KTM 250 SX 2003 Owner's Handbook Manual page 116

TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Flat head bolt release plate kickstarter
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and cover bolts
Swingarm pivot
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
Crankshaft web
GASKET THICKNESSES
Crankcase
Clutch cover
Cylinder bottom gasket
Available cylinder bottom gaskets
Cylinder-head gasket
Outer clutch cover
Water pump cover
TIGHTENING TORQUES - CHASSIS
Collar screw, front wheel spindle
Brake caliper, front
Brake disk, front
Brake disk, rear
Clamping bolts, upper fork bridge
Clamping bolts, lower fork bridge
Clamping bolts, fork stubs
Collar nut, rear wheel spindle
Hexagon nut, swing arm bolt
Hexagon collar bolt, handlebar clamp
Allan head bolt, handlebar support
Shock absorber, top
Shock absorber, bottom
Sprocket screws
Ball joint for push rod
Engine mounting bolt
Engine brace
Screw adjusting ring spring preload shock abs.
Spoke nipple
Other bolts on chassis
Other collar nuts on chassis
M 8
M 10
M 12x1
M 6x16 Loctite 648 19 Nm (14 ft.lb)
M 18x1.5 Loctite 243 150 Nm(110 ft.lb)
M 18x1.5 Loctite 243 100 Nm (74 ft.lb)
M 6
M 14
M 6
M 8
M 10
0.06 mm
0.3 – 0.4 mm
0.018– 0.032 mm
0.1 – 0.4 mm
Ø 2.5 new = 43 mm, minimum length = 42 mm
60 mm ± 0,05 mm
0.5 mm
0.8 mm
as required
0.2/0.4/ 0.5 / 0.75 mm
O-rings
Form ring
Form ring
M 24x1,5
M 8
M 6 10.9
M 6
M 8
M 8
M 8
M 20x1,5
M 14x1,5
M 8
M 10
M 12
M 12
M 8
M 6
M 10
M 8
M6
M4,5 /M5
M 6
M 8
M 10
M 6
M 8
M 10
35 Nm (25 ft.lb)
35 Nm (25 ft.lb)
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)
8-4
40 Nm
Loctite 243 + 25 Nm
Loctite 243 + 15 Nm
Loctite 243 + 15 Nm
20 Nm
15 Nm
10 Nm
80 Nm
100 Nm
20 Nm
Loctite 243 + 40 Nm
60 Nm
60 Nm
Loctite 243 + 35 Nm
Loctite 243 + 10 Nm
45 Nm
33 Nm
8 Nm
5 Nm
10 Nm
25 Nm
45 Nm
15 Nm
30 Nm
50 Nm