KTM 250/300/380 SX,MXC,EXC Engine Workshop Service Repair Manual 1999-2003

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This workshop service repair manual PDF download for the 1999-2003 KTM Engine 250/300/380 SX,MXC,EXC has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

TABLE OF CONTENTS :

1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING ON INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 TROUBLE SHOOTING
9 TECHNICAL SPECIFICATIONS
10 PERIODIC MAINTENANCE SCHEDULE
11 WIRING DIAGRAMS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 3.206.004-E
Total Pages : 153

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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NOTES AND PREFACE
Titel page and file spine
Important information
Updating instructions
Explanation updating
Introduction
Replay fax for repair manuals
TABLE OF CONTENTS
SERVICE-INFORMATIONS
GENERAL INFORMATION
OPERATING RANGES OF THE CARBURETOR
CARBURETOR ADJUSTMENT
CHECKING OF THE SETTING OF THE TVC SYSTEM
BLEEDING OF THE HYDRAULIC CLUTCH
SPECIAL TOOLS – ENGINE
CLEANING
STORAGE
REMOVING AND REFITTING ENGINE
REMOVING THE ENGINE
REFITTING THE ENGINE
DISASSEMBLING THE ENGINE
DRAINING GEAR OIL
DISMOUNTING OF SPROCKET AND SHIFT LEVER
DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON
DISMOUNTING OF CLUTCH COVER
DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS
DISMOUNTING OF THE PRIMARY DRIVE
DISMOUNTING OF KICKSTARTER
DISMOUNTING OF THE SHIFT LOCK
DISMOUNTING OF IGNITION COVER
DISMOUNTING OF THE IGNITION (KOKUSAN)
DISMOUNTING OF THE IGNITION (SEM)
DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING
PARTING OF ENGINE HOUSING HALVES
DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION
DISMOUNTING OF THE CRANKSHAFT
SERVICING ON INDIVIDUAL COMPONENTS
WORKING ON THE RIGHT-HAND HOUSING HALF
WORKING ON THE LEFT-HAND HOUSING HALF
CRANKSHAFT
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION
PISTON
PISTON RING END GAP
CHECKING CYLINDER FOR WEAR
RECOATED CYLINDER
NIKASIL COATING OF CYLINDER
CYLINDER EXHAUST CONTROL SYSTEM
CYLINDER PREASSEMBLY
EXHAUST CONTROL, CLUTCH COVER
PREASSEMBLY OF CLUTCH COVER
REED VALVE HOUSING, INTAKE FLANGE
CLUTCH
REPLACE OUTER CLUTCH HUB
SHIFT MECHANISM
PREASSEMBLY OF SHIFT SHAFT
IGNITION (KOKUSAN)
SPARK PLUG
CHECK STATOR AND PULSE GENERATOR (KOKUSAN)
IGNITION (SEM)
CHECK STATOR (SEM)
TRANSMISSION
ASSEMBLY MAINSHAFT
ASSEMBLY COUNTERSHAFT
KICKSTARTER
ASSEMBLE OF KICKSTARTER SHAFT
ASSEMBLING THE ENGINE
CRANKSHAFT
TRANSMISSION
ASSEMBLING THE ENGINE HOUSING
MOUNTING SHIFT MECHANISM
MOUNTING KICKSTARTER
MOUNT PRIMARY DRIVE AND CLUTCH
MOUNTING CLUTCH DISCS AND PRESSURE CAP
MOUNTING CLUTCH COVER
MOUNTING PISTON AND CYLINDER
ADJUSTING DIMENSION „X“
ADJUSTING CONTROL FLAP (DIMENSION „Z“)
MOUNTING STEERING COVERS
MOUNTING CYLINDER HEAD
MOUNTING REED VALVE HOUSING AND INTAKE FLANGE
MOUNTING ENGINE SPROCKET
MOUNTING THE IGNITION (KOKUSAN)
MOUNTING THE IGNITION (SEM)
ADJUSTING IGNITION POINT (SEM)
MOUNTING IGNITION COVER
MOUNTING STARTING LEVER AND SHIFT LEVER
ELECTRICAL
CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN)
CHECKING THE VOLTAGE REGULATOR (KOKUSAN)
CHECKING THE VOLTAGE REGULATOR (TYMPANIUM)
CHECKING THE CAPACITOR
IGNITION COIL (SEM)
IGNITION COIL (KOKUSAN)
CDI UNIT
CHECKING THE VOLTAGE REGULATOR (MOD. 2000)
CHECKING THE CAPACITOR (MOD. 2000)
STATIC IGNITION VALUES 250 – 380 SX, EXC
STATIC GENERATOR VALUES 250 – 380 EXC
STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC (USA)
TROUBLE SHOOTING
TROUBLE SHOOTING 250 – 380
TECHNICAL SPECIFICATIONS
MODEL 1999 ENGINE 250 – 380 USA
MODEL 1999 – ENGINE 250 – 380
MODEL 1999 – CHASSIS 250 – 380
MODEL 1999 – CARBURETOR SETTINGS
MODEL 2000 ENGINE 250 – 380 USA
MODEL 2000 – ENGINE 250 – 380
MODEL 2000 – CHASSIS 250 – 380
MODEL 2000 – CARBURETOR SETTINGS
MODEL 2001 ENGINE 250 – 380 USA
MODEL 2001 – ENGINE 250 – 380
MODEL 2001 – CHASSIS 250 – 380
MODEL 2001 – CARBURETOR SETTINGS
MODEL 2002 ENGINE 250 – 380 USA
MODEL 2002 – ENGINE 250 – 380
MODEL 2002 – CHASSIS 250 – 380
MODEL 2002 – CARBURETOR SETTINGS
MODEL 2003 – ENGINE 250 – 300
MODEL 2003 – CHASSIS 250 – 300
MODEL 2003 CARBURETOR SETTINGS
PERIODIC MAINTENANCE SCHEDULE
MODEL 1999
MODEL 2000
MODEL 2001/2002
MODEL 2003
WIRING DIAGRAMS
MODEL 1999
MODEL 2000
MODEL 2001 / 2002
MODEL 2003

 

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KTM 250/300/380 SX,MXC,EXC Engine Workshop Service Repair Manual 1999-2003.pdf

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