Page 7 - M P O R TA N T; KTM REPAIR MANUAL IN LOOSE-LEAF FORM; this purpose on the outside of the binder.
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Remove page (s) Replace by page (s) Insert page (s) after page 2-1 to 2-4 2-1C to 2-6C 3-4 3-4C 4-1 to 4-9 4-1C to 4-8C 5-1 5-1C 5-4 5-4C / 5-5C 5-13 to 5-14 5-13C to 5-14C 7-1 7-1C 7-5C to 7-10C 9-1 9-1C 9-37C to 9-42C 10-1 10-1C 10-6C to 10-8C 11...
Page 9 - Repair Manual
E X P L A N AT I O N - U P D AT I N G Edition 11/2002 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 3.205.63-E Repair Manual 250 / 300 / 380 SX, MXC, EXC Basicversion Modelyear 1999(Engine number with first digit “9“) 11/1998 3.205.87-E Updating of Rep.Manual 3.205.63-E Modelyear 2000(Engine n...
Page 11 - INTRODUCTION; WARNING; „NOTE” POINTS OUT USEFUL TIPS.; Use only; ORIGINAL KTM SPARE PARTS; when replacing parts.
INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes thelatest 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...
Page 13 - REPLY FAX FOR REPAIR MANUALS; Enter the complete item no. for the repair manual in column 1 (; Item no. of repair manual; Name mechanic/shop foreman
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible fora mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist usas follows: If you find any erro...
Page 14 - INDEX; G E N E R A L I N F O R M AT I O N
Repair manual 250 / 300 / 380 Art Nr 3206004 -E OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . .2-2 CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM . . . . . . . . . . . . . .2-4 BLEEDING OF THE HY...
Page 16 - jet needle; Idling range; Opening up; OPERATING RANGES OF THE CARBURETOR
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jetjet needle jet needle air control screwidle adjusting screw idle jetthrottle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 ...
Page 19 - Description
2-5C Fig. Part no. Description 1 560.12.001.000 Universal engine work stand 3 546.29.003.000 Clutch holder 4 560.12.004.000 Gear wheel segment 5 546.29.009.044 Magneto extractor M 27x1 Kokusan 6 6 276 807 Magneto extractor M 26x1,5 SEM 7 510.12.011.000 Circlip plier 8 544.12.012.000 Holding spanner ...
Page 20 - USE AFTER A PERIOD OF STORAGE; STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-6C Should you wish to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING)– Change engine oil (old engine oil contains aggressive contaminants).– Check antifree...
Page 22 - R E M O V I N G A N D R E F I T T I N G E N G I N E
Repair manual 250 / 300 / 380 Art No 3206004 -E R E M O V I N G A N D R E F I T T I N G E N G I N E REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 INDEX 3-1C 3
Page 24 - Dismounting the engine
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Dismounting the engine – Clean motorcycle thoroughly.– Prop up motorcycle on an appropriate stand.– Remove seat, right side paneling, and tank with spoilers. – Dismount exhaust system. – Drain coolant, and disconnect radiator hoses from engine.– Di...
Page 26 - Refitting the engine
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Refitting the engine – To install the engine, reverse the steps for removing the engine. Filling in of transmission oil:– Remove the plug 1 and top up with engine oil 15W-50 (i. e. MOTOREX TOP SPEED 4T). – In order to check the transmission oil lev...
Page 28 - D I S A S S E M B L I N G T H E E N G I N E
Repair manual 250 / 300 / 380 Art No 3206004 -E D I S A S S E M B L I N G T H E E N G I N E DRAINING GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 DISMOUNTING OF SPROCKET AND SHIFT LEVER . . . . . . . . . . . . . . .4-2 DISMOUNTING OF CYLINDER HEAD, CYLINDER AND...
Page 31 - Dismounting of clutch cover
4-3C – Undo the screws 1 and remove the right control cover. – Remove the securing clip of the ball socket 2 and unhook the ball socket 3 from the adjusting lever. – Remove gasket of the control cover. – Remove the 4 collar nuts 4 on cylinder base and remove cylinder. – Cover the crankcase.– Place p...
Page 33 - Dismounting of kickstarter; Dismounting of the shift lock
4-5C Dismounting of kickstarter – Remove circlip 1 and kickstarter intermediate gear. – Carefully release collar screw 2 kickstarter spring is tensioned, release tension on kickstarter spring and unhook spring hanger. ! CAUTION ! C AREFULLY RELEASE THE KICKSTARTER SPRING ! D ANGER OF INJURY ! – Take...
Page 35 - Dismounting of gearshift mechanism and transmission
4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws 1 . – Remove intake flange and reed valve housing. Parting of engine housing halves – Top ignition-gear upwards and remove all 11 housing screws.– Loosen the 2 engine fixtures on the engine work stand. – Lift left-...
Page 36 - Dismounting the crankshaft
4-8C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E – Pull out the shift rails and swing the shift forks aside.– Pull the shift roller out of the bearing seat.– Remove the shift forks. NOTE: During disassembly, watch out for the shift rollers 1 on the driving pins of the shift forks. They may r...
Page 37 - SERVICING ON INDIVIDUAL COMPONENTS; Engine housing
Repair manual 250 / 300 / 380 Art No 3206004 -E SERVICING ON INDIVIDUAL COMPONENTS WORKING ON THE RIGHT-HAND HOUSING HALF . . . . . . . . . . . . . .5-2WORKING ON THE LEFT-HAND HOUSING HALF . . . . . . . . . . . . . . . .5-3CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 39 - Working on the right-hand housing half
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Working on the right-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. Grooved ball bearing of crankshaft 1 Press old grooved ball-bearing inwards. Press in new ball bearing to thestop. The op...
Page 40 - Working on the left-hand housing half
Working on the left-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. Crankshaft roller bearing 1 Press old roller bearing inwards, press in new ball bearing to the stop withthe open side of ball cage downwards (outside). The inner ring on thec...
Page 41 - Crankshaft; Crankshaft webs – measure outer dimension
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be renewed. – Heat special tool 584.29.037.040 on a heating pad up to approx. 150°C and slip it on the inner ring immediately. Press the special tooltogether tightl...
Page 45 - Exhaust control, clutch cover; Preassembly of clutch cover
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Exhaust control, clutch cover – Remove screws 1 and take off the bearing support. – Take cup tappet 2 , adjusting spring 3 and auxiliary spring 4 out of clutch cover. – Take off water pump cover, remove allen head screw 6 and take off water pump wh...
Page 46 - Reed valve housing, intake flange
Reed valve housing, intake flange NOTE: Reed paddles 1 gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced.If the reed sealing surfaces 2 of the reed valve housing are also damaged, replace the complete reed valve housing. ! CAUTION ! S EC...
Page 47 - Clutch
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Clutch Thrust bearing 1 check for wear Push rod 2 Check for wear. Minimum length: 199 mm (new: 199.80 mm) Clutch springs 3 New spring length 42,5 mm / 1.7 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable. 9 Lining discs 4 Minimum thick...
Page 48 - Replace outer clutch hub
5-11C Replace outer clutch hub – Drill open the clutch rivets bl in area of retaining bracket bm and remove parts. – Check 8 absorbing elements bn for signs of mechanical damage, replace all 8 where applicable. ! CAUTION ! T HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN . T O ENSURE TH...
Page 50 - Spark plug; Check stator and pulse generator (Kokusan); K o k u s a n 2 K - 2
Ignition (Kokusan) General information The measurements described below will only reveal severe problems. Coilshort circuits leading to weak ignition sparks or low generator output,respectively, can only be detected with the help of an ignition test bench.In the case of malfunction always check the ...
Page 55 - A S S E M B L I N G T H E E N G I N E
Repair manual 250 / 300 / 380 Art No 3206004 -E A S S E M B L I N G T H E E N G I N E CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 ASSEMBLING THE ENGINE HO...
Page 57 - Transmission
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E – Secure the right-hand housing half in the engine work stand. Crankshaft – Insert crankshaft from above through grooved ball bearing and push carefully as far as stop. ! CAUTION ! W HEN PUSHING IN CRANKSHAFT , MAKE SURE CONROD IS FACING CYLINDER ....
Page 58 - Assembling the engine housing
– Fix the 4 pressure springs 1 with ample amounts of grease in the gearshift rails. – Oil gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft). Insert gearshift rails into the casingbores as far as they will go. NOTE: It must now be possible to gently tu...
Page 60 - Mount primary drive and clutch
Mount primary drive and clutch – Grease crankshaft seal ring.– Put the oiled O-ring (25x1.50 mm) onto the crankshaft and mount the distance bushing with the chamfer facing the crank web. – Insert woodruff key into crankshaft. – Place primary gear 1 onto crankshaft with collar downwards. – Put the in...
Page 62 - Mounting piston and cylinder; Adjusting dimension „X“
Mounting piston and cylinder – Before assembly, oil all parts thoroughly at the sliding points.– Insert needle bearing in conrod eye, mount piston (arrow on piston head shows direction for exhaust duct). – Mount piston pin and wire circlips with open side showing downwards (see sketch). – Mount cyli...
Page 65 - Mounting engine sprocket
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 6-10C Mounting engine sprocket – Lubricate O-ring 1 with oil and slide over counter shaft. – Slide distance bushing 2 in position so that O-ring is in correct position. – Slide sprocket onto the countershaft with the collar facing inward, and fix i...
Page 67 - E L E C T R I C A L
Repair manual 250 / 300 / 380 Art No 3206004 -E E L E C T R I C A L CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN) . . .7-2 CHECKING THE VOLTAGE REGULATOR (KOKUSAN) . . . . . . . . . . . . .7-2 CHECKING THE VOLTAGE REGULATOR (TYMPANIUM) . . . . . . . . . . .7-2 CHECKING THE CAPACITOR . . . . ...
Page 69 - Checking the voltage regulator (Tympanium)
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Checking the voltage regulator-rectifier (Shindengen) – Start the engine and switch on the low beam.– Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed...
Page 70 - Checking the capacitor; CDI unit
Checking the capacitor – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of thebattery and the positive terminal of the capacitor (m...
Page 76 - Static ignition values 250 MXC, EXC USA; Static generator values 250 MXC, EXC USA
7-9C Static ignition values 250 MXC, EXC USA Check the pulse generator for an output signal – two one-pin connectors 1 with green and red cable colors (also see circuit diagram on opposite page): – Apply the red measuring lead of the peak voltage adapter to the green cable and the black measuring le...
Page 79 - T R O U B L E S H O O T I N G
Repair manual 250 / 300 / 380 Art No 3206004 -E T R O U B L E S H O O T I N G TROUBLE SHOOTING 250 - 380 . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 INDEX 8-1C 8
Page 81 - TROUBLE SHOOTING
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 8-2C TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected.Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of...
Page 83 - T E C H N I C A L S P E C I F I C AT I O N S
Repair manual 250 / 300 / 380 Art No 3206004 -E T E C H N I C A L S P E C I F I C AT I O N S MODEL 1999 ENGINE 250 - 380 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 ENGINE 250 - 380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 CHASSIS ...
Page 85 - TECHNICAL SPECIFICA
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-2C Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC Design Liquid-cooled single-cylinder two-str oke engine with KTM T win V alve C ontr ol exhaust system and K TM T or que C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bor e / s...
Page 86 - TOLERANCES AND FITTING CLEARANCES; TABLE 3; BASIC CARBURETOR SETTING
9-3C Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 18 x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18 x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and co...
Page 88 - TABLE 4
9-5C Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 18 x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18 x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and co...
Page 89 - STANDARD ADJUSTMENT - FORK
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-6C 250/380SX 250/300/380 MXC 250/300/380 EXC 250/300/380 EGS Frame Central chrome-moly-steel frame Fork WP Extreme Ø 50 mm Wheel travel front/rear 280 / 320 mm (11.0 / 12.6 in) Rear suspension WP P rogressive D amping S ystem shock absorber, alum...
Page 90 - TEMPERA; AL; NICHT FÜR STRASSENBETRIEB
9-7C VERGASERREGULIERUNG KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38 CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F TEMPERA TUR MEERESHÖHE AL TITUDE LSCHR AS 1 1/2 1...
Page 93 - TECHNICAL DA
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-10C Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC Design Liquid-cooled single-cylinder two-str oke engine with KTM T win V alve C ontr ol exhaust system and K TM T or que C hamber Piston displacement 249 ccm 297 ccm 368 ccm Bor e / ...
Page 98 - VERGASERREGULIERUNG; KEIHIN PWK 38AG PJ; CARBURETOR SETTING; ALTIDUDE
9-15C VERGASERREGULIERUNG KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F TEMPERA TUR MEERESHÖHE ALTIDUDE LSCHR AS 1 1/2 1 3...
Page 99 - AG
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-16C VERGASERREGULIERUNG KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 1...
Page 101 - KEIHIN
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-18C VERGASERREGULIERUNG KTM 380 SX / MXC / EXC EUR / USA 2000 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F ...
Page 117 - KEIHIN PWK 38AG; Slide
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9-33C VERGASERREGULIERUNG KTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F T...
Page 127 - LUBRICATION AND MAINTENANCE SCHEDULE
Repair manual 250 / 300 / 380 Art No 3206004 -E LUBRICATION AND MAINTENANCE SCHEDULE MODEL 1999 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-2 MODEL 2000 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-3 MODEL 2001/2002 LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 ...
Page 129 - PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 10-2C PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE Check transmission oil level ● Change transmission oil ● ● ● Check spark plug and electrode gap ● ● ● Change spark plug ● Functional testing of the exhaust control system ● Check intake manifold f...
Page 134 - PERIODIC MAINTENANCE SCHEDULE 2003
10-6C PERIODIC MAINTENANCE SCHEDULE 2003 after 20 hours or 2000 kilometers 1st service after 10 hours or 1000 kilometers after 4000 kilometer or once a year IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE I NTERVALS SHOULD NEVER BE EXCEEDED BY MO...
Page 137 - W I R I N G D I A G R A M S
Repair manual 250 / 300 / 380 Art No 3206004 -E W I R I N G D I A G R A M S MODEL 1999 WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . . .11-2 WIRING DIAGRAM 250 - 380 EGS . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 WIRING DIAGRAM 250 - 380 EXC (USA) . . . . . ....
