User manual KTM EXC RACING

[. . . ] 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. [. . . ] Check the bearing bolts of the idler gear for score marks, as well. 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. Check the segments of the free wheel for wear. Free wheel gear 5 Slip the free wheel gear onto the crankshaft and check for clearance. Check the contact surface to the free wheel for pressure marks. NOTE: If damage is found on the reduction gear 2 or on the free wheel gear 5 forcing you to change parts, then 2 and 5 are only available as a set. E-starter motor 6 Renew the O-ring 7 at the flange. 5-27C Checking the free wheel ­ Insert the free wheel gear 1 into the free wheel 2. ­ It must be possible to turn the free wheel gear clockwise. ­ Counterclockwise, the free wheel gear must be blocked without backlash. 1 2 Replacing the free wheel hub 3 ­ Use the circlip pliers to compress the spreader ring 3 and remove it together with the free wheel 2. 2 A 4 ­ Remove the 6 bolts 4. ­ Use a plastic hammer to tap on the free wheel hub 5 from the side and dismount the free wheel hub. ­ Mount the new free wheel hub on the primary wheel. ­ Degrease the threads of the bolts, apply Loctite 648 and tighten the bolts in a crosswise order to 16 Nm/12 ft. lb. 5 2 ­ Oil the free wheel 2 thoroughly and insert it into the free wheel hub 5. ­ Use circlip pliers to insert the spreader ring into the groove and check its proper fit. It is best to use a punch to carefully tap on the mounted spreader ring. NOTE: The noses A on the spreader ring must engage the groove of the free wheel hub. 5 6-1C ASSEMBLING THE ENGINE INDEX 6 MOUNTING THE CRANKSHAFT AND BALANCER SHAFT . . 6-2 MOUNTING THE SHIFT MECHANSIM AND TRANSMISSION . . 6-4 MOUNTING THE PRIMARY GEAR AND FREE WHEEL . . 6-6 MOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER . . 6-6 MOUNTING THE OUTER CLUTCH HUB AND THE DRIVER . . 6-7 MOUNTING THE PRIMARY GEAR NUT (250 EXC AND ALL MOD. . 6-10 MOUNTING THE CYLINDER HEAD TOP PORTION . [. . . ] 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. 3206007 -E CHASSIS BRAKES Repair manual KTM 250-525 SX, MXC, EXC RACING IMPORTANT RECOMMENDED MAINTENANCE WORK Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact spray Treat battery connections with contact grease Change hydraulic clutch fluid Change brake fluid WHEELS THAT CAN BE CARRIED OUT BY SPECIAL REQUEST at least once a year IF MOTORCYCLE IS USED FOR COMPETITION A 15 HOUR SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS OR 15 LITERS OF FUEL. 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