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Popular manuals
362 pages
350 EXC-F EU Repair Manual
307 pages
250 sxf 2016 Repair Manual
96 pages
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300 EXC Owner’s Manual
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250 SX-F EU Owner’s Manual
91 pages
65 SX Owner’s Manual
448 pages
990 Adventure Repair Manual
191 pages
450 EXC-R EU Repair Manual
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50 SX Owner’s Manual
102 pages
350 SX-F Owner’s Manual
127 pages
150 SX Owner’s Manual
289 pages
250 EXC EU Repair Manual
267 pages
125 DUKE EU Repair Manual
90 pages
450 SX-F Owner’s Manual
159 pages
50 SX Repair Manual
387 pages
250 EXC TPI 2019 Repair Manual
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65 SX Owner’s Manual
136 pages
350 EXC-F EU Owner’s Manual
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1290 SUPERDUKE R Owner’s Manual
411 pages
890 Adventure R US 2021 Owner’s Manual
Models
Document Type
1
105 SX 2007
Owner’s Manual
105 SX 2008
Owner’s Manual
105 SX 2010
Owner’s Manual • Spare Parts Manual
105 XC 2008
Owner’s Manual
1050 Adventure
Owner’s Manual • Setup Instructions
1090 ADVENTURE 2017
Owner’s Manual
1090 Adventure R
Owner’s Manual
1090 Adventure R 2018
Setup Instructions
1190 Adventure 2016
Owner’s Manual
1190 Adventure AU 2016
Owner’s Manual
1190 Adventure AUS 2013
Setup Instructions
1190 Adventure AUS 2014
Owner’s Manual
1190 Adventure CN 2016
Owner’s Manual
1190 Adventure EU 2013
Setup Instructions
1190 Adventure EU 2014
Owner’s Manual
1190 Adventure EU 2016
Owner’s Manual
1190 Adventure FR 2013
Setup Instructions
1190 Adventure FR 2014
Owner’s Manual
1190 Adventure FR 2016
Owner’s Manual
1190 Adventure JP 2013
Setup Instructions
1190 Adventure JP 2014
Owner’s Manual
1190 Adventure JP 2016
Owner’s Manual
1190 ADVENTURE R
Owner’s Manual • Owner’s Manual
1190 Adventure R AU
Owner’s Manual
1190 Adventure R AUS
Owner’s Manual
1190 Adventure R CN
Owner’s Manual
1190 Adventure R EU
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
1190 Adventure R FR
Owner’s Manual • Owner’s Manual
1190 Adventure R JP
Owner’s Manual • Owner’s Manual
1190 Adventure R US
Owner’s Manual
1190 RC8
Owner’s Manual
1190 RC8 AUS
Owner’s Manual
1190 RC8 AUS 2008
Setup Instructions
1190 RC8 AUS/UK 2008
Repair Manual
1190 RC8 EU
Owner’s Manual
1190 RC8 EU 2008
Setup Instructions • Repair Manual
1190 RC8 FR
Owner’s Manual
1190 RC8 FR 2008
Setup Instructions • Repair Manual
1190 RC8 JP
Owner’s Manual
1190 RC8 JP 2008
Setup Instructions • Repair Manual
1190 rc8 r eu/db
Owner’s Manual
1190 RC8 R EU/UK 2009
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual
1190 rc8 r fr
Owner’s Manual
1190 RC8 R FR 2013
Setup Instructions
1190 rc8 r jp
Owner’s Manual
1190 RC8 R Track
Owner’s Manual
1190 RC8 R USA
Owner’s Manual • Owner’s Manual
1190 RC8 R USA 2013
Setup Instructions
1190 RC8 UK
Owner’s Manual
1190 RC8 UK 2008
Setup Instructions
1190 RC8-R
Owner’s Manual
125
Owner’s Handbook Manual • Repair Manual
125 D-XC
Manual
125 Duke 2016
Setup Instructions
125 Duke 2017
Owner’s Manual
125 Duke DE
Owner’s Manual • Repair Manual
125 Duke DE 2012
Setup Instructions
125 DUKE EU
Owner’s Manual • Owner’s Manual • Owner’s Manual • Installation Instructions Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions • Setup Instructions
125 Duke EU 2012
Setup Instructions
125 Duke EU 2015
Owner’s Manual • Setup Instructions
125 ECX EU
Owner’s Manual
125 EXC
Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Manual • Owner’s Manual • Owner’s Manual
125 EXC 2001
Owner’s Handbook Manual
125 EXC 2004
Owner’s Manual
125 EXC 2006
Owner’s Manual
125 EXC 2008
Owner’s Manual
125 EXC 2015
Setup Instructions
125 EXC EU 2010
Owner’s Manual
125 EXC EU 2012
Setup Instructions
125 EXC EU 2013
Setup Instructions
125 EXC EU 2014
Setup Instructions
125 EXC EU 2016
Owner’s Manual
125 EXC Factory Edition
Owner’s Manual
125 EXC SIX DAYS
Owner’s Manual • Owner’s Manual
125 EXC SIX DAYS 2008
Owner’s Manual
125 EXC Six Days 2015
Setup Instructions
125 EXC Six days EU
Owner’s Manual • Owner’s Manual • Owner’s Manual
125 EXC SIX DAYS EU 2010
Owner’s Manual
125 EXC SIX DAYS EU 2012
Setup Instructions
125 EXC SIX DAYS EU 2013
Setup Instructions
125 EXC SIX DAYS EU 2014
Setup Instructions
125 EXC Six Days EU 2016
Owner’s Manual
125 EXE 2001
Owner’s Handbook Manual
125 LC2 1998
Owner’s Handbook Manual
125 MX
Manual
125 MXC 2001
Owner’s Handbook Manual
125 SUPERMOTO 2001
Owner’s Handbook Manual
125 SX
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
125 SX 2001
Owner’s Handbook Manual
125 SX 2004
Owner’s Manual
125 SX 2006
Owner’s Manual
125 SX 2007
Owner’s Manual
125 SX 2008
Owner’s Manual • Spare Parts Manual
125 SX 2010
Owner’s Manual • Owner’s Manual
125 SX 2011
Setup Instructions
125 SX 2016
Setup Instructions
125 SX 2017
Setup Instructions
125 SX 2018
Owner’s Manual • Setup Instructions
125 SX EU 2013
Setup Instructions
125 SX EU 2015
Owner’s Manual
125 SX EU 2017
Setup Instructions
125 SX US 2015
Owner’s Manual
125 SX US 2017
Setup Instructions
125 SX USA
Owner’s Manual
125 SX USA 2013
Setup Instructions
125 XC-W 2018
Setup Instructions
125 XC-W EU 2017
Setup Instructions
125egs
Owner’s Manual • Owner’s Handbook Manual • Manual
125EXC 2004
Owner’s Manual
125MXC
Owner’s Handbook Manual • Owner’s Manual
1290 Super Adventure
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Manual • Owner’s Manual
1290 SUPER ADVENTURE R 2017
Owner’s Manual • Setup Instructions
1290 SUPER ADVENTURE R 2018
Owner’s Manual
1290 Super Adventure R EU 2017
Setup Instructions
1290 Super Adventure R EU 2018
Setup Instructions
1290 Super Adventure R EU 2019
Setup Instructions
1290 Super Adventure R JP 2018
Setup Instructions
1290 Super Adventure R TKC AU 2017
Setup Instructions
1290 Super Adventure R TKC CN 2019
Setup Instructions
1290 Super Adventure R TKC EU 2017
Setup Instructions
1290 Super Adventure R TKC EU 2019
Setup Instructions
1290 Super Adventure R TKC JP 2017
Setup Instructions
1290 Super Adventure R TKC JP 2019
Setup Instructions
1290 Super Adventure R TKC US 2017
Setup Instructions
1290 Super Adventure R TKC US 2019
Setup Instructions
1290 Super Adventure S 2017
Setup Instructions • Owner’s Manual
1290 Super Adventure S 2018
Setup Instructions • Owner’s Manual
1290 SUPER ADVENTURE S 2021
Setup Instructions
1290 Super Adventure S AU 2017
Setup Instructions
1290 Super Adventure S CN 2017
Setup Instructions
1290 Super Adventure S CN F9903T4
Owner’s Manual
1290 Super Adventure S EU 2017
Setup Instructions
1290 Super Adventure S JP 2017
Setup Instructions
1290 Super Adventure T 2017
Setup Instructions
1290 Super Duke GT
Owner’s Manual • Owner’s Manual
1290 Super Duke GT 2018
Owner’s Manual • Setup Instructions
1290 Super Duke GT 2019
Setup Instructions
1290 Super Duke GT AU
Setup Instructions
1290 Super Duke GT CN 2017
Setup Instructions
1290 Super Duke GT CN 2018
Setup Instructions
1290 Super Duke GT CN 2019
Setup Instructions
1290 Super Duke GT EU
Setup Instructions
1290 Super Duke GT EU 2017
Setup Instructions
1290 Super Duke GT EU 2018
Setup Instructions
1290 Super Duke GT EU 2019
Setup Instructions
1290 Super Duke GT JP
Setup Instructions
1290 Super Duke GT JP 2017
Setup Instructions
1290 Super Duke GT JP 2018
Setup Instructions
1290 Super Duke GT JP 2019
Setup Instructions
1290 Super Duke GT Series
Setup Instructions
1290 Super Duke GT US
Setup Instructions
1290 Super Duke GT US 2017
Setup Instructions
1290 Super Duke GT US 2018
Setup Instructions
1290 Super Duke GT US 2019
Setup Instructions
1290 Super Duke R
Owner’s Manual • Setup Instructions
1290 Super Duke R 2016
Setup Instructions
1290 Super Duke R 2017
Owner’s Manual • Setup Instructions
1290 Super Duke R 2018
Owner’s Manual • Setup Instructions
1290 Super Duke R 2019
Setup Instructions
1290 SUPER DUKE R 2021
Owner’s Manual
1290 Super Duke R AU 2017
Owner’s Manual • Setup Instructions
1290 Super Duke R EU 2017
Owner’s Manual • Setup Instructions
1290 Super Duke R JP 2017
Owner’s Manual • Setup Instructions
1290 Super Duke R US 2017
Setup Instructions
1290 Super Duke R US 2020
Owner’s Manual
1290 SUPER DUKE RR 2021
Owner’s Manual
1290 SUPERDUKE R
Owner’s Manual
144 SX
Owner’s Manual
144 SX 2008
Owner’s Manual
150 EXC TPI 2021
Setup Instructions
150 SX
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
150 SX 2010
Owner’s Manual • Owner’s Manual
150 SX 2011
Setup Instructions
150 SX 2016
Setup Instructions
150 SX 2017
Setup Instructions
150 SX 2018
Owner’s Manual • Setup Instructions
150 SX EU 2013
Setup Instructions
150 SX EU 2015
Owner’s Manual
150 SX EU 2017
Setup Instructions
150 SX US 2015
Owner’s Manual
150 SX US 2017
Setup Instructions
150 SX USA
Owner’s Manual • Owner’s Manual
150 SX USA 2013
Setup Instructions
150 XC USA
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
150 XC USA 2010
Owner’s Manual
150 XC USA 2011
Setup Instructions
150 XC USA 2013
Setup Instructions
150 XC-W 2018
Setup Instructions
150 XC-W US 2017
Setup Instructions
1998 125 EGS
Owner’s Manual
1998 125 EXC
Owner’s Manual
1998 125 MXC
Owner’s Manual
1998 125 SX
Owner’s Manual
1998 125sx
Owner’s Manual
1998 200 EGS
Owner’s Manual
1998 200 EXC
Owner’s Manual
1998 200 MXC
Owner’s Manual
1998 200 SX
Owner’s Manual
1998 250 EGS
Owner’s Manual
1998 250 EXC
Owner’s Manual
1998 250 MXC
Owner’s Manual
1998 250 SX
Owner’s Manual
1998 300 EGS
Owner’s Manual
1998 300 EXC
Owner’s Manual
1998 300 MXC
Owner’s Manual
1998 300 SX
Owner’s Manual
1998 380 EGS
Owner’s Manual
1998 380 EXC
Owner’s Manual
1998 380 MXC
Owner’s Manual
1998 380 SX
Owner’s Manual
1998 400 R
Owner’s Handbook Manual
1998 400 RXCe
Owner’s Handbook Manual
1998 50 SXR Adventure
Owner’s Handbook Manual
1998 620 R
Owner’s Handbook Manual
1998 620 RXCe
Owner’s Handbook Manual
1998 SXC 400
Spare Parts Manual
1998 SXC 540
Spare Parts Manual
2
200
Owner’s Handbook Manual • Repair Manual
200 DUKE 2013 COL
Repair Manual
200 Duke 2014 COL
Setup Instructions
200 Duke 2016
Setup Instructions
200 Duke 2016 CO 2015
Setup Instructions
200 Duke 2017
Owner’s Manual
200 DUKE 2021
Owner’s Manual
200 Duke AR 2015
Owner’s Manual • Setup Instructions
200 Duke ASIA 2015
Owner’s Manual • Setup Instructions
200 Duke BR 2015
Owner’s Manual • Setup Instructions
200 Duke CN 2015
Owner’s Manual • Setup Instructions
200 DUKE EU
Owner’s Manual • Owner’s Manual • Installation Instructions Manual • Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions
200 Duke EU 2012
Setup Instructions
200 Duke EU 2015
Owner’s Manual • Setup Instructions
200 DUKE MAL
Owner’s Manual • Setup Instructions
200 Duke MY 2015
Owner’s Manual • Setup Instructions
200 Duke US 2020
Owner’s Manual
200 EXC
Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
200 EXC 2001
Owner’s Handbook Manual
200 EXC 2004
Owner’s Manual
200 EXC 2006
Owner’s Manual
200 EXC 2008
Owner’s Manual
200 EXC 2015
Setup Instructions
200 EXC 2016
Setup Instructions
200 EXC AU 2016
Owner’s Manual
200 EXC AUS
Owner’s Manual • Owner’s Manual • Owner’s Manual
200 EXC AUS 2010
Owner’s Manual
200 EXC AUS 2012
Setup Instructions
200 EXC AUS 2013
Setup Instructions
200 EXC AUS 2014
Setup Instructions
200 EXC EU 2010
Owner’s Manual
200 EXC EU 2012
Setup Instructions
200 EXC EU 2013
Setup Instructions
200 EXC EU 2014
Setup Instructions
200 EXC EU 2016
Owner’s Manual
200 EXC2004
Owner’s Manual
200 MXC 2001
Owner’s Handbook Manual
200 SX
Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual
200 SX 2001
Owner’s Handbook Manual
200 SX 2004
Owner’s Manual
200 XC
Owner’s Manual • Owner’s Manual
200 XC 2006
Owner’s Manual
200 XC 2008
Owner’s Manual
200 XC-W
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
200 XC-W 2006
Owner’s Manual
200 XC-W 2008
Owner’s Manual
200 XC-W 2015
Setup Instructions
200 XC-W 2016
Setup Instructions
200 XC-W US 2016
Owner’s Manual
200 XC-W USA 2012
Setup Instructions
200 XC-W USA 2013
Setup Instructions
200 XC-W USA 2014
Setup Instructions
200 XC?W USA 2010
Owner’s Manual
2000 400 EXC RACING
Owner’s Handbook Manual
2000 400 SX RACING
Owner’s Handbook Manual
2000 520 EXC RACING
Owner’s Handbook Manual
2000 520 SX RACING
Owner’s Handbook Manual
2000 60 SX
Owner’s Manual
2000 640 Duke
Spare Parts Manual
2000 65 SX
Owner’s Manual
2000 LC4 ADVENTURE R 640
Owner’s Handbook Manual
2001 50 JR ADVENTURE
Owner’s Handbook Manual
2001 50 SX Pro Senior LC
Owner’s Handbook Manual
2002 200 EXC AUS
Owner’s Manual
2002 200 EXC EU
Owner’s Manual
2002 200 XC-W USA
Owner’s Manual
2002 250 EXC AUS
Owner’s Manual
2002 250 EXC EU
Owner’s Manual
2002 250 XC-W USA
Owner’s Manual
2002 300 EXC Aus
Owner’s Manual
2002 300 EXC EU
Owner’s Manual
2002 300 XC-W usa
Owner’s Manual
2002 400 EXC Racing
Owner’s Handbook Manual
2002 400 MXC
Owner’s Handbook Manual
2002 400 SX
Owner’s Handbook Manual
2002 50 SX PRO SENIOR LC
Owner’s Handbook Manual
2002 520 EXC Racing
Owner’s Handbook Manual
2002 520 MXC
Owner’s Handbook Manual
2002 520 SX
Owner’s Handbook Manual
2003 125 EXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 125 MXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 125 SX
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 200 EXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 200 MXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 200 SX
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 250 EXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 250 MXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 250 SX
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 300 EXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 300 MXC
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 300 SX
Owner’s Handbook Manual • Owner’s Handbook Manual
2003 640 DUKE II
Owner’s Manual
2003 950 Super Enduro
Repair Manual
2003 950 SuperMoto
Repair Manual
2003 990 Adventure
Repair Manual
2003 990 Super Duke
Repair Manual
2004 105 SX
Spare Parts Manual
2004 250 EXC RACING
Owner’s Manual • Owner’s Manual
2004 450 EXC RACING
Owner’s Manual
2004 450 MXC
Owner’s Manual
2004 525 EXC RACING
Owner’s Manual
2004 525 MXC
Owner’s Manual
2004 640 DUKE II
Spare Parts Manual
2004 660 SMC
Spare Parts Manual
2004 950 Super Enduro
Repair Manual
2004 950 SuperMoto
Repair Manual
2004 990 Adventure
Repair Manual
2004 990 Super Duke
Repair Manual
2005 85 SX
Owner’s Manual
2005 950 Adventure
Owner’s Manual • Repair Manual
2005 950 Super Enduro
Repair Manual
2005 950 SuperMoto
Repair Manual
2005 990 Adventure
Repair Manual
2005 990 Super Duke
Repair Manual
2006 660 SMC
Owner’s Manual
2006 950 Super Enduro
Repair Manual
2006 950 SuperMoto
Repair Manual
2006 990 Adventure
Repair Manual
2006 990 Super Duke
Repair Manual
2007 250 EXC-F SIX DAYS
Owner’s Manual • Repair Manual
2007 505 SX-F
Repair Manual
2007 950 Super Enduro R
Owner’s Manual
2007 950 SUPERMOTO
Owner’s Manual
2007 990 ADVENTURE
Owner’s Manual
2007 990 Super Duke
Owner’s Manual
2007 SMR 450
Owner’s Manual
2007 SMR 560
Owner’s Manual
2008 1190 RC8 USA
Owner’s Manual
2008 690 Enduro
Repair Manual
2008 990 SUPER DUKE
Owner’s Manual
2008 990 SUPERMOTO
Owner’s Manual
2009 250 EXC-F SIX DAYS
Owenrs Manual
2009 250 SX-F
Owenrs Manual
2009 250 XC-F
Owenrs Manual
2009 250 XCF-W
Owenrs Manual
2009 400 EXC
Owner’s Manual
2009 400 XC-W
Owner’s Manual
2009 450 EXC SIX DAYS
Owner’s Manual
2009 450 SC-F USA
Owner’s Manual
2009 450 SX-F EU
Owner’s Manual
2009 450 SX-F USA
Owner’s Manual
2009 450 XC-W
Owner’s Manual
2009 530 EXC SIX DAYS
Owner’s Manual
2009 530 XC-W
Owner’s Manual
2009 550 SC-F USA
Owner’s Manual
2009 65 XC
Owner’s Manual
2009 690 DUKE EU
Owner’s Manual
2009 690 ENDURO EU
Owner’s Manual • Repair Manual
2009 690 Rally Factory Replica
Owner’s Manual
200egs
Owner’s Manual • Owner’s Handbook Manual
200MXC
Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual
2010 1190 RC8
Owner’s Manual
2010 1190 RC8 R AUS
Owner’s Manual
2010 1190 RC8 R FR
Owner’s Manual
2010 1190 RC8 R JP
Owner’s Manual
2010 125 EXC EU
Owner’s Manual
2010 150 XC USA
Owner’s Manual
2010 200 EXC EU
Owner’s Manual
2010 200 XC-W USA
Owner’s Manual
2010 250 EXC EU
Owner’s Manual • Owner’s Manual
2010 250 EXC SixDays
Owner’s Manual
2010 250 EXC-F AUS
Owner’s Manual
2010 250 EXC-F EU
Owner’s Manual
2010 250 SX-F EU
Owner’s Manual
2010 250 XC-W USA
Owner’s Manual • Owner’s Manual
2010 250 XCF-W ZA
Owner’s Manual
2010 300 EXC EU
Owner’s Manual • Owner’s Manual
2010 300 EXC SixDays
Owner’s Manual
2010 300 SX
Owner’s Manual
2010 300 XC EU/USA
Owner’s Manual • Owner’s Manual
2010 300 XC-W USA
Owner’s Manual • Owner’s Manual
2010 400 EXC EU
Owner’s Manual
2010 400 XC-W USA
Owner’s Manual
2010 450 EXC EU
Owner’s Manual
2010 450 SX-F EU
Owner’s Manual
2010 450 SX-F USA
Owner’s Manual
2010 450 XC-W SIX DAYS USA
Owner’s Manual
2010 50 SX MINI
Owner’s Manual
2010 530 EXC EU
Owner’s Manual
2010 530 XC-W SIX DAYS USA
Owner’s Manual
2010 690 SMC AUS
Repair Manual
2010 690 SMC EU
Repair Manual • Setup Instructions
2010 690 SMC UK
Repair Manual
2010 990 Super Duke R
Owner’s Manual
2011 400 EXC Factory Edition
Owner’s Manual
2011 450 EXC Factory Edition
Owner’s Manual
2011 450 EXC SIX DAYS
Owner’s Manual
2011 450 XC-W SIX DAYS
Owner’s Manual
2011 530 EXC Factory Edition
Owner’s Manual
2011 530 EXC SIX DAYS
Owner’s Manual
2011 530 XC-W SIX DAYS
Owner’s Manual
2011 690 Duke R
Owner’s Manual
2011 690 SMC AUS
Repair Manual • Owner’s Manual
2011 690 SMC EU
Repair Manual • Owner’s Manual
2011 690 SMC UK
Repair Manual • Owner’s Manual
2011 990 Adventure
Owner’s Manual
2011 990 Supermoto T USA
Owner’s Manual • Owner’s Manual • Owner’s Manual
2012 125 DUKE
Owner’s Manual
2012 125 ECX EU
Owner’s Manual
2012 125 EXC Six days EU
Owner’s Manual
2012 125 SX
Owner’s Manual
2012 150 SX
Owner’s Manual
2012 150 XC
Owner’s Manual
2012 200 DUKE
Owner’s Manual
2012 250 EXC-F SIX DAYS
Owner’s Manual
2012 250 SX
Owner’s Manual
2012 250 SX-F
System Maintenance And Repair Manual
2012 250 XC
Owner’s Manual
2012 250 XCF-W
Owner’s Manual
2012 300 XC
Owner’s Manual
2012 350 EXC-F SIX DAYS
Owner’s Manual
2012 350 XCF-W
Owner’s Manual
2012 450 EXC SIX DAYS
Owner’s Manual
2012 450 SX-F EU
Owner’s Manual
2012 450 SX-F USA
Owner’s Manual
2012 450 XC-W
Owner’s Manual
2012 500 EXC SIX DAYS
Owner’s Manual
2012 500 XC-W
Owner’s Manual
2012 990 Adventure
Owner’s Manual
2013 1190 Adventure R
Owner’s Manual
2013 1190 RC8 R JP
Owner’s Manual • Setup Instructions
2013 125 DUKE
Owner’s Manual
2013 125 EXC SIX DAYS
Owner’s Manual
2013 125 SX
Owner’s Manual
2013 150 SX
Owner’s Manual
2013 150 XC
Owner’s Manual
2013 200 DUKE
Owner’s Manual
2013 200 EXC
Owner’s Manual
2013 200 XC-W
Owner’s Manual
2013 250 EXC SIX DAYS
Owner’s Manual
2013 250 SX
Owner’s Manual
2013 250 XC
Owner’s Manual
2013 250 XC-W
Owner’s Manual
2013 300 EXC SIX DAYS
Owner’s Manual
2013 300 XC
Owner’s Manual
2013 300 XC-W
Owner’s Manual
2013 450 EXC EU
Owner’s Manual
2013 450 Rally Factory Replica
Owner’s Manual
2013 450 SX-F EU
Owner’s Manual
2013 450 SX-F USA
Owner’s Manual
2013 450 SX-F USA Factory edition
Owner’s Manual
2013 450 XC-F USA
Owner’s Manual
2013 450 XC-W USA
Owner’s Manual
2013 500 EXC AUS
Owner’s Manual • Repair Manual • Setup Instructions
2013 500 EXC EU
Owner’s Manual
2013 500 XC-W USA
Owner’s Manual
2013 690 Duke R
Owner’s Manual
2013 690 SMC R EU
Owner’s Manual • Repair Manual
2013 990 SUPER DUKE R
Owner’s Manual
2013 990 SUPERMOTO T
Owner’s Manual
2014 1190 Adventure
Owner’s Manual
2014 125 EXC SIX DAYS
Owner’s Manual
2014 125 SX
Owner’s Manual
2014 1290 Super Duke R FR
Owner’s Manual
2014 150 SX
Owner’s Manual
2014 150 XC
Owner’s Manual
2014 200 EXC
Owner’s Manual
2014 200 XC-W
Owner’s Manual
2014 250 EXC SIX DAYS
Owner’s Manual
2014 250 SX
Owner’s Manual
2014 250 XC
Owner’s Manual
2014 250 XC-W
Owner’s Manual
2014 300 EXC SIX DAYS
Owner’s Manual
2014 300 XC
Owner’s Manual
2014 300 XC-W SIX DAYS
Owner’s Manual
2014 350 EXC-F SIX DAYS
Owner’s Manual
2014 350 XCF-W SIX DAYS
Owner’s Manual
2014 450 EXC SIX DAYS
Owner’s Manual
2014 450 XC-W
Owner’s Manual
2014 500 EXC SIX DAYS
Owner’s Manual
2014 500 XC-W
Owner’s Manual
2014 65 SX
Owner’s Manual • Setup Instructions
2014 690 Enduro R EU
Owner’s Manual
2014 690 SMC R EU
Owner’s Manual • Repair Manual
2014 Freeride 350
Owner’s Manual
2015 125 SX EU
Owner’s Manual • Setup Instructions
2015 150 SX EU
Owner’s Manual • Setup Instructions
2015 200 Duke
Owner’s Manual
2015 250 SX EU
Owner’s Manual • Setup Instructions
2015 250 XC EU/US
Owner’s Manual • Setup Instructions
2015 300 XC EU/US
Owner’s Manual • Setup Instructions
2015 450 Rally Factory Replica
Owner’s Manual
2015 450 SC-F USA
Owner’s Manual
2015 450 SX-F EU
Owner’s Manual
2015 450 SX-F USA
Owner’s Manual
2015 RC 390 ASIA
Owner’s Manual
2015 RC 390 AU
Owner’s Manual
2015 RC 390 BR
Owner’s Manual
2015 RC 390 CN
Owner’s Manual
2015 RC 390 EU
Owner’s Manual
2015 RC 390 JP
Owner’s Manual
2015 RC 390 MY
Owner’s Manual
2016 690 DUKE R
Owner’s Manual • Owner’s Manual
2016 RC 250
Owner’s Manual
2016 RC 390
Owner’s Manual
2018 50 SX
Owner’s Manual
25 EXC 2016
Setup Instructions
25 EXC Six Days
Owner’s Manual
250 AUS
Owner’s Manual
250 DUKE
Owner’s Manual
250 EXC
Repair Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
250 EXC 2001
Owner’s Handbook Manual
250 EXC 2006
Owner’s Manual
250 EXC 2008
Owner’s Manual
250 EXC 2015
Setup Instructions
250 EXC 2016
Setup Instructions
250 EXC 2018
Owner’s Manual
250 EXC AU 2016
Owner’s Manual
250 EXC AU 2017
Setup Instructions
250 EXC AUS
Owner’s Manual • Owner’s Manual • Repair Manual
250 EXC AUS 2010
Owner’s Manual
250 EXC AUS 2012
Setup Instructions
250 EXC AUS 2013
Setup Instructions
250 EXC AUS 2014
Setup Instructions
250 EXC EU
Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual
250 EXC EU 2010
Owner’s Manual
250 EXC EU 2012
Setup Instructions
250 EXC EU 2013
Setup Instructions
250 EXC EU 2014
Setup Instructions
250 EXC EU 2016
Owner’s Manual
250 EXC EU 2017
Setup Instructions
250 EXC Factory Edition
Owner’s Manual
250 EXC RACING 2003
Owner’s Manual
250 EXC RACING 2004
Owner’s Manual
250 EXC RACING 2005
Owner’s Manual • Owner’s Manual
250 EXC RACING 2006
Owner’s Manual
250 EXC Six Day TPI 2019
Setup Instructions
250 EXC SIX DAYS
Owner’s Manual • Owner’s Manual • Owner’s Manual
250 EXC SIX DAYS 2008
Owner’s Manual
250 EXC Six Days 2015
Setup Instructions
250 EXC Six days EU
Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual
250 EXC SIX DAYS EU 2010
Owner’s Manual
250 EXC SIX DAYS EU 2012
Setup Instructions
250 EXC SIX DAYS EU 2013
Setup Instructions
250 EXC SIX DAYS EU 2014
Setup Instructions
250 EXC Six Days EU 2016
Owner’s Manual
250 EXC Six Days EU 2017
Setup Instructions
250 EXC Six Days TPI
Owner’s Manual
250 EXC Six Days TPI 2019
Repair Manual
250 EXC Six Days TPI 2020
Owner’s Manual
250 EXC Six Days TPI EU 2018
Setup Instructions
250 EXC SIX DAYS TPI EU 2021
Setup Instructions
250 EXC TPI
Owner’s Manual
250 EXC TPI 2019
Repair Manual • Setup Instructions
250 EXC TPI 2020
Owner’s Manual
250 EXC TPI EU 2018
Setup Instructions
250 EXC TPI EU 2021
Setup Instructions
250 EXC-F 2017
Owner’s Manual
250 EXC-F 2018
Setup Instructions
250 EXC-F 2019
Setup Instructions
250 EXC-F AR 2019
Setup Instructions
250 EXC-F AU 2017
Owner’s Manual
250 EXC-F AU 2018
Owner’s Manual • Setup Instructions
250 EXC-F AU 2019
Setup Instructions
250 EXC-F AUS
Owenrs Manual • Owner’s Manual • Owner’s Manual
250 EXC-F AUS 2012
Setup Instructions
250 EXC-F BR 2017
Owner’s Manual
250 EXC-F BR 2018
Owner’s Manual • Setup Instructions
250 EXC-F BR 2019
Setup Instructions
250 EXC-F EU
Owenrs Manual • Owner’s Manual • Owner’s Manual • Setup Instructions
250 EXC-F EU 2010
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
250 EXC-F EU 2012
Setup Instructions
250 EXC-F EU 2015
Setup Instructions
250 EXC-F EU 2017
Owner’s Manual
250 EXC-F EU 2018
Owner’s Manual • Setup Instructions
250 EXC-F EU 2019
Setup Instructions
250 EXC-F Factory Edition
Owner’s Manual
250 EXC-F Factory Edition EU
Owner’s Manual
250 EXC-F Six Days
Owner’s Manual • Owner’s Manual
250 EXC-F Six Days 2018
Setup Instructions
250 EXC-F Six Days 2019
Setup Instructions
250 EXC-F Six Days EU
Owenrs Manual • Owner’s Manual • Setup Instructions
250 EXC-F SIX DAYS EU 2012
Setup Instructions
250 EXC-F SIX DAYS EU 2015
Setup Instructions
250 EXC-F Six Days EU 2017
Owner’s Manual
250 EXC-F Six Days EU 2018
Owner’s Manual • Setup Instructions
250 EXC-F Six Days EU 2019
Setup Instructions
250 EXC-F SIX DAYS EY
Owner’s Manual
250 EXC-F US 2018
Setup Instructions
250 EXC-F US 2019
Setup Instructions
250 EXC-W USA
Owner’s Manual • Owner’s Manual
250 MXC
Repair Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual
250 MXC 2001
Owner’s Handbook Manual
250 SC
Owner’s Manual
250 SC-F USA
Owner’s Manual
250 sc-f usa 2014
Owner’s Manual
250 scf 2016
Repair Manual
250 SX
Repair Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Setup Instructions • Owner’s Manual
250 SX 2019
Owner’s Manual
250 SX 2001
Owner’s Handbook Manual
250 SX 2004
Owner’s Manual
250 SX 2006
Owner’s Manual
250 SX 2007
Owner’s Manual
250 SX 2008
Owner’s Manual
250 SX 2010
Owner’s Manual • Owner’s Manual
250 SX 2011
Setup Instructions
250 SX 2016
Setup Instructions
250 SX 2017
Setup Instructions
250 SX EU
Owner’s Manual • Owner’s Manual • Setup Instructions
250 SX EU 2013
Setup Instructions
250 SX EU 2015
Owner’s Manual
250 SX EU 2017
Setup Instructions
250 SX Series
Setup Instructions
250 SX US
Setup Instructions
250 SX US 2015
Owner’s Manual
250 SX US 2017
Setup Instructions
250 SX USA 2013
Setup Instructions
250 SX-F
Owner’s Manual • Owner’s Manual • Setup Instructions
250 SX-F 2006
Owner’s Manual • Repair Manual • Repair Manual
250 SX-F 2007
Owner’s Manual • Repair Manual
250 sx-f 2011
Repair Manual
250 SX-F 2016
Owner’s Manual
250 SX-F EU
Owenrs Manual • Owner’s Manual • Owner’s Manual • Setup Instructions
250 SX-F EU 2010
Owner’s Manual
250 SX-F EU 2012
Owner’s Manual • Owner’s Manual
250 sx-f eu 2014
Owner’s Manual
250 sx-f Musquin replica 2011
Repair Manual
250 SX-F ROCKZEN REPLICA EU 2012
Owner’s Manual
250 SX-F Roczen Replica EU
Owner’s Manual
250 SX-F ROCZEN REPLICA EU 2012
Owner’s Manual
250 SX-F US
Owner’s Manual
250 SX-F USA
Owenrs Manual • Owner’s Manual • Owner’s Manual
250 SX-F USA 2010
Owner’s Manual
250 SX-F USA 2012
Owner’s Manual • Owner’s Manual
250 sx-f usa 2014
Owner’s Manual
250 SX-FUSA
Owner’s Handbook Manual • Setup Instructions • Setup Instructions
250 sxf 2016
Repair Manual
250 SXF2012
Owner’s Manual
250 XC
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
250 XC 2006
Owner’s Manual
250 XC 2008
Owner’s Manual
250 XC 2016
Setup Instructions
250 XC 2017
Setup Instructions
250 XC 2019
Owner’s Manual
250 XC EU
Owner’s Manual
250 XC EU 2011
Setup Instructions
250 XC EU 2015
Owner’s Manual
250 XC EU/USA 2010
Owner’s Manual • Owner’s Manual
250 XC Series
Setup Instructions
250 XC TPI
Owner’s Manual
250 XC US
Setup Instructions
250 XC US 2015
Owner’s Manual
250 XC US 2017
Setup Instructions
250 XC USA
Owner’s Manual
250 XC USA 2011
Setup Instructions
250 XC-F 2007
Owner’s Manual • Repair Manual
250 xc-f 2011
Repair Manual
250 XC-F 2016
Owner’s Manual
250 XC-F AU 2015
Setup Instructions
250 XC-F EU
Owner’s Manual
250 XC-F EU 2012
Owner’s Manual
250 XC-F USA
Owenrs Manual • Owner’s Manual
250 XC-F USA 2012
Owner’s Manual
250 XC-F, XCF-W, EXC-F, 400 XC-W, EXC RACING, 450 XC, XC-W, EXC RACING, 525 XC, XC-W, EXC RACING, 525 XC DESERT RACING
Owner’s Manual
250 XC-W
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual
250 XC-W 2006
Owner’s Manual
250 XC-W 2008
Owner’s Manual
250 XC-W 2015
Setup Instructions
250 XC-W 2016
Setup Instructions
250 XC-W 2018
Owner’s Manual
250 XC-W TPI
Owner’s Manual
250 XC-W TPI 2019
Repair Manual • Setup Instructions
250 XC-W TPI 2020
Owner’s Manual
250 XC-W TPI US 2018
Setup Instructions
250 XC-W TPI US 2021
Setup Instructions
250 XC-W US 2016
Owner’s Manual
250 XC-W US 2017
Setup Instructions
250 XC-W USA 2012
Setup Instructions
250 XC-W USA 2013
Setup Instructions
250 XC-W USA 2014
Setup Instructions
250 XC?W USA 2010
Owner’s Manual
250 XCF-W 2007
Owner’s Manual • Repair Manual
250 XCF-W Six Days USA
Owner’s Manual
250 XCF-W US 2015
Setup Instructions
250 XCF-W USA
Owenrs Manual
250 XCF-W USA 2012
Setup Instructions
250 XCF-W ZA
Owenrs Manual
250 XCF-W ZA 2010
Owner’s Manual • Owner’s Manual • Owner’s Manual
250egs
Owner’s Manual • Manual • Owner’s Handbook Manual
250EXC 2004
Owner’s Manual
25370313211
Owner’s Manual
3
300
Owner’s Handbook Manual
300 ECX BR 2015
Setup Instructions
300 EXC
Repair Manual • Owner’s Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual • Owner’s Manual
300 EXC 2001
Owner’s Handbook Manual
300 EXC 2004
Owner’s Manual
300 EXC 2006
Owner’s Manual
300 EXC 2015
Setup Instructions
300 EXC 2016
Setup Instructions
300 EXC 2018
Owner’s Manual
300 EXC AU 2016
Owner’s Manual
300 EXC AU 2017
Setup Instructions
300 EXC AUS
Owner’s Manual • Owner’s Manual • Repair Manual
300 EXC AUS 2010
Owner’s Manual
300 EXC AUS 2012
Setup Instructions
300 EXC AUS 2013
Setup Instructions
300 EXC AUS 2014
Setup Instructions
300 EXC BR 2016
Owner’s Manual
300 EXC BR 2017
Setup Instructions
300 EXC Erzberg Edition TPI
Owner’s Manual
300 EXC EU 2010
Owner’s Manual
300 EXC EU 2012
Setup Instructions
300 EXC EU 2013
Setup Instructions
300 EXC EU 2014
Setup Instructions
300 EXC EU 2016
Owner’s Manual
300 EXC EU 2017
Setup Instructions
300 EXC Factory Edition
Owner’s Manual
300 EXC Six Day TPI 2019
Setup Instructions
300 EXC SIX DAYS
Owner’s Manual • Owner’s Manual • Owner’s Manual
300 EXC Six Days 2015
Setup Instructions
300 EXC Six days eu
Owner’s Manual • Owner’s Manual • Repair Manual
300 EXC SIX DAYS EU 2010
Owner’s Manual
300 EXC SIX DAYS EU 2013
Setup Instructions
300 EXC SIX DAYS EU 2014
Setup Instructions
300 EXC Six Days EU 2016
Owner’s Manual
300 EXC Six Days EU 2017
Setup Instructions
300 EXC Six Days TPI
Owner’s Manual
300 EXC Six Days TPI 2019
Repair Manual
300 EXC Six Days TPI 2020
Owner’s Manual
300 EXC SIX DAYS TPI CN
Setup Instructions
300 EXC Six Days TPI EU 2018
Setup Instructions
300 EXC SIX DAYS TPI EU 2021
Setup Instructions
300 EXC TPI
Owner’s Manual
300 EXC TPI 2019
Repair Manual • Setup Instructions
300 EXC TPI 2020
Owner’s Manual
300 EXC TPI ERZBERGRODED EU 2021
Setup Instructions
300 EXC TPI ERZBERGRODEO 2020
Owner’s Manual
300 EXC TPI EU 2018
Setup Instructions
300 EXC TPI EU 2021
Setup Instructions
300 EXC-E SIX DAYS 2008
Owner’s Manual
300 EXS SIX DAYS EU 2012
Setup Instructions
300 MXC
Repair Manual • Owner’s Manual • Spare Parts Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual • Owner’s Manual
300 MXC 2001
Owner’s Handbook Manual
300 MXC 2004
Owner’s Manual
300 SC
Owner’s Manual
300 SX
Repair Manual • Owner’s Handbook Manual • Owner’s Handbook Manual • Owner’s Manual
300 SX 2001
Owner’s Handbook Manual
300 XC 2006
Owner’s Manual
300 XC 2008
Owner’s Manual
300 XC 2016
Setup Instructions
300 XC 2017
Setup Instructions
300 XC 2019
Owner’s Manual
300 XC EU
Owner’s Manual
300 XC EU 2011
Setup Instructions
300 XC EU 2013
Setup Instructions
300 XC EU 2015
Owner’s Manual
300 XC EU/USA
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
300 XC Series
Setup Instructions
300 XC TPI
Owner’s Manual
300 XC US
Setup Instructions
300 XC US 2015
Owner’s Manual
300 XC US 2017
Setup Instructions
300 XC USA
Owner’s Manual
300 XC USA 2011
Setup Instructions
300 XC USA 2013
Setup Instructions
300 XC-W
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual
300 XC-W 2006
Owner’s Manual
300 XC-W 2008
Owner’s Manual
300 XC-W 2015
Setup Instructions
300 XC-W 2016
Setup Instructions
300 XC-W 2018
Owner’s Manual
300 XC-W Six Day 2018
Owner’s Manual
300 XC-W Six Day TPI 2019
Setup Instructions
300 XC-W Six Days
Owner’s Manual • Owner’s Manual
300 XC-W Six Days 2015
Setup Instructions
300 XC-W Six Days TPI
Owner’s Manual
300 XC-W Six Days TPI 2019
Repair Manual
300 XC-W Six Days TPI 2020
Owner’s Manual
300 XC-W Six Days US 2016
Owner’s Manual
300 XC-W Six Days US 2017
Setup Instructions
300 XC-W SIX DAYS USA
Owner’s Manual • Repair Manual
300 XC-W SIX DAYS USA 2014
Setup Instructions
300 XC-W TPI
Owner’s Manual
300 XC-W TPI 2019
Repair Manual • Setup Instructions
300 XC-W TPI 2020
Owner’s Manual
300 XC-W TPI ERZBERGRODEO 2020
Owner’s Manual
300 XC-W TPI ERZBERGRODEO US 2021
Setup Instructions
300 XC-W TPI US 2021
Setup Instructions
300 XC-W US 2016
Owner’s Manual
300 XC-W US 2017
Setup Instructions
300 XC-W USA 2012
Setup Instructions
300 XC-W USA 2013
Setup Instructions
300 XC-W USA 2014
Setup Instructions
300 XC?W USA 2010
Owner’s Manual
300egs
Owner’s Manual • Manual • Owner’s Handbook Manual
3200 XC
Owner’s Manual
3213432
Setup Instructions
3213887en
Instruction Manual
3214300
Owner’s Manual
3214400en
Setup Instructions
3214445
Setup Instructions
350 EFC-F AUS
Owner’s Manual
350 EXC-F 2015
Owner’s Manual
350 EXC-F 2017
Owner’s Manual • Setup Instructions
350 EXC-F 2018
Owner’s Manual
350 EXC-F 2022
Owner’s Manual
350 EXC-F AU 2015
Setup Instructions
350 EXC-F AU 2018
Owner’s Manual
350 EXC-F AU 2019
Setup Instructions
350 EXC-F AUS
Owner’s Manual
350 EXC-F AUS 2012
Repair Manual
350 EXC-F AUS 2014
Setup Instructions
350 EXC-F BR 2018
Owner’s Manual
350 EXC-F BR 2019
Setup Instructions
350 EXC-F EU 2012
Repair Manual
350 EXC-F EU 2014
Setup Instructions
350 EXC-F EU 2015
Setup Instructions
350 EXC-F EU 2018
Owner’s Manual
350 EXC-F EU 2019
Setup Instructions
350 EXC-F Six Days 2017
Setup Instructions
350 EXC-F Six Days 2018
Owner’s Manual
350 EXC-F Six Days BR 2018
Owner’s Manual
350 EXC-F Six Days BR 2019
Setup Instructions
350 EXC-F SIX DAYS EU
Owner’s Manual • Owner’s Manual • Repair Manual • Owner’s Manual • Owner’s Manual • Setup Instructions
350 EXC-F SIX DAYS EU 2012
Repair Manual
350 EXC-F SIX DAYS EU 2014
Setup Instructions
350 EXC-F SIX DAYS EU 2015
Setup Instructions
350 EXC-F Six Days EU 2018
Owner’s Manual
350 EXC-F Six Days EU 2019
Setup Instructions
350 EXC-F US 2015
Setup Instructions
350 EXC-F US 2019
Setup Instructions
350 EXC-F US 2022
Owner’s Manual
350 EXC-F USA 2012
Repair Manual
350 EXC-F USA 2014
Setup Instructions
350 EXC-F WESS
Setup Instructions
350 EXC-Factory Edition
Owner’s Manual
350 SC-F
Owner’s Manual
350 SX-F 2011
Owner’s Manual
350 SX-F 2012
Owner’s Manual
350 SX-F 2013
Owner’s Manual
350 SX-F 2016
Setup Instructions
350 SX-F 2017
Setup Instructions
350 SX-F Cairoli replica
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Setup Instructions
350 SX-F Cairoli Replica 2011
Owner’s Manual
350 SX-F EU 2011
Setup Instructions
350 SX-F EU 2017
Setup Instructions
350 SX-F US 2017
Setup Instructions
350 SX-F USA 2011
Setup Instructions
350 XC-F
Owner’s Manual • Owner’s Manual • Setup Instructions
350 XC-F 2012
Owner’s Manual
350 XC-F 2013
Owner’s Manual
350 XC-F 2016
Setup Instructions
350 XC-F 2017
Setup Instructions
350 XC-F US 2017
Setup Instructions
350 XC-F USA 2011
Setup Instructions
350 XCF-W SIX DAYS US 2015
Setup Instructions
350 XCF-W SIX DAYS USA 2014
Setup Instructions
350 XCF-W US 2015
Setup Instructions
350 XCF-W USA
Owner’s Manual • Owner’s Manual • Repair Manual • Owner’s Manual • Owner’s Manual • Setup Instructions
350 XCF-W USA 2012
Repair Manual
350 XCF-W USA 2014
Setup Instructions
380 EXC
Repair Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual
380 EXC 2001
Owner’s Handbook Manual
380 MXC
Repair Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual
380 MXC 2001
Owner’s Handbook Manual
380 SX
Repair Manual • Owner’s Handbook Manual • Owner’s Manual • Owner’s Handbook Manual
380 SX 2001
Owner’s Handbook Manual
380EGS
Owner’s Manual • Owner’s Handbook Manual
390 Adventure 2020
Owner’s Manual
390 ADVENTURE 2022
Setup Instructions
390 ADVENTURE AR 2022
Setup Instructions
390 ADVENTURE ASEAN 2022
Setup Instructions
390 ADVENTURE B.D. 2 EU 2022
Setup Instructions
390 ADVENTURE B.D. EU 2022
Setup Instructions
390 ADVENTURE CN 2022
Setup Instructions
390 ADVENTURE CO 2022
Setup Instructions
390 ADVENTURE EU 2022
Setup Instructions
390 ADVENTURE JP 2022
Setup Instructions
390 ADVENTURE PH 2022
Setup Instructions
390 ADVENTURE UK 2022
Setup Instructions
390 ADVENTURE US 2022
Setup Instructions
390 Duke 2014 COL 2013
Repair Manual
390 Duke 2015 COL
Owner’s Manual • Installation Instructions Manual • Owner’s Manual • Setup Instructions • Setup Instructions
390 DUKE 2017
Owner’s Manual
390 Duke AR
Owner’s Manual • Setup Instructions
390 Duke AR 2018
Setup Instructions
390 Duke AR 2019
Owner’s Manual
390 Duke ASIA
Setup Instructions
390 Duke AU
Owner’s Manual • Setup Instructions
390 Duke AU 2018
Setup Instructions
390 Duke AU 2019
Owner’s Manual
390 Duke AUS 2013
Repair Manual
390 DUKE B.D. 2 EU
Owner’s Manual
390 DUKE B.D. 3 EU
Owner’s Manual
390 DUKE B.D. EU
Owner’s Manual
390 Duke B.D. EU 2019
Owner’s Manual
390 DUKE BR
Owner’s Manual
390 Duke BR 2018
Setup Instructions
390 Duke BR 2019
Owner’s Manual
390 Duke CN
Owner’s Manual • Setup Instructions
390 Duke CN 2018
Setup Instructions
390 Duke CN 2019
Owner’s Manual
390 DUKE CO
Owner’s Manual
390 Duke CO 2018
Setup Instructions
390 Duke CO 2019
Owner’s Manual
390 Duke EU
Owner’s Manual • Setup Instructions
390 Duke EU 2013
Repair Manual
390 Duke EU 2018
Setup Instructions
390 Duke EU 2019
Owner’s Manual
390 Duke JP
Owner’s Manual • Setup Instructions
390 Duke JP 2018
Setup Instructions
390 Duke JP 2019
Owner’s Manual
390 Duke MAL 2013
Repair Manual
390 Duke MY
Owner’s Manual • Setup Instructions
390 Duke MY 2018
Setup Instructions
390 Duke MY 2019
Owner’s Manual
390 DUKE PH
Owner’s Manual
390 Duke PH 2018
Setup Instructions
390 Duke PH 2019
Owner’s Manual
390 Duke Series 2018
Setup Instructions
390 Duke Series 2019
Owner’s Manual
390 DUKE TH
Owner’s Manual
390 Duke TH 2018
Setup Instructions
390 Duke TH 2019
Owner’s Manual
390 Duke US
Setup Instructions
390 Duke US 2018
Setup Instructions
3CF6001G4EN
Manual
4
400 EGS
Owner’s Handbook Manual
400 EXC AUS
Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions
400 EXC AUS 2009
Setup Instructions
400 EXC AUS 2010
Owner’s Manual
400 EXC AUS 2011
Repair Manual • Setup Instructions
400 EXC EU 2009
Repair Manual • Setup Instructions
400 EXC EU 2010
Owner’s Manual
400 EXC EU 2011
Repair Manual • Setup Instructions
400 EXC FACTORY EDITION EU
Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions
400 EXC RACING
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual
400 EXC RACING 2000
Owner’s Handbook Manual
400 EXC RACING 2005
Owner’s Manual • Owner’s Manual
400 EXC RACING 2006
Owner’s Manual
400 EXC RACING 2007
Owner’s Manual
400 LC4-E
Owner’s Handbook Manual
400 LC4-E 2001
Owner’s Handbook Manual
400 LC4R
Owner’s Handbook Manual
400 LS-E/MIL
Owner’s Handbook Manual • Owner’s Handbook Manual • Owner’s Handbook Manual • Owner’s Manual
400 SC
Owner’s Handbook Manual
400 SX RACING 2000
Owner’s Handbook Manual • Owner’s Handbook Manual
400 SXC 1999
Owner’s Handbook Manual
400 XC-W 2007
Owner’s Manual
400 XC-W USA
Repair Manual • Setup Instructions
400 XC-W USA 2009
Repair Manual • Setup Instructions
400 XC-W USA 2010
Owner’s Manual • Owner’s Manual
400LC4
Owner’s Handbook Manual
450 ECX
Owner’s Manual
450 ESC USA 2011
Setup Instructions
450 EX-W AUS
Owner’s Manual
450 EX-W EU
Owner’s Manual
450 EXC 2003
Owner’s Manual
450 EXC AUS
Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions
450 EXC AUS 2009
Repair Manual • Setup Instructions
450 EXC AUS 2010
Owner’s Manual
450 EXC AUS 2011
Repair Manual • Setup Instructions
450 EXC AUS 2013
Repair Manual • Setup Instructions
450 EXC Champions EU
Setup Instructions
450 EXC Champions USA
Setup Instructions
450 EXC DAYS EU 2011
Setup Instructions
450 EXC EU
Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions
450 EXC EU 2009
Repair Manual • Setup Instructions
450 EXC EU 2010
Owner’s Manual
450 EXC EU 2011
Repair Manual • Setup Instructions
450 EXC EU 2013
Repair Manual • Setup Instructions
450 EXC RACING
Owner’s Manual
450 EXC RACING 2005
Owner’s Manual • Owner’s Manual
450 EXC RACING 2006
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Setup Instructions
450 EXC RACING 2007
Owner’s Manual
450 EXC SIX DAYS
Owner’s Manual • Setup Instructions
450 EXC SIX DAYS 2013
Owner’s Manual
450 EXC SIX DAYS EU
Owner’s Manual • Owner’s Manual • Owner’s Manual • Owner’s Manual • Repair Manual • Setup Instructions
450 EXC SIX DAYS EU 2009
Repair Manual • Setup Instructions
450 EXC SIX DAYS EU 2010
Owner’s Manual
450 EXC SIX DAYS EU 2011
Repair Manual
450 EXC SIX DAYS EU 2013
Repair Manual • Setup Instructions
450 EXC USA
Repair Manual • Setup Instructions
450 EXC USA 2009
Repair Manual • Setup Instructions
450 EXC USA 2011
Repair Manual
450 EXC-F 2020
Owner’s Manual • Setup Instructions
450 EXC-F 2022
Setup Instructions
450 EXC-F EU 2022
Setup Instructions
450 EXC-F SIX DAYS 2022
Setup Instructions
450 EXC-F SIX DAYS EU 2022
Setup Instructions
450 EXC-R AUS/UK
Repair Manual
450 EXC-R AUS/UK 2008
Owner’s Manual
450 EXC-R EU
Owner’s Manual • Repair Manual
Pages:
- 0-999
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1000-1999
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Сборник руководств (92 штуки) на английском языке по эксплуатации и техническому обслуживанию мотоциклов KTM 2000-2014 годов выпуска.
- Издательство: KTM-Sportmotocycle AG
- Год издания: 1999-2013
- Страниц: —
- Формат: PDF
- Размер: 341,5 Mb
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- Издательство: KTM-Sportmotocycle AG
- Год издания: 2007
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Руководство на английском языке по ремонту двигателя мотоциклов KTM 250 SX.
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- Размер: 2,7 Mb
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- Размер: 7,3 Mb
Руководство на английском языке по ремонту двигателей мотоциклов KTM 250/300 SX/SXS/MXC/EXC/EXC Six Days/XC/XC-W 2004-2006 годов выпуска.
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Руководство на английском языке по ремонту двигателей мотоциклов KTM 250/300/380 EXC, MXC, SX.
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Руководство на английском языке по ремонту двигателей мотоциклов KTM 250 EXC Racing, 400/450 SX, MXC, XC, EXC, SMR, SXS Racing, 520/525 SX, MXC, XC, EXC, SMR Racing, 540 SXS, 560 SMR, 640 Crate 2000-2006 годов выпуска.
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Руководство на немецком языке по ремонту двигателей KTM 400/620 LC4/LC4e 1997 года выпуска.
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В руководстве представлена информация об устройстве и работе всех узлов и агрегатов мотоцикла.
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- Год издания: —
- Страниц: 220
- Формат: —
- Размер: —
В данном разделе вы можете скачать инструкции по эксплуатации для техники KTM в формате pdf.
Нажмите на ссылку с названием нужного мотоцикла, и вы будете перенаправлены на страницу для скачивания файла.
Для вашего удобства все модели рассортированы по годам выпуска, с 2012 по 2019.
2012
200 Duke
250 EXC-F
350 EXC-F
450/500 EXC
690 DUKE
690 ENDURO R
690 SMC R
2013
125/300 EXC
250 EXC-F
350 EXC-F
350 FREERIDE
390 DUKE
500 EXC
690 DUKE R
1190 ADVENTURE
1190 ADVENTURE R
2014
250 FREERIDE
50 SX
65 SX
85 SX
250 SX-F
350 SX-F
450 SX-F
690 ENDURO R
690 SMC R
1190 ADVENTURE
1290 SUPERDUKE R
125/300 EXC
350 EXC-F
450/500 EXC
2015
1290 SUPER ADVENTURE
RC200
RC390
2016
250 SX-F
350 SX-F
450 SX-F
690 DUKE
2017
125-250 SX
250 DUKE
250 EXC-F
250-300 EXC/125-300 XC-W
350 EXC-F
390 DUKE
450-500 EXC-F
1090 ADVENTURE
1090 ADVENTURE R
1290 ADVENTURE R
1290 ADVENTURE S
1290 ADVENTURE T
1290 SUPER DUKE GT
1290 SUPER DUKE R
RC 390
2018
250-300 EXC
2019
690 ENDURO R
690 SMC R
790 ADVENTURE R
790 ADVENTURE
790 DUKE
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Contents
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Table of Contents
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Troubleshooting
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Bookmarks
Quick Links
250/300/380 SX,MXC,EXC
REPAIR MANUAL
ENGINE
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at
Related Manuals for KTM EXC
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Motorcycle KTM 125 EXC, EXC SIX DAYS, 200 XC, XC-W, EXC, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, XC-W, EXC-E, EXC-E SIX DAYS Owner’s Manual
Ktm owner’s manual motorcycle 125 exc, exc six days 200 xc, xc-w, exc 250 xc, xc-w, exc, exc six days 300 xc, xc-w, exc-e, exc-e six days (74 pages)
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Summary of Contents for KTM EXC
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Page 1
250/300/380 SX,MXC,EXC REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.at… -
Page 3
250 — 380 SX,MXC,EXC REPAIR MANUAL ENGINE… -
Page 5: Table Of Contents
1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS…
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Page 7
5-13 to 5-14 10-1 11-1 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 (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -
Page 9
3.206.004-E Updating of Rep.Manual 3.205.63-E Modelyear 2003 (Engine number with first digit “3“) Modification / Updating: Technical Specification, Periodic Maintenance Schedule, Wiring Diagrams P D AT I N G 250 / 300 / 380 SX, MXC, EXC 11/1998 2/2000 3/2001 11/2002 Edition 11/2002… -
Page 11
„NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an on going total reengineered quality plan for a brighter tomorrow. -
Page 13
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –… -
Page 14: Table Of Contents
2-1C GENERAL INFORMATION INDEX OPERATING RANGES OF THE CARBURETOR ….2-2 CARBURETOR ADJUSTMENT ……2-3 CHECKING OF THE SETTING OF THE TVC SYSTEM .
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Page 16: Operating Ranges Of The Carburetor
OPERATING RANGES OF THE CARBURETOR mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve. This range is influenced by the position of the air control screw .
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Page 17: Carburetor Adjustment
2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 –…
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Page 18: Bleeding Of The Hydraulic Clutch
Make sure that the oil does not overflow. CAUTION – H AVING COMPLETED THE BLEEDING PROCEDURE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT – KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS – A…
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Page 19: Special Tools — Engine
2-5C SPECIAL TOOLS – ENGINE Fig. Part no. 560.12.001.000 546.29.003.000 560.12.004.000 546.29.009.044 6 276 807 510.12.011.000 544.12.012.000 584.29.037.040 584.29.037.043 510.12.016.000 546.29.012.100 501.12.013.000 501.12.030.000 6 899 785 151.12.017.000 151.12.018.100 151.12.018.000 151.12.018.200 546.29.027.000 0276 179 000 503.29.050.000 250 / 300 / 380 Description Universal engine work stand Clutch holder…
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Page 20: Cleaning
Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. EVER CLEAN YOUR MOTORCYCLE WITH A HIGH ELECTRICAL COMPONENTS CONNECTORS…
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Page 22: Removing And Refitting Engine
3-1C REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ……. . .3-2 REFITTING THE ENGINE .
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Page 24
3-2C 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. – Dismount engine strut –… -
Page 25
3-3C – Loosen the 3 screws, and remove intermediate flange chamber KTC system together with O-ring. – Remove engine fastening screw – Remove cable ties and loose the cable of ignition from frame. – Loosen both hose clamps, and pull caburetor out of carburetor connection boot and intake flange. -
Page 26
Refitting the engine – To install the engine, reverse the steps for removing the engine. Filling in of transmission oil: – Remove the plug and top up with engine oil 15W-50 (i. e. MOTOREX TOP SPEED 4T). – In order to check the transmission oil level the control screw clutch cover is to be removed. -
Page 28: Disassembling The Engine
4-1C DISASSEMBLING THE ENGINE INDEX DRAINING GEAR OIL ……..4-2 DISMOUNTING OF SPROCKET AND SHIFT LEVER .
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Page 30
– Cleaning the engine thoroughly. – Clamp the engine into the workstand. – Remove the kickstarter together with the distance bushing behind. Draining gear oil NOTE: The transmission oil should already be drained when the engine is dismounted. Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch. -
Page 31
4-3C – Undo the screws and remove the right control cover. – Remove the securing clip of the ball socket socket from the adjusting lever. – Remove gasket of the control cover. – Remove the 4 collar nuts – Cover the crankcase. –… -
Page 32
Dismounting of pressure cap and clutch discs – Loosen collar screws wedging of discs as springs expand. – Remove collar screws, springs and spring retainers. – Take pressure cap and disc package out of outer clutch hub. – Take thrust bearing off the drive shaft. -
Page 33
4-5C Dismounting of kickstarter – Remove circlip – Carefully release collar screw tension on kickstarter spring and unhook spring hanger. AREFULLY RELEASE THE KICKSTARTER SPRING – Take the complete kickstarter shaft out of the housing. – Take care of the stop disc, which could stay in the housing. Dismounting of the shift lock –… -
Page 34
Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel. – Undo the 3 screws and remove the stator together with the base plate. -
Page 35
4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws – 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. –… -
Page 36
– 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 driving pins of the shift forks. They may remain in the shift roller. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. -
Page 37: Table Of Contents
SERVICING ON INDIVIDUAL COMPONENTS WORKING ON THE RIGHT-HAND HOUSING HALF ….5-2 WORKING ON THE LEFT-HAND HOUSING HALF ….5-3 CRANKSHAFT .
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Page 39
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 Press old grooved ball-bearing inwards. Press in new ball bearing to the stop. -
Page 40
5-3C 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 Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside). -
Page 41: Crankshaft
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 tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft.
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Page 42: Checking Cylinder For Wear
5-5C 10mm Checking cylinder for wear Measure diameter of cylinder approx. 10 mm (0.4 in.) below top of cylinder edge. Check diameter in several corresponding places to see if cylinder in worn oval. Engine Cylinder Ø 67,500 — 67,512 67,513 — 67,525 72,000 — 72,012 72,013 — 72,025 78,000 — 78,012…
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Page 43: Cylinder Preassembly
only 250 Cylinder exhaust control system Dismantle and clean all exhaust control components, check for signs of wear and damage. Control rollers – Check clearance of bearings. Remove oil-derived deposits. Check toothing of control rollers for signs of wear. Gear segments –…
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Page 44
5-7C – Mount and grease silicon O-rings (15×1,50 mm) – Slightly grease the bearing sleeves – Mount toothed segments (the toothed segment with the cylindrical pin has to be mounted on the right side). – On the right-hand side, mount bearing bushing spring with short leg on outside and spring sleeve –… -
Page 45: Exhaust Control, Clutch Cover
LOCTITE 243 LOCTITE 243 Exhaust control, clutch cover – Remove screws and take off the bearing support. – Take cup tappet , adjusting spring clutch cover. – Take off water pump cover, remove allen head screw water pump wheel – The centrifugal timer can be pulled out of the bearing.
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Page 46: Reed Valve Housing, Intake Flange
5-9C Reed valve housing, intake flange NOTE: Reed paddles gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced. If the reed sealing surfaces of the reed valve housing are also damaged, replace the complete reed valve housing. CAUTION 243.
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Page 47
5-10C 13,5 mm LOCTITE 242 Clutch Thrust bearing check for wear Push rod Check for wear. Minimum length: 199 mm (new: 199.80 mm) Clutch springs New spring length 42,5 mm / 1.7 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable. 9 Lining discs Minimum thickness 2.60 mm (0.102 in) / new disc 2.70 mm (0.106 in). -
Page 48: Replace Outer Clutch Hub
5-11C Replace outer clutch hub – Drill open the clutch rivets remove parts. – Check 8 absorbing elements replace all 8 where applicable. HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN THAT THE OUTER CLUTCH HUB ON THE PRIMARY GEAR CROWN TENSION WITH THE CLUTCH RIVETTING TOOL in area of retaining bracket for signs of mechanical damage,…
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Page 49: Shift Mechanism
LOCTITE 243 LOCTITE 243 0,40 — 0,80 mm LOCTITE 243 Shift mechanism Shift forks Check shift fork blades and shift roller driving pin Shift roller Check shift grooves for wear. Check position of shift roller in grooved ball bearings Slide plate Check slide plate at meshing points Check return surface for wear (renew, if strongly notched).
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Page 50: Ignition (Kokusan)
5-13C Kokusan 2K-1/2K-4 Kokusan 2K-2 Kokusan 2K-3 Ignition (Kokusan) General information The measurements described below will only reveal severe problems. Coil short 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 cables and the plug and socket connections of the ignition system first.
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Page 51: Ignition (Sem)
Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short 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 cables and the plug and socket connections of the ignition system first.
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Page 52: Assembly Mainshaft
5-15C Transmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels – Tooth faces of all gears –…
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Page 53: Assembly Countershaft
Transmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels – Tooth faces of all gears –…
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Page 54: Assemble Of Kickstarter Shaft
5-17C LOCTITE 243 LOCTITE 243 Kickstarter Starter gear Check clearance of starter gear. Starter intermediate gear Check clearance of starter intermediate gear. Locking pawl Check for signs of wear and damage. Kickstarter shaft Check for signs of wear and damage. For changing the locking pawl, press bearing needle kickstarter shaft.
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Page 55: Table Of Contents
6-1C ASSEMBLING THE ENGINE INDEX CRANKSHAFT ………6-2 TRANSMISSION .
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Page 57
– 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. HEN PUSHING IN CRANKSHAFT Transmission – Grease the driving pins of the shift forks and mount the shift rollers –… -
Page 58: Assembling The Engine Housing
6-3C M6 x … – Fix the 4 pressure springs gearshift rails. – Oil gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft). Insert gearshift rails into the casing bores as far as they will go. NOTE: It must now be possible to gently turn gear shafts.
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Page 59: Mounting Shift Mechanism
Mounting shift mechanism – Place locating spring with bent leg upwards into engine housing. – Insert collar sleeve into spring with collar upwards. – Coat collar screw – Insert locating lever screw. – Hook locking spring must abut the casing nose –…
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Page 60: Mount Primary Drive And Clutch
6-5C Mount primary drive and clutch – Grease crankshaft seal ring. – Put the oiled O-ring (25×1.50 mm) onto the crankshaft and mount the distance bushing with the chamfer facing the crank web. – Insert woodruff key into crankshaft. – Place primary gear –…
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Page 61: Mounting Clutch Discs And Pressure Cap
M6x … Mounting clutch discs and pressure cap – Oil the thrust bearing , and slide it over the drive shaft. – Oil lining discs before mounting. – Beginning with one lining disc, mount alternately 9 lining discs ( 2.70 mm / 0.10 in) and 8 intermediate discs ( 1.20 mm / 0.047 in), with a lining disc forming the final layer upwards.
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Page 62: Mounting Piston And Cylinder
6-7C 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).
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Page 63
control flap Adjusting control flap (dimension “Z“) Note: Dimension “Z“ is the distance from the lower edge of the control flap to the upper edge of the cylinder, as measured in the centre of the exhaust port. 250 Model 1999 : 48,0 mm 250 Model 2000 : 50,5 mm 250 ab Model 2001 : 49,5 mm 300 : 46,0 mm… -
Page 64: Mounting Steering Covers
6-9C Mounting steering covers – Mount the right-hand control cover – Place gasket in position and fix left-hand steering cover Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O-rings in grooves. – Mount cylinder head with water nozzle on the exhaust side. –…
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Page 65: Mounting Engine Sprocket
Mounting engine sprocket – Lubricate O-ring with oil and slide over counter shaft. – Slide distance bushing in position so that O-ring is in correct position. – Slide sprocket onto the countershaft with the collar facing inward, and fix it with the circlip (sharp edge facing outward).
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Page 66: Mounting The Ignition (Sem)
6-11C Mounting the ignition (SEM) – Insert woodruff key into crankshaft. – Apply Loctite 243 to the threads of the 3 screws – Mount base plate – Mount the cable guide – Mount the rotor. – Mount the detent edged ring and the nut. –…
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Page 67
CHECKING THE CAPACITOR (MOD. 2000) ….7-4 STATIC IGNITION VALUES 250 — 380 SX, EXC ….7-5 STATIC GENERATOR VALUES 250 — 380 EXC . -
Page 69
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 of 5000 r.p.m. and read off the voltage. -
Page 70
7-3C 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 the battery and the positive terminal of the capacitor (marked +) is made with a test lamp –… -
Page 71
Checking the voltage regulator – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor. – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage. In the case of a significant deviation from the nominal value: –… -
Page 72
7-5C STATIC IGNITION VALUES 250-380 SX, EXC (KOKUSAN 2K-1, 2K-3, 2K-4) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –… -
Page 73
7-6C 250-380 EXC 2000 S P O R T M O T O R C Y C L E S… -
Page 74
NOTE: – the black measuring lead applied to the ground. – 300/380 USA corresponds to 300/380 EXC Europe but with less accessories (blinkers, horn, no capacitor installed). Features no rectifi- cation, only an over-voltage regulation. (also see circuit diagram on opposite… -
Page 75
7-8C 250-380 EXC 2000 S P O R T M O T O R C Y C L E S… -
Page 76
7-9C STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC USA (KOKUSAN 2K-2) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –… -
Page 77
7-10C 250 EXC 2001… -
Page 79
8-1C TROUBLE SHOOTING INDEX TROUBLE SHOOTING 250 — 380 ……8-2… -
Page 81: 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 error. TROUBLE Engine fails to start Operating error…
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Page 82
8-3C TROUBLE Engine has not enough Reed paddles tensionless or dama- power ged, surface of reed valve housing damaged Wear Electronical ignition timing faulty Engine revs not high and Carburetor overflows if level adjust running with four stroke too high, float needle seating is cycle dirty or enlarged Loose carburetor jets… -
Page 83: Technical Specifications
9-1C TECHNICAL SPECIFICATIONS INDEX MODEL 1999 ENGINE 250 — 380 USA ……..9-2 ENGINE 250 — 380 .
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Page 85
9-2C… -
Page 86
60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 100 Nm (74 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.08 mm (380) 380 SX, MXC, EXC Keihin PWK 38 070598 170(168,172,175) 48(45,50) NOZ H(NOZ G,NOZ I) 1,5 Umdr. -
Page 87
9-4C… -
Page 88
100 Nm (74 ft.lb) (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 380 EGS 380 SX, MXC, EXC AUSTRALIA Keihin PWK 38 Keihin PWK 38 070598 060598 170(168,172,175) 175(168,170,172) 48(45,50) 45(48,50) NOZ H(NOZ G,NOZ I) NOZ G(NOZ H,NOZ I) 1,5 Umdr. -
Page 89
TECHNICAL SPECIFICATIONS CHASSIS 250 / 300 / 380 SX / MXC / EXC / EGS ‘99 250/380SX Frame Fork Wheel travel front/rear Rear suspension Front brake Rear brake Front tires 80/100 — 21“ 51M – Air pressure offroad 1.0 bar (14 psi) Air press. -
Page 90
9-7C… -
Page 91
9-8C… -
Page 92
9-9C… -
Page 93
9-10C… -
Page 94
10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.06 mm (300) 0.08 mm (380) 300 MXC, EXC 380 SX, MXC, EXC Keihin PWK 38 AG Keihin PWK 38 AG 140499 150499 175 (172,178) 170 (168,172) 45 (48) -
Page 95
9-12C… -
Page 96
Loctite 648 19 Nm (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 0.08 mm (380) 250/300 EXC 380 SX, MXC, EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 150499 050799 170 (168,172) -
Page 97
Rebound adjuster Spring PDS3–250 Spring preload 5 mm (0.2 in) 250/300/380 SX, MXC, EXC 2000 250/300/380 MXC Central chrome-moly-steel frame White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø… -
Page 98
9-15C 21.06.99… -
Page 99
9-16C 21.06.99… -
Page 100
9-17C 21.06.99… -
Page 101
9-18C 21.06.99… -
Page 103
9-19C… -
Page 104
Loctite 648 19 Nm (14 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 300 MXC, EXC 380 SX, MXC, EXC Keihin PWK 38 AG Keihin PWK 38 AG 050300 070300 175 (172,178) 170 (168,172) 45 (48) 45 (48) -
Page 105
9-21C… -
Page 106
Ø 2.5 new = 43 mm, minimum length = 42 mm 0.5 mm 0.5 mm as required 0.2/0.4/ 0.5 / 0.75 mm O-rings 250 EXC AUS 300 EXC AUS throttled throttled Keihin PWK 38 AG Keihin PWK 38 AG 040300… -
Page 107
Rebound adjuster Spring PDS7–265 Spring preload 5 mm (0.2 in) 250/300/380 SX, MXC, EXC 2001 250/300/380 MXC Central chrome-moly-steel frame White Power – Up Side Down 43 MA 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø… -
Page 108
9-24C… -
Page 109
9-25C… -
Page 110
9-26C… -
Page 111
9-27C… -
Page 112
9-28C… -
Page 113
35 Nm (25 ft.lb) 60 Nm (44 ft.lb) 8 Nm (6 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 380 SX, MXC, EXC Keihin PWK 38 AG 050201 170 (168,172) 45 (48) NOZ G (NOZ H) – –… -
Page 114
9-30C… -
Page 115
NOZ E (NOZ F/D) Needle position from top Slide Air adjustment screw open Performance restrictor – Power jet jet – BASIC CARBURETOR SETTING 250 EXC USA Carburetor Keihin PWK 38 AG Carburetor setting number 030201 Main jet 178 (175,180) Idling jet 45 (48) -
Page 116
Rebound adjuster Spring PDS7–260 Spring preload 4 mm (0.16 in) 250/300/380 SX, MXC, EXC 2002 250/300/380 MXC Central chrome-moly-steel frame 295/320 mm (11,3/12,6 in) WP Progressive Damping System shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Disc brake with carbon-steel brake disc Ø… -
Page 117
9-33C… -
Page 118
9-34C… -
Page 119
9-35C… -
Page 120
9-36C… -
Page 121
9-37C… -
Page 122
(6 ft.lb) 100 Nm (74 ft.lb) 10 Nm (7 ft.lb) 25 Nm (19 ft.lb) 45 Nm (33 ft.lb) 300 EXC AUS 300 MXC / EXC throttled Keihin PWK 38 AG Keihin PWK 38 AG 130202 150202 175 (172,178) 175 (172,178) -
Page 123
5 mm (0.20in) Air chamber length 110 mm (4,3 in) Fork oil SAE 5 250/300 MXC, EXC 2003 250/300 MXC Central chrome-moly-steel frame White Power – Up Side Down 48 MA 300/335 mm (11.8/13.2 in) WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Disc brake with carbon-steel brake disc Ø… -
Page 124
9-40C Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, fork stubs Collar nut, rear wheel spindle Hexagon nut, swing arm bolt Hexagon collar screw, handlebar clamp Allan head screw, handlebar support Shock absorber, top Shock absorber, bottom… -
Page 125
9-41C… -
Page 126
9-42C… -
Page 127
10-1C LUBRICATION AND MAINTENANCE SCHEDULE INDEX 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 AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE 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 for leaks and cracks Drain and clean carburetor float chamber… -
Page 131
PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE 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 for leaks and cracks Drain and clean carburetor float chamber… -
Page 132
NTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN AINTENANCE WORK DONE BY AINTENANCE ORK THAT CAN BE CARRIED OUT BY EXTRA ORDER AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER 250/300/380 SX/MXC/EXC 1. service after after after 10 hours… -
Page 133
10-5C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean fork dust bellows regulary Clean and lubricate chain, check tension and adjust if necessary… -
Page 134: Periodic Maintenance Schedule
NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN AINTENANCE WORK DONE BY AINTENANCE ORK THAT CAN BE CARRIED OUT BY EXTRA ORDER AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER 250/300 MXC/EXC 1st service after after after 10 hours…
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Page 135
10-7C MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary… -
Page 136
Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED. 250/300 EXC ADDITIONAL ORDER FOR THE hours 250/300 EXC… -
Page 137: Wiring Diagrams
MODEL 1999 WIRING DIAGRAM 250 — 380 EXC ……11-2 WIRING DIAGRAM 250 — 380 EGS ……11-3 WIRING DIAGRAM 250 — 380 EXC (USA) .
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Page 139: 250-380 Exc Wiring Diagram
11-2C…
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Page 140
11-3C… -
Page 141
11-4C… -
Page 142
11-5C… -
Page 143
11-6C… -
Page 144
11-7C S P O R T M O T O R C Y C L E S… -
Page 145
11-8C… -
Page 146: 380 Exc 2000 Wiring Diagram
11-9C…
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Page 147
11-10C… -
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11-11C… -
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11-12C… -
Page 150
11-13C… -
Page 151
11-14C 250-300 EXC 2003… -
Page 152
11-15C KTM 250-300 EXC 2003… -
Page 153
11-16C…
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- 250 SX-F 2005
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Contents
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REPAIRMANUAL2005-2008
250 SX-F, EXC-F, EXC-F
SIX DAYS
SIX DAYS
XCF-W, XC-F, SXS-F
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
Related Manuals for KTM 250 SX-F 2005
Summary of Contents for KTM 250 SX-F 2005
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Page 1
REPAIRMANUAL2005-2008 250 SX-F, EXC-F, EXC-F SIX DAYS SIX DAYS XCF-W, XC-F, SXS-F REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN… -
Page 3
KTM Group Partner… -
Page 5
1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS… -
Page 7
11-1 to 11-11 12-1 to 12-3 12-1 to 12-10 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 (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -
Page 9
X P L A N A T I O N P D A T I N G 3.206.027-E Repair Manual 250 SX-F 5/2005 Basic version Model year 2005/06 (Engine number with first digit «5» and «6») 3.206.052-E Updating of Rep.Manual 3.206.027-E 10/2007 Model year 2007/08 (Engine number with first digit «7»… -
Page 11
„NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. -
Page 13
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –… -
Page 15: General Information
GENERAL INFORMATION INDEX BLEEDING THE COOLING SYSTEM ……..2-2 CHANGING THE OIL FILTER .
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Page 17: Bleeding The Cooling System
Bleeding the cooling system The cooling liquid can be drained by removing the screw on the water pump cover. To bleed the cooling system add approx. 1 liter of cooling liquid and remove the bleeder screw . Do not replace the bleeder screw until cooling liquid starts to leak out of the hole without bubbles.
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Page 18: Oil Circuit
Oil circuit Oil circuit The oil pump draws the engine oil from the transmission oil sump through the long oil screen and conveys it to the oil filter , where any contamination is filtered out. The cleansed engine oil is pumped past the bypass valve through the hole in the crankshaft to the conrod bearing…
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Page 19: Bleeding Of The Hydraulic Clutch
Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove bolts and cover together with the rubber boot . The oil level in the horizontal-standing master cylinder should be 4 mm (0,157 in) below the upper edge.
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Page 20
SPECIAL TOOLS – ENGINE 250 -F… -
Page 21
SPECIAL TOOLS – ENGINE 250 -F PART NO. DESCRIPTION 560.12.001.000 Universal engine work stand 770.29.002.000 Engine holder for engine work stand 770.29.003.000 Engine holder for engine work stand 503.29.050.000 Bleeding syringe for hydraulic clutch 600.29.073.000 Spark plug wrench 16 mm 770.29.026.000 Limit plug gauge 5 mm 590.29.034.000… -
Page 23: Removing And Refitting Engine
REMOVING AND REFITTING ENGINE INDEX DISMOUNTING THE ENGINE ……..3-2 MOUNTING THE ENGINE .
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Page 25: Dismounting The Engine
Dismounting the engine – Thoroughly clean the motorcycle and jack up on a suitable assembly stand. Make sure it cannot tip over. – Remove the seat and tank with the spoiler. – Remove the frame protector on both sides. NOTE: you do not need to take the screws on the outside of the swing arm pivot all the way out.
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Page 26
– Pull the manifold pipe forward and remove from the motorcycle. – Open the drain plug on the water pump and allow the cooling liquid to drain into a suitable vessel. – Loosen the hose clamp and pull the radiator hoses off of the engine. -
Page 27
– Disconnect generator connector throttle potentiometer connector – Unscrew the hot start control from the carburetor. – Remove both upper engine braces – Carefully disconnect the engine vent and remove from the motorcycle together with the hose. NOTE: only pull the connection upwards, otherwise it can easily break. –… -
Page 28
– Loosen the chain guide and tilt upwards. – Remove the front and lower engine fixing screws and lift the engine out of the frame from the left side. CAUTION AKE SURE THE MOTORCYCLE CANNOT TIP OVER… -
Page 29: Mounting The Engine
Mounting the engine – Lift the engine into the frame from the left, position and screw in the lower and the front engine fixing screws but do not tighten them yet. – Mount the chain guide and tighten the screw. –…
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Page 30
– Mount the engine vent – Mount both upper engine braces but do not tighten the screws yet. NOTE: the hose the engine vent should run between the two engine braces. – Screw the hot start control into the carburetor. –… -
Page 31
– Connect the radiator hoses to the engine and tighten the hose clamp – Attach the manifold pipe to the front of the motorcycle and slide into the main silencer. – Mount the fixing screw for the manifold pipe with washers the rubber sleeve –… -
Page 32
– Mount the foot brake cylinder , apply Loctite 243 to the screws and tighten to 10 Nm. – Apply Loctite 243 to the ball joint of the pushrod and tighten to 10 – Attach the return spring for the foot brake lever. –… -
Page 33
DISASSEMBLING THE ENGINE INDEX PREPARATORY WORK ……… . .4-2 MOVING THE ENGINE INTO THE TDC POSITION . -
Page 35: Preparatory Work
Preparatory work – Thoroughly clean the outside of the engine and screw onto the engine work stand 560.12.001.000 with both engine holders 770.29.002.000 and 770.29.003.000. – Unscrew the shift lever, drain the oil and remove the oil filter cover. Discard the O-ring in the oil filter cover and the seal ring on the oil drain plug.
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Page 36: Moving The Engine Into The Tdc Position
– Remove the valve cover. Moving the engine into the TDC position – Turn the crankshaft until the two marks on the camshaft gears are aligned and precisely above the dividing line between the two camshaft bearing bridges. – Unscrew the engine locking screw , remove the seal ring and screw the engine locking screw back in (tightening torque 20 Nm).
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Page 37: Removing The Camshafts
Removing the camshafts – Open the plug on the chain tensioner and pull out the chain tensioner – Discard the sealing washer on the plug and the O-ring on the chain tensioner. – Loosen all of the screws and nuts on the upper camshaft bearing bridge and carefully remove the camshaft bearing bridge.
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Page 38: Removing The Cylinder Head And Piston
Removing the cylinder head and piston – Remove the lower camshaft bearing bridge , remove the dowels. – Take the shims out of the spring retainers and mark their mounted positions. NOTE: you will only need to check the valve clearance after assembling;…
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Page 39
– Lift off the cylinder head, paying attention to the chain tensioning rail. – Discard the cylinder head gasket, remove the dowels. – Lift off the cylinder, paying attention to the chain tensioning rail. – Discard the cylinder base gasket, remove the dowels. –… -
Page 40
– Loosen the rotor nut and remove together with the detent edged lock washer. – Screw the special tool 580.12.009.000 on the rotor, hold with a wrench and pull the rotor off the crankshaft by turning in the ejector screw. Remove the special tool from the rotor again. Removing the clutch cover –… -
Page 41
Dismantling the clutch – Pull out the pushrod. – Loosen the screws on the pressure cap crosswise and remove together with the washers and springs. – Remove the pressure cap. – Take the clutch disks out of the outer clutch hub. –… -
Page 42
– Remove the outer clutch hub with the needle bearing and inner ring. Removing the chain drive and primary gear – Push the timing chain towards the rear sprocket and pull the rear sprocket off the timing train idler shaft. –… -
Page 43
4-10 Dismantling the shift mechanism – Push back the shift rail and pull out the shift shaft together with the stop disk underneath. – Remove the screw on the shift lock , push back the locking lever and pull off the shift lock; let go of the locking lever. –… -
Page 44
4-11 Removing the oil pumps – Remove the oil pump gear and the oil pump idler. – Pull the needle roller out of the oil pump shaft – Remove the screws and remove the pump cover from the pressure pump –… -
Page 45: Separating The Casing Halves, Removing The Crankshaft And Transmission Shafts
4-12 Separating the casing halves, removing the crankshaft and transmission shafts – Turn the engine over and remove all of the casing screws as well as both nuts on the engine work stand holders. – Lift off the left casing half; if necessary, gently tap on the shaft with a plastic hammer.
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Page 47
SERVICING INDIVIDUAL COMPONENTS INDEX LEFT CASING HALF ……….5-2 RIGHT CASING HALF . -
Page 48
IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING Read through the following section before commencing work. Then determine the assembly sequence so that the engine housing halves only need to be heated up once before replacing the bearings. Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. -
Page 49
Left casing half Remove all shaft seal rings and the bearing fixing screws, heat the casing half in the oven to approx. 150° C. – Roller bearing for the crankshaft Press in the roller bearing from the outside with a suitable driver. Press in a new roller bearing from the inside up to the stop. -
Page 50
Right casing half Remove the shaft seal ring and the bearing fixing screws, heat the casing half in the oven to approx. 150° C. – Roller bearing for the crankshaft Press in the roller bearing from the outside with a suitable driver. Press in a new roller bearing from the inside up to the stop. -
Page 51: Clutch Cover
Bypass valve – Check the valve piston, sealing seat and pressure spring for damage. Minimum length of the pressure spring : 23.5 mm NOTE: if the length of the pressure spring is less than 23.5 mm, the opening pressure of the bypass valve will be reduced. This will lead to a drop in the oil pressure and consequently to increased wear.
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Page 52
Crankshaft If replacing the conrod bearing, make sure the crank pin is in the right position. The holes in the crankshaft web must align with the holes in the crank pin CAUTION F YOU PRESS IN THE CRANK PIN IN THE WRONG POSITION THE CONROD BEARING WILL NOT BE SUPPLIED WITH ENGINE OIL WHICH WILL RESULT IN DAMAGE TO THE… -
Page 53: Crankshaft Bearings
Measuring the outside dimension of the crankshaft webs – Measure the outside dimension of the crankshaft webs using a sliding gauge, as illustrated. Outside dimension of the crankshaft webs = 54 mm ± 0.05 mm Crankshaft bearings – Fix the crankshaft in the vise with protective jaws. –…
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Page 54: Nikasil Cylinder Coating
Nikasil cylinder coating Nikasil is the brand name for a cylinder coating process developed by the Mahle piston company. The name is derived from the two materials used in the process — one layer of nickel in which the exceptionally hard silicon carbite is embedded.
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Page 55
Piston – Replace the piston if oil consumption is high or the piston skirt is excessively grooved. – If the piston is to be remounted: 1. Check the piston bearing surface for damage 2. Piston ring grooves: the piston rings must move freely in the groove. Use old piston rings or sandpaper (400 grit) to clean the piston ring grooves. -
Page 56: Lubricating System
Lubricating system – Replace the O-rings and sealing washer each time you change the oil filter. – Replace the oil filter each time you change the oil. – Check whether the O-rings are brittle and replace if necessary; always replace the O-rings when you repair the engine. –…
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Page 57
5-10 Camshaft bearing – Clamp the camshaft in a vise with protective aluminum jaws. Position one of the cams so that the camshaft cannot be turned. – Loosen the camshaft gear (A/F 21) and remove the screw. – Pull off the camshaft gear using the extractor 590.29.033.000 and pressure tool 770.29.035.000. -
Page 58: Automatic Decompression
5-11 Camshafts – Check pivot points and cams for wear and damage. – Check the toothing of the camshaft gears for wear and damage. – Replace the camshaft bearings (see pages 5-10). Automatic decompression – Remove the camshaft gear and camshaft bearing (see pages 5-10). –…
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Page 59
5-12 Camshaft bearing bridges – Check both camshaft bearing bridges for wear, seizing marks and damage. – Pull out the cam lever shafts ; they are inserted loosely, and can easily be removed by tapping gently on the camshaft bearing bridge. NOTE: if remounting the cam lever, write down the installation position. -
Page 60: Timing Chain Tensioner
5-13 Timing chain tensioner CAUTION F YOU DO NOT FOLLOW THESE INSTRUCTIONS THE TIMING CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP RESULTING IN ENGINE DAMAGE NOTE: – The timing chain tensioner operates with spring force and with oil pressure.
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Page 61: Timing Train
5-14 Timing train Thoroughly clean all parts and check for wear. – Check the toothing of the control idler for breakout and wear. – Check the timing chain tensioning rail for seizing marks and damage. – Check the timing chain guide for seizing marks and damage.
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Page 62: Cylinder Head
5-15 Cylinder head – Loosen the screws and remove the exhaust flange together with the gasket. – Remove the shims from the valve spring retainers (if still mounted). – Dismount the valve keys using the special tools 590.29.019.000 and 770.29.041.000 and relieve the valve springs. NOTE: Used valves must be remounted in the same valve guide as before.
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Page 63
5-16 – Remove the valve spring retainer and valve springs from the cylinder head. – Pull the valve stem sealing off the valve guides and take out the spring washers – Check the sealing areas of the spark plug thread and the valve seats for damage and cracks. -
Page 64
5-17 Clutch – Check the pressure piece for seizing marks and smooth operation. – Check the axial bearing for damage. – Lay the pushrod on an even surface and check for runout. – Check the length of the clutch springs ;… -
Page 65: Pre-Mounting The Kickstarter Shaft
5-18 Kickstarter – Remove all parts from the kickstarter shaft and clean. – Check the toothing on the kickstarter pinion for wear and the clearance of the mounting. – Check the toothing of the kickstarter idler for wear and the clearance of the mounting.
-
Page 66
5-19… -
Page 67
5-20 Shift mechanism – Check the shift forks on the leaf for wear. The forks have a thickness of 4.8 to 4.9 mm when new, the wear limit is 4.6 mm. – Check the shift grooves on the shift drum for wear. -
Page 68: General Information On Servicing The Transmission
5-21 General information on servicing the transmission Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gear wheels and check the following parts for wear and seizing marks: – Bearings – Pivot points on the main shaft and countershaft and pivot points on the idler gears –…
-
Page 69: Assembling The Countershaft
5-22 General information on servicing the transmission Clamp the main shaft or countershaft in the vise (use protective jaws). Remove the gears and check the following parts for wear and seizing marks: – Bearings – Pivot points on the main and countershaft and pivot points on idler gears –…
-
Page 71: Assembling The Engine
ASSEMBLING THE ENGINE INDEX INSTALLING THE TRANSMISSION SHAFTS AND CRANKSHAFT, ASSEMBLING THE CASING HALVES . . .6-2 ……..6-4 MOUNTING THE OIL PUMPS MOUNTING THE SHIFT MECHANISM .
-
Page 73
Installing the transmission shafts and crankshaft, assembling the casing halves – Place the right casing half on the engine work stand in an upright position. – Put the two transmission shafts together and insert in the casing half with one hand while you guide the transmission shafts into the bearings with the other hand. -
Page 74
– Mount the crankshaft. NOTE: the cone for the rotor must face up. – Degrease the entire sealing area and apply a thin coat of permanently elastic sealing compound (309 098). – Mount the dowels; do not forget the stop disk for the main shaft. –… -
Page 75
Mounting the oil pumps – Mount the oil pump shaft with the pressure pump rotors and the needle roller as illustrated. The marks on both rotors must be opposite the needle roller. – Slide the preassembled oil pump shaft into the right engine case half. -
Page 76
– Mount the suction pump rotors with the marks facing the case. The marks should no longer be visible when mounted. – Insert the needle roller in the recess of the oil pump shaft and inner rotor. – Fill the oil pump with engine oil. –… -
Page 77
Mounting the shift mechanism – Mount the locking lever with the washer , bushing spring . Apply Loctite 243 to the screw and tighten to 6 Nm. – Press the locking lever away from the shift drum and slip on the shift lock. -
Page 78
Mounting the primary pinion and the chain drive – Move the crankshaft into the TDC position and lock in place with the locking screw (20 Nm). – Mount the woodruff key (if previously removed). – Mount the primary gear, detent edged lock washer and nut (+ Loctite 243, A/F 27, LH thread). -
Page 79
Mounting the clutch – Slide the inner ring , needle bearing and outer clutch hub on the main shaft. NOTE: Turn the starter idler , oil pump gear and outer clutch hub back and forth until the toothing engages. – Slide on the stop disk and driver. –… -
Page 80: Mounting The Clutch Cover
– Mount the pressure cap and gradually tighten the screws with the washers and springs crosswise to 10 Nm. Mounting the clutch cover – Mount a new gasket and the clutch cover (do not forget the dowels). – Turn in the screws as illustrated and tighten to 10 Nm. M6x35 M6x25+Cu M6x55…
-
Page 81
6-10 – Insert the woodruff key in the crankshaft groove. – Slip on the rotor. – Mount the spring washer and nut. Tighten the nut to 60 Nm. Mounting the piston and cylinder head – Place the well-oiled piston on the cylinder and clamp the piston rings together with the piston ring compressor 600.29.015.000. -
Page 82
6-11 – Attach thrust bushings to the cylinder and mount a new cylinder head gasket. – Pull the timing chain through the timing chain compartment with the cable clips and mount the cylinder head, being careful not to damage the chain tensioning rail. –… -
Page 83
6-12 – Place the shims in the spring retainers in accordance with their mounted position. NOTE: check the valve clearance after assembling; adjust the valve clearance if valves or other parts in the valve control were replaced. – Mount the thrust bushings and pull the timing chain up. –… -
Page 84: Mounting The Camshafts
6-13 Mounting the camshafts – Place the intake camshaft in the bearing seat, mark aligned with the dividing edge between the camshaft bearing bridges, and run the chain over the camshaft gear such that the chain is tensioned on the intake side. NOTE: –…
-
Page 85: Mounting The Chain Tensioner
6-14 Mounting the chain tensioner – Press the chain tensioner together up to the first notch and lock in this position. Slide into the hole in the cylinder heads together with a new O-ring. NOTE: – Check and lock the chain tensioner: see Chapter 5. –…
-
Page 86
6-15 Assembling the engine – Mount the valve cover with a new gasket and tighten the screws. – Place the oil screen on a pin wrench approx. 300 mm long. Insert the pin wrench through the opening in the bore of the opposite engine case wall and slide the oil screen all the way into the engine case. -
Page 87
ELECTRICAL INDEX CDI UNIT ……….. .7-2 CHECKING THE IGNITION COIL . -
Page 89: Checking The Ignition Coil
CDI unit Check the cables and socket connections to the CDI unit. The CDI unit can only be tested on an ignition test bench. CAUTION EVER TEST THE UNIT WITH A CONVENTIONAL MEASURING DEVICE IGHLY SENSITIVE ELECTRONIC COMPONENTS COULD BE DESTROYED Checking the ignition coil –…
-
Page 90: Ignition System
Ignition system General information The measurements described below will only detect serious defects. Short circuits in the coil that lead to a weak ignition spark or poor generator capacity can be established with the peak voltage adapter 584.29.042.000. In case of a defect, check the cable and the plug and socket connections in the ignition system first.
-
Page 91
– Q UICK CHARGES WITH HIGH VOLTAGE WILL IMPAIR THE SERVICE LIFE OF YOUR BATTERY – Connect KTM battery charger no. 584.29.074.000. The battery charger can also be used to test the offload voltage, the battery’s startability and the generator capacity. This battery charger cannot be overcharged. -
Page 92
Checking the charging voltage NOTE: the following figures only apply to fully charged batteries (charging condition at least 90 %). – Connect a voltmeter to both battery terminals. – Start the engine. – Rev the engine up to 5000 rpm and read the voltage. Setpoint value: 14.0 –… -
Page 93
Measuring with the peak voltage adapter 584.29.042.000: static ignition values Measuring conditions: – cold engine – seat and tank removed – all plug and socket connectors and the ground connection in a non-corroding condition, plugs tightly connected – depress the kickstarter forcefully at least 5 times for each measurement Connecting the peak voltage adapter and setting the multimeter The peak voltage adapter is equipped with 4 cables: 2 red and 2 black. -
Page 94
Measuring with the peak voltage adapter 584.29.042.000: static generator values Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded (if installed) and light switch turned off –… -
Page 95
FUEL SYSTEM INDEX DISMOUNTING AND INSTALLING THE CARBURETOR ….. .8-3 DISASSEMBLING THE CARBURETOR ……. . .8-4 CHOKE KNOB AND HOT START SLIDE . -
Page 97
CARBURATOR — KEIHIN FCR-MX 39 550 mm 630 mm 550 mm 400 mm 630 mm… -
Page 98
Dismounting and mounting the carburetor NOTE: clean the motorcycle thoroughly before you start to work on the carburetor. – Remove the seat and tank with the spoilers. – Remove the carburetor cover – Loosen the 2 nuts and disconnect both throttle cables from the carburetor. -
Page 99: Disassembling The Carburetor
Disassembling the carburetor NOTE: Before you start disassembling the carburetor, you should look for a clean workplace. It should offer you enough space to lay out all individual components of the carburetor in perfect order. – Dismount the carburetor and remove any coarse dirt. –…
-
Page 100
– Turn the carburetor around, remove the 3 screws and remove the cover of the accelerator pump. NOTE: When dismounting the cover, watch out for the spring and the sealing rings as they may get lost easily. – Remove the 2 sealing rings, the spring and the diaphragm from the pump housing. -
Page 101
– Remove screws and the throttle sensor NOTE: the throttle sensor should only be dismounted if defective. If the screws are loosened, the throttle sensor must be adjusted again. – Remove screw and pull the connecting piece out of the carburetor. -
Page 102: Checking The Accelerator Pump
Checking the choke knob and hot start slide Choke knob: The choke knob must be easy to actuate . The piston of the choke knob must not have any pronounced score marks or deposits. Hot start slide: The hot start slide must be easily actuated. The piston on the hot start slide may not have any scores or deposits.
-
Page 103
Assembling the carburetor – Mount the idle-air jet and the main air jet – Place the O-ring in the groove and secure the intake trumpet to the carburetor by means of the 2 screws. – Insert the fuel port in the carburetor and fix with screw NOTE: In the mounted state, the connection piece must be easy to turn. -
Page 104
– Position the float and the float needle valve and mount the float hinge pin – Check the float level (see page 8-14). – Mount the float chamber and the gasket, position the bracket for the adjustment screw and fix the float chamber with the screws NOTE: When positioning the float chamber, make sure that the push of the accelerator pump slides into the bore. -
Page 105
8-10 – Apply Loctite 243 to the screw and tighten. – Mount the jet needle and fix with the screw – Position the slide cover with the gasket and fasten with the 2 screws – Fix the vent hoses on the float chamber with the 2 screws… -
Page 106
8-11 Adjusting the position of the throttle valve sensor NOTE: Before checking the position of the throttle valve sensor, you have to adjust the idle speed correctly. – Disengage the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve resistance. -
Page 107
8-12 Checking the throttle valve sensor NOTE: The following measurement must be taken at a component temperature of approx. 20°C. – Open the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor. -
Page 108
8-13 CARBURETOR – Adjust idling Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel the mixture control screw . -
Page 109
8-14 Checking the float level (float height) For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it. In this position, the edge of the float should be parallel with the float chamber sealing surface (see illustration). -
Page 111: Troubleshooting
TROUBLE SHOOTING INDEX TROUBLE SHOOTING ……….9-2…
-
Page 113
Discharged battery. Recharge the battery and investigate the causes for discharg- ing; contact a KTM dealer. Engine cranks but doesn’t start (E- Operating error Open fuel tap, tank fuel, actuate choke. Pay attention to starter). -
Page 114
Use thicker engine oil; see chapter “Engine oil“ The battery is discharged The battery isn’t charged by the generator Remove seat and fuel tank and check voltage regulator because connections; voltage regulator and generator should be checked by a KTM dealer. -
Page 115
10-1 TECHNICAL SPECIFICATIONS INDEX ENGINE 250 SX-F MODEL 2005-07 ……. .11-2 ENGINE 250 SXS-F MODEL 2006-07 . -
Page 117
10-2 TECHNICAL DATA – ENGINE 250 SX-F 2005/06/07, SXS-F 2006/07 Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.8 : 1 Fuel unleaded fuel with at least RON 95 Valve timing 4 valves controlled by finger levers and 2 camshafts,… -
Page 118
10-3 TECHNICAL DATA – CHASSIS 250 SX-F 2005/06, SXS-F 2006 Frame Central tube chrome-moly-steel frame Fork 4860 MA/PA Wheel travel front/rear 300/335 mm Rear suspension WP Progressive Damping System shock absorber, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm, brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø… -
Page 119
10-4 TECHNICAL DATA – CHASSIS 250 SX-F/SXS-F 2007 Frame Central tube chrome-moly-steel frame Fork WP 4860 CC MA Wheel travel front/rear 300/335 mm Rear suspension WP PDS shock absorber 5018 DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm, brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø… -
Page 120
10-5 TECHNICAL DATA – ENGINE 250 XC-F, XCF-W, EXC-F 2007 ENGINE 250 XC-F 250 XCF-W, EXC-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.8 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91) Valve timing 4 valves controlled by finger levers and 2 camshafts, driven by a pair of spur gears and a tooth-type chain… -
Page 121
10-6 TECHNICAL DATA – CHASSIS 250 250 XC-F, XCF-W, EXC-F 2007 Frame Central tube chrome-moly-steel frame Fork WP Suspension – 4860 MXMA / MXMA + PA Wheel travel front/rear 300/335 mm Rear suspension WP Suspension – 5018 PDS MCC / DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø… -
Page 122
10-7 TECHNICAL DATA – ENGINE 250 SX-F, XC-F, XCF-W, EXC-F 2008 ENGINE 250 SX-F, XC-F 250 XCF-W, EXC-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.8 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91) Valve timing 4 valves controlled by finger levers and 2 camshafts, driven by a pair of spur gears and a tooth-type chain… -
Page 123
10-8 TECHNICAL DATA – CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F 2008 Frame Central tube chrome-moly-steel frame Fork WP Suspension – 4860 MXMA CC / MXMA + PA Wheel travel front/rear 300/335 mm Rear suspension WP Suspension – 5018 PDS DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø… -
Page 124
10-9 STANDARD ADJUSTMENT – FORK 250 SX-F 250 XC-F 250 XCF-W, EXC-F 250 EXC-F Six Days WP 4860 MXMA CC WP 4860 MXMA CC WP 4860 MXMA PA WP 4860 MXMA PA 14.18.7D.03 14.18.7D.28 14.18.7D.04 14.18.7D.34 Compression adjuster Rebound adjuster Spring 4.4 N/mm 4.4 N/mm… -
Page 125
10-10 ASSEMBLY CLEARANCE, WEAR LIMIT Crankshaft axial clearance 0.25 — 0.35 mm run out of crank stud max 0.15 mm crankshaft webs — measure outer dimension 54 mm ± 0.05 mm Conrod bearing radial clearance max. 0.03 mm axial clearance max. -
Page 126
10-11 TIGHTENING TORQUES — ENGINE Oil drain plug M12x1.5 20 Nm HH plug, long oil screen M20x1.5 15 Nm AH plug, short oil screen M16x1.5 oil + 15 Nm Pressure relief valve plug M12x1.5 20 Nm HH/AH screws on oil pump cover Loctite 222 + 6 Nm Cylinder head screws oil + 40/50 Nm… -
Page 127
10-12 TIGHTENING TORQUES — CHASSIS Collar screw, front wheel spindle M24x1,5 40 Nm Brake caliper, front Loctite 243 + 25 Nm Brake disks 14 Nm Clamping screws, upper fork bridge XCF-W ZA, EXC-F 20 Nm Clamping screws, lower fork bridge XCF-W ZA, EXC-F 15 Nm Clamping screws, upper fork bridge SX-F, XC-F, XCF-W USA, EXC-F Six Days 17 Nm… -
Page 129: Periodic Maintenance Schedule
11-1 PERIODIC MAINTENANCE SCHEDULE INDEX MODEL 2005 ……….12-2 MODEL 2006 .
-
Page 130
IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. -
Page 131
Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Check tightness of screws, nuts and hose clamps regularly RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP) every… -
Page 132
IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. -
Page 133
Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Check tightness of screws, nuts and hose clamps regularly RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP) every… -
Page 134
Change brake fluid Clean Sparkarrestor (XC-W USA) Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. -
Page 135
Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) -
Page 136
Change brake fluid Clean Sparkarrestor (XC-F USA) Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. -
Page 137
Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly 250 SX-F/XC-F IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) every… -
Page 138
Change brake fluid Clean Sparkarrestor (XCF-W USA) Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. -
Page 139
Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly 250 XCF-W/EXC-F IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) COMPETITIVE… -
Page 141: Wiring Diagrams
12-1 WIRING DIAGRAMS INDEX MODEL 2005 250 SX-F ………..13-2 250 EXC-F USA .
-
Page 143
13-2 red-white red-black… -
Page 144
13-3 headlight multi-func.-digital-speedometer ye-bl bl-wh bu-wh ye-bl re-wh re-bl ye-re wh-re black ye-re re-bl wh-re re-wh ye-re rear light/brakelight… -
Page 145
13-4 headlight multi-func.-digital-speedometer driving light lamp flasher control lamp front brake switch ye-bl bl-wh ye-re ye-re ye-re bu-wh ye-bl re-wh re-bl ye-bl ye-re wh-re black ye-re re-bl wh-re re-wh ye-re wh-gn rear light/brakelight… -
Page 146
13-5 red-white red-black… -
Page 147
13-6 headlight multi-func.-digital-speedometer ye-bl bl-wh bu-wh ye-bl re-wh re-bl ye-re wh-re black ye-re re-bl wh-re re-wh ye-re rear light/brakelight… -
Page 148
13-7 red-white red-black… -
Page 149
13-8 headlight multi-func.-digital-speedometer ye-bl bl-wh bu-wh ye-bl re-wh re-bl ye-re wh-re black ye-re re-bl wh-re re-wh ye-re rear light/brakelight… -
Page 150
13-9 headlight multi-func.-digital-speedometer driving light lamp flasher control lamp front brake switch C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 C_AK1/2 C_CW2/2 C_DG/4 C_CW3/2 C_AH1/2 C_CX2/2 C_CX3/2 C_BP/4 ye-bl bl-wh C_BA/1 C_BF/1 bu-wh bu-wh ye-re ye-re ye-re ye-bl re-wh re-bl C_BA2/1 ye-bl ye-re wh-re black… -
Page 151: Cable Colours
13-10 Cable colours bl: black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple…
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The Austrian company KTM is one of the largest and most famous manufacturers of sports motorcycles in Europe. The official date of foundation of the enterprise is 1934. It was
then that a young but very ambitious engineer named Hans Trunkenpolz, who lived in the city of Mattinghofen, opened a metal processing workshop, which received the name Kraftfahrzeuge Trunkenpolz
Mattighofen (KTM).
This series consists of two machines: the dual-use 125EXE and the urban enduro 125 Supermoto. They differ from each other mainly in wheels, dressed in universal
tires (125ЕХЕ) and highway «rubber» (125 Supermoto). Both motorcycles are equipped with a new two-stroke engine, unified in design with sports power units. The frame is tubular, welded, made of
chrome-molybdenum steel. Telescopic front fork — inverted type. The rear suspension of the PDS (Progressive Damping System) system, as on all “adult” KTMs, provides a progressive characteristic
without an intermediate linkage only due to the design of the shock absorber itself.
Motorcycles for enduro competitions in their design are as close as possible to cross-country motorcycles. They install a wide range of two-stroke engines (models 125EXC, 200EXC,
250EXC, 300EXC and 380EXC), including the new 250 cc engine. The new generation four-stroke engines are used on 400EXC Racing and 520EXC Racing motorcycles.
The company is also developing a two-cylinder V-shaped four-stroke 1000 cc LC8 engine. This power unit is designed for a powerful motorcycle for a rally and for the future road version of Super
Duke. The debut of the novelty will take place in the fall of 2000.
Parade Horse of the company — the famous model 640 Duke II. This is an urban enduro-style motorcycle with 17-inch alloy wheels. The futuristic half fairing with two headlights located one above
the other looks peculiar. The 640 cc engine is equipped with an electric starter.
Dual-use motorcycles 400LC4-E Hard Enduro and 640LC4-E Hard Enduro, unlike many of their classmates, really have excellent off-road qualities. Both cars are equipped with a four-stroke engine
with an electric starter, two-seat saddles and steps for the passenger. The 640 cc modification is also available as the urban enduro 640LC4-E Supermoto.
Option 620LC4 SC (Supercompetition) closer to purely sports models. It is made single, the engine is deprived of an electric starter. Tires are distinguished by off-road tread patterns.
Nevertheless, the presence of a complete set of lighting equipment allowed to certify this car for driving on ordinary roads. It is also available in the 620LC4 SC Super-moto variant.
For serious off-road raids, the 640LC4 Adventure-R is designed, which is equipped with a 640-cc engine with an electric starter, a Paris-Dakar-style fairing with two headlights, a 30-liter gas
tank and a strong rear trunk.
In collaboration with the Italian company Lem, KTM produces a wide range of children’s cross-country motorcycles. The 50 Mini Adventure is designed for the youngest athletes, ages 4 to 6 years.
It is equipped with a single-cylinder, two-stroke air-cooled engine with automatic centrifugal clutch and without gearbox. Modification 50SX Junior features a forced engine and increased
suspension travels. The engine of the 50SX Senior motorcycle, designed for athletes aged 7 to 9 years, is even stronger.
At a higher level of technical excellence is a motorcycle with an index of 60 / 65SX. It is equipped with a two-stroke liquid-cooled motor (60 or 65 cc) installed in a frame made of
chrome-molybdenum steel. The machine has a six-speed gearbox, disc brakes on both wheels and is designed for 9-11 year old athletes.
Motorcycles 125SX, 250SX and 380SX are equipped with single-cylinder two-stroke power units. The 250 cc version of the engine received a new cylinder, cylinder head and crank group by the 2000
season. Compared with last year’s version, the dimension of the motor has changed (66.4×72 mm instead of 67.5×69.5 mm).
A new four-stroke engine is also installed on the 400SX Racing and 520SX Racing motorcycles. This is an exceptionally lightweight and compact unit — it is narrower than a 250 cc two-stroke
engine. In the cross version, the motor is aggregated with a four-speed gearbox.