KTM EXC Repair Manual
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KTM EXC Repair Manual

Ktm automobile parts user manual
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See also: Owner's Manual
250/300/380 SX,MXC,EXC
REPAIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at

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  • Page 1 250/300/380 SX,MXC,EXC REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.at...
  • Page 3 250 - 380 SX,MXC,EXC REPAIR MANUAL ENGINE...

  • Page 5: Table Of Contents

    1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS...
  • Page 7 5-13 to 5-14 10-1 11-1 KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder.
  • Page 9 3.206.004-E Updating of Rep.Manual 3.205.63-E Modelyear 2003 (Engine number with first digit “3“) Modification / Updating: Technical Specification, Periodic Maintenance Schedule, Wiring Diagrams P D AT I N G 250 / 300 / 380 SX, MXC, EXC 11/1998 2/2000 3/2001 11/2002 Edition 11/2002...
  • Page 11 „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an on going total reengineered quality plan for a brighter tomorrow.
  • Page 13 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –...

  • Page 14: Table Of Contents

    2-1C GENERAL INFORMATION INDEX OPERATING RANGES OF THE CARBURETOR ....2-2 CARBURETOR ADJUSTMENT ......2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM .

  • Page 16: Operating Ranges Of The Carburetor

    OPERATING RANGES OF THE CARBURETOR mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve. This range is influenced by the position of the air control screw .

  • Page 17: Carburetor Adjustment

    2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 –...

  • Page 18: Bleeding Of The Hydraulic Clutch

    Make sure that the oil does not overflow. CAUTION – H AVING COMPLETED THE BLEEDING PROCEDURE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT – KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS – A...

  • Page 19: Special Tools - Engine

    2-5C SPECIAL TOOLS – ENGINE Fig. Part no. 560.12.001.000 546.29.003.000 560.12.004.000 546.29.009.044 6 276 807 510.12.011.000 544.12.012.000 584.29.037.040 584.29.037.043 510.12.016.000 546.29.012.100 501.12.013.000 501.12.030.000 6 899 785 151.12.017.000 151.12.018.100 151.12.018.000 151.12.018.200 546.29.027.000 0276 179 000 503.29.050.000 250 / 300 / 380 Description Universal engine work stand Clutch holder...

  • Page 20: Cleaning

    Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. EVER CLEAN YOUR MOTORCYCLE WITH A HIGH ELECTRICAL COMPONENTS CONNECTORS...

  • Page 22: Removing And Refitting Engine

    3-1C REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ....... . .3-2 REFITTING THE ENGINE .
  • Page 24 3-2C Dismounting the engine – Clean motorcycle thoroughly. – Prop up motorcycle on an appropriate stand. – Remove seat, right side paneling, and tank with spoilers. – Dismount exhaust system. – Drain coolant, and disconnect radiator hoses from engine. – Dismount engine strut –...
  • Page 25 3-3C – Loosen the 3 screws, and remove intermediate flange chamber KTC system together with O-ring. – Remove engine fastening screw – Remove cable ties and loose the cable of ignition from frame. – Loosen both hose clamps, and pull caburetor out of carburetor connection boot and intake flange.
  • Page 26 Refitting the engine – To install the engine, reverse the steps for removing the engine. Filling in of transmission oil: – Remove the plug and top up with engine oil 15W-50 (i. e. MOTOREX TOP SPEED 4T). – In order to check the transmission oil level the control screw clutch cover is to be removed.

  • Page 28: Disassembling The Engine

    4-1C DISASSEMBLING THE ENGINE INDEX DRAINING GEAR OIL ........4-2 DISMOUNTING OF SPROCKET AND SHIFT LEVER .
  • Page 30 – Cleaning the engine thoroughly. – Clamp the engine into the workstand. – Remove the kickstarter together with the distance bushing behind. Draining gear oil NOTE: The transmission oil should already be drained when the engine is dismounted. Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch.
  • Page 31 4-3C – Undo the screws and remove the right control cover. – Remove the securing clip of the ball socket socket from the adjusting lever. – Remove gasket of the control cover. – Remove the 4 collar nuts – Cover the crankcase. –...
  • Page 32 Dismounting of pressure cap and clutch discs – Loosen collar screws wedging of discs as springs expand. – Remove collar screws, springs and spring retainers. – Take pressure cap and disc package out of outer clutch hub. – Take thrust bearing off the drive shaft.
  • Page 33 4-5C Dismounting of kickstarter – Remove circlip – Carefully release collar screw tension on kickstarter spring and unhook spring hanger. AREFULLY RELEASE THE KICKSTARTER SPRING – Take the complete kickstarter shaft out of the housing. – Take care of the stop disc, which could stay in the housing. Dismounting of the shift lock –...
  • Page 34 Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel. – Undo the 3 screws and remove the stator together with the base plate.
  • Page 35 4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws – Remove intake flange and reed valve housing. Parting of engine housing halves – Top ignition-gear upwards and remove all 11 housing screws. – Loosen the 2 engine fixtures on the engine work stand. –...
  • Page 36 – Pull out the shift rails and swing the shift forks aside. – Pull the shift roller out of the bearing seat. – Remove the shift forks. NOTE: During disassembly, watch out for the shift rollers driving pins of the shift forks. They may remain in the shift roller. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused.

  • Page 37: Table Of Contents

    SERVICING ON INDIVIDUAL COMPONENTS WORKING ON THE RIGHT-HAND HOUSING HALF ....5-2 WORKING ON THE LEFT-HAND HOUSING HALF ....5-3 CRANKSHAFT .
  • Page 39 Working on the right-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. Grooved ball bearing of crankshaft Press old grooved ball-bearing inwards. Press in new ball bearing to the stop.
  • Page 40 5-3C Working on the left-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. Crankshaft roller bearing Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside).

  • Page 41: Crankshaft

    Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be renewed. – Heat special tool 584.29.037.040 on a heating pad up to approx. 150°C and slip it on the inner ring immediately. Press the special tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft.

  • Page 42: Checking Cylinder For Wear

    5-5C 10mm Checking cylinder for wear Measure diameter of cylinder approx. 10 mm (0.4 in.) below top of cylinder edge. Check diameter in several corresponding places to see if cylinder in worn oval. Engine Cylinder Ø 67,500 - 67,512 67,513 - 67,525 72,000 - 72,012 72,013 - 72,025 78,000 - 78,012...

  • Page 43: Cylinder Preassembly

    only 250 Cylinder exhaust control system Dismantle and clean all exhaust control components, check for signs of wear and damage. Control rollers – Check clearance of bearings. Remove oil-derived deposits. Check toothing of control rollers for signs of wear. Gear segments –...
  • Page 44 5-7C – Mount and grease silicon O-rings (15x1,50 mm) – Slightly grease the bearing sleeves – Mount toothed segments (the toothed segment with the cylindrical pin has to be mounted on the right side). – On the right-hand side, mount bearing bushing spring with short leg on outside and spring sleeve –...

  • Page 45: Exhaust Control, Clutch Cover

    LOCTITE 243 LOCTITE 243 Exhaust control, clutch cover – Remove screws and take off the bearing support. – Take cup tappet , adjusting spring clutch cover. – Take off water pump cover, remove allen head screw water pump wheel – The centrifugal timer can be pulled out of the bearing.

  • Page 46: Reed Valve Housing, Intake Flange

    5-9C Reed valve housing, intake flange NOTE: Reed paddles gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced. If the reed sealing surfaces of the reed valve housing are also damaged, replace the complete reed valve housing. CAUTION 243.
  • Page 47 5-10C 13,5 mm LOCTITE 242 Clutch Thrust bearing check for wear Push rod Check for wear. Minimum length: 199 mm (new: 199.80 mm) Clutch springs New spring length 42,5 mm / 1.7 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable. 9 Lining discs Minimum thickness 2.60 mm (0.102 in) / new disc 2.70 mm (0.106 in).

  • Page 48: Replace Outer Clutch Hub

    5-11C Replace outer clutch hub – Drill open the clutch rivets remove parts. – Check 8 absorbing elements replace all 8 where applicable. HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN THAT THE OUTER CLUTCH HUB ON THE PRIMARY GEAR CROWN TENSION WITH THE CLUTCH RIVETTING TOOL in area of retaining bracket for signs of mechanical damage,...

  • Page 49: Shift Mechanism

    LOCTITE 243 LOCTITE 243 0,40 - 0,80 mm LOCTITE 243 Shift mechanism Shift forks Check shift fork blades and shift roller driving pin Shift roller Check shift grooves for wear. Check position of shift roller in grooved ball bearings Slide plate Check slide plate at meshing points Check return surface for wear (renew, if strongly notched).

  • Page 50: Ignition (Kokusan)

    5-13C Kokusan 2K-1/2K-4 Kokusan 2K-2 Kokusan 2K-3 Ignition (Kokusan) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.

  • Page 51: Ignition (Sem)

    Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first.

  • Page 52: Assembly Mainshaft

    5-15C Transmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels – Tooth faces of all gears –...

  • Page 53: Assembly Countershaft

    Transmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels – Tooth faces of all gears –...

  • Page 54: Assemble Of Kickstarter Shaft

    5-17C LOCTITE 243 LOCTITE 243 Kickstarter Starter gear Check clearance of starter gear. Starter intermediate gear Check clearance of starter intermediate gear. Locking pawl Check for signs of wear and damage. Kickstarter shaft Check for signs of wear and damage. For changing the locking pawl, press bearing needle kickstarter shaft.

  • Page 55: Table Of Contents

    6-1C ASSEMBLING THE ENGINE INDEX CRANKSHAFT .........6-2 TRANSMISSION .
  • Page 57 – Secure the right-hand housing half in the engine work stand. Crankshaft – Insert crankshaft from above through grooved ball bearing and push carefully as far as stop. HEN PUSHING IN CRANKSHAFT Transmission – Grease the driving pins of the shift forks and mount the shift rollers –...

  • Page 58: Assembling The Engine Housing

    6-3C M6 x ... – Fix the 4 pressure springs gearshift rails. – Oil gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft). Insert gearshift rails into the casing bores as far as they will go. NOTE: It must now be possible to gently turn gear shafts.

  • Page 59: Mounting Shift Mechanism

    Mounting shift mechanism – Place locating spring with bent leg upwards into engine housing. – Insert collar sleeve into spring with collar upwards. – Coat collar screw – Insert locating lever screw. – Hook locking spring must abut the casing nose –...

  • Page 60: Mount Primary Drive And Clutch

    6-5C Mount primary drive and clutch – Grease crankshaft seal ring. – Put the 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 –...

  • Page 61: Mounting Clutch Discs And Pressure Cap

    M6x ... Mounting clutch discs and pressure cap – Oil the thrust bearing , and slide it over the drive shaft. – Oil lining discs before mounting. – Beginning with one lining disc, mount alternately 9 lining discs ( 2.70 mm / 0.10 in) and 8 intermediate discs ( 1.20 mm / 0.047 in), with a lining disc forming the final layer upwards.

  • Page 62: Mounting Piston And Cylinder

    6-7C Mounting piston and cylinder – Before assembly, oil all parts thoroughly at the sliding points. – Insert needle bearing in conrod eye, mount piston (arrow on piston head shows direction for exhaust duct). – Mount piston pin and wire circlips with open side showing downwards (see sketch).
  • Page 63 control flap Adjusting control flap (dimension “Z“) Note: Dimension “Z“ is the distance from the lower edge of the control flap to the upper edge of the cylinder, as measured in the centre of the exhaust port. 250 Model 1999 : 48,0 mm 250 Model 2000 : 50,5 mm 250 ab Model 2001 : 49,5 mm 300 : 46,0 mm...

  • Page 64: Mounting Steering Covers

    6-9C Mounting steering covers – Mount the right-hand control cover – Place gasket in position and fix left-hand steering cover Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O-rings in grooves. – Mount cylinder head with water nozzle on the exhaust side. –...

  • Page 65: Mounting Engine Sprocket

    Mounting engine sprocket – Lubricate O-ring with oil and slide over counter shaft. – Slide distance bushing in position so that O-ring is in correct position. – Slide sprocket onto the countershaft with the collar facing inward, and fix it with the circlip (sharp edge facing outward).

  • Page 66: Mounting The Ignition (Sem)

    6-11C Mounting the ignition (SEM) – Insert woodruff key into crankshaft. – Apply Loctite 243 to the threads of the 3 screws – Mount base plate – Mount the cable guide – Mount the rotor. – Mount the detent edged ring and the nut. –...
  • Page 67 CHECKING THE CAPACITOR (MOD. 2000) ....7-4 STATIC IGNITION VALUES 250 - 380 SX, EXC ....7-5 STATIC GENERATOR VALUES 250 - 380 EXC .
  • Page 69 Checking the voltage regulator-rectifier (Shindengen) – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage.
  • Page 70 7-3C Checking the capacitor – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp –...
  • Page 71 Checking the voltage regulator – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor. – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage. In the case of a significant deviation from the nominal value: –...
  • Page 72 7-5C STATIC IGNITION VALUES 250-380 SX, EXC (KOKUSAN 2K-1, 2K-3, 2K-4) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –...
  • Page 73 7-6C 250-380 EXC 2000 S P O R T M O T O R C Y C L E S...
  • Page 74 NOTE: – the black measuring lead applied to the ground. – 300/380 USA corresponds to 300/380 EXC Europe but with less accessories (blinkers, horn, no capacitor installed). Features no rectifi- cation, only an over-voltage regulation. (also see circuit diagram on opposite...
  • Page 75 7-8C 250-380 EXC 2000 S P O R T M O T O R C Y C L E S...
  • Page 76 7-9C STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC USA (KOKUSAN 2K-2) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –...
  • Page 77 7-10C 250 EXC 2001...
  • Page 79 8-1C TROUBLE SHOOTING INDEX TROUBLE SHOOTING 250 - 380 ......8-2...

  • Page 81: Trouble Shooting

    If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. TROUBLE Engine fails to start Operating error...
  • Page 82 8-3C TROUBLE Engine has not enough Reed paddles tensionless or dama- power ged, surface of reed valve housing damaged Wear Electronical ignition timing faulty Engine revs not high and Carburetor overflows if level adjust running with four stroke too high, float needle seating is cycle dirty or enlarged Loose carburetor jets...

  • Page 83: Technical Specifications

    9-1C TECHNICAL SPECIFICATIONS INDEX MODEL 1999 ENGINE 250 - 380 USA ........9-2 ENGINE 250 - 380 .
  • Page 85 9-2C...
  • Page 86 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 100 Nm (74 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.08 mm (380) 380 SX, MXC, EXC Keihin PWK 38 070598 170(168,172,175) 48(45,50) NOZ H(NOZ G,NOZ I) 1,5 Umdr.
  • Page 87 9-4C...
  • Page 88 100 Nm (74 ft.lb) (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 380 EGS 380 SX, MXC, EXC AUSTRALIA Keihin PWK 38 Keihin PWK 38 070598 060598 170(168,172,175) 175(168,170,172) 48(45,50) 45(48,50) NOZ H(NOZ G,NOZ I) NOZ G(NOZ H,NOZ I) 1,5 Umdr.
  • Page 89 TECHNICAL SPECIFICATIONS CHASSIS 250 / 300 / 380 SX / MXC / EXC / EGS ‘99 250/380SX Frame Fork Wheel travel front/rear Rear suspension Front brake Rear brake Front tires 80/100 - 21“ 51M – Air pressure offroad 1.0 bar (14 psi) Air press.
  • Page 90 9-7C...
  • Page 91 9-8C...
  • Page 92 9-9C...
  • Page 93 9-10C...
  • Page 94 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.06 mm (300) 0.08 mm (380) 300 MXC, EXC 380 SX, MXC, EXC Keihin PWK 38 AG Keihin PWK 38 AG 140499 150499 175 (172,178) 170 (168,172) 45 (48)
  • Page 95 9-12C...
  • Page 96 Loctite 648 19 Nm (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.08 mm (380) 250/300 EXC 380 SX, MXC, EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 150499 050799 170 (168,172)
  • Page 97 Rebound adjuster Spring PDS3–250 Spring preload 5 mm (0.2 in) 250/300/380 SX, MXC, EXC 2000 250/300/380 MXC Central chrome-moly-steel frame White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø...
  • Page 98 9-15C 21.06.99...
  • Page 99 9-16C 21.06.99...
  • Page 100 9-17C 21.06.99...
  • Page 101 9-18C 21.06.99...
  • Page 103 9-19C...
  • Page 104 Loctite 648 19 Nm (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 300 MXC, EXC 380 SX, MXC, EXC Keihin PWK 38 AG Keihin PWK 38 AG 050300 070300 175 (172,178) 170 (168,172) 45 (48) 45 (48)
  • Page 105 9-21C...
  • Page 106 Ø 2.5 new = 43 mm, minimum length = 42 mm 0.5 mm 0.5 mm as required 0.2/0.4/ 0.5 / 0.75 mm O-rings 250 EXC AUS 300 EXC AUS throttled throttled Keihin PWK 38 AG Keihin PWK 38 AG 040300...
  • Page 107 Rebound adjuster Spring PDS7–265 Spring preload 5 mm (0.2 in) 250/300/380 SX, MXC, EXC 2001 250/300/380 MXC Central chrome-moly-steel frame White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø...
  • Page 108 9-24C...
  • Page 109 9-25C...
  • Page 110 9-26C...
  • Page 111 9-27C...
  • Page 112 9-28C...
  • Page 113 35 Nm (25 ft.lb) 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 380 SX, MXC, EXC Keihin PWK 38 AG 050201 170 (168,172) 45 (48) NOZ G (NOZ H) – –...
  • Page 114 9-30C...
  • Page 115 NOZ E (NOZ F/D) Needle position from top Slide Air adjustment screw open Performance restrictor – Power jet jet – BASIC CARBURETOR SETTING 250 EXC USA Carburetor Keihin PWK 38 AG Carburetor setting number 030201 Main jet 178 (175,180) Idling jet 45 (48)
  • Page 116 Rebound adjuster Spring PDS7–260 Spring preload 4 mm (0.16 in) 250/300/380 SX, MXC, EXC 2002 250/300/380 MXC Central chrome-moly-steel frame 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Disc brake with carbon-steel brake disc Ø...
  • Page 117 9-33C...
  • Page 118 9-34C...
  • Page 119 9-35C...
  • Page 120 9-36C...
  • Page 121 9-37C...
  • Page 122 (6 ft.lb) 100 Nm (74 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 300 EXC AUS 300 MXC / EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 130202 150202 175 (172,178) 175 (172,178)
  • Page 123 5 mm (0.20in) Air chamber length 110 mm (4,3 in) Fork oil SAE 5 250/300 MXC, EXC 2003 250/300 MXC Central chrome-moly-steel frame White Power – Up Side Down 48 MA 300/335 mm (11.8/13.2 in) WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø...
  • Page 124 9-40C Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, fork stubs Collar nut, rear wheel spindle Hexagon nut, swing arm bolt Hexagon collar screw, handlebar clamp Allan head screw, handlebar support Shock absorber, top Shock absorber, bottom...
  • Page 125 9-41C...
  • Page 126 9-42C...
  • Page 127 10-1C LUBRICATION AND MAINTENANCE SCHEDULE INDEX MODEL 1999 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 ..10-2 MODEL 2000 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 ..10-3 MODEL 2001/2002 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 .
  • Page 129 PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE Check transmission oil level Change transmission oil Check spark plug and electrode gap Change spark plug Functional testing of the exhaust control system Check intake manifold for leaks and cracks Drain and clean carburetor float chamber...
  • Page 131 PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE Check transmission oil level Change transmission oil Check spark plug and electrode gap Change spark plug Functional testing of the exhaust control system Check intake manifold for leaks and cracks Drain and clean carburetor float chamber...
  • Page 132 NTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN AINTENANCE WORK DONE BY AINTENANCE ORK THAT CAN BE CARRIED OUT BY EXTRA ORDER AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER 250/300/380 SX/MXC/EXC 1. service after after after 10 hours...
  • Page 133 10-5C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean fork dust bellows regulary Clean and lubricate chain, check tension and adjust if necessary...

  • Page 134: Periodic Maintenance Schedule

    NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN AINTENANCE WORK DONE BY AINTENANCE ORK THAT CAN BE CARRIED OUT BY EXTRA ORDER AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER 250/300 MXC/EXC 1st service after after after 10 hours...
  • Page 135 10-7C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary...
  • Page 136 Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED. 250/300 EXC ADDITIONAL ORDER FOR THE hours 250/300 EXC...

  • Page 137: Wiring Diagrams

    MODEL 1999 WIRING DIAGRAM 250 - 380 EXC ......11-2 WIRING DIAGRAM 250 - 380 EGS ......11-3 WIRING DIAGRAM 250 - 380 EXC (USA) .

  • Page 139: 250-380 Exc Wiring Diagram

    11-2C...
  • Page 140 11-3C...
  • Page 141 11-4C...
  • Page 142 11-5C...
  • Page 143 11-6C...
  • Page 144 11-7C S P O R T M O T O R C Y C L E S...
  • Page 145 11-8C...

  • Page 146: 380 Exc 2000 Wiring Diagram

    11-9C...
  • Page 147 11-10C...
  • Page 148 11-11C...
  • Page 149 11-12C...
  • Page 150 11-13C...
  • Page 151 11-14C 250-300 EXC 2003...
  • Page 152 11-15C KTM 250-300 EXC 2003...
  • Page 153 11-16C...

This manual is also suitable for:

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