KTM 250 SX ENGINE REPAIR MANUAL - PDF DOWNLOAD

KTM 250 SX ENGINE REPAIR MANUAL - PDF DOWNLOAD

FILE DETAILS:

KTM 250 SX ENGINE REPAIR MANUAL - PDF DOWNLOAD

Language :English
Pages :80
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

KTM 250 SX ENGINE REPAIR MANUAL - PDF DOWNLOAD

IMPORTANT INFORMATION/UPDATING INSTRUCTIONS

KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5 3 = chapter 3 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience.
The respective headings can be entered in the list of contents.

INTRODUCTION

• This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.
• A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed.
• We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work.

TABLE OF CONTENTS:

KTM 250 SX ENGINE REPAIR MANUAL - PDF DOWNLOAD

HOME 0
NOTES AND PREFACE 1
Title page and file spine 1
Important information 7
Explanation update 9
Introduction 11
Reply fax for repair manuals 13
TABLE OF CONTENTS 5
SERVICE-INFORMATIONS 0
GENERAL INFORMATION 15
OPERATING RANGES OF THE CARBURETOR 17
CARBURETOR ADJUSTMENT 18
CHECKING OF THE SETTING OF THE TVC SYSTEM 19
BLEEDING OF THE HYDRAULIC CLUTCH 19
SPECIAL TOOLS 20
CLEANING 21
STORAGE 21
DISASSEMBLING ENGINE 22
REMOVING OF KICKSTARTER 24
DRAINING GEAR OIL 24
DISMOUNTING OF SPROCKET AND SHIFT LEVER 24
DISMOUNTING OF ZYLINDER HEAD, CYLINDER AND PISTON 24
DISMOUNTING OF CLUTCH COVER 25
DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS 26
DISMOUNTING OF THE PRIMARY DRIVE 26
DISMOUNTING OF KICKSTARTER 27
DISMOUNTING OF THE SHIFT LOCK 27
DISMOUNTING OF IGNITION COVER 27
DISMOUNTING OF THE IGNITION 28
DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING 29
PARTING OF ENGINE HOUSING HALVES 29
DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION 29
DISMOUNTING OF THE CRANKSHAFT 30
SERVICING INDIVIDUAL COMPONENTS 31
WORKING ON THE RIGHT-HAND HOUSING HALF 33
WORKING ON THE LEFT-HAND HOUSING HALF 34
CRANKSHAFT 35
PISTON 35
PISTON RING END GAP 35
CHECKING CYLINDER FOR WEAR 36
RECOATED CYLINDER 36
NIKASIL COATING OF CYLINDER 36
CYLINDER EXHAUST CONTROL SYSTEM 37
CYLINDER PREASSEMBLY 37
EXHAUST CONTROL, CLUTCH COVER 39
PREASSEMBLY OF CLUTCH COVER 39
REED VALVE HOUSING, INTAKE FLANGE 40
CLUTCH 41
REPLACE OUTER CLUTCH HUB 42
SHIFT MECHANISM 43
PREASSEMBLY OF SHIFT SHAFT 43
IGNITION 44
CHECK STATOR AND PULSE GENERATOR 44
ASSEMBLY MAINSHAFT 45
ASSEMBLY COUNTERSHAFT 46
KICKSTARTER 47
ASSEMBLE OF KICKSTARTER SHAFT 47
ASSEMBLING ENGINE 48
CRANKSHAFT 50
TRANSMISSION 50
ASSEMBLING THE ENGINE HOUSING 51
MOUNTING SHIFT MECHANISM 52
MOUNTING KICKSTARTER 52
MOUNT PRIMARY DRIVE AND CLUTCH 53
MOUNTING CLUTCH DISCS AND PRESSURE CAP 54
MOUNTING CLUTCH COVER 54
MOUNTING PISTON AND CYLINDER 55
ADJUSTING DIMENSION „X“ 55
ADJUSTING CONTROL FLAP (DIMENSION „Z“) 56
MOUNTING STEERING COVERS 57
MOUNTING CYLINDER HEAD 57
MOUNTING REED VALVE HOUSING AND INTAKE FLANGE 57
MOUNTING ENGINE SPROCKET 58
MOUNTING THE IGNITION 58
MOUNTING IGNITION COVER 59
MOUNTING STARTING LEVER AND SHIFT LEVER 59
FILL IN TRANSMISSION OIL 59
CHECK TRANSMISSION OIL LEVEL 59
ELECTRICAL 60
STATIC IGNITION VALUES 62
IGNITION COIL 62
CDI UNIT 62
WIRING DIAGRAM 63
TROUBLE SHOOTING 64
TROUBLE SHOOTING 250 SX 66
TECHNICAL SPECIFICATIONS 68
ENGINE 70
CARBURETOR 70
CHASSIS 71
STANDARD ADJUSTMENT SHOCK ABSORBER / FORK 71
TOLERANCES AND FITTING CLEARANCES 72
TIGHTENING TORQUES ENGINE 72
TIGHTENING TORQUES CHASSIS 72
CARBURETOR SETTING 73
PERIODIC MAINTENANCE SCHEDULE 74
LUBRICATION AND MAINTENANCE SCHEDULE 250 SX 76
WIRING DIAGRAM 78
WIRING DIAGRAM 250 SX 2003 80

S.M 13/3/2025