Tightening Torques; Tolerances And Fitting Clearances; Gasket Thicknesses; Basic Carburetor Setting - KTM EXC Repair Manual

9-3C

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

TOLERANCES AND FITTING CLEARANCES

Piston fitting clearance
Piston ring end gap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length

GASKET THICKNESSES

Crankcase
Clutch cover
Cylinder bottom gasket
Available cylinder bottom gaskets
Cylinder-head gasket

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
M 8
M 10
M 12x1
M 18x1.5
M 18x1.5
M 6
M 14
M 6x16
M 6
M 8
M 10
0.05 mm (250)
0.3 – 0.4 mm
0.021 – 0.032 mm
0.1 – 0.2 mm
Ø 2.5 new = 43 mm, minimum length = 42 mm
0.5 mm
0.5 mm
as required
0.2/0.4/ 0.5 / 0.7 mm
O-rings
250 MXC, EXC
250 SX
300 MXC, EXC
Keihin PWK 38 Keihin PWK 38
090598
172(168,170,175) 175(170,172,178)
45(48,50)
85
NOZ G(NOZ H,NOZ I) N85 C(N85 D)
II
6
1,5
35 Nm (25 ft.lb)
35 Nm (25 ft.lb)
60 Nm (44 ft.lb)
Loctite 243 150 Nm (110 ft.lb)
Loctite 243 100 Nm (74 ft.lb)
8 Nm
100 Nm (74 ft.lb)
Loctite 648 19 Nm (14 ft.lb)
10 Nm
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)
0.06 mm (300) 0.08 mm (380)
380 SX, MXC, EXC
Keihin PWK 38
100598 070598
170(168,172,175)
45(42,48) 48(45,50)
85 85
NOZ H(NOZ G,NOZ I)
III II
6 6
1,5 Umdr. 1,5 Umdr.
(6 ft.lb)
(7 ft.lb)