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250 EXC RACING
KTM 250 EXC RACING User Manual
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Disassembly & Assembling
Workshop manual
5018 PDS 2003
W
erkplaatshandbo
ek
33
Shock absorber 5018 PDS 2003
05/2002
There is a separated workshop
manual for the DCC.
-----------------------------------------------------
Damping holder MCC.
Remove the disk.
Pay attention to the assembling
direction!!!
Clamp the damping holder with
clamping block T1202S.
Not too tight!
Disassembly MCC
343
345
Table of Contents
Table of Contents
5
Important Limited Warranty and Limited Guarantee Information
4
Table of Contents
5
Engine Number, Engine Type
6
Serial Number Locations
6
Chassis Number
6
Operation Instruments
7
Clutch Lever
7
Hand Decompression Lever
7
Hand Brake Lever
7
Combination Switch (EXC)
7
Short Circuit Button (SX/MXC)
7
Flasher Switch
8
Starter Button (EXC)
8
Emergency off Switch (EXC Australia)
8
Digital Speedometer, Indicator Lamps
8
Electronic Speedometer
9
Setting the Clock
13
Overview of Electronic Speedometer Functions
13
Hot Start Device (450/525 SX)
14
Filler Cap
14
Choke
14
Fuel Tap
14
Shift Lever
15
Kickstarter
15
Foot Brake Pedal
15
Side Stand
15
Steering Lock
15
Compression Damping of Fork
16
Rebound Damping of Fork
16
Damping Action During Compression of Shock Absorber (SX)
16
Compression Damping of Shock Absorber (MXC, EXC)
17
Rebound Damping of Shock Absorber (SX, MXC, EXC)
17
General Tips and Warnings for Starting the Motorcycle
18
Instructions for Initial Operation
18
Running in the Racing Models
18
Driving Instructions
19
Check the Following before each Start
19
Starting When the Engine Is Warm
20
What to Do When the Engine Is "Flooded
20
Starting off
20
Shifting/Riding
20
Starting When the Engine Is Cold
20
Braking
21
Stopping and Parking
21
Fuel
21
Periodic Maintenance
22
Maintenance Work on Chassis and Engine
26
Changing the Spring Preloading of the Shock Absorber
26
Pivot Bearing
26
Determining the Static Sag of the Shock Absorber
27
Determining the Riding Sag of the Shock Absorber
27
Checking the Shock Absorber and Spring
27
Basic Suspension Setup for the Weight of the Driver
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 (MXC/EXC Models)
28
Replacing Fork Springs
28
Checking and Adjusting the Steering Head Bearing
29
Cleaning the Dust Sleeves of the Telescopic Fork
29
Breather Plug Front Fork
29
Changing the Fork Offset (Caster) (SX)
30
Checking and Adjusting the Steering Head Bearing
31
Check Chain Tension
32
Correct Chain Tension
32
Chain Maintenance
33
Chain Wear
33
General Information about KTM Disc Brakes
34
Checking the Front Brake Pads
35
Refilling the Front Brake Fluid Reservoir
35
Checking the Brake Fluid Level - Front Brake
35
Adjusting the Free Travel at the Hand Brake Lever
35
Replacing the Front Brake Pads
36
Changing the Basic Position of the Foot Brake Pedal
36
Checking the Rear Brake Fluid Level
36
Refilling the Rear Brake Fluid Reservoir
36
Checking the Rear Brake Pads
37
Replacing the Rear Brake Pads
37
Dismounting and Mounting the Front Wheel
37
Dismounting and Mounting the Rear Wheel
38
Checking Spoke Tension
38
Tires, Air Pressure
39
Check/Set Distance of the Magnetic Sensor
39
Replacing the Battery of the Digital Speedometer
39
Battery (MXC/EXC)
40
Charging the Battery
40
Fuse (MXC/EXC)
41
Replacing Headlight Lamp/Parking Light Lamp
41
Cooling System
42
Checking the Coolant Level
42
Bleeding the Cooling System
42
Replacing the Glassfiber Yarn Packing of the Silencer
43
Cleaning the Spark Arrester (MXC/EXC USA)
43
Cleaning the Air Filter
44
Checking the Adjustment of the Hand Decompression Release Cable
44
Adjusting the Throttle Cables
44
Changing the Original Position of the Clutch Lever
45
Checking the Oil Level of the Hydraulic Clutch
45
Bleeding of the Hydraulic Clutch
45
CARBURETOR - Adjust Idling (Keihin-FCRMX 37/39/41)
46
Adjusting the Mixture Control Screw
46
Checking the Float Level (Float Height)
46
Checking the Engine Oil Level
47
Oil Circuit
47
Draining the Float Chamber of the Carburetor
47
Engine Oil
48
Changing the Engine Oil
48
Changing Oil Filters
49
Troubleshooting
50
Storage
52
Conservation for Winter Operation
52
Use after a Period of Storage
52
Cleaning
52
Technical Data - Engine
53
Technical Data - Chassis
56
Cylinder Head
127
Checking Charging Voltage
162
Ignition Coil
163
Troubleshooting in Ignition System
163
Basic Carburator Setting
207
4860 MX Multi Adjuster 2003
261
Introduction
262
Exploded View
263
Disassembly Forkleg
264
Disassembly Cartridge
277
Disassembly Tap Rebound
287
Assembling Tap Rebound
291
Assembling Cartridge
294
Assembling Forkleg
297
Table of Contents
312
Introduction
313
Exploded View
314
Disassembly Shock Absorber
315
Disassembly Tube Side
324
Disassembly MCC
344
Assembling MCC
350
Assembling Tube Side
353
Disassembly Piston-Rod Side
364
Diassembly Adaptor DU-Bush
374
Assembling Adaptor DU-Bush
378
Assembling Piston-Rod Side
381
Assembling Shock Absorber
392
Bleeding
398
On Pressure with Nitrogen
403
Adjustment
409
4
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KTM 250 EXC RACING Specifications
General
Brand
KTM
Model
250 EXC RACING
Category
Motorcycle
Language
English
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