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250 SX 2003
KTM 250 SX 2003 User Manual
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Disassembly & Assembling
Workshop manual
4860 MXMA
37
Frontfork 4860 MXMA 2003
05/2002
Replace a new O-ring in the groove of
the axle-clamp.
12_180
Wetting the thread of the axle-clamp
with T132.
12_181
Wetting the thread of the inner-tube with
T132.
12_182
Assembling forkleg
259
261
Table of Contents
Section 1
6
Table of Contents
6
Serial Number Locations
7
Chassis Number
7
Engine Number, Engine Type
7
Operation Instruments
7
Clutch Lever
7
Hand Brake Lever
7
Short Circuit Button
7
Filler Cap
8
Fuel Tap
8
Choke Knob
8
Shift Lever
8
Kickstarter
9
Foot Brake Pedal
9
Compression Damping of Fork
9
Rebound Damping of Fork
9
Compression Damping of Shock Absorber
10
Rebound Damping of Shock Absorber
10
General Tips and Warnings for Starting the Motorcycle
12
Instructions for Your First Ride
12
Running in
12
Driving Instructions
13
What You Should Check before each Start
13
Starting When the Engine Is Cold
14
Starting When the Engine Is Warm
14
What to Do When the Engine Is "Flooded
14
Starting off
14
Shifting/Riding
14
Braking
15
Stopping, Parking
15
Refueling, Fuel
15
Periodic Lubrication - and Maintenance-Schedule
16
Maintenance Work on Chassis and Engine
18
Checking and Adjusting the Steering Head Bearing
18
How to Change the Handlebar Position
19
Breather Plug Front Fork
19
Cleaning the Dust Sleeves of the Telescopic Fork
19
Basic Suspension Setup for the Weight of the Driver
20
Checking the Shock Absorber and Spring
20
Determining the Static Sag of the Shock Absorber
20
Determining the Riding Sag of the Shock Absorber
20
Checking the Basic Setup of the Telescopic Fork
21
Changing the Spring Preload on the Telescopic Fork
21
Replacing Fork Springs
21
Adjusting the Spring Preload on the Fork
22
Changing the Spring Preloading of the Shock Absorber
22
Pivot Bearing
22
Checking the Chain Tension
23
Correct the Chain Tension
23
Chain Maintenance
24
Chain Wear
24
General Information about KTM Disc Brakes
25
Adjusting the Free Travel at the Hand Brake Lever
26
Checking the Brake Fluid Level - Front Brake
26
Refilling the Front Brake Fluid Reservoir
26
Checking the Front Brake Pads
26
Replacing the Front Brake Pads
27
Changing the Basic Position of the Foot Brake Pedal
27
Checking the Rear Brake Fluid Level
27
Refilling the Rear Brake Fluid Reservoir
27
Checking the Rear Brake Pads
28
Replacing the Rear Brake Pads
28
Dismounting and Mounting the Front Wheel
28
Dismounting and Mounting the Rear Wheel
29
Tires-Air Pressure
30
Checking the Spoke Tension
30
Cooling System
31
Checking the Coolant Level
31
Refilling/Bleeding the Cooling System
32
Cleaning the Air Filter
32
Exhaust System
33
Changing the Original Position of the Clutch Lever
33
Checking the Oil Level of the Hydraulic Clutch
33
Bleeding of the Hydraulic Clutch
33
Carburetor Adjustment
34
Draining the Float Chamber of the Carburetor
35
Checking the Float Level
35
Check Transmission Oil Level
36
Changing the Transmission Oil
36
Cleaning
37
Storage
37
Using RE Iniation
37
Technical Specifications Chassis
38
Technical Specifications - Engine
40
Index
42
Carburetor Setting
114
Section 2
125
Introduction
126
Exploded View
127
Disassembly Shock Absorber
128
Disassembly Tube Side
137
Disassembly MCC
157
Assembling MCC
163
Assembling Tube Side
166
Disassembly Piston-Rod Side
177
Diassembly Adaptor DU-Bush
187
Assembling Adaptor DU-Bush
191
Assembling Piston-Rod Side
194
Assembling Shock Absorber
205
Bleeding
211
On Pressure with Nitrogen
216
Adjustment
222
MX Multi Adjuster 2003
224
Introduction
225
Exploded View
226
Disassembly Forkleg
227
Disassembly Cartridge
240
Disassembly Tap Rebound
250
Assembling Tap Rebound
254
Assembling Cartridge
257
Assembling Forkleg
260
4
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KTM 250 SX 2003 Specifications
General
Brand
KTM
Model
250 SX 2003
Category
Motorcycle
Language
English
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