanket Do not use non airtight materials as a possible humidity might not be able to escape and thereby cause corrosion CAUTION WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURIN
70. SION AND CLUTCH WILL SUBJECT AXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL I E MOTOREX TOP SPEED 41 Filling in of cooling liquid Make sure that the drain screw is fastened Pour approx 0 50 litres 0 13 US gallons coolant into the system 4096 coolant 6096 water Remove the screw on the right radiator and tilt the motorcycle to the right approx 30 degree angle Now add cooling liquid until it emerges free of bubbles at the right radiator Then immediately mount the screw so that no more air can enter the right radiator Return the motorcycle to its original position and top up the left radiator until the coolant can be seen approx 10 mm 0 4 in above the radiator fins Art No 3206004 E Repair manual 250 300 380 DISASSEMBLING THE ENGINE INDEX DRAINING GEAR 4 2 DISMOUNTING OF SPROCKET AND SHIFT LEVER 4 2 DISMOUNTING OF CYLINDER HEAD CYLINDER AND PISTON 4 2 DISMOUNTING OF CLUTCH COVER 4 3 DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS 4 4 DISMOUNTING OF THE PRIMARY DRIVE 4 4 DISMOUNTING OF KICKSTARTER 4 5 DISMOUNTING OF THE SHIFT LOCK 4 5 DISMOUNTING OF IGNITION COVER 4 5 DISMOUNTING OF THE IGNITION KOKUSAN 4 6 DISMOUNTING OF THE IGNITIO
71. SOd 5 31033N Y 0001 00 W SOd 41d44N fl SV W SOd 41d44N fl SV IW SOd 41d44N fl SV rw Y 1067 SCH LOEZ JIG3IN Y 00001 SV 000 pajeas A nJ uado Mads 01 466 186 01 464 184 01 419 109 dolt Jolt O2 461 FOL 0 doc IGNGILIV 26 54 DLE 54 DGC Doyl SIG DIL 9 54 29 54 9 54 DoOC univi3dWil JHOHS3 33W AMd NIHITA TOOT VSN UN3 OST WLM aunannommssvoun 3 ON HV 08 00 OST WL 9 34C G6 ZOM papeajun Jadns 01n3 ISN AVMHDIH LON G6 ZO 1914191 Jedns oJn3 Moslem do uonisod SCH 5 415 UNA LHDIN Suipi f uado 25 JY SV 01 466 186 01 464 184 01 419 109 dolt Jolt 461 26 54 DLE 2e8t 54 DGC 519 DIL 9 54 29 54 3 9 DV 8 AMd NIHIZA WSN YNA 2X3 2XW OSC WL 1 06 01 doc Ja 519 JUE 19 5192 9 19491425 esnpjdneH uonisod 415 SOd W SOd 41d44N fl SV W SOd 371993 fl SV W SOd 41d44N fl SV W SOd 31033N fl SV IW SOd 31033N fl SV uajyo 295 4 0001 00 4 1094
72. SPECTION OF THE 250 300 EXC AND MXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR WORKSHOP ADDITIONAL ORDER FOR THE WORKSHOP 30 45 60 hours hours hours Check the reed type intake valve for wear e 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 piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear RECOMMENDED INSPECTION OF THE 250 300 EXC MXC ENGINE USED FOR HOBBY ENDURO BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP 60 90 120 180 hours hours hours hours 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 piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmis
73. SSIS 250 880 1 5 51 8 505 8 3 505 39 05 ARNES 9 23 CARBURETOR SETTINGS 9 24 MODEL 2002 ENGINE 250 380 USA 9 28 ENGINE 250 380 nazareno 9 30 CHASSIS 250 980 seso rieron 9 32 CARBURETOR SETTINGS OR RECREAR 9 33 MODEL 2003 ENGINE 250 300 aem pon 9 37 CHASSIS 250 300 9 39 CARBURETOR SETTINGS EEN 9 41 9 2C adA LUPO Jom 9 q8 995 Sunjes 2 2 opi s 1e Jognqie EL Do GZ 1s 9 1 2PM 9509 9299 nue 950t Sam EL 3ugoo x 8 10 161 1 1 19320105 a qe reAv 92ue py I 9US 0 8 0 Jean JID Ap JID 1890 pE 1290 ul Ones pajenpe paads UOISSILUSUBA GLI 4H 1 5 parado 03n ayd ynu 429 uado DAL 21 97 Arewud seag Inds 1431635 21 87 Arewud seag unds 4nd 1431635 UW OOTZ UW OGZZ UILU OGGZ uluJ 00cG ulu 00 G6 utu 00rG uado HES DAL U ee U GOG U U 6 1 gp quo 7 ul 200 9 0 de3 9po1199 3 W23 8 ADN yueds 2019 o ZL U 600 wu 2018 1 ut 8070 O 32019 o 41 U
74. T WEBS MEASURE OUTER DIMENSI N 5 4 Kate HEET EE 5 4 PISTON RING END GAP 5 4 CHECKING CYLINDER FOR WEAR 5 5 RECOATED 5 5 NIKASIL COATING OF CYLINDER 5 5 CYLINDER EXHAUST CONTROL SYSTEM 5 6 CYLINDER PREASSEMBLY 5 6 EXHAUST CONTROL CLUTCH COVER 5 8 PREASSEMBEY OF CLUTCH COVER xax xu em xm mmn tuo t tee 5 8 REED VALVE HOUSING INTAKE FLANGE 5 9 CLUTCH 5 10 REPLACE OUTER CLUTCH HUB 5 11 SHIFT ef TEE 5 12 PREASSEMBLY OF SHIFT SHAFT 5 12 IGNITION KOKUSAN 5 13 SPARK E E ENEE 5 13 CHECK STATOR AND PULSE GENERATOR KOKUSAN 5 13 IGNITION CSEM serenos reses EORR 808 8 390809 ee eee 5 14 CHECK STATOR SEM 5 14 TRANSMISSION ccc sau sete seat eaten een 5 15 ASSEMBLY MAINSHAFT 5 15 ASSEMBLY 5 5 16 KICKSTARTER 5 17 ASSEMBLE OF KICKSTARTER SHAFT 5 17 Engine housing NOTE Read through the following section before commencing work Then determine the assembly sequence so that the engin
75. a changed adjustment the engine does not run properly look for mechanical faults and check the ignition system Basic information on carburetor wear As a result of engine vibrations throttle valve jet needle and needle jet are subjected to increased wear This wear may cause carburetor malfunction e g overly rich mixture Therefore these parts should be replaced after 10000 kilometers 6000 miles jet needle throttle valve open Explanation Example N85A N 85 B Compared to the needle N 85 A the jet needle N 85 is two steps leaner N 85 C in the range from the closed position of the throttle to 1 4 throttle Otherwise there are not differences N85D N 85 E N 85 C 0 OO NOZ C NOZ D NOZ E OO CAUTION NOZ NOZ 60009 CHANGING THE JET NEEDLE MAKE SURE THAT YOU USE THE CORRECT NEEDLE TYPE 85 NOZ THE TECHNICAL DATASHEET TELLS YOU WHICH JET NEEDLE CAN BE USED FOR WHICH MODEL NOZ H NOZ NOZ J 60000 60000 600000 N3CG N3CH N3CW Art No 3206004 E Repair manual KTM 250 300 380 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
76. aa 205 SOd 5 31033N 1 Y 0001 00 IW SOd 371993 fl SV W SOd 41d44N fl SV W SOd 31033N fl SV rw Y LOSZ SCH LOEZ JIG3IN Y 00001 Sv 000 JoOCL 01 466 186 01 464 184 01 419 109 dolt Jolt 0 461 0 doc 26 54 DLE 54 DGC 519 DIL 9 54 DI 54 9 54 DoOC JHOHS3A3IW DV 8E AMd 0007 VSN YNI XIXW 00 WLM 9 18C G6 ZO papeajun jal urew esnpjdned d ISN AVMHDIH LON do uonisod di SOd 277 1990 445 SOd E G6 ZOY 9241914 199 5 3 OISHBAN 191 Sup q1 GAM 138N3SSV3 LS YNA LHIIN pajees Ap nj uado Mans SV LU aqnelyosial nsa14n7 He rw Jana 295 SOd NCIAIUSIIII VJ 31033N Y 0001 00 W SOd 41d44N fl SV W SOd 41d44N fl SV IW SOd 41d44N fl SV rw Y 1052 SCH LOEZ JIG3IN Y 00001 SV 000 01 466 186 464 184 01 419 109 dolt Jolt 461 O2 doc 26 54 DLE 54 DGC Jove 54 DIL 9 54 29 54 9 54 DoOC anLvasIdW il JHOHS3 33W DV 8E AMd NIHI33 0007 WSN YNA 2X3 2XW XS OBE 3 70090TE ON HV
77. age Inner clutch hub Check contact surfaces of steel discs on the inner clutch hub maximum 0 50 mm 0 02 in indentations Pressure Check contact surfaces between lining disc and pressure for signs of mechanical damage and score marks Outer clutch hub O Check start surfaces of clutch discs on for wear If indentations exceed 0 50 mm 0 02 in replace outer clutch hub see below Check inner ring O and needle cage for wear Replace clutch hub Drill open the clutch rivets in area of retaining bracket and remove parts Check 8 absorbing elements for signs of mechanical damage replace all 8 where applicable CAUTION THE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED DIRECTLY ON THE PRIMARY GEAR CROWN THE PARTS MUST BE HELD IN POSITION UNDER TENSION WITH THE CLUTCH RIVETTING TOOL 9 WHILE RIVETING Art No 3206004 E Repair manual KTM 250 300 380 5 12C LOCTITE 243 0 eo 2 LOCTITE 243 ue LOCTITE 243 1 eu O gt A N Ka Shift mechanism Shift forks Check shift fork blades and shift roller driving pin for signs of wear Shift roller 0 40 Check shift grooves for wear 0 80 mm Check position of shift roller in grooved ball bearings Slide plate Check slide plate at meshing points
78. alue Check the capacitor Check the connector between the stator and the voltage regulator rectifier and between the voltage regulator and the cable tree Check the stator Replace the voltage regulator rectifier Checking the voltage regulator Start the engine 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 regulator rectifier and between the voltage regulator and the cable tree Check the stator Replace the voltage regulator rectifier Checking the capacitor Discharge the capacitor by bridging the two connections with a cable bridge and dismount it 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 is made with a test lamp When the power circuit is closed the test lamp must light up briefly and return to its dark state after 1 second at the latest If the test lamp does not go out or does not light up at all the capacitor is faulty 7 5C STATIC IGNITION VALUES 250 380 SX EXC KOKUSAN 2K 1 2K 3 2K 4 Measuring conditions cold engine seat and tank removed
79. ap ZN p fng uo Sua 271 Joydnuuyayu Depu D JoydnJuJayul 020 495 18 0 4 J10u anou JUBA 51 16 46 unaq na1q 19 y a1d13 nu s ndw Jnai3oJauaD 10 81d 31nu 328uuo2 naj Dnog au qoq JJ8ju 19110 p aJoud 5 1502004 86 9X3 082 521 1 86 USN IX 521 zaq6up 1351 N CH CO CO N CN CO CO puo ssGunsapuy 0333101 05504 8uo 12UDJD apJa 015116 2 011016 auoJJpu nig 14 109 y O 215 0101085 1 15 1109 0 2 840143 50d 3 0U0y 01409 sus ip 106834 san 0118p 0 1N94190 409 JJayul 0 04 1931 USN 8IZZ Jus unuy9 187 N mo CON OO gt CO a3 1 Um 18 0 4 43019 0 fias6 16 mo ah umoJq Jq anq 14 p 8n1d yuos diy nw 1102 Jas nd 1un 109 Enid yuos di31nu 146 14084 Bnjd 12035 1102 uo 311 uDI 8803104 ydzims 14611 41 9 12 3 0 5 14
80. aulty Check ignition system Engine revs not high and Carburetor overflows if level adjust Clean carburetor if necessary replace float needle and adjust running with four stroke too high float needle seating is level cycle dirty or enlarged Loose carburetor jets Tighten jets High rpm misfiring Incorrect heat range spark plug or Refer to technical data section low quality spark plug Incorrect or faulty spark plug connector Test and or replace spark plug connectors correct type Loose corroded or non conductive Check and seal with silicon ignition socket connector Engine spluters into the Lack of fuel Clean fuel pipes examine tank aeration and clean carburetor Spark plug with incorrect heat value Fit correct spark plug Ignition by incandescence Engine takes air out of control Check intake flange and carburettor if firmly setted Engine overheating Insufficient liquid in cooling system Top up coolant and bleed cooling system check cooling system for leaks Cooling system not or insufficiently Bleed cooling system see operating instructions bleeded Radiator fins clogged Clean radiator fins with water jet Frothing in cooling system Renew coolant using branded anti freeze anti corrosive Pinched or kinked water hoses Replace with correct routed hoses Incorrect ignition timing because of Readjust to correct ignition timing specifications secure loose stator bolts screws properly with Loctite 243 Incorrect
81. blue blu bleu azul br braun brown marrone brun marron ge gelb yellow g allo jaune amarillo gr grau grey grigio gris gris gr n green verde vert verde orange orange arancione orange naranja rot red rosso rouge rojo schwarz black nero noir negro violett violet violetto violet violeta wei white bianco blanc blanco faro luz de posicion nterm izquierdo delantero intermitente derecho delantero luz tacometro lampara aviso luces largas lampara aviso intermitentes conector multiple 2 conector multiple 3 interruptor combinado interr luz de freno del interr luz de fren tras claxon conjunto del intermintente CDI bujia bobina de encendido generador condensador regulador de tension generado de impulsos nteruptor clignoteur conector mult ple 6 CO CD J OF OU J4 amp WN Kontaktbelegung Lichtschalter 9610 Bl inkerschal ter intermitente izquierdo trasero intermitente derecho trasero luz de freno trasero 11 13C ofou DF UD JBU ap Jan 5146 6 ee 011 1720 19 3 oe TEs p a1d 31nu ap popiun 19131 018501 271 0 oif ng opipua2ua 9 uoisuaj y znj p Joydnuuayju E H DGDu Joydnyuyayul 2 oe EE 35 5 Yaz npas
82. 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 advance 250 Model 1999 5400 U min 7550 U min 250 from Modell 2000 on 5000 U min 7000 U min 300 up to Modell 2000 5300 U min 7750 U min 300 from Modell 2001 on 5900 U min 7750 U min 5200 U min 7200 U min f necessary turn the adjusting screw NOTE Twisting the adjusting screw in delays the commencement of adjustment by the TVC system twisting the adjusting screw out means that the TVC system will perform the adjustment earlier Bleeding of the hydraulic clutch Take off cover together with rubber bellows At the slave cylinder of the clutch remove the bleeder nipple It its place mount the bleeder syringe which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubble free state Make sure that the oil does not overflow CAUTION HAVING COMPLETED THE BLEEDING PROCEDURE YOU VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT KIM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID 2 5C
83. ch cover Fit bearing support with control lever and linkage Secure both screws with Loctite 243 Mount water pump wheel coat screw with Loctite 243 and mount with washer Mount dowels of the water pump cover Position gasket and fix water pump cover with 5 collar screws The two screws mounted at the dowels must each be provided with one copper gasket 5 9C LOCTITE 243 PA 0 Loctite 243 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 SECURE ALL SCREWS OF THE REED VALVE HOUSING WITH LOCTITE 243 Velocity insert O Check for firm mounting and for signs of damage Intake flange O Check for cracks and other signs of damage Art No 3206004 E Repair manual KTM 250 300 380 5 10C 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 Discs must be plane there must be minimum spacing of 13 50 mm 0 531 in between starting surfaces 8 Steel discs Must be plane check for mechanical dam
84. ch holder Remove inner clutch hub and outer clutch hub together with bearing from main shaft Pulling the primary gear and the distance bushing off the crankshaft NOTE The primary gear and the outer clutch hub belong together Always replace both together 4 5C Dismounting of kickstarter Remove circlip and kickstarter intermediate gear Carefully release collar screw kickstarter spring is tensioned release tension on kickstarter spring and unhook spring hanger CAUTION CAREFULLY RELEASE THE KICKSTARTER SPRING DANGER OF INJURY 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 Press the sliding plate back with a screw driver so it no longer engages with the driver for the shaft roller at the same time remove shift shaft from the housing NOTE Watch the stop disc which remains in the housing Remove allan head screw and take driver for roller and locking piece O from the shift roller NOTE From model 2002 driver for roller and locking piece are made of aluminium NOTE Disassemble locating lever only if the engine case must be replaced Remove screw and locking lever with spring and bush Dismounting of ignition cover Undo the 5 screws and remove the ignition cover together with the gasket 4 6C Dismounting of the ignition Kokusan Ho
85. connect multiple 3 O commodo contact de stop av zum Kombischalter multicomando Bremslichtsch vo int luce arresto ant Bremslichtsch hi Horn Bl nkgeber CDI ndkerze stopl ght switch f N N NO stoplight switch r int luce arresto post contact Harr de stop OO CO ODO clacson klaxon trasmett d CDI candela horn turn indicator CDI spark plug gt gt centrale cl gnot CDI bougie bobine d allumage generateur condensateur gl O O O2 J 1 bobina d accens Ziindspule Ignition coil dinamo CO CO CO Kondensator capacitor condensatore NO N O NO O regol di tens regulateur trasmett d mpuls voltage regulator pulser coil blink switch multip cont plug 6 Spannungsregler Impulsgeber Blinkerschalter Stecker Blinker li hi Blinker re hi Brems Schlu l cht KN KN N generateur d mpuls KN NO NO NO N N contact d cl gnateur connect mult ple 6 clign arr gauche clign arr droite feu arr et de stop int Lampeggiator connettore a 6 poli NO 4 NO ODO NO wm NO gt NO T NO bl nker left rear lampegg post sn NO gl NO NO blinker right rear lampegg post dx N O D O NO O rear stoplight fanal post di freno bl bl bl bl N blau bl
86. cylinder all exhaust control components must be removed The intermediate flange remains with the cylinder The piston size is stamped into the bottom of the piston Nikasil coating of cylinder Nikasil is the brand name for a cylinder coating process developed by the piston manufacturer Mahle The name is derived from the two materials used in this process a nickel layer into which the particularly hard silicon carbide is inbedded The main advantages of the Nikasil coating are excellent heat dissipation and thus better power output e low wear low weight of the cylinder NOTE The worn coating can be regenerated at low cost provided that the cylinders running surface is flawless Art No 3206004 E Repair manual KTM 250 300 380 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 Check toothing of gear segments and control rollers for signs of wear Bearing sleeves O Check bearing sleeves of the control for play and easy operation Control O Clean the control The control must not graze inside the exhaust port Silicon O rings O Check silicon O rings of control flap and control rollers for signs of wear Renew if necessary Cylinder preassembly
87. diate flange chamber of 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 caburetor out of carburetor connection boot and intake flange Remove transmission oil drain plug together with sealing ring and drain the transmission oil Remove the 2 screws and dismount clutch slave cylinder CAUTION DO ACTUATE THE CLUTCH LEVER WITH THE CLUTCH SLAVE CYLINDER DISMOUNTED Remove engine fastening screw Remove hexagon nut of swingarm pivot O Remove swingarm pivot and pull swing arm backward out of the frame so as to make lifting the engine out of the frame easier Lift engine out of frame NOTE Cylinder head and cylinder can be dismounted even if the engine remains mounted Likewise work on clutch primary drive gearshift mechanism and ignition system can be carried out Art No 3206004 E Repair manual KTM 250 300 380 3 4C 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 41 In order to check the transmission oil level the control screw 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 CAUTION TRANSMIS
88. dimension X Measure and adjust to correct specification Emission of white smoke Cylinder head or O ring of cylinder Check cylinder head replace O ring steam head gasket leaks Excessive oil escapes from Excessive oil quantity in trans Correct transmission oil level transmission breather tube mission Water pump shaft seal ring or right Replace shaft seal ring and change gear oil check coolant hand crankshaft seal ring defect Silicon O rings of control roller or of control flap leaks Replace O rings All switched on lamps Voltage regulator faulty Control connections of voltage regulator Check voltage blown out regulator Art No 3206004 E Repair manual 250 300 380 TECHNICAL SPECIFICATIONS INDEX MODEL 1999 ENGINE 250 380 USA 9 2 ENGINE 250 380 9 4 CHASSIS 200 gt 8380 9 6 CARBURETOR SETTINGS 32 9 7 MODEL 2000 ENGINE 250 380 USA 9 10 ENGINE 250 380 9 12 CHASSIS 250 380 Gm nn mn na XS NOS X ee eee 9 14 CARBURETOR SETTINGS 9 15 MODEL 2001 ENGINE 250 380 USA 9 19 ENGINE 250 380 SLL LECCE CCCI CDC CCC SSC CEC 9 21 CHA
89. discs Assembly countershaft Fix countershaft in vice with toothed end use covered clamps Oil all parts before assembly Push stop disc 26x40x1 5 mm onto countershaft Mount 3rd idler gear with shift dog recesses upwards and circlip O 25x2 mm with sharp edge upwards Mount 5th sliding gear O with shift groove downwards stop disc 22 2x33x1 5 mm needle cage 1st free gear with shift dog recesses downwards and stop disc 17 2x34x1 5 mm with collar upwards on the countershaft Remove countershaft from vice and fix again with toothed end upwards Mount 4th sliding gear with shift dog upwards stop disc 28 2x40x1 5 mm needle cage 2nd idler gear with shift dog recesses downwards and stop disc 25 7x40x1 5 mm Finally check all gears for easy running 5 17C 0 LOCTITE 243 0 LOCTITE 243 0 LOCTITE 648 Kickstarter Starter gear Check clearance of starter gear Starter intermediate gear O Check clearance of starter intermediate gear Locking Check signs of wear and damage Kickstarter shaft O Check for signs of wear and damage For changing the locking pawl press bearing needle O out of the kickstarter shaft Assemble of kickstarter shaft Fix the kickstarter shaft O in a vice with the toothed end upwards use covered vice clamps Mount ratchet spring on kickstarter shaft as shown in the illustration
90. druff key into crankshaft Apply Loctite 243 to the threads of the 3 screws Mount base plate together with stator and tighten the 3 screws Mount the cable guide 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 Ib Aguas ignition point SEM Make sure that the stator can be turned on the intermediate plate Otherwise loosen the 3 screws Mount flywheel Screw dial gauge into spark plug thread Place adjusting pin in flywheel bore 91 2 mm 0 08 in and turn flywheel until pin slots into recess in stator Turn flywheel and stator jointly to TDC Turn dial gauge scale to O and turn flywheel with stator clockwise accordingly to preignition Ignition point Carefully remove flywheel to prevent further turning of stator Tighten the three stator cylinder screws Mount flywheel and tighten collar nut with 60 Nm 45 ft Ib Check ignition point once more Remove dial gauge and fit spark plug with OR Mounting ignition cover Put on a new gasket and fix the ignition cover by means of the 5 screws Mounting starting lever and shift lever Push distance bushing onto kickstarter shaft and mount kickstarter Mount shift lever Operate the kickstarter a few times and check if the engine turns freely Oil the
91. e housing halves only need to be heated up once before replacing the bearings Having first removed the dowels in order to expel the bearings or remove them with light mallet blows the housing halves must be placed on a suitably large plane surface supporting the whole of the sealing surface without damaging it A wooden panel is best used as a base Bearings or shaft seal rings should not be hammered into their seats If no suitable press is available use a suitable mandrel and hammer them in with great care Cold bearings will practically drop into their seats at an engine housing temperature of approx 150 After cooling should the bearings fail to lock in the bore they are bound to rotate after warming In that event the housing must be replaced Art No 3206004 E Repair manual KTM 250 300 380 En 5 2C 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 The open side of the ball cage must be towards the bottom outside of the case Grooved ball bearing of main shaft Press in new ball bearing from inside up to the stop CAUTION DO USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE RETAINING BRACKET 6 TO AVOID A BENDING OF THE BRACKET WHICH WOULD RESULT IN EXCESSIVE AXIAL PLAY OF
92. ead bolt handlebar support Shock absorber top M 10 M 12 30 ft Ib 44 16 Shock absorber bottom M 12 44 ft Ib Screw adjusting ring spring preload Other bolts on chassis Spring Spring preload PDS3 250 5 mm 0 2 in PDS2 250 5 mm 0 2 in 6 7 ft Ib 19 ft Ib 33 ft Ib M 6 M 6 M 8 M 10 9 15C G6 ZO papeajun jal urew esnpjdned JSN AVMHDIH LON do UONISOd di SOd DE _ 1990 dD SOd z G6 ZOY 9241914 199 5 013 HOJSYELIY yal SUPLI g 5 91 q1 AIIULIANISSVALS LHIIN pazeas Ajjnj uado Mans SV 4H2S1 rw Jana 295 SOd 5 41d44N Y 0001 SV 00 W SOd 41d44N fl SV W SOd 41d44N fl SV W SOd 31033N fl SV 829191 rw Y 1052 SOd LOEZ JZON 31031N Ch Y 00001 SV 000 01 466 186 01 464 184 01 419 109 dolt Jolt 0 461 0 doc IGNGILIV 306 54 DLE 54 DGC 519 DIL 9 54 29 54 9 54 DoOC anLvasIdW l JHOHSIJITW DV8E MMd 0007 VSN ANA WLY 5 9 16C G6 ZO Papeajun Jon jal asnpydneH E JSN AVMHDIH LON do uonisod di
93. ed clamps Oil all parts before assembly Mount the split needle cage on mainshaft push 5th idler gear over it with collar downwards Place internally toothed stop disc 22 4x25 7x32 0x1 5 mm in position and mount circlip O 25x1 64 mm with sharp edge upwards Place sliding gear in position with shift groove downwards mount circlip 25x1 64 mm with sharp edge downwards and internally toothed stop disc 22 4x25 7x32 0x1 5 mm Mount the split needle cage 4th idler gear O with shift dogs downwards 2nd gear with collar downwards and stop disc 20 2x33x1 5 mm Finally check all gears for easy running Art No 3206004 E Repair manual KTM 250 300 380 5 16C 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 Tooth profile of mainshaft and countershaft and correspondending gears Easy operation of gear change Carefully clean components and replace damaged components NOTE Always place circlips with sharp edge facing the components secured ensuring that they are not overexpanded use special pliers Check that after any repair of the transmission circlips should axially not move more than 0 20 mm 0 006 in and must not seize between stop
94. efects e Excessive voltage in the circuit The bulbs burn out Connect a voltmeter yellow cable positive brown cable negative to check the voltage Start the engine and switch on the power consumers y T 1 d 1 t P 7 rz mme E Hu m gt m At an engine speed of 3000 r p m the voltage regulator must supply a voltage of 12 0 14 0 V A C At higher engine speeds the limit of 14 0 V should not be exceeded either If the reading significantly deviates from the nominal value replace the voltage regulator 1 4 EH 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 O 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 The test lamp must go out after 0 5 2 seconds depending on the lamp capacity If the test lamp does not go out or does not light up at all the capacitor is faulty CAUTION DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST WHEN INSTALLING THE CAPACITOR MAKE SURE THAT THE TERMINALS ARE CONN
95. ep 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 of our repair manual whether these are technical errors incorrect or unclear repair procedures tool problems missing technical data or torques inaccurate or incorrect translations or wording etc please enter the error s in the table below and fax the completed form to us at 0043 7742 6000 5349 NOTE to table Enter the complete item no for the repair manual in column 1 e g 3 210 66 E You will find the number on the cover page or in the left margin on each right page of the manual Enter the corresponding page number in the repair manual e g 5 7c in column 2 Enter the current text inaccurate or incomplete in column 3 by quoting or describing the respective passage of the text If your text deviates from the text contained in the repair manual please write your text in German or English if possible Enter the correct text in column 4 Your corrections will be reviewed and incorporated in the next issue of our repair manual Item no of repair manual Current text Correct text Additional suggestions requests or comments on our Repair Manuals in German or English Name mechanic shop foreman Company work shop Art Nr 3206004 E Repair manual 250 300 380 GENERAL INFORMATION INDEX OPERATING RANGES OF THE C
96. er If a spark now occurs replace spark plug cap If no spark is produced check ignition system Kill button wire or Disconnect yellow black coloured cable from CDI and check short circuit switch faulty ignition spark If the spark is O K repair defective part of cable ignition lock or ignition switch Loose ignition cable connectors Inspect cable connectors Spark too weak Examine ignition system Water in the carburetor and jets Dismantle and clean carburetor blocked Art No 3206004 E Engine without idle Idle adjusting screw out of Readjust idle running or replace idle adjusting screw running adjustment Ignition system damaged Examine ignition system Wear Overhaul engine Engine has not enough Charred glass fiber yarn in silencer Renew filling power Air filter obstructed Clean or renew airfilter Control flap does not work Check control flap joint rod and centrifugal timer Fuel supply partly interrupted or Blow through fuel pipe and clean carburetor blocked Loss of compression through loose Tighten spark plug spark plug Exhaust system damaged Check exhaust system for damage Engine has not enough preignition Check and adjust ignition Repair manual KTM 250 300 380 8 3C TROUBLE CAUSE REMEDY Engine has not enough Reed paddles tensionless or dama Replace reed paddles or reed valve housing ged surface of reed valve housing damaged Wear Overhaul engine Electronical ignition timing f
97. et jet 9 23C TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 SX MXC EXC 2001 250 380 SX 250 300 380 MXC 250 300 380 EXC Frame Fork Central chrome moly steel frame White Power Up Side Down 43 Wheel travel front rear 295 320 mm 11 3 12 6 in Rear suspension Front brake WP Progressive Damping System shock absorber aluminium swingarm Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Front tires Front tires USA Air pressure offroad Air pressure road driver only 80 100 21 51M 80 100 21 51M 1 0 bar 14psi Wear limit max 0 4 mm 0 016 in 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi 90 90 21 54R 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi Rear tires Rear tires USA Air pressure offroad Air pressure road driver only 100 90 19 62M 100 90 19 62M 1 0 bar 14psi 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi 140 80 18 708 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi Fuel tank capacity Final drive ratio Final drive ratio USA 7 5 liter 2 US Gallons 11 liter 2 9 US Gallons 14 52t 8 5 11 liter 2 2 2 9 US Gallons 15 48t 14 50t 14 52t Chain Available final sprockets 5 8 x 1 4 38t 40t 42t 45t 48t 50t 521 Steering head angle 63 5
98. ews lower fork bridge Clamping screws fork stubs Collar nut rear wheel spindle M 8 M 8 M 20x1 5 15 Nm 10 Nm 80 Nm Hexagon nut swing arm bolt Hexagon collar screw handlebar clamp Allan head screw handlebar support M 14x1 5 M 8 M 10 100 Nm 20 Nm Loctite 243 40 Nm Shock absorber top Shock absorber bottom Sprocket screws M 12 M 12 M 8 60 Nm 60 Nm Loctite 243 35 Nm Ball joint for push rod Engine mounting bolt Engine brace M 6 M 10 M 8 Loctite 243 10 Nm 45 Nm 33 Nm Screw adjusting ring spring preload shock abs Spoke nipple Other screws on chassis Other collar nuts on chassis M6 M4 5 M5 8 Nm 5 Nm 9 41C G6 ZO papeajun Jadns 01n3 J NJ 19ZIWONY 5197 G 9 3PIIS 9 19491425 ISN LON jeu fW asnpidney Ou G6 ZOU 1941914 Jedns oJn3 do uon sod dij SCH EE uaqo uonisog dil SOd 9314138 355 415 LHOIN 191 Sui p H uado Mans SV 8v 8v 0G fl Y 0001 L L L L L SV 00 081 CSL CSL Gel 881 W e SOd HOEN HOEN HOEN HOEN DODEN 41d44N fl L L L L SV SLL 081 CHL CSL Gel W 5 SOd MIEN HOEN HOEN HOEN HOEN 41d44N GV 81 fl L
99. fibre yarn filling of the exhaust main silencer Change hydraulic clutch fluid Change break fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR kml MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER Art No 3206004 E Repair manual KTM 250 300 380 10 7C IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check gear box oil level Before each After every cleaning For cross country use Once a year 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 float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly 10 8C RECOMMENDED IN
100. fit clutch springs spring retainer and collar screws Tighten the collar screws crosswise Do not apply more than 6 Nm 4 5 ft lb to prevent damaging of the threads in the inner clutch hub Mounting clutch cover Check whether both dowels are mounted in clutch cover or engine housing Grease kickstarter shaft seal ring and position clutch cover gasket Secure gasket with a little grease Carefully position preassembled clutch cover and press into place turning crankshaft so that centrifugal timer can engage in the primary gear Fit collar screws see sketch for screw lengths and tighten with 8 Nm 6 ft Ib Then check easy running of all shafts NOTE If the clutch cover cannot be mounted verify whether or not the kickstarter spring has been positioned correctly 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 Adjusting dimension Dimension is the dimension from upper edge of piston to upper edge of cylinder with cylinder under low tension and piston i
101. for wear Check return surface 6 for wear renew if strongly notched Check that guide pin is securely fixed and check for wear Sliding guides Check sliding guides excess between guide pin and shift quadrant not to be more than 0 7 mm 0 03 in Grooved ball bearings O Check grooved ball bearings for easy movement Shift mechanism Assemble shift mechanism see below and check free play between slide plate O and shift quadrant Free play should be 0 40 0 80 mm 0 016 0 032 in Preassembly of shift shaft Fix shift shaft in vice at shorter end use covered clamps Mount slide plate with guide pins downwards hook guide pins into shift quadrant O Mount pressure spring Slide on spring guide slide on return spring with offset end upwards over the spring guide and lift offset end over bolt see illustration Mount the stop disc 14x30x1 mm 2 2 2 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 Make sure to select the correct measuring range when performing measurements Spark plug Set the electr
102. g surface thinly with silicon and mount intermediate flange with 4 O rings 11 3x2 4 mm Mount exhaust flange and spring hangers If you are dealing with a throttled version do not forget the exhaust throttle Finally check smooth running of exhaust control system NOTE It must be possible to push adjusting lever further upwards against the spring force d a I M Art No 3206004 E Repair manual KTM 250 300 380 5 8C 0 0 gt LOCTITE 243 LOCTITE 243 Exhaust control clutch cover Remove screws and take off the bearing support Take cup tappet adjusting spring and auxiliary spring O out of clutch cover Take off water pump cover remove allen head screw and take off water pump wheel The centrifugal timer can be pulled out of the bearing Clean all parts and check for signs of wear Check play and easy operatability of the adjusting lever in the bearing Check pin of adjusting lever for wear Check linkage ball heads for clearance Remove circlip and check axial bearings and washers for signs of wear If the water pump shaft seal ring is replaced it should be coated with Loctite 243 on the outside Check grooved ball bearing for clearance Preassembly of clutch cover Grease water pump shaft seal ring and mount centrifugal timer 6 Fit adjusting spring auxiliary spring and cup tappet in the clut
103. haft seal ring Press in the new shaft seal ring until it is flush with machined surface Shift shaft seal ring Press in the new shaft seal ring until it is flush with machined surface When housing half has cooled off check to see that the bearings are tight Finally check clear passage of the crankshaft roller bearing lubrication bore Art No 3206004 E Repair manual KTM 250 300 380 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 CAUTION NEVER CLAMP THE CRANKSHAFT WITH A STUD OR WEB IN THE VICE AND NEVER TRY TO KNOCK THE BEARING INNER RING FREE THE CRANKSHAFT WEBS MAY BE COMPRESSED AND THE CONROD PLUG AND BEARING MAY BE DAMAGES MAKING THE CRANKSHAFT UNUSABLE NOTE Distance adjustment of the main bearings is not requested Crankshaft webs measure outer dimension Crankshaft webs measure outer dimension with a sliding caliper as illustrated Crankshaft webs outer dimension 60 mm 0 05 mm Piston If a used piston is to remain
104. he 4 collar nuts on cylinder base and remove cylinder 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 Remove piston and piston pin needle bearing from conrod eye Remove the cylinder base gaskets CAUTION THE PISTON PIN MUST NEVER FORCED OUT WITH PUNCH THIS WOULD DAMAGE THE CONROD BEARING Dismounting of clutch cover Remove collar screws and clutch cover including gasket NOTE The water pump cover the outer cover and the cover lid do not need to be removed The water pump and the centrifugal timer remain in the clutch cover Art No 3206004 E Repair manual KTM 250 300 380 4 4C Dismounting of pressure cap and clutch discs Loosen collar screws 6 in diagonally opposite sequence to prevent 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 Dismounting of the primary drive Block the primary gear with the gear wheel segment see illustration Undo the hexagon nut LH thread and remove it together with the detent edged ring Release the lock washer of the inner clutch hub Connect clutch holder to inner clutch hub and loosen hexagon nut see illustration Remove clut
105. he motorcycle Especially dirty parts should also be cleaned with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all the gliding bearing parts Treat the chain with a chain spray To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch the short circuit button the light switch and the socket connectors with contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take precautions against the aggressive road salt clean the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent A R NING A KEEP THE ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKI
106. i Mi 0196 A39 GAL 10425342 7 a6 13 8 1010 gt 6 SHO S 15 ap e 502 ap san JJajul 9 ouauy ap san G 8401 y 20 zn E M 506101 San 1023002 2 y gt s upds Jq 9 4q E 2uD1q ay ym m 1810 4 0333101 a101 131810 EI JI OU oJau 2019 2 10425 0550 pau 303 10 I 2 0 0 31 apJa usaub unub 26 B 51 6 16 016146 16 haub 6 16 6 J O aunor ab 011016 4126 unaq 8auoJJpu umouq Jq na1q 19 na 14 19 19 s a o 5af 818110208 9 03150duo2 01 110 09 9 J03128uuo23 131 10 JapuiqJa 18110J0g 9 J 6 81d 31nu 9 110d 84033auuo2 94 6 6 19 yuos d yjnu Ja42335 100 6 91 Aq lt y a d yjnw 32auuo2 G 1109 6019 yuos d yjnu 4854283198 10d p GI m 6 m 81d 31nu 32auuo2 y 1109 14 d yjnu 48542818 10d g p a6 26 2 2 81d 31nu 1109 7 840338auuco2 7 6019 yuos d yjnu 48528319 100 2 1q 19 JnayoJauab 7 oupu p Z 2030 Z 6 D yuods azJaypunz
107. ing preload Repair manual KTM 250 300 380 PDS7 265 5 mm 0 2 in PDS2 250 6 mm 0 24 in 7 ft Ib 19 ft Ib 33 ft Ib 9 24C G6 ZO papeajun Jadns 01n3 ISN AVMHDIH G6 ZOU sadns 01n3 0153j amp 4 9314138 55 15 403 LHOIN pazeas Ajjnj uado M NS JI V JoOCL 01 466 186 01 464 184 01 419 26 54 DLE 2e8t 54 DGC JVC 54 DIL fd DYSE NIHI3 9 Z jal do uonisod SOd jal sup fl Lo 109 dolt Jolt 0 461 9 54 29 54 3 9 1006 VSN ANI 1 06 01 doc 2847 519 20 9 15197 L 19491435 osnpidneH uaqo uonisog 415 SOd oasnpjne i92 4 251 IW SOd 41d44N fl SV W SOd 371993 fl SV W SOd 41d44N fl SV W SOd 31033N fl SV W SOd 31033N fl SV 295 4 0001 ul 0 4 1094 LOEC 1 00001 000 JHOHS333W ONILI3S YOLIANAAVI 5 9 25C G6 ZOY Jadns 01n3 J NJ 9 92 9 19qNE15197 G 9 5 a gt G 9 19qetu s Ad AM en do uonisod dij ECH 7 di SOd AIIUL3INISSVALS 403 LHIIN 191 Su
108. ipi fl gt 5 qi uado Mans SV uajo eqneJupsisinSoJn YHIST rw 205 SOd 5 31033N Y 0001 SV 00 W SOd 41d44N fl SV W SOd 41d44N fl SV IW SOd 41d44N fl SV rw Y 1067 SCH LOEZ JIG3IN Y 00001 SV u 000 01 466 186 01 464 184 01 419 109 dolt Jolt O2 461 O2 doc IGNGILIV 26 54 DLE 54 DGC IVC 54 DIL DGL 54 29 9 54 9 54 DoOC univi3dWil JHOHS3 33W DV NIHDN LOOT VWSN ANI IXI IXW OST WLM 3 ON HV 08 00 OST WL 9 26C G6 ZOY papeajun e 9 5 G 9 19491425 451 yal ure fI E e asnpidney G6 ZOU 1944199 190AS 01N3 0154845 do wol du 5094 9 UOA uonisod 45 SOd ala L3aN3SSVALS 403 LHOIN jal Sui p fl d m 95 1997 qi pa3eas Ap n UOJ uado Mans SV rw ana eas SOd 5 41d44N Y 0001 SV 00 W SOd 371993 fl SV W SOd 41d44N fl SV W SOd 31033N fl SV W 4 1094 SOd LOEZ 31033N Y 00001 SV 000 JoOCL 01 466 186 01 464 184 01 419 109 dolt Jolt 0 461 0 d
109. ires for cuts and air pressure Check cables for damage and free movement Adjust and oil control cables Check electrical system Check battery holder and connections CH Singapore Check adjustment of headlight Apply contact spray to light switches flasher switches and ignition lock Check all bolts nuts screws and clamps for proper tightness e e lef NA Art No 3206004 E Repair manual KTM 250 300 380 10 3C PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE 125 380 6 99 SPORTMOTORCYCLES AT A REGULAR COMPETITION USE OF THE BIKE THE 4000 KM 2500 MILES SERVICE 15 TO BE DONE AFTER EVERY RACE B e L N gt Loi e 8 gt O A O O RK SC E 5 E O LO N nn before each start 600 miles or 10 hours gt 22 x 3 O O gt O O 55 i L e e O Check cooling system for leaks visual inspection Check exhaust system for cracks and leaks Check brake fluid level front and rear Change brake fluid Check thickness of disc brake pads Check quality of antifreeze Grease swingarm needle bearings dont grease the pivot bearing for the shock absorber EE Replace glass fiber yarn of silencer Check of the exhaust suspension system Check or even spoke tension and rim Jo e Check tres for cuts and ar pressure Check cables for damage and fee movement
110. l lelverbinder parallel connector parallele connecteur N de N 3 pol Stecker mult p cont plug 3 connettore a 3 poli connect multiple 9 blau blue blu bleu azul braun broun marrone brun marron gelb yellow g allo Jaune amarillo grau grey gris gris gr n green verde vert verde orange orange aranc one orange luz rot red rosso rouge rojo lampara aviso luces largas schwarz black nero no r negro lampara aviso intermitentes violett violet violetto violet violeta conector multiple 4 white bianco blanco llave de contacto faro luz de posicion interm izquierdo delantero intermitente derecho delantero interruptor combinado Kontaktbelegung nterr luz de freno del Zundschlof Typ 7 pol Blinkerschalter interr luz de fren tras claxon conjunto del intermintente diodo bujia bobina de encendido generador condensador regulador de tension Lichtschalter Typ CEV 9610 bateria 12V I 20h fus ble pr nc pal 108 conector multiple 4 intermitente izquierdo trasero intermitente derecho trasero Abb lend luz de freno trasero feto 28 parattete connecteur MANE conector multiple 3 11 5C 03ub1Q of ou pF upupu ap12 5126 6 011 1720 19 p 219 1 328u02 s ndw JopoJauab popiun 81d 31nu y9auo9 DJaspJj
111. l ring Putthe 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 onto crankshaft with collar downwards Put the inner ring onto the main shaft with the collar facing downwards then mount the oiled needle cage Mount outer clutch hub and stop disc 6 Apply Loctite 243 to the thread of the main shaft Mount inner clutch hub new lock washer and hexagon nut to main shaft Position clutch holder and tighten hexagon nut with 100 Nm 74 ft Ib Remove the clutch holder and secure the hexagon nut by bending both brackets of the lock washer upwards Apply Loctite 243 to thread of the crankshaft Fit locking washer and hexagon nut left hand thread by hand Block primary drive with gear segment and tighten primary gear hexagon nut with 150 Nm 110 ft Ib Remove gear segment and check easy running of primary drive by turning crankshaft Art No 3206004 E Repair manual KTM 250 300 380 6 6C Mounting clutch discs and pressure cap Oil the thrust bearing O 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 Place pressure cap into position
112. ld the flywheel with the holding spanner and undo the collar nut 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 Art No 3206004 E Dismounting of the ignition SEM Hold the flywheel with the special tool and undo the collar nut Place protective cap on crankshaft thread Twist in the flywheel extractor and remove the flywheel Loosen the 3 collar screws and take base plate with stator out of the casing Repair manual KTM 250 300 380 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 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 I CAUTION LEVERING APART WITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED SINCE THE SEAL FACES ARE EASILY DAMAGED NOTE Watch gear shaft stop discs to prevent them sticking to inside of housing Dismounting of gearshift mechanism and transmission Take the two stop discs off the transmission shafts Pull the 2 pressure springs out of the
113. m shock absorber aluminium swingarm Front brake Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Front tires 80 100 21 51M 80 100 21 51M 90 90 21 54R 90 90 21 54R 80 100 21 51M Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air press road driver only 1 5 bar 21 psi 1 5 bar 21 psi Rear tires 110 90 19 62M 110 100 18 64M 140 80 18 7OR 140 80 18 7OR 8 110 100 18 64 Air pressure 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air press road driver only 2 0 bar 28 psi 2 0 bar 28 psi Fuel tank capacity 7 5 liter 12 liter 9 5 or 12 liter 95 of 12 liter 2 US gallons 3 2 US gallons 2 5 or 3 2 US gallons 2 5 or 3 2 US gallons Final drive ratio 14 50 14 52 14 50 14 52 14 50 15 48 Chain 5 8 x 1 4 Available final sprockets 38 40 42 45 48 50 52 Steering head angle 63 5 Wheel base 1481 10 mm 58 3 0 4 in Seat height unloaded 925 mm 36 4 in Ground clearance unloaded 385 mm 15 in Dead weight without fuel 101 kg 223 lbs 102 5 kg 226 3 lbs 103 7 kg 229 lbs 109 kg 240 6 Ibs STANDARD ADJUSTMENT FORK STANDARD ADJUSTMENT SHOCK ABSORBER WP 918T768 WP 918T769 WP 12187712 WP 121874 Compression adjuster 12 Compre
114. ment with CDI unit connected Multimeter display 2 volts 0 5 volt Check the generator charging coil for ignition capacitor charge for out put voltage two pin connector with black red and red white cable colors also see circuit diagram on opposite page apply the red measuring lead of the peak voltage adapter to the black red cable and the black measuring lead to the red white cable disconnect connector to disconnect the CDI unit Multimeter display 45 volts 5 volts Same measurement with connectors CDI unit connected Multimeter display 220 volts 10 volts Check the primary voltage output O for ignition coil control also see cir cuit diagram on opposite page for output voltage blue white cable color apply the red measuring lead of the peak voltage adapter to the black white cable ground and the black measuring lead to the blue white cable CDI unit and ignition coil connected Multimeter display 210 volts 10 volts NOTE the ignition coil does not need to be removed to measure Static generator values 250 MXC EXC USA Check the generator output for the lighting system also see circuit diagram on opposite page for voltage between yellow and brown ground connector disconnected Multimeter display 10 5 volts 1 volt Art No 3206004 E u b Ee Repair manual KTM 250 300 380 7 10C Modell Kabe lstrangnummer Land Datum Name KIM 5 E H V C E 250 EXC 2
115. n TDC position The dimension should be adjusted extremely carefully by inserting cylinder base gaskets of suitable thicknesses CAUTION IF THE DIMENSION X IS TOO LARGE THE COMPRESSION RATIO WILL BE REDUCED AND THE ENGINE LOOSES POWER ON THE OTHER HAND IF THE DIMENSION X IS TOO SMALL THE ENGINE WILL PING AND OVERHEAT Set the piston to TDC and apply a sliding gage or straight edge to the cylinder Now check the distance between the piston s upper edge and the sliding gage This distance should be from O mm to 0 10 mm at the most It can be corrected if necessary by adding or removing of cylinder base gaskets CAUTION THE PISTON MUST PROTRUDE BEYOND THE CYLINDER S UPPER EDGE Dimension X O mm 7977 Mount the 2 remaining collar nuts at the cylinder base and tighten each of the 4 collar nuts to 35 Nm 27 ft Ib Art No 3206004 E Repair manual KTM 250 300 380 control D SS 6 8C Adjusting control dimension Z Note Dimension 2 15 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 9 06mm 250 Model 2000 50 5 mm 02 06mm 250 ab Model 2001 49 5 mm 92 mm 300 46 0 mm 92 06mm 380 50 5 mm 2 06 Undo the screws of the stop plate left side of the cylinder and O and apply Loctite
116. ngine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking Part throttle range C Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer Full throttle range D Operation with the throttle fully open flat out This range is influenced by the main jet and the jet needle If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings after a short distance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one 2 3C Carburetor adjustment Basic information on the original carburetor se
117. ngnummer vorne 503 11 075 700 Land eb cmo Name Doteina e Kia CE RV ICH h nten 503 14 040 100 EU SPORTMOTORCYCLES 29 380 EXC 2001 SE 2n At E 04 05 00 KE EXC2001 5 13 E amp H Q9 gt d 1 sd per Le a 2t n gt d lp 23 A Er 22 T muni w ILL bro ma wie m 4 E E 8 ge lt 11 an or KOKUSAN 2K 3 de 520 er TT 1 Ss 8 9 Ca T Wn 310 2 054 S Ya Art No 3206004 E Repair manual KTM 250 300 380 11 12C KIM 12 380 CAL 2001 Scheinwerfer headlight faro Standl cht position light Blinker Li vo turn indic left fr Blinker re vo turn ndic right fr luce di posizione feu de position lampegg ant sn lampegg ant dx clignoteur av gauche clignoteur av droit luce di tachimetro ecla r comp vitesse Tachobeleuchtung speedometer Light spia abbagliante temoin feu route spia lampeggiator connettore a 2 poli connettore a 3 poli Fernlichtkontrolle high beam indicator turn indicator temoin de clignoteur multip cont plug 2 cont plug 3 to combinat switch Bl nkerkontrolle 2 pol Stecker 3 Bol Stecker E s CD sch O s CO CO 0 Q3 CO J E OO connect mult ple 2
118. oc IGNGILIV J06 54 DLE 54 DGC JVC 54 DIL 9 54 29 54 9 54 DoOC anLvasIdW l JHOHS3A3IW DV 8 NIHIDM LOOT WSN YNA IXI DXW 00 WLY 9 27C G6 ZO papeajun Jadns 01n3 J NJ 9 eem pen GO 5 d G6 ZOU 1941914 190AS 01N3 40154845 do uon sod dif SCH Ce uaqo uonisog AND SOd 83113 5 415 aNd LHOIN Sui p H 5 991 uado Mans SV eqneJubsjerjnsedn HOST rw eas SOd 5 31033N Y 0001 SV 00 W SOd 41d44N fl SV W SOd 41d44N fl SV IW SOd 41d44N fl SV W 4 1094 SOd LOEC 31033N fl 1 00001 SV 000 01 466 186 01 464 184 01 419 109 dolt Jolt 461 O2 doc IGNGILIV 26 54 DLE 54 JVC 54 DIL 9 54 29 9 54 9 54 DoOC anLvasIdW il JHOHS3 33W DV SC LOOT WSN YANI WI 222 3 ON HV 00 OST WL 9 28C adA Jom 9 qe1 295 Sunjes JOJOINGUeD 2 ap js Jey MOLL ACL J0 e19u9s ou ACL J0ye 19uas ou EIC NVSNION NVSMION 21 97 Oel seag 1195 143126135 00 0
119. ode distance Electrode distance 0 60 mm 0 024 in Insulator Check for cracks and fissures CAUTION ALWAYS USE A SPARK PLUG WITH RESISTOR OTHERWISE PROBLEMS OCCUR IN THE CDI UNIT Check stator and pulse generator Kokusan Use an ohmmeter to perform the following measurements Cable colours Resistance 2K 1 Pulser coil red green 100 15 Exciter black red red white 240 15 Pulser coil red green 100 Q 15 Exciter black red red white 24 Q 15 Charge coil ground yellow 0 74 15 Pulser coil red green 15 Exciter black red red white 15 Charge coil ground yellow 15 white yellow 15 Pulser coil red green 100 Q 15 Exciter black red red white 24 Q 15 Charge coil yellow yellow 0 650 15 NOTE The measuring must be performed at a temperature of 20 C Otherwise significant deviations must be expected Replace the stator if the measured values deviate significantly from the setpoint values Art No 3206004 E Repair manual KTM 250 300 380 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 cor
120. oin feu route 7 Blinkerkontrolle 7 turn indicator 7 spia lampeggiatori temoin de clignoteur gt lt 8 4 pol Stecker 8 multip cont plug 4 8 connettore 4 8 connect multiple 4 L zum Kombischalter to combinat switch 10 multicomando commodo C Bremslichtsch vo stoplight switch f 11 int luce arresto ant contact de stop av CLA Bremslichtsch hi stoplight switch r 12 int luce arresto pos contact Harr de stop CY Horn horn 13 clacson klaxon Bl nkgeber turn indicator 14 trasmett di lampeg centrale clignot LA CDI E nne t CUlL unit 15 CDI seatola boitier CDI ES Z ndkerze spark plug 16 candela bougie ndspule ignition coil 17 bobina d accens bobine d allumage Generator generator 18 dinamo generateur KS Kondensator capacitor 19 condensatore condensateur Spannungsreg ler voltage regulator 20 regol di tens regulateur fusible TUR connect multiple 6 clign gauche clign arr droite fusibile 108 connettore a 6 fuse 108 multip cont plug 6 Stecksicherung 108 6 pol Stecker Blinker li hi Blinker re hi Brems Sch lu l cht Blinkerschalter blinker left rear lampegg post sn blinker right rear lampegg post dx N N N N MD O rear stoplight fanal post di freno feu arr et de stop blink switch NO int lLampeggiator contact cl gnoteur NO 3 pol Stecker mult p cont plug 3 connettore a 3 pol connect mult ple 9 blau blue blu bleu azul braun brown marrone br
121. olts 10 volts Check the primary voltage output O for ignition coil control also see cir cuit diagram on opposite page for output voltage blue white cable color Apply the red measuring lead of the peak voltage adapter to the black white cable ground and the black measuring lead to the blue white cable CDI unit and ignition coil connected Multimeter display 200 volts 10 volts NOTE the ignition coil does not need to be removed to measure 7 6C Kabelstrangnummer vorne 503 11 075 600 Land KIM SERVICE 350 380 EXC 2000 orae 509 17 060 10 i MON k 11 1 SPORTMOTORCYCLES 5 en Se 11 ben vg Europa 07 04 99 Hei I 9 8 5 St um g SE FIL os a e 01 ET i d im 5 o s ge ge 16 g 11 bl w Sw KOKUSAN Cka 57W o bl u g r Art 3206004 E ohne Funktion Repair manual KTM 250 300 380 310 Q 054 26 br Blinkerstrang f r Wet tbewerbseinsatz demontierbor Stecker 29 br 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
122. or leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check oil level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting ADD ON PARTS Check function of electric systems low beam high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake lining e Check brake lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean dust bellows Bleed fork legs Check swing arm bearings CHASSIS Check adjust steering head bearings Check tightness of all chassis screws triple clamps fork leg axle passage axle nuts and screws swing arm bearings shock absorber Check spoke tension and rim joint Check tires and air pressure Check chain rear sprockets and chain guides for wear fitment and tension Lubricate chain WHEELS Check clearance of wheel bearings at least every 2 years once a year or 20000 km Check function of exhaust control Complete maintenance of shock absorber Complete maintenance of fork Clean and adjust carburetor Replace glass
123. puls contact clignateur connect mult ple 6 cl gn arr gauche clign arr droite feu arr et de stop luz de posicion interm izquierdo delantero intermitente derecho delantero tacometro lampara aviso luces largas lampara aviso intermitentes conector multiple 2 conector multiple 3 interruptor combinado interr luz de freno del interr luz de fren tras claxon conjunto del CDI bujia bobina de encendido generador condensador regulador de tension generado de impulsos interuptor clignoteur conector multiple 6 izquierdo trasero grau gr gr n 9 orange rot schwarz v olett weih grey gr grigio green g verde orange arancione red rosso black nero violet violetto white b anco gris vert orange rouge noir violet blanc gris verde naran ja negro v oleta blanco intermintente Kontaktbelegung Lichtschalter oem s n 11177 Lo H gt _ _ O 0 Repair manual KTM 250 300 380 Blinkerschalter intermitente intermitente derecho trasero luz de freno trasero gt gt Engine off X Horn eter TT MANCO L bp 02UD1q D1810 4A ofou DF UD JOU 5146 46 011 1 uoJJow Jq 1720 1q p 81d 31nu 51 ap popiun 81d 31nu 043504 Zn1 p fng
124. push rod and insert it into the drive shaft NOTE The transmission oil should be filled in only after the engine has been mounted Otherwise a part of the transmission oil would leak out through the drive shaft Art No 3206004 E Repair manual 250 300 380 ELECTRICAL INDEX CHECKING THE VOLTAGE REGULATOR RECTIFIER SHINDENGEN 7 2 CHECKING THE VOLTAGE REGULATOR KOKUSAN 7 2 CHECKING THE VOLTAGE REGULATOR TYMPANIUM 7 2 CHECKING THE CAPACITOR 7 3 IGNITION SEM rr na 7 3 IGNITION COIL KOKUSAN 7 3 COLUNIT 533 535 3979 ARRA BEER REOR RE RARA 7 3 CHECKING THE VOLTAGE REGULATOR MOD 2000 7 4 CHECKING THE CAPACITOR MOD 2000 7 4 STATIC IGNITION VALUES 250 380 SX EXC 7 5 STATIC GENERATOR VALUES 250 380 EXC 7 7 STATIC IGNITION AND GENERATOR VALUES 250 MXC EXC USA 7 9 Art No 3206004 E Repair manual KTM 250 300 380 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 0 V In the case of a significant deviation from the nominal value Check
125. r hoses of engine case and gas tank for correct position without buckles Clean and check airfilter element box and carburetor connection boot Check chain sprockets guides and chain wear Clean and oil chain Check chain tension Check coolant level Check quality of antifreeze Check cooling system for leaks visual inspection Check exhaust system for cracks and leaks Replace glass fiber yarn of silencer Check of the exhaust suspension system Check brake fluid level front and rear Change brake fluid Check thickness of disc brake pads Check brake discs Inspect condition and installation of front and rear brake hoses Check free travel and free movability of hand brake lever and foot brake lever Check the oil level in the master cylinder of the hydraulic clutch Change the oil of the hydraulic clutch Check telescopic fork action Check telescopic fork for leaks Push up the protective bellows and remove the dirt the drain holes must be free of obstructions Clean the dust scrabbers of the telescopic force Undo the bleeder screws at the fork legs Change oil of telescopic fork Service telescopic fork completely Check steering head bearing free play Clean and regrease steering head bearing Check setting and damping of shock absorber Service shock absorber completely Grease swingarm needle bearings don t grease the pivot bearing for the shock absorber Check for even spoke tension and rim alignment Check wheel bearings Check t
126. rect measuring range when performing measurements Spark plug Set the electrode distance 0 Electrode distance 0 60 mm 0 024 in p 0 Insulator Check for cracks and fissures CAUTION ALWAYS USE A SPARK PLUG WITH RESISTOR OTHERWISE PROBLEMS OCCUR IN THE CDI UNIT Check stator SEM Perform the following measurements with an ohmmeter Resistance 1650 20 0 NOTE The measuring must be performed at a temperature of 20 C Otherwise significant deviations must be expected Replace the stator if the measured values deviate significantly from the setpoint values 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 Tooth profile of mainshaft and countershaft and correspondending gears Easy operation of gear change Carefully clean components and replace damaged components NOTE Always place circlips with sharp edge facing the components secured ensuring that they are not overexpanded use special pliers Check that after any repair of the transmission circlips should axially not move more than 0 20 mm 0 006 in and must not seize between stop discs Assembly mainshaft Fix mainshaft in vice with toothed end upwards use cover
127. rews with new copper gaskets and tighten them crosswise taking three turns to achieve the total tightening torque of 35 Nm 25 ft lb In first stage only tighten until slight resistance is felt Mounting reed valve housing and intake flange Place reed valve housing with velocity insert in inlet duct and fix intake flange with the 5 collar screws Art No 3206004 E Repair manual KTM 250 300 380 6 10C 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 Mounting the ignition Kokusan Insert the woodruff key into the crankshaft Apply Loctite 243 to 3 screws and fix the stator do not yet tighten the 3 screws all the way Turn stator such that the mark on the stator coincides with the mark in the casing and tighten the 3 screws of the stator At engines with ignition type 2K 4 the marking must coincide with the marking on the stator At engines with all other ignitions not SEM the marking must coincide with the marking on the stator 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 Ib Mounting the ignition SEM Insert woo
128. 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 profesionally trained mechanics Read through the repair manual before beginning with the repair work A WARNING A STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB CAUTION NON COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC NOTE POINTS OUT USEFUL TIPS Use only ORIGINAL KTM SPARE PARTS when replacing parts The KTM high performance engine 15 only able to meet user expectations if the maintenance work 15 performed regularly and professionally 150 9001 REG NO 12 100 6061 KTM Austria s certificate of achievement for 15 quality system ISO 9001 15 the beginning of an on going total reengineered quality plan for a brighter tomorrow KTM Sportmotorcycle AG 5230 Mattighofen Austria All design and assembly modification rights reserved by KTM SPORTMOTORCYCLE AG AUSTRIA All rights reserved 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 cre
129. shift rails 4 8 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 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 from the engine case Pull the drive shaft together with the countershaft out of the bearing seats ig ATI Tr IM hi Art No 3206004 E i ID f K Remove 1 gear idler gear with needle cage and the two stop discs from the engine case Dismounting the crankshaft Pull crankshaft from the bearing seat if necessary use a plastic hammer and tap carefully on the crankshaft journal Repair manual KTM 250 300 380 Remove O ring from crankshaft Clean all parts and check for wear replace if necessary NOTE When an engine is completely overhauled it is recommended that all gaskets shaft seal rings and O rings are renewed Art No 3206004 E Repair manual 250 300 380 5 1C SERVICING ON INDIVIDUAL COMPONENTS 5 INDEX WORKING ON THE RIGHT HAND HOUSING HALF 5 2 WORKING ON THE LEFT HAND HOUSING HALF 5 3 CRANKSHAFT 5 4 CRANKSHAF
130. side of the binder or insert this page on the beginning of the manual Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page Example page no 3 5 3 chapter 3 5 page 5 All pages with a page number that begins with the digit 3 for example must be put under the index heading Chapter 3 Index sheets that have not been marked with a certain chapter are for your personal convenience The respective headings can be entered in the list of contents Art No 3206004 E Repair manual KTM 250 300 380 SPORTMOTORCYCLES EXPLANATION UPDATING 3 205 63 E 3 205 87 E 3 210 02 E 3 206 004 E Repair Manual 250 300 380 SX MXC EXC Basicversion Modelyear 1999 Engine number with first digit 9 Updating of Rep Manual 3 205 63 E Modelyear 2000 Engine number with first digit 0 Updating of Rep Manual 3 205 63 E Modelyear 2001 2002 Engine number with first digit 4 Engine number with first digit 2 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 11 1998 2 2000 3 2001 11 2002 Edition 11 2002 INTRODUCTION This repair manual offers extensiv repair instructions and is an up to date version that describes the latest models of the
131. sion including roller and bearings for wear NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED Art No 3206004 E Repair manual 250 300 380 WIRING DIAGRAMS INDEX MODEL 1999 WIRING DIAGRAM 250 380 EXC WIRING DIAGRAM 250 380 EGS WIRING DIAGRAM 250 380 EXC USA MODEL 2000 WIRING DIAGRAM 250 300 EXCUSA WIRING DIAGRAM 250 380 EXC WIRING DIAGRAM 380 EXC USA MODEL 2001 2002 WIRING DIAGRAM 250 EXC USA WIRING DIAGRAM 250 380 EXC WIRING DIAGRAM 300 380 EXC USA MODEL 2003 WIRING DIAGRAM 250 300 EXC EU AUS WIRING DIAGRAM 250 300 EXC USA 11 1C 11 2C ofou DFUDJDU VSO OLE ON3INBISANTT 5146 0 9309 11M WJS 5 COMME COM LL 011 1 uoJJDpu 1720 19 01 10 09 03203 6 81d 31nu 203258u02 p 81d 31nu 20328u02 a1d13 nu 40328002 Z 81d 31nu 203128u02 a MOE 0 ET el eem 6 9 D El Y 29 H irs ei mn LO p1 Wl T Jero ou qoq 3 Dm P A O 4 cuc acin
132. ssion adjuster 5 6 Rebound adjuster Rebound adjuster 14 12 Spring 4 0 N mm Spring PDS3 250 PDS2 250 Spring preload 5 mm 0 2 in 5 mm 0 2 in Spring preload 5 mm 0 20 in 6 mm 0 23 in Air chamber length 155 mm 6 1 in Capacity per fork leg approx 750 ccm approx 750 ccm Fork oil SAE 5 SAE 5 NOTE The damping units in the left and the right fork leg are of different design Make sure not to mix them up in case of repair or service jobs TORQUES The clamping bolts of the fork plates must be tightened in several 3 steps Otherwise the bolts might come loose Brake caliper front 25 19 16 Loctite 243 Clamping bolts upper fork bridge 15 Nm 11 ft Ib Clamping bolts lower fork bridge M 8 15 ft 1b Clamping bolts fork stubs M8 11 16 Collar nut rear wheel spindle M 20x1 5 59 ft Ib Hexagon nut swing arm bolt M 14x1 5 74 ft Ib Shock absorber top M 12 44 ft Ib Shock absorber bottom M 12 30 ft Ib Other bolts on chassis 7 ft Ib 19 33 ft Ib G6 ZOU papeajun Jadns 9ny jal urew asnpidneH CH ISN AVMHDIH LON do uonisod di 50 did 504 G6 ZOU Jedns Morse jal Sum fi ke AIIULIANISSVALS YNA LHDIN pazeas Ajjnj uado Mans SV z b uayo eqneJubsjerinson HOST 295 SOd neaAlusaJaaw 31033N 1 Y 0001 00 IW SOd 371993 fl SV W SOd 41d
133. ssure offroad 1 0 bar 14psi 1 0 bar 14psi Air pressure road driver only 1 5 bar 21psi 1 5 bar 21psi Rear tires 140 80 18 7OR Rear tires USA 100 100 18 64M 100 100 18 64M Air pressure offroad 1 0 bar 14psi 1 0 bar 14psi Air pressure road driver only 2 0 bar 28psi 2 0 bar 28psi Fuel tank capacity 11 liter 2 9 US Gallons 9 11 liter 2 3 2 9 US Gallons Final drive ratio 15 48t 14 50t Final drive ratio USA 14 52t Chain 5 8 x 1 4 headlight HS1 12V 35 35W parking light 12V 5W base W2 1x9 5d instrument light 12V 1 2W base W2 1x4 6d brake rear light 12V 21 5W base BaY15d flasher light 12V 10W basel Ba15s license plate illumination 12V 1 2W base 1x4 6d Steering head angle 63 5 Wheel base 1481 10 mm 58 3 0 4 in Seat height unloaded 925 mm 36 5 in Ground clearance unloaded 385 mm 15 2 in STANDARD ADJUSTMENT FORK STANDARD ADJUSTMENT SHOCK ABSORBER WP 4860 MXMA WP 5018 MCC Compression adjuster 20 Compression adjuster 17 Rebound adjuster 20 Rebound adjuster Spring 4 0 N mm Spring Air chamber length 110 mm 4 3 in Fork oil SAE 5 9 40C TIGHTENING TORQUES Collar screw front wheel spindle Brake caliper front M 24x1 5 M 8 CHASSIS 40 Nm Loctite 243 25 Nm Brake disk front Brake disk rear Clamping screws upper fork bridge M 6 10 9 M 6 M 8 Loctite 243 15 Nm Loctite 243 15 Nm 20 Nm Clamping scr
134. the capacitor Check the connector between the stator and the voltage regulator rectifier and the connector between the voltage regulator rectifier and the cable tree Check the stator Replace the voltage regulator rectifier Checking the voltage regulator Kokusan A defect voltage regulator can cause different kinds of trouble No voltage in the circuit In this case the voltage regulator must be disconnected at idle speed The voltage regulator is defect if the power consumers now work properly If the power consumers are still not supplied with power the switch the wiring harness or the ignition system must be checked for defects e Excessive voltage in the circuit The bulbs burn out In this case the voltage regulator must be replaced Checking the voltage regulator Tympanium NOTE The voltage regulators are connected downstream of the switches One of the voltage regulators regulates only the brake light circuit the other regulates the circuit for the head light the tail light the speedometer illumination and the horn A defect voltage regulator can cause different kinds of trouble e No voltage in the circuit In this case the voltage regulator must be disconnected at idle speed The voltage regulator is defect if the power consumers now work properly If the power consumers are still not supplied with power the switch the wiring harness or the ignition system must be checked for d
135. tting 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 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 requirements are a clean air filter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance RULE OF THUMB high altitude or high temperatures gt choose leaner carburetor adjustment low altitude or low temperatures gt choose richer carburetor adjustment A WARNING A ONLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE AND USE OF SAME WILL VOID YOUR WARRANTY ONLY USE HIGH GRADE 2 STROKE ENGINE OIL OF KNOWN BRANDS NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON USING TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL THE SPARK PLUG IN THE CASE OF LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID OVERHEATING AND PISTON SEIZURE NOTE If despite
136. un marron gelb yellow g allo Jaune amarillo grau grey grigio gris gris grun green verde vert verde orange orange arancione orange naranja rot red rosso rouge rojo schwarz black nero no r negro violett violet violetto violet violeta white bianco blanco faro luz de posicion nterm izquierdo delantero intermitente derecho delantero luz tacometro lampara aviso luces largas lampara aviso intermitentes conector multiple 4 Art No 3206004 E interruptor combinado nterr luz de freno del interr luz de fren tras claxon con junto del unidad cdi bu bobina de encendido generador condensador regulador de tension Blinkerschalter intermintente Kontaktbelegung Lichtschalter Tup CEV 9610 fusible principal 108 conector multiple 6 intermitente izquierdo trasero intermitente derecho trasero luz de freno trasero nteruptor clignoteur Repair manual KTM 250 300 380 NN elel asl iste ZUNDUNG aus SE conector multiple 13 oJbau of ou Of UD JDU 51 16 011 1 1720 p 319 32auo2 s ndw ap popiun 19141 23u09 5 p fng qoq Jopouauab uoisuay ap zn P Joydnuyayu 20 9 040 N CH ON TM

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