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KTM EXC Manuals
Manuals and User Guides for KTM EXC. We have
3
KTM EXC manuals available for free PDF download: Repair Manual, Owner's Manual
KTM EXC Repair Manual (154 pages)
KTM Automobile Parts User Manual
Brand:
KTM
| Category:
Engine
| Size: 5 MB
Table of Contents
Table of Contents
5
Updating Instructions
7
Explanation - Updating
9
General Information
14
Operating Ranges of the Carburetor
16
Basic Information on a Change of the Carburetor Setting
17
Basic Information on the Original Carburetor Setting
17
Carburetor Adjustment
17
Bleeding of the Hydraulic Clutch
18
Checking the Setting of the TVC System
18
Special Tools - Engine 250/300/380
19
Cleaning
20
Conservartion for Winter Operation
20
Storage
20
Removing and Refitting Engine
22
Dismounting the Engine
24
Filling in of Cooling Liquid
26
Filling in of Transmission Oil
26
Refitting the Engine
26
Disassembling the Engine
28
Dismounting of Cylinder Head, Cylinder and Piston
30
Dismounting of Sprocket and Shift Lever
30
Draining Gear Oil
30
Dismounting of Clutch Cover
31
Dismounting of Pressure Cap and Clutch Discs
32
Dismounting of the Primary Drive
32
Dismounting of Ignition Cover
33
Dismounting of Kickstarter
33
Dismounting of the Shift Lock
33
Dismounting of the Ignition (Kokusan)
34
Dismounting of the Ignition (SEM)
34
Dismounting of Gearshift Mechanism and Transmission
35
Dismounting of Intake Flange and Reed Valve Housing
35
Parting of Engine Housing Halves
35
Dismounting the Crankshaft
36
Servicing of Individual Components
37
Working on the Right-Hand Housing Half
39
Working on the Left-Hand Housing Half
40
Crankshaft
41
Crankshaft Webs – Measure Outer Dimension
41
Piston
41
Piston Ring End Gap
41
Checking Cylinder for Wear
42
Nikasil Coating of Cylinder
42
Recoated Cylinder
42
Cylinder Exhaust Control System
43
Cylinder Preassembly
43
Exhaust Control, Clutch Cover
45
Preassembly of Clutch Cover
45
Reed Valve Housing, Intake Flange
46
Clutch
47
Replace Outer Clutch Hub
48
Preassembly of Shift Shaft
49
Shift Mechanism
49
Check Stator and Pulse Generator (Kokusan)
50
Ignition (Kokusan)
50
Kokusan Ignition & Spark Plug
50
Check Stator (SEM)
51
Ignition (SEM)
51
SEM Ignition & Spark Plug
51
Assembly Mainshaft
52
Transmission
52
Assembly Countershaft
53
Assemble of Kickstarter Shaft
54
Assembling the Engine
55
Assembling the Engine Housing
58
Mounting Kickstarter
59
Mounting Shift Mechanism
59
Mount Primary Drive and Clutch
60
Mounting Clutch Discs and Pressure Cap
61
Adjusting Dimension „X“
62
Mounting Piston and Cylinder
62
Adjusting Control Flap (Dimension “Z“)
63
Mounting Cylinder Head
64
Mounting Reed Valve Housing and Intake Flange
64
Mounting Steering Covers
64
Mounting Engine Sprocket
65
Mounting the Ignition (Kokusan)
65
Adjusting Ignition Point (SEM)
66
Mounting Starting Lever and Shift Lever
66
Mounting the Ignition (SEM)
66
Electrical
67
Checking the Voltage Regulator (Kokusan)
69
Checking the Voltage Regulator (Tympanium)
69
Checking the Voltage Regulator-Rectifier (Shindengen)
69
CDI Unit
70
Checking the Capacitor
70
Ignition Coil (Kokusan)
70
Ignition Coil (SEM)
70
Checking the Voltage Regulator
71
Static Ignition Values 250-380 SX, EXC (Kokusan 2K-1, 2K-3, 2K-4)
72
Static Generator Values 250-380 EXC (Kokusan 2K-3) (Except 250 USA)
74
Static Ignition Values 250 MXC, EXC USA (Kokusan 2K-2)
76
Troubleshooting
79
Trouble Shooting
81
Technical Specifications
83
Technical Specifications - Engine 250/300/380 SX/MXC/EXC ‘99 (Only for USA)
85
Basic Carburetor Setting
86
Gasket Thicknesses
86
Tightening Torques
86
Tolerances and Fitting Clearances
86
Technical Specifications - Engine 250/300/380 SX/EXC/EGS ‘99 (All Models out of USA)
87
Standard Adjustment - Fork
89
Standard Adjustment - Shock Absorber
89
Technical Specifications Chassis 250/300/380 SX/MXC/EXC/EGS ‘99
89
Carburetor Setting KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38
90
Carburetor Setting KTM 250 SX Europe, USA ‘99 KEIHIN PWK 38
91
Carburetor Setting KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38
92
Technical Data - Engine 250/300/380 SX/MXC/EXC 2000 (Only USA)
93
Technical Data - Engine 250/300/380 SX/EXC 2000 (All Models out of USA)
95
Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2000
97
Carburetor Setting G KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ
98
Carburetor Setting KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
99
Carburetor Setting KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG
100
Carburetor Setting KTM 380 SX/MXC/ EXC/EUR/USA 2000 KEIHIN PWK 38 AG
101
Technical Data - Engine 250/300/380 SX/MXC EXC 2001 (Only USA)
103
Technical Data - Engine 250/300/380 SX / EXC 2001 (All Models out of USA)
105
Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2001
107
Carburetor Setting KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ
108
Carburetor Setting KTM 250 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
109
Carburetor Setting KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG
110
Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2001 KEIHIN PWK 38 AG
111
Technical Data - Engine 250/300/380 SX / MXC / EXC 2002 (Only USA)
112
Technical Data - Engine 250/300/380 SX / EXC 2002 (All Models out of USA)
114
Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2002
116
Carburetor Setting KTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG
117
Carburetor Setting KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG
118
Carburetor Setting KTM 300 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG
119
Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2002 KEIHIN PWK 38 AG
120
Technical Data - Engine 250/300 MXC/EXC 2003
121
Periodic Lubrication and Maintenance Schedule
131
Periodic Maintenance Schedule 2001/02
132
Important Chacks and Maintenance to be Carried by the Rider
133
Periodic Maintenance Schedule 2003
134
Recommended Inspection of the 250/300 EXC and MXC Engine Used for Enduro Competitions by Your KTM Workshop
136
Recommended Inspection of the 250/300 EXC and MXC Engine Used for Hobby Enduro by Your KTM Workshop
136
Wiring Diagrams
137
250-380 EXC Wiring Diagram
139
25-38- EGS '98 Wiring Diagram
140
125/250/300 EXC '98, '99 Wiring Diagram
142
125/200/250/300/380 EXC 2000 Wiring Diagram
143
125-380 EXC 2000 Wiring Diagram
144
380 EXC 2000 Wiring Diagram
146
125/200/250 EXC 2001 Wiring Diagram
147
125-380 EXC 2001 Wiring Diagram
148
300/380 EXC 2001 Wiring Diagram
150
250-300 EXC 2003 Wiring Diagram
151
250/300 EXC 2003 Wiring Diagram
153
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KTM EXC Owner's Manual (74 pages)
KTM Owner's Manual Motorcycle 125 EXC, EXC SIX DAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXC SIX DAYS 300 XC, XC-W, EXC-E, EXC-E SIX DAYS
Brand:
KTM
| Category:
Motorcycle
| Size: 9 MB
Table of Contents
Intended Purpose
3
Warranty
4
Table of Contents
5
Serial Number Locations
6
Chassis Number
6
Engine Number, Engine Type
6
Operation Instruments
6
Clutch Lever
6
Hand Brake Lever
6
Electronic Speedometer
7
Activating and Deactivating Display Modes
8
Kilometers or Miles
10
Setting the Clock
10
Overview of the Electronic Speedometer Functions
11
Indicator Lamps (EXC)
11
Short Circuit Button
11
Combination Switch (EXC)
12
Headlamp Switch (XC-W)
12
Flasher Switch
12
Starter Button
12
Emergency off Switch (Australia)
12
Filler Cap
13
Fuel Tap
13
Choke Knob
13
Shift Lever
14
Kickstarter
14
Foot Brake Pedal
14
Side Stand
14
Steering Lock
14
Compression Damping of Fork
15
Rebound Damping of Fork
15
Spring Preload of the Fork
15
Standard Adjustment
16
Shock Absorber Compression Damping
16
Shock Absorber Rebound Damping
16
General Tips and Warnings for Starting the Motorcycle
17
Instructions for Your First Ride
17
Running in
17
Driving Instructions
18
What You Should Check before each Start
18
Starting When the Engine Is Cold
19
Starting When the Engine Is Warm
19
What to Do When the Engine Is „Flooded
19
Starting off
19
Shifting/Riding
20
Braking
20
Stopping and Parking
20
Refueling, Fuel
20
Periodic Maintenance Schedule
21
Maintenance Work on Chassis and Engine
25
Changing the Spring Preloading of the Shock Absorber
25
Pivot Bearing
25
Basic Suspension Setup for the Weight of the Driver
26
Checking the Shock Absorber and Spring
26
Determining the Static Sag of the Shock Absorber
26
Determining the Riding Sag of the Shock Absorber
26
Checking the Basic Setup of the Telescopic Fork
27
Changing the Spring Preload on the Telescopic Fork
27
Standard Setting
27
Breather Plug Front Fork
27
Cleaning the Dust Sleeves of the Telescopic Fork
28
Checking and Adjusting the Steering Head Bearing
28
Changing the Fork Offset (Caster) XC/EXC Six Days
29
How to Change the Handlebar Position
30
Check Chain Tension
31
Adapting Chain Guide to the Rear Sprocket
31
Correct Chain Tension
32
Chain Maintenance
32
Chain Wear
32
General Information about KTM Disc Brakes
33
Changing Basic Position of the Hand Brake Lever
34
Checking the Brake Fluid Level - Front Brake
34
Refilling the Front Brake Fluid Reservoir
34
Checking the Front Brake Pads
34
Replacing the Front Brake Pads
35
Checking the Rear Brake Fluid Level
35
Refilling the Rear Brake Fluid Reservoir
35
Changing the Basic Position of the Foot Brake Pedal
36
Checking the Rear Brake Pads
36
Replacing the Rear Brake Pads
36
Dismounting and Mounting the Front Wheel
37
Dismounting and Mounting the Rear Wheel
38
Tires, Air Pressure
38
Checking Spoke Tension
39
Replacing the Battery of the Digital Speedometer
39
Replacing the Headlight Lamp/Parking Light Lamp
39
To Remove the Battery
40
Charging the Battery
40
Fuse
41
Cooling System
41
Checking the Coolant Level
42
Refilling/Bleeding the Cooling System
42
Cleaning the Air Filter
42
Checking the Oil Level of the Hydraulic Clutch
43
Exhaust System
43
Changing the Original Position of the Clutch Lever
43
Bleeding the Hydraulic Clutch
44
Carburetor Adjustment
44
Maintenance Work on Chassis and Engine
45
Draining the Float Chamber of the Carburetor
46
Checking the Float Level
46
Adjusting the Engine Characteristic Via the Ignition Curve
46
Adjusting the Engine Characteristic Via the Auxiliary Spring
47
Check Transmission Oil Level
48
Changing the Transmission Oil
48
Use after a Period of Storage
49
Cleaning
49
Conservation for Winter Operation
49
Storage
49
Technical Specifications - Chassis 125 / 200
51
Technical Specifications - Engine 125 / 200
53
Technical Specifications - Chassis 250 / 300
55
Technical Specifications - Engine 250
57
Technical Specifications - Engine 300
59
Wiring Diagram
61
Carburetor Table
68
Index
73
KTM EXC Owner's Manual (68 pages)
KTM-Sportmotorcycle AG Motorcycle User Manual
Brand:
KTM
| Category:
Motorcycle
| Size: 2 MB
Table of Contents
Important Warranty and Guarantee Information
4
Table of Contents
5
Serial Number Locations
6
Chassis Number
6
Engine Number, Engine Type
6
Operation Instruments
6
Clutch Lever
6
Hand Brake Lever
6
Electronic Speedometer, Indicator Lamp (EXC)
7
Electronic Speedometer
7
Tripmaster Switch
8
Setting the Clock
10
Activating/Deactivating the Display Modes
10
Kilometers or Miles
11
Overview of Tripmaster Functions
11
Short Circuit Button (SX)
12
Combination Switch (EXC)
12
Headlamp Switch (EXC USA)
12
Flasher Switch
12
Emergency off Switch (Australia)
12
Filler Cap
13
Fuel Tap
13
Choke Knob
13
Shift Lever
13
Kickstarter
14
Foot Brake Pedal
14
Side Stand
14
Steering Lock
14
Compression Damping of Fork
15
Rebound Damping of Fork
15
Damping Action During Compression of Shock Absorber (SX)
15
Compression Damping of Shock Absorber (MXC, EXC)
16
Rebound Damping of Shock Absorber (SX, MXC, EXC)
16
General Tips and Warnings for Starting the Motorcycle
17
Instructions for Your First Ride
17
Running in
17
Driving Instructions
18
What You Should Check before each Start
18
Starting When the Engine Is Cold
19
Starting When the Engine Is Warm
19
What to Do When the Engine Is "Flooded
19
Starting off
19
Shifting/Riding
19
Braking
20
Stopping and Parking
20
Refueling, Fuel
20
Periodic Maintenance Schedule
21
Maintenance Work on Chassis and Engine
25
Checking and Adjusting the Steering Head Bearing
25
How to Change the Handlebar Position
26
Breather Plug Front Fork
26
Cleaning the Dust Sleeves of the Telescopic Fork
26
Basic Suspension Setup for the Weight of the Driver
27
Checking the Shock Absorber and Spring
27
Determining the Static Sag of the Shock Absorber
27
Wiring Diagram, Carburetor Setting. . . .Appendix
27
Determining the Riding Sag of the Shock Absorber
27
Checking the Basic Setup of the Telescopic Fork
28
Changing the Spring Preload on the Telescopic Fork (SX Models)
28
Changing the Spring Preload on the Telescopic Fork
28
(MXC/EXC Models)
28
Replacing Fork Springs
28
Adjusting the Spring Preload on the Fork (SX)
29
Changing the Spring Preloading of the Shock Absorber
29
Pivot Bearing
29
Check and Correct Chain Tension
30
Check Chain Tension
30
Correct Chain Tension
30
Chain Maintenance
31
Chain Wear
31
General Information about KTM Disc Brakes
32
Adjusting the Free Travel at the Hand Brake Lever
33
Checking the Brake Fluid Level - Front Brake
33
Refilling the Front Brake Fluid Reservoir
33
Checking the Front Brake Pads
33
Replacing the Front Brake Pads
34
Checking the Rear Brake Pads
35
Replacing the Rear Brake Pads
35
Dismounting and Mounting the Front Wheel
35
Dismounting and Mounting the Rear Wheel
36
Tires-Air Pressure
37
Checking Spoke Tension
37
Replacing the Battery of the Digital Speedometer
37
Check/Set Distance of the Magnetic Sensor
38
Replacing the Headlight Lamp/Parking Light Lamp
38
Cooling System
39
Radiator Cover for the Cold Season
39
Checking the Coolant Level
39
Refilling/Bleeding the Cooling System
40
Cleaning the Air Filter
40
Changing the Original Position of the Clutch Lever
41
Checking the Oil Level of the Hydraulic Clutch
41
Bleeding of the Hydraulic Clutch
41
Exhaust System
41
Carburetor Adjustment
42
Cleaning the Spark Arrestor (EXC USA)
42
Draining the Float Chamber of the Carburetor
43
Checking the Float Level
43
Engine Characteristic 250/300 SX/MXC/EXC
44
Check and Change Transmission Oil
45
Check Transmission Oil Level (125/200)
45
Changing the Transmission Oil (125/200)
45
Check Transmission Oil Level (250/300)
45
Changing the Transmission Oil (250/300)
45
Cleaning
46
Conservation for Winter Operation
46
Storage
46
Use after a Period of Storage
46
Technical Specifications - Chassis 125 / 200
47
Technical Data - Engine 125 / 200
49
Technical Specifications - Chassis 250/300
51
Technical Data - Engine 250/300 2004
53
Tightening Torques
54
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