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2004-2006-250 300 sx mxc exc ex w E service repair manual

2004-2006 KTM 250 300 sx mxc exc ex w E Service Repair Manual download

Table of Contents

2004-2006 KTM 250 300 Service-Information

General Information
Special Tools-engine
Checking The Setting Of The TVC System
Engine Characteristic
Bleeding The Hydraulic Clutch (up To Model 2005)
Bleeding The Hydraulic Clutch (as Of Model 2006)
Changing The Front Brake Fluid
Changing The Rear Brake Fluid
Checking Brake Pads And Brake Discs

Removing And Refitting Engine
Removing The Engine
Refitting The Engine

Disassembling The Engine
Preparation
Draining The Gear Oil
Dismounting The Sprocket And Shift Lever
Dismounting The Cylinder Head, Cylinder And Piston
Dismounting The Clutch Cover
Dismounting The Pressure Cap And The Clutch Discs
Dismounting The Primary Drive
Dismounting The Kickstarter Shaft
Dismounting The Shift Lock
Dismounting The Ignition Cover
Dismounting The Ignition
Dismounting The Reed Valve Housing
Parting The Engine Housing Halves
Dismounting The Gearshift Mechanism And Transmission
Dismounting The Crankshaft

Servicing Individual Components
Servicing The Right Engine Housing Half
Servicing The Left Engine Housing Half
Crankshaft
Crankshaft Webs Measure Outer Dimension
Check The Piston
Piston Ring End Gap
Measuring Pistons And Cylinders
Establishing The Piston Mounting Clearance
Recoated Cylinder
Nikasil Coating Of Cylinder
Cylinder Exhaust Control System
Cylinder Preassembly
Exhaust Control, Clutch Cover
Preassembly Of Clutch Cover
Reed Valve Housing
Clutch
Replace Outer Clutch Hub
Shift Mechanism
Preassembly The Shift Shaft
Assembly Mainshaft
Assembly Countershaft
Checking The Kickstarter For Wear
Assembling The Kickstarter Shaft

Assembling The Engine
Crankshaft
Transmission
Assembling The Engine Housing
Mounting The Shift Mechanism
Mounting The Kickstarter Shaft
Mounting The Primary Drive And Clutch
Mounting The Clutch Discs And Pressure Cap
Mounting The Clutch Cover
Mounting The Piston And Cylinder
Adjusting Dimension x
Adjusting The Control Flap (dimension z)
Mounting The Steering Covers
Mounting The Cylinder Head
Mounting The Reed Valve Housing
Mounting The Engine Sprocket
Mounting The Ignition
Mounting The Ignition Cover
Mounting The Starting Lever And Shift Lever
Filling Up The Transmission Oil
Check The Transmission Oil Level

Electrical
Ignition Coil
Cdi Unit
Checking The Voltage Regulator
Checking The Capacitor
Spark Plug
Ignition
Check The Stator And Pulse Generator (pick Up)
Measurements With Peak Voltage Adapter
Model 2004
Static Ignition Values 250 SX, 250 / 300 MXC / EXC
Static Generator Values 250 / 300 MXC / EXC
Static Ignition And Generator Values 250 EXC Usa
Model 2005
Static Ignition Values 250 SX, 250 / 300 MXC / EXC
Static Generator Values 250 / 300 MXC / EXC
Static Ignition And Generator Values 250 EXC Usa
Model 2006
Static Ignition Values
250 SX / SXS, 250 / 300 EXC / EXC Six Days, 300 XC / XC-W
Static Generator Values 250 / 300 EXC / EXC Six Days, 300 XC-W
Static Ignition And Generator Values 250 XC / XC-W

Fuel System
Operating Ranges Of The Carburetor
Carburetor Adjustment
Dismounting And Installing The Carburetor
Disassembling The Carburetor
Checking The Jet Needle And Throttle Slide
Checking The Starting Piston
Checking The Float Needle Valve
Checking The Carburetor Jets And Gaskets
Assembling The Carburetor
Draining The Carburetor Float Chamber
Checking The Float Level

Trouble Shooting
Troubleshooting The 250 And 300

Technical Specifications
Model 2004
Engine
Chassis
Model 2005
Engine
Chassis
Model 2006
Engine 250
Engine 300
Chassis SX / SXS / EXC / EXC Six Days
Chassis XC / XC-W
Tightening Torques Engine
Tolerances And Fitting Clearances
Gasket Thicknesses
Tightening Torques Chassis
Carburator Specification
Model 2004
Model 2005
Model 2006

Periodic Maintenance Schedule

Wiring Diagram
Model 2004
250 / 300 EXC
250 / 300 EXC-usa
250 SX
Terms / Translations, Cable Colors
List Of Switches
Model 2005
250 / 300 EXC / EXC Six Days
250 EXC-usa
300 EXC-usa
250 SX
Terms / Translations, Cable Colors
List Of Switches
Model 2006
250 / 300 EXC
250 / 300 EXC Six Days
250XC-W
300XC-W
250 SX / SXS / XC
300 XC
Terms / Translations, Cable Colors
List Of Switches
File Data

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