Related Manuals for KTM 250 1998
Summary of Contents for KTM 250 1998
- Page 1 REPARATURANLEITUNG MOTOR REPAIR MANUAL ENGINE MANUALE DI RIPARAZIONE MOTORE MANUEL DE RÉPARATION MOTEUR MANUAL DE REPARACIÓN MOTOR 250 / 300 / 380 ‘98 7. 97 ART. NR. 3.205.20...
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Page 2: Table Of Contents
1 General 2 Removing engine / Refitting engine 3 Dismantling engine 4 Servicing on individual components 5 Engine assembly 6 Electrical 7 Trouble shooting 8 Technical data / maintenance schedule 9 Wiring diagrams (see at the end of this repair manual) -
Page 3: General
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCY- CLES UNFIT FOR TRAFFIC. „NOTE” POINTS OUT USEFUL TIPS. ORIGINAL KTM SPARE PARTS SE ONLY WHEN REPLACING PARTS HIGH PERFORMANCE ENGINE IS ONLY ABLE TO MEET USER EXPECTATIONS IF THE MAINTENANCE WORK IS PERFORMED REGU... - Page 4 1.0 General Chap. Component / Component unit Page Bleeding the cooling system ..........1-2 Carburetor adjustment .
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Page 5: Bleeding The Cooling System
1.1 Bleeding the cooling system If the coolant has been drained, the cooling system must be bled as follows after refilling. – Make sure that the drain screw is fastened. – Pour approx. 0.5 litres coolant into the system. – Remove the screw on the right radiator and tilt the motorcycle to the right approx. -
Page 6: Definitions
1.3 Definitions Mixture too rich: Too much fuel in proportion to air. Mixture too lean: Not enough fuel in proportion to air. 1.3.1 Idling range Operation with closed throttle valve. This range is influenced by the position of the air control screw and the idle adjusting screw . -
Page 7: Checking The Setting Of The Tvc System
1.5 Checking the setting of the TVC system HE FUNCTION OF THE SYSTEM IS CHECKED WITH THE ENGINE RUNNING HIS TEST CHECKS THE START OF ADVANCE AND THE END OF ADVANCE – For this, remove the left control cover. – Connect a rev counter (either to the ignition cable or to the blue/white cable in the electronics box, depending on the rev counter design). -
Page 8: Special Tools
1.6 Special tools FIG. PARTNO. DESCRIPTION 560.12.001.000 REPAIR STAND ‘96 546.29.003.000 HOLDING PLATE 250 560.12.004.000 GEAR WHEEL SEGMENT 546.29.009.044 PULLER FOR FLYWHEEL 6 276 807 PULLER FOR FLYWHEEL 510.12.011.000 SPECIAL CIRCLIP PLIER 544.12.012.000 HOLDING SPANNER FOR FLYWHEEL SEM 510.12.014.000 TIMING DEGREE DISC 510.12.016.000 PROTECTION CAP 546.29.012.000... - Page 9 – Notices –...
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Page 10: Removing Engine / Refitting Engine
2.0 Removing engine / Refitting engine Chap. Component / Component unit Page Removing engine ..........2-1 Refitting engine . - Page 11 2.2 Installing the engine – Lift the engine into the frame from the left side, slightly grease and mount the swingarm pivot. – Twist in the engine mounting screws. – Mount the engine brace. – Insert a new O-ring into the groove of the compensation chamber of KTC system with O-ring.
- Page 12 3.0 Dismantling engine Cap. Component / Component unit Page Drain gear oil ............3-2 Cylinder head, cylinder, piston .
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Page 13: Drain Gear Oil
– Cleaning the engine thoroughly. – Place engine work stand in a vice and clamp the engine into the workstand. – Remove the kickstarter together with the distance bushing behind and the foot shift lever. 3.1 Draining gear oil – Unscrew plug , allowing oil to drain. -
Page 14: Clutch Cover
– Cover the crankcase. – Place piston on wooden jig and remove both piston pin locking pins. – Expel piston pin from piston without exerting undue force. Use a suitable mand- rel if necessary. – Remove piston and piston pin needle-bearing from conrod eye. –... -
Page 15: Kickstarter
– Pulling the primary gear off the crankshaft. HE PRIMARY GEAR AND THE OUTER CLUTCH HUB BELONG TOGETHER LWAYS REPLACE BOTH TOGETHER 3.6 Kickstarter – Remove circlip and kickstarter intermediate gear. – Carefully release collar screw kickstarter spring is tensioned, release tension on kickstarter spring and unhook spring hanger. -
Page 16: Ignition (Sem)
3.9 Ignition system (SEM) – Remove ignition cover and gasket. – Hold the flywheel with the special tool and undo the collar nut. – Place protective cap on crankshaft thread. – Screw flywheel extractor in position and remove flywheel. – Unscrew screws and remove stator. –... -
Page 17: Shift Mechanism, Transmission
3.13 Parting of engine housing halves – Top ignition-gear upwards and remove all housing screws. – Release engine mounting brackets on work stand. – Lift left-hand housing half with suitable tools by on the bosses provided, or part with a few light plastic mallet blows against the countershaft from the right-hand housing half. -
Page 18: Servicing On Individual Components
4.0 Servicing on individual components Chap. Component / Component unit Page Right housing half ........... . .4-2 Left housing half . -
Page 19: Left Housing Half
4.1 Right-hand housing half Heat housing half to 150° C by means of hot plate. ROOVED BALL BEARING OF CRANKSHAFT Press old grooved ball-bearing inwards. Press in new ball bearing to the stop. The open side of the ball cage must be towards the bottom (outside) of the case. ROOVED BALL BEARING OF MAIN SHAFT Press in new ball bearing from inside up to the stop. - Page 20 – Remove shaft seal rings, heat housing half to 150° C by means of hot plate. RANKSHAFT ROLLER BEARINGS Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside). EEDLE BEARING OF DRIVE SHAFT Pull out the old bearing with a bearing extractor.
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Page 21: Crankshaft
4.3 Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be rene- wed. Heat the inner ring until it drops out of its seat. – Before pressing the new inner ring in position, an intermediate plate must always be placed between the two crank webs. - Page 22 If the cylinder diameter is greater than 67, 525 mm / 72,025 mm or 78,025 mm, the Nikasil cylinder must be reconditioned or replaced. OR RECONDITIONING OF THE OLD CYLINDER ALL EXHAUST CONTROL COMPONENTS MUST BE REMOVED HE INTERMEDIATE FLANGE REMAINS WITH THE CYLINDER ECONDITIONED CYLINDERS ARE AVAILABLE ON ORDER FROM YOUR DEALER...
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Page 23: Nikasil Coating Of Cylinder
4.9 Nikasil coating of cylinder Nikasil is the brand name for a cylinder coating process, developed by the piston manufacturer Mahle. The name is derived from the two materials used in this pro- cess - a nickel layer into which the particularly hard silicon carbide is inbedded. The main advantages of the Nikasil coating are: ●... -
Page 24: Kickstarter
ELOCITY INSERT Check for firm mounting and for signs of damage. NTAKE FLANGE Check for cracks and other signs of damage. 4.13 Kickstarter TARTER GEAR Check clearance of starter gear. TARTER INTERMEDIATE GEAR Check clearance of starter intermediate gear. OCKING PAWL Check for signs of wear and damage. -
Page 25: Transmission
4.15 Transmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: EEDLE BEARING AINSHAFT AND COUNTERSHAFT PIVOT POINTS INCLUDING IDLER GEARS HIFT DOGS AND GEAR WHEELS OOTH FACES OF ALL GEARS OOTH PROFILE OF MAINSHAFT AND COUNTERSHAFT AND CORRESPONDENDING GEARS ASY OPERATION OF GEAR CHANGE... -
Page 26: Clutch
min. 13,5 mm 14 15 4.16 Clutch Check the following parts for wear: HRUST BEARING USH ROD LUTCH SPRINGS New spring length 43 mm (1.69 in). Used springs may not be more than 1 mm (0.04 in) shorter than the new ones; replace all 6 springs if applicable. INING DISCS Minimum thickness 2.6 mm (0.102 in) / new disc 2.7 mm (0.106 in). -
Page 27: Shift Mechanism
4.18 Shift mechanism HIFT FORKS Check shift fork blades and shift roller driving pin for signs of wear. HIFT ROLLER Check shift grooves for wear. Check position of shift roller in grooved ball bearings LIDE PLATE LOCTITE 242 Check slide plate at meshing points for wear. -
Page 28: Ignition (Kokusan)
4.20 Ignition (Kokusan) General information The measurements described below will only reveal severe problems. Coil short cir- cuits 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 29: Ignition (Sem)
4.21 Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short cir- cuits 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 30: Engine Assembly
5.0 Engine assembly Cap. Component / Component unit Page Mounting crankshaft ............5-2 Transmission, shift mechanism . - Page 31 – Secure the right-hand housing half in the engine work stand. 5.1 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 5.2 Transmission –...
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Page 32: Assembly Of Engine Housing
5.3 Assembling the engine housing – Remove engine fastener from engine work stand. – Check that both dowels are in proper place in right-hand housing and that trans- mission shaft stop discs have been mounted. – Apply light coat of grease to sealing surfaces of the housing and position new gasket. –... -
Page 33: Kickstarter
5.6 Kickstarter – Place spacing washer on the stop face an place preassembled kickstarter shaft in bearing bore in such a way that the locking pawl is outside the release plate. – Hook spring hanger to starter spring, coat allan head screw with Loctite 242, tighten starter spring approx. -
Page 34: Clutch Discs, Pressure Cap
5.8 Clutch discs, pressure cap – Oil lining discs before mounting. – Beginning with one lining disc, mount alternately 9 lining discs (≠ 2,7 / 0.1 in) mm) and 8 intermediate discs (≠ 1,2 mm / 0.047 in), with a lining disc forming the final layer upwards. -
Page 35: Piston And Cylinder
5.10 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 36: Cylinder Head
– Secure bump plate fastening screws – Remove depth gauge. – Press linkage of control flap down-wards as far as stop and press ball socket onto ball of adjusting lever. When pressing ball socket do not: ● pull the linkage too far up (max. 1 mm / 0.04 in). ●... -
Page 37: Mounting Ignition (Kokusan)
5.15 Left-hand steering cover – Place gasket in position and fix left-hand steering cover on cylinder. 5.16 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. –... -
Page 38: Adjusting Ignition Point (Sem)
5.19 Adjusting ignition point (SEM) – Mount flyweel. – Screw dial gauge into spark plug thread. – Place adjusting pin in flywheel bore (“91“) 2 mm (0.08 in) and turn flywheel until pin slots into recess in stator. – Turn flywheel and stator jointly to TDC. –... - Page 39 – Notices –...
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Page 40: Electrical
6.0 Electrical Cap. Component / Component unit Page Checking voltage regulator (Tympanium) ........6-2 Checking voltage regulator-rectifier (Shindengen) . -
Page 41: Checking The Voltage Regulator Tympanium
6.1 Checking the voltage regulator (Tympanium) HE VOLTAGE REGULATORS ARE CONNECTED DOWNSTREAM OF THE SWITCHES NE OF THE VOLTAGE REGULATORS REGULATES ONLY THE BRAKE LIGHT CIRCUIT THE OTHER REGULA TES THE CIRCUIT FOR THE HEAD LIGHT THE TAIL LIGHT THE SPEEDOMETER ILLUMINATION AND THE HORN A defect voltage regulator can cause different kinds of trouble: ●... -
Page 42: Checking The Capacitor
6.4 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 posi- tive terminal of the capacitor (marked +) is made with a test lamp –... - Page 43 – Notices –...
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Page 44: Trouble Shooting
7.0 Trouble shooting Cap. Component / Component unit Page Trouble shooting ........... .7-2... - Page 45 7.1 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevert- heless, we advise you to use the trouble shooting chart in order to find the cause of error. TROUBLE CAUSE REMEDY...
- Page 46 TROUBLE CAUSE REMEDY Engine has not enough power Reed paddles tensionless or damaged, Replace reed paddles or reed valve housing surface of reed valve housing damaged Wear Overhaul engine Electronical ignition timing faulty Have ignition system checked Engine revs not high and run- Carburetor overflows if level adjust too Clean carburetor, if necessary replace float needle and adjust level ning with four stroke cycle...
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Page 48: Technical Data / Maintenance Schedule
8.0 Technical data / maintenance schedule Cap. Component / Component unit Page Technical data - engine ..........8-2 8.1.1 Tolerance, assembly clearance . - Page 53 8.3PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE rider dealer 125-380 7.97 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 ●...
- Page 59 K T M - S P O R T M O T O R C Y C L E A - 5 2 3 0 M a t t i g h o f e n • P o s t f a c h 9 1 • A u s t r i a I n t e r n e t : h t t p : / / w w w .