KTM 250 SX 2003 Owner's Handbook Manual
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KTM 250 SX 2003 Owner's Handbook Manual

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  • Page 3 (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS...
  • Page 4 Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.
  • Page 5 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.

  • Page 6: Table Of Contents

    Chain maintenance ............22 Short circuit button ............5 Chain wear ..............22 Filler cap ................6 General information about KTM disc brakes ....23 Fuel tap................6 Adjusting the free travel at the hand brake lever ...24 Choke knob ..............6 Checking the brake fluid level - front brake ....24 Shift lever.................6...

  • Page 7: Serial Number Locations

    SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and engine type are embossed on the left side of the engine above the shift lever.

  • Page 8: Filler Cap

    Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON When the motorcycle is running the grip is must be in the ON position to enable fuel to flow to the carburetor.

  • Page 9: Kickstarter

    Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work). Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed.

  • Page 10: Compression Damping Of Shock Absorber

    Damping action during compression of shock absorber The shock absorber on the SX models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle.

  • Page 12: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for your first ride WARNING – Verify that your KTM dealer performed the PREPARATION – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE SMART OF VEHICLE jobs (see Customer Service Manual).

  • Page 13: Driving Instructions

    Arrange for the braking system to be checked by an authorized KTM dealer, as complete failure of the braking system can be expected.Also check the state of the brake hose and the thickness of the brake linings.Check free travel of the hand brake lever and foot brake...

  • Page 14: Starting When The Engine Is Cold

    Starting when the engine is cold 1 Open fuel tap 2 Put the gear in neutral 3 Activate cold-starting aid (choke) 4 Leave throttle closed or open it no more than and kick down kickstar- ter vigorously all the way. WARNING –...

  • Page 15: Braking

    Fuel and engine oil should only be mixed immediately before NE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHAN use. KTM recommends SHELL ADVANCE RACING X. CE TO WARM UP FTER THAT NO FURTHER PRECAUTIONS IN THIS RES...

  • Page 16: Periodic Lubrication - And Maintenance-Schedule

    PERIODIC MAINTENANCE SCHEDULE 250 SX 1st service after after after 10 hours 20 hours 4000 kilometer A clean motorcycle can be checked more quickly which saves money! 1000 kilometers 2000 kilometers once a year 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...
  • Page 17 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 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...

  • Page 18: Maintenance Work On Chassis And Engine

    MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF.

  • Page 19: How To Change The Handlebar Position

    How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper tri- ple clamp includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another.

  • Page 20: Basic Suspension Setup For The Weight Of The Driver

    To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing).

  • Page 21: Checking The Basic Setup Of The Telescopic Fork

    The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. 4,4 N/mm...

  • Page 22: Adjusting The Spring Preload On The Fork

    Adjusting the spring preload on the fork The spring preload on the models can be adjusted (changed) by 10 mm by turning adjusting screw Turning in a clockwise direction will increase the prestress, turning in a coun- terclockwise direction will decrease the prestress. Changing the spring preload will not affect the rebound damping adjustment.

  • Page 23: Checking The Chain Tension

    Check chain tension To check the chain tension, park the motorcycle. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 15 mm (0.6 in). In the course of this procedure, the upper chain portion A must be taut (see drawing).

  • Page 24: Chain Maintenance

    Chain maintenance For long chain life, good maintenance is very important. X-ring chains requi- re only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X- ring chain spray (Shell Advance Bio Chain).

  • Page 25: General Information About Ktm Disc Brakes

    KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake fluid, one of the best brake fluids is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 26: Adjusting The Free Travel At The Hand Brake Lever

    Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw . In this way, the position of the point of pressure (i.e. the resis-tance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size.

  • Page 27: Replacing The Front Brake Pads

    Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips and pull out bolt . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air.

  • Page 28: Checking The Rear Brake Pads

    Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings 1 mm may not be less than 1 mm (0.04 in). WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN ’...

  • Page 29: Dismounting And Mounting The Rear Wheel

    WARNING – I ’ F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A DEALER AS SOON AS POSSIBLE LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE –...

  • Page 30: Tires-Air Pressure

    (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING –...

  • Page 31: Cooling System

    Cooling system The water pump in the engine circulates the cooling liquid. However, the cooling liquid can only circulate properly if the cooling circuit contains no air bubbles. Bleeding of the cooling system is therefore required a) after adding more than 0.25 l cooling liquid and b) after refilling the entire cooling system.

  • Page 32: Refilling/Bleeding The Cooling System

    CAUTION O NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE . KTM FOAM RECOMMENDS THE PRODUCTS MADE BY IR FOR AIR FILTER MAINTE NANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER Thoroughly wash the air filter in special cleaning fluid and allow it to dry well.

  • Page 33: Exhaust System

    SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased at your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with biodegradable hydraulic...

  • Page 34: Carburetor Adjustment

    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 (95 ROZ). Mixing ratio (2-stroke motor oil : super fuel) 1:40 –...

  • Page 35: Draining The Float Chamber Of The Carburetor

    Part-throttle range main jet Operation with partly open throttle valve. This range is only influenced by jet needle the jet needle (shape and position). The optimum part-throttle setting is con- trolled by the idling setting in the lower range and by the main jet in the upper range.

  • Page 36: Check Transmission Oil Level

    Check transmission oil level In order to check the transmission oil level the control screw is to be removed. Oil should just barely escape from the inspection opening when the motorcycle is in an upright position. If necessary, remove the plug and top up with oil (see technical data- engine).

  • Page 37: Cleaning

    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 EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 38: Technical Specifications Chassis

    TECHNICAL SPECIFICATIONS CHASSIS 250 SX 2003 250 SX Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 (Progressive Damping System)shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø...
  • Page 39 TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle M 24x1,5 40 Nm Brake caliper, front Loctite 243 + 25 Nm Brake disk, front M 6 10.9 Loctite 243 + 15 Nm Brake disk, rear Loctite 243 + 15 Nm Clamping screws, upper fork bridge 20 Nm Clamping screws, lower fork bridge...

  • Page 40: Technical Specifications - Engine

    TECHNICAL DATA - ENGINE – MOTOR 250 SX 2003 Engine 250 SX Desgin Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system Piston displacement 249 cm Bore / stroke 66,4 / 72 mm (2.62 / 2.84 in) Fuel...
  • Page 41 TIGHTENING TORQUES Flange bolts - cylinder-head 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm...

  • Page 42: Index

    Breather plug front fork ......17 General information about KTM disc brakes ...23 Carburetor adjustment .
  • Page 45 250 SX REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.at...
  • Page 47 250 SX REPAIR MANUAL ENGINE...
  • Page 49 1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 DISASSEMBLING ENGINE 4 SERVICING INDIVIDUAL COMPONENTS 5 ASSEMBLING ENGINE 6 ELECTRICAL 7 TROUBLE SHOOTING 8 TECHNICAL SPECIFICATIONS 9 PERIODIC MAINTENANCE SCHEDULE 10 WIRING DIAGRAM...
  • Page 51 N F O R M AT I O N P D AT I N G I N S T R U C T I O N S KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER –...
  • Page 53 X P L A N AT I O N P D AT I N G 3206003 Repair Manual 250 SX Basicversion Modelyear 2003 10/2002 Edition 10/2002...
  • Page 55 „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 ongoing total reengineered quality plan for a brighter tomorrow.
  • Page 57 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 59 GENERAL INFORMATION INDEX OPERATING RANGES OF THE CARBURETOR ......2-2 CARBURETOR ADJUSTMENT ........2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM .
  • Page 61 OPERATING RANGES OF THE CARBURETOR main jet jet needle 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.
  • Page 62 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 63 – H AVING COMPLETED THE BLEEDING PROCEDURE YOU HAVE TO VERIFY THAT THE 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 –...
  • Page 64 SPECIAL TOOLS – ENGINE 250 SX Fig. Part no. Description 560.12.001.000 Universal engine work stand 548.29.001.000 Adjusting plate „dimension X“ 546.29.003.000 Clutch holder 560.12.004.000 Gear wheel segment 546.29.009.044 Magneto extractor M 27x1 510.12.011.000 Circlip plier 510.12.016.000 Protection cap 546.29.012.100 Holding spanner for flywheel 501.12.013.000 Dial gauge 0-10 mm 501.12.030.000...
  • Page 65 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 EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...
  • Page 66 DISASSEMBLING THE ENGINE INDEX CLAMP THE ENGINE INTO THE MOUNTING RACK, REMOVING OF KICKSTARTER ........3-2 DRAINING GEAR OIL .
  • Page 68 – Cleaning the engine thoroughly. – Clamp the engine into the workstand. – Remove the kickstarter. 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 69 – Undo the bolts and remove the right control cover together with the gasket. – Remove the securing clip of the ball socket and unhook the ball socket from the adjusting lever. – Remove the 4 collar nuts on cylinder base and remove cylinder. –...
  • Page 70 Dismounting of pressure cap and clutch discs – Loosen collar bolts in diagonally opposite sequence to prevent wedging of discs as springs expand. – Remove collar bolts, springs and spring retainers. – Take pressure cap and disc package out of outer clutch hub. –...
  • Page 71 Dismounting of kickstarter – Remove circlip and kickstarter intermediate gear. – Carefully release collar bolt kickstarter spring is tensioned, release tension on kickstarter spring and unhook spring hanger. CAUTION AREFULLY RELEASE THE KICKSTARTER SPRING ANGER OF INJURY – Pull the kickstarter shaft together with ratchet gear, spring, and disc out of the engine casing.
  • Page 72 Dismounting of the ignition – Apply the holding spanner and undo the collar nut. – Remove the collar nut and the locking cant ring. – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel. –...
  • Page 73 Dismounting of intake flange and reed valve housing – Remove the 4 collar bolts – Remove intake flange and reed valve housing. Parting of engine housing halves – Top ignition-gear upwards and remove all 12 housing bolts. – Loosen the 2 engine fixtures on the engine work stand. –...
  • Page 74 – 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: When dismounting, pay attention to the needle rollers , which could stay behind in the shift drum. Since the shift forks differ from each other, be sure to mark them accordingly when you remove them.
  • Page 75 SERVICING ON INDIVIDUAL COMPONENTS INDEX WORKING ON THE RIGHT-HAND HOUSING HALF ....4-2 WORKING ON THE LEFT-HAND HOUSING HALF ....4-3 CRANKSHAFT .
  • Page 77 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. The bearings usually fall out of their seat of their own accord by knocking the housinq half on a plane piece of wood when the housing has a temperature of 150°...
  • Page 78 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. The bearings usually fall out of their seat of their own accord by knocking the housinq half on a plane piece of wood when the housing has a temperature of 150°...
  • Page 79 Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be renewed. – Heat special tool 584.29.037.043 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 80 Checking cylinder for wear Measure diameter of cylinder approx. 10 mm (0.4 in.) below top of 10mm cylinder edge. Check diameter in several corresponding places to see if cylinder in worn oval. Engine Cylinder Ø Piston size 67,500 - 67,512 67,513 - 67,525 Recoated cylinder Note: If the cylinder diameter is greater than 67, 525 mm, the Nikasil...
  • Page 81 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 –...
  • Page 82 – Mount and grease silicon O-rings (15x1,50 mm) on control flap 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). –...
  • Page 83 LOCTITE 243 LOCTITE 243 Exhaust control, clutch cover – Remove bolts , spring insert , control spring and auxiliary spring from the clutch cover. – Remove bolt with rocker arm and control lever 7. – Take off water pump cover, remove allen head bolt and take off water pump wheel –...
  • Page 84 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. CAUTION 243. ECURE ALL SCREWS OF THE REED VALVE HOUSING WITH OCTITE Rubber sleeve LOCTITE 243 Check for firm mounting and for signs of damage.
  • Page 85 4-10 13,5 mm LOCTITE 242 Clutch Thrust bearing check for wear Push rod Check for wear. Minimum length: 192 mm (new: 192.50 mm) Clutch springs New spring length 42 mm / 1.69 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 86 4-11 Replace outer clutch hub – Drill open the clutch rivets in area of retaining bracket remove parts. – Check 8 absorbing elements for signs of mechanical damage, replace all 8 where applicable. CAUTION HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN O ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED...
  • Page 87 4-12 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 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. Check position of shift roller in grooved ball bearings 0,80 mm Slide plate Check slide plate at meshing points...
  • Page 88 4-13 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.
  • Page 89 4-14 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 90 4-15 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 91 4-16 LOCTITE 243 LOCTITE 243 Checking the kickstarter for wear Take all components off the kickstarter shaft and clean them. Kickstarter gear Check the toothing for wear and the bearing for clearance. Kickstarter idler gear Check the bearing for clearance and seizing marks. Check the toothing for wear.
  • Page 92 ASSEMBLING THE ENGINE INDEX CRANKSHAFT ......... . .5-2 TRANSMISSION .
  • Page 94 – 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 HEN PUSHING IN CRANKSHAFT MAKE SURE CONROD IS FACING CYLINDER NOTE: To make it easier to mount the crankshaft, heat the crankshaft bearing with a hot air blower.
  • Page 95 – Fix the 3 pressure springs with ample amounts of grease in the gearshift rails. NOTE: The bottom of the longer gearshift rail does not have a spring. – Oil gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft).
  • Page 96 Mounting shift mechanism – Slip the disc , the locking lever , the locking spring sleeve the locking lever spring onto the bolt (M5x20). – Apply Loctite 243 to the thread of bolt and mount all parts at the same time. LOCTITE 243 –...
  • Page 97 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. – Place primary gear onto crankshaft with collar downwards. –...
  • Page 98 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 99 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 100 Adjusting control flap (dimension “Z“) control NOTE: Dimension “Z“ is the distance from the lower edge of the control flap flap to the upper edge of the cylinder, as measured in the centre of the exhaust port. + 0,2 / - 0,6 mm Dimension „Z“...
  • Page 101 Mounting steering covers – Mount the right control cover including the gasket and fasten with 3 bolts. – Place gasket in position and fix left-hand steering cover cylinder. Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O-rings in grooves.
  • Page 102 5-10 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 103 5-11 Mounting ignition cover – Put on a new gasket, and fix the ignition cover by means of the 4 bolts. Mounting starting lever and shift lever – Mount kickstarter. Secure the bolt of the kickstarter with Loctite 243. – Mount shift lever. Secure the bolt of the shift lever with Loctite 243. –...
  • Page 104 ELECTRICAL INDEX STATIC IGNITION VALUES ........6-2 IGNITION COIL .
  • Page 106 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 –...
  • Page 108 TROUBLE SHOOTING INDEX TROUBLE SHOOTING 250 SX .......7-2...
  • Page 110 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 CAUSE REMEDY...
  • Page 111 TROUBLE CAUSE REMEDY Engine has not enough Reed paddles tensionless Replace reed paddles or reed valve housing power damaged, surface of reed valve housing damaged Wear Overhaul engine Electronical ignition timing faulty 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...
  • Page 112 INDEX TECHNICAL SPECIFICATIONS MODEL 250 SX 2003 ENGINE ..........8-2 CARBURETOR .

  • Page 114: Carburetor Setting

    TECHNICAL DATA - ENGINE – MOTOR 250 SX 2003 Engine 250 SX Desgin Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system Piston displacement 249 cm Bore / stroke 66,4 / 72 mm (2.62 / 2.84 in) Fuel...
  • Page 115 TECHNICAL SPECIFICATIONS CHASSIS 250 SX 2003 250 SX Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 (Progressive Damping System)shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø...
  • Page 116 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 60 Nm (44 ft.lb) Flat head bolt release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb) Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm(110 ft.lb)
  • Page 118 LUBRICATION AND MAINTENANCE SCHEDULE INDEX MODELL 2003 LUBRICATION AND MAINTENANCE SCHEDULE 250 SX ...9-2...
  • Page 120 PERIODIC MAINTENANCE SCHEDULE 250 SX 1st service after after after 10 hours 20 hours 4000 kilometer A clean motorcycle can be checked more quickly which saves money! 1000 kilometers 2000 kilometers once a year 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...
  • Page 121 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 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...
  • Page 122 10-1 WIRING DIAGRAM INDEX WIRING DIAGRAM 250 SX 2003 ......10-2...
  • Page 124 10-2...
  • Page 125 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Shock absorber 5018 PDS 2003 Introduction Exploded view Disassembly shock absorber Disassembly tube side Disassembly MCC Assembling MCC Assembling Tube side Disassembly piston-rod side Diassembly adaptor DU-bush Assembling adaptor DU-bush Assembling piston-rod side Assembling shock absorber Bleeding...

  • Page 126: Introduction

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Introduction General notice Pay attention to the following notes, when you are working with WP suspension products as described in this workshop manual: Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.

  • Page 127: Exploded View

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Exploded view...

  • Page 128: Disassembly Shock Absorber

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly Shock absorber Take note of the rebound (REB) position. Fully closed is turning the adjustment screw (“ ”) clockwise. MCC = Mono Compression Control Take note of the compression (COM) position.
  • Page 129 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Take note of the compression High-Speed position. Fully closed is turning the hexagonal (size 17) screw clockwise. Measure the length of the spring. Spring preload. Unscrew the Allen bolt (size 4). We r k p l a a t s h a n d b o e k...
  • Page 130 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Release the spring preload with open spanner T106. Screw the screw retainer against the lock retainer. Disassemble the spring retainer and springring. We r k p l a a t s h a n d b o e k...
  • Page 131 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the washer. Remove the spring. Pay attention to the assembling direction!!! Remove the second washer. We r k p l a a t s h a n d b o e k...
  • Page 132 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Spring with washers, spring retainer and springring. We r k p l a a t s h a n d b o e k...
  • Page 133 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassemble the rubber cap. Unscrew slowly the nitrogen plug (size 4) to release the pressure. Nitrogen plug with O-ring. We r k p l a a t s h a n d b o e k...
  • Page 134 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tap the cap from the tube. 1. Place disassembling bush T1216 on the adaptor DU-bush. We r k p l a a t s h a n d b o e k...
  • Page 135 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push the adaptor DU-bush downwards. Disassemble the springring out of the tube. Springring. We r k p l a a t s h a n d b o e k...
  • Page 136 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Pull carefully but firmly the piston-rod “complete” out of the tube. Push with depth-stop T107S the separation piston downwards. We r k p l a a t s h a n d b o e k...

  • Page 137: Disassembly Tube Side

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly tube-side Drain the oil out the tube. Clamp the tube side in the vice. Remove the springring out of the groove and slide it a little bit downwards. We r k p l a a t s h a n d b o e k...
  • Page 138 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Slide the guiding bush downwards. Remove the upper springring. Remove the guiding bush. Pay attention to the assembling direction!!! We r k p l a a t s h a n d b o e k...
  • Page 139 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the springring. Spring guiding bush with the two springrings. We r k p l a a t s h a n d b o e k...
  • Page 140 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the screw-retainer of the tube. Screw-retainer with the Allen bolt. We r k p l a a t s h a n d b o e k...
  • Page 141 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Unscrew the screw-cap of the MCC (size 24) (DCC also size 24) Remove the screw-cap. Remove the washer inside the screw- cap, or on top of the spring inside the bottom.
  • Page 142 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the spring. Pull the damping holder “cpl” out of the bottom. Srew-cap with adjustment needle, spring and the MCC damping holder “cpl”. We r k p l a a t s h a n d b o e k...
  • Page 143 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Heat the lock retainer. Unscrew the lock retainer with open spanner T1233. Screw the lock retainer of the bottom. We r k p l a a t s h a n d b o e k...
  • Page 144 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Heat the bottom near the tube. Use slide-spanner T146 with bush T1201. Unscrew the tube. We r k p l a a t s h a n d b o e k...
  • Page 145 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Screw the tube out of the bottom. Screw the lock retainer of the tube. Tube with lock retainer. We r k p l a a t s h a n d b o e k...
  • Page 146 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassemble the O-ring out of the groove inside the bottom. Place dis- / assembling tool T145S on top of the screw-cap Place pin spanner T125S onto T145S. We r k p l a a t s h a n d b o e k...
  • Page 147 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Heat the reservoir near the bottom. Unscrew the screw-cap. Turn the reservoir from the bottom. We r k p l a a t s h a n d b o e k...
  • Page 148 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the O-ring. Bottom “cpl” with both O-rings. We r k p l a a t s h a n d b o e k...
  • Page 149 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Pay attention to the assembling direction!!! Push the separation piston out of the reservoir. Separation piston. Disassemble the O-ring. We r k p l a a t s h a n d b o e k...
  • Page 150 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Separation piston, piston ring and O-ring. We r k p l a a t s h a n d b o e k...
  • Page 151 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Clamp the bottom in the vice. Use disassembling tool T120 for disassembling the adaptor bushes. Tap the adaptor bush out of the heim- joint. We r k p l a a t s h a n d b o e k...
  • Page 152 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the seal. Disassemble the springring. Tap the other adaptor bush out of the heim-joint. We r k p l a a t s h a n d b o e k...
  • Page 153 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Use Dis- / assembling tool T1207S for disassembling the heim-joint. Press the heim-joint out of the bottom at the side were the springring is removed. Adaptor bushes, seals, springrings and heim-joint.
  • Page 154 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Replace one springring. Assemble the heim-joint with the bevelled edge into the direction of the bottom with assembling tool T1206. Press the heim-joint into the bottom with support of the vice. We r k p l a a t s h a n d b o e k...
  • Page 155 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Press with T1207(A) the heim-joint against the springring. Assemble the springring into the groove. Replace the seals. We r k p l a a t s h a n d b o e k...
  • Page 156 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Assemble the adaptor bushes with support of T1206. We r k p l a a t s h a n d b o e k...

  • Page 157: Disassembly Mcc

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly MCC There is a separated workshop manual for the DCC. ----------------------------------------------------- Damping holder MCC. Remove the disk. Pay attention to the assembling direction!!! Clamp the damping holder with clamping block T1202S.
  • Page 158 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Unscrew the nut (size 10). Turn the nut of. Remove the piston with check-valve. We r k p l a a t s h a n d b o e k...
  • Page 159 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Piston with the check-valve side. Compression side. Damping holder with shims (setting). We r k p l a a t s h a n d b o e k...
  • Page 160 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the shims of the damping holder. Pay attention to the assembling order and direction!!! - Nut M6 - piston with check-valve - setting (shims) - damping holder - disk. We r k p l a a t s h a n d b o e k...
  • Page 161 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the O-ring of the screw-cap. Turn clockwise the adjustment needle out of the screw-cap. Adjustment needle “complete”. We r k p l a a t s h a n d b o e k...
  • Page 162 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling - Steel ball - spring - adjustment needle with O-ring - screw-cap - O-ring We r k p l a a t s h a n d b o e k...

  • Page 163: Assembling Mcc

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling MCC Assemble the spring and steel ball, and grease, also the O-ring, these with water proof grease T159. Assemble the O-ring. Assemble the needle. We r k p l a a t s h a n d b o e k...
  • Page 164 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the needle fully open. Replace the setting and piston with the check-valve Wet the thread of the nut with Loctite 2701 (T132) and turn the nut on the holder.
  • Page 165 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tighten the nut to a torque of 6Nm. Replace the disk. We r k p l a a t s h a n d b o e k...

  • Page 166: Assembling Tube Side

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling tube side Assemble the O-ring on the bottom. Assemble the O-ring inside the bottom. Grease the O-ring groove of the separation piston with O-ring grease T158. We r k p l a a t s h a n d b o e k...
  • Page 167 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the O-ring. Grease the O-ring with T158. Pay attention to the groove of the nitrogen reservoir. We r k p l a a t s h a n d b o e k “groove”.
  • Page 168 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Assemble the separation piston and piston ring with the hollow surface into the reservoir at the groove side. Push the separation piston into the reservoir. We r k p l a a t s h a n d b o e k...
  • Page 169 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Wet the thread of the bottom with T132. Wet the thread of the reservoir with T132 on both sides. Wet the thread of the screw-cap. We r k p l a a t s h a n d b o e k...
  • Page 170 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the reservoir with screw-cap on the bottom. Tighten the reservoir wit T125S and T145S. Wet the thread inside the bottom with T132. We r k p l a a t s h a n d b o e k...
  • Page 171 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the lock retainer as far as possible onto the tube. Wet the thread of the tube with T132. Turn the tube into the bottom. We r k p l a a t s h a n d b o e k...
  • Page 172 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tighten the tube with T146 and T1201. Screw the lock retainer against the bottom and tighten it with T1233. Turn the screw spring retainer onto the tube and... We r k p l a a t s h a n d b o e k...
  • Page 173 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling ...completely downwards. Assemble the springring passed the groove of the tube. Slide the spring guide onto the tube. We r k p l a a t s h a n d b o e k...
  • Page 174 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the first springring into the groove. Slide the guiding bush over the springring. Assemble the second springring. We r k p l a a t s h a n d b o e k...
  • Page 175 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Wet the O-ring of the piston MCC with T158. Assemble the damping holder MCC “cpl” into the housing of the bottom. Assemble the spring. We r k p l a a t s h a n d b o e k...
  • Page 176 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Place the ring into the screw-cap. Turn the screw-cap into the bottom. Tighten the screw-cap. We r k p l a a t s h a n d b o e k...

  • Page 177: Disassembly Piston-Rod Side

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly piston-rod side Clamp the piston-rod “cpl” in the vice. Unscrew the nut (size 22) We r k p l a a t s h a n d b o e k...
  • Page 178 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn off the nut. Place a screwdriver on top of the piston- rod and lift the entire assembly onto the screwdriver. - Rebound bush plane - compression setting 1 (shims) - piston 1 - rebound setting 1 (shims) - intermediate bush...
  • Page 179 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the adaptor DU-bush. Remove the cap. Remove the bump rubber. We r k p l a a t s h a n d b o e k...
  • Page 180 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Clamp the mounting-fork in the vice. Unscrew the screw-cap of the rebound adjustment (size 15). Turn the screw-cap out of the mounting- fork. We r k p l a a t s h a n d b o e k...
  • Page 181 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Turn the rebound adjustment needle anti clockwise out of the mounting-fork. Rebound adjustment needle with the screw-cap. We r k p l a a t s h a n d b o e k...
  • Page 182 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Push the rubber plug out of the mounting-fork. Push with an pin (d2) on top of the piston- rod the rebound needle out of the piston- rod. We r k p l a a t s h a n d b o e k...
  • Page 183 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Take the rebound needle out. Rebound needle. Clamp the mounting-fork in the vice and unscrew the locking nut (size 24). We r k p l a a t s h a n d b o e k...
  • Page 184 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Clamp the piston-rod in clamping block T1202S. Heat de mounting-fork. Unscrew the mounting-fork. We r k p l a a t s h a n d b o e k...
  • Page 185 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the mounting-fork of the piston-rod. Turn the nut of the piston-rod. Push with een Allenkey (size 5) the rebound tube out of the piston-rod. We r k p l a a t s h a n d b o e k...
  • Page 186 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Piston-rod and rebound tube “cpl”. We r k p l a a t s h a n d b o e k...

  • Page 187: Diassembly Adaptor Du-Bush

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly adaptor DU-bush Adaptor DU-bush. 1. Lift the rebound spring out of the adaptor. We r k p l a a t s h a n d b o e k...
  • Page 188 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the steel washer. Pay attention to the back-up ring in the washer. Remove the quad ring. Remove the second back-up ring. We r k p l a a t s h a n d b o e k...
  • Page 189 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Lift the dirt scraper out of the adaptor. Disassemble the O-ring. Dis- / assembling tool T1504, adaptor and support bush T1209. We r k p l a a t s h a n d b o e k...
  • Page 190 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Press the DU-bush out of the adaptor. We r k p l a a t s h a n d b o e k...

  • Page 191: Assembling Adaptor Du-Bush

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling adaptor DU-bush Press the DU-bush into the adaptor with T1504 and T1209. Calibrate the DU-bush with the calibration thorn T1205. Important: wet the thorn with oil before the calibration. Press the dirt scraper into the adaptor with assembling bush T1204.
  • Page 192 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the first the back-up ring and then the quad ring into the adaptor. Replace the steel disk with the back-up ring. Assemble the rebound spring with support of T1209. We r k p l a a t s h a n d b o e k...
  • Page 193 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the O-ring. Grease the O-ring with T158. We r k p l a a t s h a n d b o e k...

  • Page 194: Assembling Piston-Rod Side

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling piston-rod side Turn the lock nut on the piston-rod. Grease the O-ring of the rebound tube with T158. Assemble the tube into the piston-rod. We r k p l a a t s h a n d b o e k...
  • Page 195 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Wet the thread of the piston-rod with T132. Turn the mounting-fork on the piston- rod. Tighten the mounting-fork. We r k p l a a t s h a n d b o e k...
  • Page 196 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the lock nut against the mounting- fork. Tighten the nut. 1. Place assembling tool T1215 on top of the piston-rod. We r k p l a a t s h a n d b o e k...
  • Page 197 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the bump rubber. Replace the cap. We r k p l a a t s h a n d b o e k...
  • Page 198 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Replace carefully the adaptor DU-bush. Replace the entire damping package. Pay attention to the first shim, this one must be centered on the ring. We r k p l a a t s h a n d b o e k...
  • Page 199 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Grease the thread of the piston-rod with a little bit of T158. Turn the nut on the piston-rod. Turn the nut just so far so that the pistons can still be turned. We r k p l a a t s h a n d b o e k...
  • Page 200 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Place the center sleeve T1214..over both pistons and adaptor DU-bush. Place T107S through T1214, intermediate bush and piston rod. We r k p l a a t s h a n d b o e k...
  • Page 201 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tighten the piston-rod nut to a torque of 40Nm. Check if you can lift the shim. Grease the O-ring of the rebound needle with T158. We r k p l a a t s h a n d b o e k...
  • Page 202 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the needle into the piston-rod. Push the needle further. Grease the O-ring and steel ball of the rebound adjustment needle with T159. We r k p l a a t s h a n d b o e k...
  • Page 203 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Screw the adjustment needle into the mounting-fork. Turn de rebound screw-cap into the mounting-fork. Tighten the screw-cap. We r k p l a a t s h a n d b o e k...
  • Page 204 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the adjustment completely open. Push the needle downwards. Assemble the rubber plug. We r k p l a a t s h a n d b o e k...

  • Page 205: Assembling Shock Absorber

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling shock absorber Turn the compression adjustment fully open. (DCC High and Low-speed) Fill the tube with oil, just under the springring groove inside the tube. Place plunger T1210S into the tube. We r k p l a a t s h a n d b o e k...
  • Page 206 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push the plunger downwards. Push with T107S the separation piston in the reservoir as far as possible. Slide the O-ring of T107S against the screw-cap. We r k p l a a t s h a n d b o e k...
  • Page 207 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push again with T1210S. Push with T107S the separation piston..to the correct position, the O-ring of T107S must have a distance of about 10mm from the screw-cap. We r k p l a a t s h a n d b o e k...
  • Page 208 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Fill oil till 10mm under the groove. Close the compression adjustment. (DCC Low-speed) Push both pistons under the oil. We r k p l a a t s h a n d b o e k...
  • Page 209 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Open the compression adjustment. Push the adaptor DU-bush just under the O-ring groove. We r k p l a a t s h a n d b o e k...
  • Page 210 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the springring. Pull the piston-rod fully out. Tap the cap into the tube. We r k p l a a t s h a n d b o e k...

  • Page 211: Bleeding

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Bleeding Clamp “not too tight” the shock absorber in the vice like picture. 1. Unscrew the screw-cap and remove the entire MCC. We r k p l a a t s h a n d b o e k...
  • Page 212 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn adaptor T1502S of the air release bottle T144S into the MCC (DCC) housing of the bottom. Ensure that there is sufficient oil in the bottle. Hold the bottle up so that the oil wil flow into the shock absorber.
  • Page 213 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push the piston rod slowly completely inwards. And out. Repeat those handlings several times. Cant the shock absorber several times. We r k p l a a t s h a n d b o e k...
  • Page 214 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Repeat all the handling till all air is out of the shock absorber. Push the separation piston to the correct position. Remove the adaptor. We r k p l a a t s h a n d b o e k...
  • Page 215 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the MCC (DCC). We r k p l a a t s h a n d b o e k...

  • Page 216: On Pressure With Nitrogen

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling On pressure with nitrogen Turn the nitrogen plug with O-ring several turns into the screw-cap of the reservoir Nitrogen charging device T170S. We r k p l a a t s h a n d b o e k...
  • Page 217 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Place the shock absorber in T170S and open de tap for about 20 seconds. Close the nitrogen plug. Close the tap. We r k p l a a t s h a n d b o e k...
  • Page 218 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the rubber cap. We r k p l a a t s h a n d b o e k...
  • Page 219 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling spring Assemble the washer. Assemble the spring. We r k p l a a t s h a n d b o e k...
  • Page 220 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the second washer. Assemble the spring retainer. Assemble the springring. We r k p l a a t s h a n d b o e k...
  • Page 221 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Adjust the spring..to the correct preload. Tighten the bolt to a torque of 5Nm. We r k p l a a t s h a n d b o e k...

  • Page 222: Adjustment

    Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Adjustment Turn the mounting-fork to the correct position. Compression position (MCC)! Compression Low-speed position (DCC)! We r k p l a a t s h a n d b o e k...
  • Page 223 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Compression High-Speed position (DCC)! Rebound position! We r k p l a a t s h a n d b o e k...
  • Page 224 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling 12_234 Frontfork 4860 MX Multi Adjuster 2003 Introduction Exploded view Disassembly forkleg Disassembly cartridge Disassembly compression holder Assembling compression holder Disassembly tap rebound Assembling tap rebound Assembling cartridge Assembling forkleg...

  • Page 225: Introduction

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Introduction General notice: Pay attention to the following notes, when you are working with WP Suspension products as described in this workshop manual. Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.

  • Page 226: Exploded View

    Workshop manual 4860 MXMA Product Exploded View Disassembly & assembling Exploded view...

  • Page 227: Disassembly Forkleg

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly forkleg Note the rebound position by turning the knob to the right. 12_062 After removing the rubber cap. Note the compression position by turning the screw to the right. 12_063 Clamp the outer-tube in T1403S and unscrew the screw-cap PA with T103.
  • Page 228 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards... 12_067 ...and place open-end spanner (size 22) on the hydraulic stop. 12_068 Unscrew the screw-cap.
  • Page 229 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the screw-cap from the piston- rod. 12_070 Remove the preload spacers. 12_074 Pull the spring downwards and remove the spanner. 12_075...
  • Page 230 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the spring. 12_076 Remove the adjustment tube with the O-ring. 12_089...
  • Page 231 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Drain the oil out the forkleg. 12_094 Clamp the axle-clamp in the vice so that the forkleg is at an angle of ±45 degrees. 12_095 Unscrew the compression holder out of the axle-clamp.
  • Page 232 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove holder compression. Caution: oil iscoming out the cartridge. 12_097 Disassemble the cartridge out the forkleg. 12_098 Disassemble the dust-wiper. 12_099...
  • Page 233 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the circlip. 12_100 Heat the outer-tube near the oilseal. (not too hot) Heat the outer-tube at this level..
  • Page 234 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull with both hands the outer-tube from the inner-tube. Remove DU-bush inner-tube. 1. Remove DU-bush.
  • Page 235 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove DU-bush inner-tube. Remove DU-bush outer-tube.
  • Page 236 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove support ring. 12_105 Disassemble the oilseal. Pay attention to the assembling direction!!! 12_106...
  • Page 237 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the circlip. 12_107 Remove the dust wiper. 12_108...
  • Page 238 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Heat the axle-clamp. 12_111 Use T1404S... 12_112...
  • Page 239 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling ...and unscrew the inner-tube from the axle-clamp. 12_113 Remove the inner-tube. 1 2 - 1 1 4 Remove the O-ring out the groove of the axle-clamp. 12_115...

  • Page 240: Disassembly Cartridge

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly cartridge 1. Clamp the tube with plug in the clamping-block (Tool T508S + T509). 12_116 12_117 12_118...
  • Page 241 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Unscrew the screw sleeve (size 22). 12_119 Turn the screw sleeve out of the tube. 12_120 Disassemble the piston-rod “complete”. Pay attention to the piston ring!!! 12_121...
  • Page 242 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the piston rod in T508S “not too tight” and unscrew the hydraulic stop from the piston-rod. 12_164 Remove the hydraulic stop. 12_165...
  • Page 243 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the screw sleeve with spring retainer. 12_167 Disassemble the DU-bush with T507 and press it out the screw sleeve with support of the vice. 12_168 - Spring retainer - screw sleeve - DU-bush 12_169...
  • Page 244 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly holder compression Clamp the compression holder in the vice and unscrew the check-valve nut. (size 17) Version with a locking: remove the locking with a file. 12_124 Remove the check-valve nut. 12_125 Remove the check-valve spring.
  • Page 245 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the check-valve shim. 12_127 Disassemble the compression piston with O-ring. Pay attention to the assembling direction!!! 12_128 Place a screwdriver on top of the holder and remove the entire shim packet. 12_129...
  • Page 246 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the O-ring. 12_130 Remove the copper washer. 12_131 - Holder compression - copper washer - O-ring - shims compression - piston compression with O- 12_132 ring - shim check-valve - spring check-valve - nut check-valve...
  • Page 247 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling holder compression Replace copper washer. 12_133 Assemble the O-ring. 12_134 Replace the entire shim packet. 12_135...
  • Page 248 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Replace piston. Pay attention to the assembling direction!!! 12_136 Replace shim check-valve. 12_137 Replace spring check-valve. Pay attention to the assembling direction!!! 12_138...
  • Page 249 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Wetting the thread of the nut with T132 and tighten it... 12_140 ...to a torque of 5Nm. 12_141 Check if the spring is correctly placed in the chamber of the nut. 12_142...

  • Page 250: Disassembly Tap Rebound

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly tap rebound Clamp the piston-rod (at the level where the hydraulic stop is mounted) in T508S and unscrew the rebound tap. (Size 17) 12_143 Remove the rebound tap “complete”. 12_144/ 145/146 - posterize...
  • Page 251 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull the rebound needle with spring out of the tap rebound. 12_148 Check the O-ring. 12_149 Pay attention to the position of the triangular shims on the piston!!! Clamp the tap in the vice and unscrew the nut.
  • Page 252 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the nut. Pay attention to the assembling direction!!! 12_151 Place a screwdriver on top of the tap and remove the entire shim packet. 12_152 Remove piston rebound. Pay attention to the assembling direction!!! 12_153...
  • Page 253 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove check-valve shims. 12_154 Remove spring check-valve. 12_155 - Rebound adjustment needle with O-ring - spring - tap rebound - spring check-valve 12_156 - shims check-valve - piston rebound - shims - nut M6x0.5...

  • Page 254: Assembling Tap Rebound

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling tap rebound Assemble the spring and shims check- valve. 12_157 Assemble the piston rebound. Pay attention to the assembling direction!!! 12_158 Replace the shims. Pay attention to the position of the triangular shims on the piston!!! 12_159...
  • Page 255 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Wetting the thread of the nut with T132. Screw the nut on the tap... 12_160 ...tighten the nut to a torque of 5 Nm. 12_161 Grease the O-ring of the adjustment needle with T158.
  • Page 256 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Mount the needle with spring into the tap rebound. 12_163...

  • Page 257: Assembling Cartridge

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling cartridge Press with T507 the DU-bush into the screw sleeve. 12_171 Clamp the piston-rod in T508S. At the level where the hydraulic stop is mounted. 12_172 Wetting the thread with T131. And screw the tap in the piston-rod.
  • Page 258 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Tighten the tap rebound. 12_174 Clamp the piston-rod “not too tight” in at the other side and replace the screw sleeve with spring retainer. 12_175 Screw the hydraulic stop “hand tight” to the end of the thread of the piston-rod.
  • Page 259 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the tube with plug in the clamping block (T508S and T509) and assemble the piston-rod “cpl.” into the tube. Guide the piston ring!!! 12_177 Before assembling wet the thread of the screw sleeve with T131.

  • Page 260: Assembling Forkleg

    Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling forkleg Replace a new O-ring in the groove of the axle-clamp. 12_180 Wetting the thread of the axle-clamp with T132. 12_181 Wetting the thread of the inner-tube with T132. 12_182...
  • Page 261 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the inner-tube in the axle- clamp. 12_183 Screw very tight the inner-tube with T503S / T1404S. 12_184 Apply the dust wiper with T511. 1 4 _ 0 0 0 7...
  • Page 262 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Place T1401 over the inner-tube and assemble the dust wiper. 14_0008 Replace the circlip. 14_0011 Apply the innerside of the oilseal with T511 and the outerside with frontfork oil. 14_0010...
  • Page 263 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the oilseal. Pay attention to the assembling direction!!! 14_0012 Remove the tool and replace the support ring. 12_190...
  • Page 264 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Replace the DU-bush. Replace the tube. Replace the DU-bush.
  • Page 265 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Replace the DU-bush on the inner-tube. Slide carefully the outer-tube over the inner-tube.
  • Page 266 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble with T1402S the DU-bush - with the flat side- and... 12_194 ...tap or push it into the outer-tube. 12_195...
  • Page 267 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Use the other side of T1402S... 12_196 ...and tap the oilseal into the outer-tube. 12_197 Assemble the circlip into the groove of the outer-tube. Important: Check this very carefully!!! 12_198...
  • Page 268 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the dust wiper with T1402S. 12_199 Place the cartridge into the forkleg. Apply the O-ring of the compression piston with frontfork oil. 12_202...
  • Page 269 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the cartridge in the center of the axle-clamp and tighten the holder compression to a torque of 25Nm. 12_203 Assemble the adjustment tube with the O-ring into the piston-rod. 12_204...
  • Page 270 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Keep the outer-tube down and the piston- rod a little bit extended (like picture), fill the forkleg with oil till the edge of the outer-tube, wait a few moments, you will see air bubbles rising 12_206 The oil must stay above the 4 holes of the inner-tube, if necesarry fill some...
  • Page 271 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull the piston-rod out and assemble the spring. 12_211 Pull the spring downwards and place open-end spanner 22 on the hydraulic stop. 12_212 Replace first the steel washer on the spring, then the preload spacer(s).
  • Page 272 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Screw handtight the screw-cap on the piston-rod. Screw down the screw-cap, till the hydr. stop is against the screw-cap and tighten it to a torque of 25Nm.
  • Page 273 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull the spring downwards and remove the spanner. Tighten the screw-cap with T103. Position rebound!
  • Page 274 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Position compression! And replace the rubber cap. 12_226...

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