User manual KTM 250-525 SX

[. . . ] 250-525 SX, MXC, EXC RACING REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www. ktm. at 250-525 SX, MXC, EXC RACING REPAIR MANUAL ENGINE 1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS 12 13 14 15 16 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, 21-24, 30-47, 50-52, 56-76, 79-92, 97-124, 134-140, 142, 150-154, 165-167 Remove page (s) 2-1 / 2-7 3-1 4-1 to 4-14 5-1 / 5-3 5-6 to 5-8 5-12 to 5-26 6-1 / 6-4 6-7 to 6-16 7-1 to 7-2 Art. -No. 3206007 -E Replace by page (s) 2-1C 3-1C 4-1C to 4-13C 5-1C / 5-3C 5-6C to 5-8C 5-12C to 5-27C 6-1C / 6-4C 6-7C to 6-17C 7-1C to 7-2C 7-7C to 7-11C 8-1C to 8-21C 9-1C 9-10C to 9-16C 10-1C 11-1C Insert page (s) 2-7C to 2-9C after page 7-7 to 7-11 8-1 to 8-13 9-1 9-10 to 9-13 10-1 11-1 10-8C to 10-11C 11-11C to 11-13C KTM REPAIR MANUAL IN LOOSE-LEAF FORM Repair manual KTM 250-525 SX, MXC, EXC RACING 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. [. . . ] ­ Mount the split needle bearing 2 and the 2nd speed idler gear 1 - with the recess for shift dogs facing upward - on the countershaft. ­ Mount the stop disc 3 (25. 2x32x1. 5mm) and circlip 4 with the sharp edge facing upward. ­ Mount the 6th speed sliding gear 5 with the shift groove facing upward. ­ Mount the 2 split needle bearings 9 + bl and the 4th speed idler gear 8 with the recess for shift dogs facing downward. ­ Mount the 3rd speed idler gear bk with the recess for shift dogs facing upward. ­ Slip on the 5th speed sliding gear bo with the shift groove facing downward and the stop disc bp (20x32x1mm). ­ Mount the needle bearing bq, the 1st speed idler gear br with the recess facing downward and the stop disc bs (17. 2x30x1. 5mm). 5-25C Ignition 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. The CDI unit can only be checked on the ignition test bench. Ignition 4K-3A Measure Pulser coil Exciter Charge coil Pulser coil Exciter Charge coil cable colours red ­ green black/red­ red/white ground ­ yellow red ­ green black/red ­ red/white ground ­ yellow white ­ yellow Resistance 100 24, 8 0, 74 100 12, 7 0, 65 0, 16 20% 20% 20% 20% 20% 20% 20% Check stator and pulse generator Use an ohmmeter measurements: to perform the following 4K-3B NOTE: The measuring must be performed at a temperature of 20° C. Replace the stator and/or the pulse generator if the measured values deviate significantly from the setpoint values. Replacing the stator 400/450/525 SX (4K-3A) 3 1 2 ­ Remove the bolt 1 and dismount the retaining plate. ­ Remove the 2 bolts 2 and take the stator out from the ignition cover. ­ Place the wire harness in a non-energized condition and secure it with the retaining plate. Do not forget the cable socket 3. 2 4 5 5 Replacing the stator 250/400/450 MXC, EXC, 520 SX, MXC, EXC, 525 MXC, EXC (4K-3B) ­ Remove the bolt 4 and dismount the retaining plate. ­ Remove the 2 bolts 5 and take the stator out from the ignition cover. ­ Place the wire harness in a non-energized condition and secure it with the retaining plate. 5-26C 7 6 1 2 3 A 4 5 Art. -No. 3206007 -E E-starter drive gear Idler gear 1 Check toothing and bearing position of the idler gear for wear. Reduction gear 2 Check toothing and bearing position of the idler gear for wear. Slip the reduction gear together with the needle cage onto the bearing bolt and check the clearance. Repair manual KTM 250-525 SX, MXC, EXC RACING Free wheel hub 3 Take the free wheel out of the free wheel hub and check the contact surface A for pressure marks. Free wheel 4 Thoroughly clean the free wheel with petroleum and compressed air. Free wheel gear 5 Slip the free wheel gear onto the crankshaft and check for clearance. [. . . ] 0, 4 mm (0, 016 in) 80/100 - 21" 90/90 - 21" 80/100 - 21" 1. 0 bar (14 psi) 1. 0 bar (14 psi) 1. 0 bar (14 psi) ­ 1. 5 bar 1. 5 bar (21 psi) 110/90 - 19" 140/80 - 18" 110/100 - 18" 1. 0 bar (14 psi) 1. 0 bar (14 psi) 1. 0 bar (14 psi) ­ 2. 0 bar (28 psi) 2. 0 bar (28 psi) 7 liters (2 US gallons) EXC 8 liters (2. 1 US gallons) MXC 13 Liter (3. 5 gallons) 450-14:50t / 525-14:48t 250-12:52t / 450-15:45t / 525-15:40t 450-14:50t / 525-14:48t X-Ring 5/8 x 1/4 " 38t, 40t, 42t, 45t, 48t, 50t, 52t headlight HS1 12V 35/35W parking light 12V 5W (Sockel W2, 1x9, 5d) brake - rear light 12V 21/5W (Sockel BaY15d) flasher light 12V 10W (Sockel Ba15s) license plate illmination 12V 1, 2W (Sockel 1x4, 6d) maintenance-free battery 12V 8Ah 63. 5° 1481 ± 10 mm (58. 3 ± 0. 4 in) 925 mm (36. 5 in) 380 mm (15. 1 in) STANDARD ADJUSTMENT - FORK WP4860MXMA WP4860MXMA 1418X727 1418X737 Compression adjuster 18 21 Rebound adjuster 19 20 Spring 4. 4 N/mm 4. 2 N/mm Spring preload 5 mm (0. 20 in) 5 mm (0. 20 in) Air chamber length 90 mm (3. 6 in) 110 mm (4. 4 in) Fork oil SAE 5 SAE 5 TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, fork stubs Collar nut, rear wheel spindle Hexagon nut, swing arm bolt Hexagon collar screw, handlebar clamp Allan head screw, handlebar support Shock absorber, top Shock absorber, bottom Sprocket screws Ball joint for push rod Engine mounting bolt Engine brace Screw adjusting ring spring preload shock abs. Spoke nipple Other screws on chassis M24x1, 5 M8 M6 10. 9 M6 M8 M8 M8 M20x1, 5 M14x1, 5 M8 M10 M12 M12 M8 M6 M10 M8 M6 M4, 5 / M5 M6 M8 M10 M6 M8 M10 40 Nm Loctite 243 + 25 Nm Loctite 243 + 15 Nm Loctite 243 + 15 Nm 20 Nm 15 Nm 10 Nm 80 Nm 100 Nm 20 Nm Loctite 243 + 40 Nm 60 Nm 60 Nm Loctite 243 + 35 Nm Loctite 243 + 10 Nm 45 Nm 33 Nm 8 Nm 5 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm Repair manual KTM 250-525 SX, MXC, EXC RACING STANDARD ADJUSTMENT-SHOCK ABSORBER WP 5018 PDS WP 5018 PDS DCC MCC 1218X760 1218X761 Compression adjuster 15 LS (low speed) 17 2 HS (high speed) Rebound adjuster 26 26 Spring 76-95/260 71-90/260 Spring preload 6 mm (0. 24 in) 8 mm (0. 32 in) Other collar nuts on chassis 10-1C PERIODIC MAINTENANCE SCHEDULE INDEX 10 MODEL 2000 PERIODIC MAINTENANCE SCHEDULE . 3206007 -E Repair manual KTM 250-525 SX, MXC, EXC RACING 10-2C PERIODIC MAINTENANCE SCHEDULE 11. 99 400/520 SX RACING 400/520 EXC RACING KTM rider 1st service, after 3 hours or 20 l fuel consumption before each start KTM dealer after 15 hours or 100 l fuel consumption after 30 hours or 200 l fuel consumption at least once a year IF THE MOTORCYCLE IS USED PRIMARILY FOR OFF-ROAD RIDING OR COMPETITIVE RACING, THE 15 HOUR SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RACE Check engine oil level Change engine oil Clean short and long oil screen and magnet of the drain plug whenever you exchange the engine oil Change short and long oil filter unit Check oil line for leakage and proper installation Check valve clearance and adjust if necessary Change spark plug Drain and clean carburetor float bowl Adjust idling Check breather hoses of engine case, gas tank and carburetor for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreeze Check cooling system for leaks Check exhaust system for leakage Art. -No. 3206007 -E Change exhaust muffler packing Clean spark arrestor (EXC USA) Check exhaust brackets Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs for wear and damage Check condition and correct installation of brake hoses Check free play and easy operation of hand brake lever and foot brake lever Check oil level of the master cylinder of the hydraulic clutch Change the oil of the hydraulic clutch Check adjustment and function of telescopic fork Check telescopic fork for leaks Repair manual KTM 250-525 SX, MXC, EXC RACING Loosen breather bolts at fork legs (overpressure) Change fork oil Perform a full maintenance job for the telescopic fork Clean dust bellows on telescopic fork Check steering head bearing clearance and adjust if necessary Clean and grease steering head bearings and its seals Check adjustment and function of shock absorber Perform a full maintenance job for the shock absorber Servicing swing arm pivots Check tightness of spokes and rim joint Check wheel bearings for clearance Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check adjustment of headlight Spray emergency OFF switch, short circuit button and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding components after washing 10-3C SUPPLEMENTARY MAINTENANCE INSTRUCTIONS FOR THE 400/520 RACING ENGINE MODEL 2000 (ADDITIONAL ORDER FOR KTM WORKSHOP) Hours 15 30 45 60 75 90 105 120 400 SX Small Maintenance Kit Small Maintenance Kit Large Maintenance Kit Small Maintenance Kit Small Maintenance Kit Large Maintenance Kit Small Maintenance Kit Small Maintenance Kit 400 MXC/EXC ­ Small Maintenance Kit ­ Large Maintenance Kit ­ Small Maintenance Kit ­ Large Maintenance Kit 520 SX Small Maintenance Kit Small Maintenance Kit Large Maintenance Kit Small Maintenance Kit Small Maintenance Kit Large Maintenance Kit Small Maintenance Kit Small Maintenance Kit 520 MXC/EXC ­ Small Maintenance Kit ­ Large Maintenance Kit ­ Small Maintenance Kit ­ Large Maintenance Kit Spare Part Numbers of the Maintenance Kits - Model 2000 Maintenance Kit Small 400/520: 590. 12. 099. 044 Maintenance Kit Large 400: 595. 12. 099. 144 Maintenance Kit Large 520: 590. 12. 099. 144 Please observe KTM TECHNICAL INFORMATION No: 0003/30/02-E !!! 10-4C PERIODIC MAINTENANCE SCHEDULE 2001 A washed motorcycle can be checked more quickly which saves money! Change engine oil, short and long oil filters Clean oil screen and drain plug magnet Check oil lines for damage or bends Replace spark plug (after 30 hours) Check and adjust valve clearance Check engine mounting bolts for tightness Check carburetor connection boot for cracks and leaks Check idle speed setting Check vent hoses for damage or bends Check cooling system for leaks, check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage, smooth operation and bends adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems (low/high beams, brake light, indicator indicator lamps, speedometer illumination, horn, emergency OFF switch or button Check brake fluid level, lining thickness, brake discs Check brake lines for damage and leaks Check smooth operation and adjust free travel of handbrake/foot brake lever Check tightness of brake system bolts Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs Check swing arm bearings Check/adjust steering head bearings Check tightness of chassis bolts (triple clamps, fork leg axle passage) Check spoke tension and rim joint Check tires and air pressure Check chain, rear sprockets and chain guides for wear, fit and tension Lubricate chain Check clearance of wheel bearings 400/520 SX/MXC/EXC RACING 1st service after 3 hours or 20 l fuel after/every 15 hours or 100 l fuel ADD- ON PARTS CARBURETOR ENGINE Art. -No. [. . . ]