KTM 250 SX-MXC-EXC, 525 SX-MXC-EXC 2003 Service Manual

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250-525

SX, MXC, EXC RACING

REPAIR MANUAL

ENGINE

KTM SPORTMOTORCYCLE AG

5230 Mattighofen Austria www.ktm.at

REPAIR

MANUAL

ENGINE

250-525

SX, MXC,

EXC RACING

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 TECHNICAL SPECIFICATIONS

10 PERIODIC MAINTENANCE SCHEDULE

11 WIRING DIAGRAMS

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

IMPORTANT INFORMATION/UPDATING INSTRUCTIONS

To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions:

14, 21-24, 30-47, 50-52, 56-76, 79-92, 97-124, 134-140, 142, 150-154, 165-167

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 (210x297 mm) into the transparent pocket provided for

this purpose on the outside of the binder.

– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the

spine of the binder.

– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this

purpose on the inside of the binder or insert this page on the beginning of the manual.

– Then insert the individual chapters of the manual between the sheets of the index according to

the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“.

– Index sheets that have not been marked with a certain chapter are for your personal convenience. T

respective headings can be entered in the list of contents.

Remove page (s) Replace by page (s) Insert page (s) after page

2-1 / 2-7 2-1C 2-7C to 2-9C

3-1 3-1C

4-1 to 4-14 4-1C to 4-13C

5-1 / 5-3 5-1C / 5-3C

5-6 to 5-8 5-6C to 5-8C

5-12 to 5-26 5-12C to 5-27C

6-1 / 6-4 6-1C / 6-4C

6-7 to 6-16 6-7C to 6-17C

7-1 to 7-2 7-1C to 7-2C

7-7 to 7-11 7-7C to 7-11C

8-1 to 8-13 8-1C to 8-21C

9-1 9-1C

9-10 to 9-13 9-10C to 9-16C

10-1 10-1C 10-8C to 10-11C

11-1 11-1C 11-11C to 11-13C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

EXPLANATION - UPDATING

Edition 01/2003

3.205.85-E Repair Manual

400/520 SX, MXC, EXC RACING

Basic version Model year 2000 (Engine number with first digit “0“)

2/2000

3.210.01-E Updating of Rep.Manual 3.205.85-E

Model year 2001 (Engine number with first digit “1“)

1/2001

3.210.44-E Updating of Rep.Manual 3.205.85-E

Model year 2002 (Engine number with first digit “2“)

2/2002

3.206.007-E Updating of Rep.Manual 3.205.85-E

Model year 2003 (Engine number with first digit “3“)

1/2003

Modification / Updating:

Technical Details Model 2003 (clutch, valve spring, camshaft gear, carburetor) Technical Specifications, Periodic Maintenance Schedule, Wiring Diagrams

INTRODUCTION

This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.

A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics.

Read through the repair manual before beginning with the repair work.



WARNING



STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.

CAUTION

NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC !

„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 ongoing total reengineered quality plan for a brighter tomorrow.

KTM Sportmotorcycle AG

5230 Mattighofen, Austria

All design and assembly modification rights reserved.

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 – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349.

NOTE to table:

– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.66-E).

You will find the number on the cover page or in the left margin on each right page of the manual.

– Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.

– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective

passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible.

– Enter the correct text in column 4.

Your corrections will be reviewed and incorporated in the next issue of our repair manual.

Item no. of repair manual Page Current text Correct text

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

Name mechanic/shop foreman Company/work shop

GENERAL INFORMATION

Repair manual KTM 250-525 SX, MXC, EXC RACING

Art.-No. 3206007 -E

OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

CHANGING THE OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

CHECKING THE OIL LEVEL OF THE HYDRAULIC CLUTCH . . . . . . . . . . . .2-6

BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .2-6

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

CLEANING, STORAGE OF MOTORBIKE . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

INDEX

2-1C

2-2C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Oil circuit

Via the long oil screen 2, the oil pump 1draws engine oil from the oil sump of the transmission. This engine oil flows through an oil line

into the cylinder head for camshaft lubrication 4; the oil quantity is controlled

by the jet bolt

. An oil duct branches off to the long oil filter 6where the coarser particles contained in

the engine oil are filtered away. Then, the engine oil arrives at the short oil filter

which also filters the fine particles. Now, the purified engine oil is pumped past the bypass valve

to the conrod bearing 9and sprayed from

below onto the piston through a nozzle

The second oil pump

draws the engine oil via the short oil screen bmout of the crankcase, thereby

lubricating the transmission gears

Engine oil

Only use fully synthetic brand oils (Motorex Power Synt. 4T) that meet or surpass the quality requirements of API classes SG or SH (see specifications on the container).

CAUTION

NSUFFICIENT AMOUNTS OR LOW-GRADE ENGINE OIL LEAD TO PREMATURE WEAR OF

THE ENGINE

Checking the engine oil level

The engine oil level can be checked with the engine being either warm or cold. Place the motorcycle in an upright position and on a horizontal surface (not on the side stand).

If the engine is cold, the engine oil must be visible at the lower edge of the inspection glass

If the engine is warm, the engine oil must be visible up to the upper edge of the inspection glass

Replenish the engine oil, if necessary.

CAUTION

NSUFFICIENT AMOUNTS OR LOW

-GRADE ENGINE OIL LEAD TO PREMATURE WEAR OF

THE ENGINE

NOTE: Engines up to the 2001 model have a sight glass and an oil dipstick. If the inspection glass is heavily soiled (e.g. after a race in muddy terrain), the engine oil level can also be measured with the oil dipstick. For this purpose, unscrew the dipstick and wipe it clean with a cloth. Screw the dipstick back in and screw it out again. If the engine is warm, the oil level should be near the MAX mark

Check engine for leaks.

2-3C

 

–

0°C

32°F

15W 40 15W 50

10W 40 10W 50

API: SG, SH

TEMPERATURE

Changing the engine oil

NOTE: When changing the engine oil, it is necessary to clean the short and long oil screens and to replace both oil filters. Engine oil has be changed with the engine being at an operating temperature.



WARNING



N ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE VERY

HOT

- DO NOT BURN OR SCALD YOURSELF!

Place the motorcycle on a horizontal surface, remove the plug

1 and

allow the oil to drain into a receptacle. Clean plug (with magnet) thoroughly. Once the entire oil has been drained, clean the sealing surface, mount the plug together with the sealing ring and tighten it to 20 Nm/ 15ft.lb.

CLEANING THE SHORT OIL SCREEN The short oil screen

2 is accommodated in the hex-socket plug 3 on the

engine bottom. Insert a pin-type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug. Dismount the oil screen, clean the components thoroughly and blow compressed air through them. Check the O-rings for damage and, if necessary, replace them. Mount the oil screen together with the plug again and tighten the plug to 10 Nm.

CLEANING THE LONG OIL SCREEN The long oil screen is accommodated in the hexagon plug

4 adjacent the

engine number. Dismount the plug together with the oil screen, clean the components thoroughly and blow compressed air through them. Check the O-rings for damage and, if necessary, replace them.

To mount the long oil screen

5, place it on an approx. 300 mm/

11.8 in long pin-type key or a similar tool. Insert the pin-type key through the opening into the bore of the opposite engine casing wall. Then, push the oil screen into the engine casing as far as possible. Remove the pin-type key, mount the plug and tighten it to 15 Nm/ 11 ft.lb.

CAUTION

THE OIL SCREEN IS MOUNTED SLIGHTLY DOWNWARDS, IF INCORRECTLY FITTED, THE

SCREEN LOOSES ITS FUNCTION AND THIS CAN CAUSE INCREASED ENGINE WEAR

2-4C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Changing the oil filters

Remove the bolt 1 and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 bolts

2 and dismount the two oil filter covers.

Using circlip pliers, you may now pull the oil-filter inserts

3 out of the

housing. Clean the oil filter cover, the sealing surfaces of the O-rings and the engine casing. Check the O-rings of the oil filter covers for damage and, if necessary, replace them.

Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil. Insert the long oil filter at the front and the short oil filter at the back of the housing. Grease the O-rings

4 of the oil filter covers and mount the cover. Mount

the bolts and tighten them to 6 Nm/5 ft.lb.

Position the brake fluid container and tighten the bolt to 8 Nm/ 6 ft.lb.

Return the motorcycle to an upright position.

Remove the oil dipstick

5 at the clutch cover and fill in 1.2 liters of fully

synthetic engine oil (Motorex Power Synt. 4T).

Start the engine and check all screwed connections and oil filter covers for leaks.

Finally, check the engine oil level and, if necessary, correct it.

2-5C

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

1 and cover together with the

rubber boot

2. The oil level in the horizontal-standing master cylinder

should be 4 mm (0,157 in) below the upper edge. If necessary add SAE 10 biodegradable hydraulic oil.

CAUTION

NLY USE SAE 10 BIODEGRADABLE HYDRAULIC OIL TO REFILL THE MASTER CYLINDER.

EVER USE BRAKE FLUID!

Bleeding of the hydraulic clutch

For bleeding, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove screws

1 and take off cover together

with rubber bellows

2. At the slave cylinder of the clutch, remove the

bleeder nipple. At its place, mount the bleeder syringe

3 which is filled

with biodegradable hydraulic oil.

Refill oil, until oil is discharged from the bore

A of the master cylinder in

a bubble-free state. Make sure that the oil does not overflow.

CAUTION

AVING COMPLETED THE BLEEDING PROCEDURE

, YOU HAVE TO VERIFY THAT THE OIL

LEVEL IN THE MASTER CYLINDER IS CORRECT

. FOR FILLING OF THE MASTER CYLINDER,

USE SAE 10 BIODEGRADABLE HYDRAULIC OIL ONLY. NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS

2-6C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

2-7C

2-8C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

FIG PART NO. DESCRIPTION

1 560.12.001.000 Universal engine work stand 2 590.29.002.000 Engine holder for engine work stand 3 590.29.020.000 Rivetting tool for steering chain 4 590.29.005.010 Mounting sleeve for shaft seal ring water pump 5 510.12.011.000 Circlip pliers 6 590.29.021.000 Puller for driving hub and primary gear 7 598.29.015.075

Piston ring spanner

Ø 75 mm

580.12.015.089 Piston ring spanner Ø 89 mm

580.12.015.095 Piston ring spanner Ø 95 mm

86 899 785 Loctite 243 blue 6 cm

584.29.059.000 Loctite 648 green 20 ml

9 151.12.017.000 Gear puller

10 151.12.018.000 Internal gear puller 12-16 mm

151.12.018.100 Internal gear puller 18-23 mm 11 590.29.026.006 Limit plug gauge 6.05 mm 12 590.29.035.000 Mounting sleeve for driving pin 13 590.29.036.000 Protection sleeve for primary gear 14 590.29.033.000 Puller for camshaft bearings 15 590.29.019.000 Valve spring mounter 16 584.29.037.037 Mounting tool for inner rings of crankshaft bearings 17 590.29.034.000 Wrench for mixture regulating screw 18 580.12.009.000 Magneto extractor 19 309098 Seal (Three-Bond) 20 510.12.012.000 Chain sprocket holder 21 590.29.072.000 Spark plug wrench 16 mm 22 503.29.050.000 Bleeding syringe for hydraulic clutch 23 590.29.041.000 Feeler gauge for valve clearance 24 590.29.003.100 Clutch holder

SPECIAL TOOLS

– ENGINE

2-9C

Should you desire to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly. – Change engine oil, short and long oil filters (old engine oil contains aggressive contaminants). – Check antifreeze and amount of cooling liquid. –Warm up the engine once again, close the fuel cock and wait until the engine dies. Then open the drain plug from the float

chamber to remove the remaining fuel.

– Remove spark plug and fill in approx. 5 cc of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in

order to distribute the oil onto the cylinder walls and mount the spark plug.

– Set piston to compression so that the valves will be closed (slowly operate the kickstarter until you can hear the automatic

decompressor click (release). – Let fuel flow out of tank into an appropriate container. – Correct tire pressure. – Lubricate pivot points of the control levers, footrests, etc. as well as the chain. – Service the shock absorber linkage. – Disassemble and charge battery. – The storage place should be dry and not subject to excessive temperature fluctuations. – Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use non air permeable materials as any humidity may

not be able to escape and could cause corrosion.

CAUTION

DO NOT LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS

DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST

RE-INITIATION AFTER TIME OF STORAGE

– Mount the charged battery (match polarity). – Fill up tank with fresh fuel. – Check motorcycle as before each start (see driving instructions). –Take a short, careful test ride first.

STORAGE

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.

CAUTION

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH

-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE

ELECTRICAL COMPONENTS

, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR, ETC. AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE

DESTRUCTION OF THESE PARTS

–You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should be cleaned additionally with

the help of a paint brush. – Before cleaning with water, plug the exhaust pipe to prevent water ingress. – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber

of the carburetor. Then take a short drive until the engine has reached the working temperature and also apply the brakes. By

warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes. – Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of

the motorcycle is allowed to evaporate. – Once the motorcycle has cooled down, oil or grease all sliding and bearing points. Treat the chain with a chain spray. Also oil the

fuel tap. –To avoid malfunctioning of the electric system, you should treat the emergency-OFF switch, short-circuit button, light switch and

socket connectors with a contact spray.

CLEANING

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions against the aggressive road salt. – clean motorcycle thoroughly and let it dry after each ride. –treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corro-

sion agent.



WARNING



EEP ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING

POWER

CAUTION

AFTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL!

CONSERVATION FOR WINTER OPERATION

Repair manual KTM 250-525 SX, MXC, EXC RACING

Art.-No. 3206007 -E

DISMOUNTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

MOUNTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

BLEEDING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION

RELEASE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

ADJUSTING THE THROTTLE CABLES . . . . . . . . . . . . . . . . . . . . . . . .3-5

INDEX

DISMOUNTING AND MOUNTING THE ENGINE

3-1C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Dismounting the engine

– Clean the motorcycle thoroughly and prop it up on a stable stand. – Dismount the seat and the tank with spoilers. – Disconnect the ground cable

1 of the battery.

– Remove the screw

2 and detach the 2 tension springs 3.

– Detach the 2 tension springs

4, pull exhaust pipes forward and take

them off the vehicle.

– Detach the 2 tension springs

6 and remove the screw 5.

– Pull the intermediate pipe forward and take it off the vehicle.

– Disconnect all plug-and-socket connections of the ignition system.

– Unhitch the cable of the hand decompressor at the engine. – Pull out the spark plug connector.

3-2C

– Remove the carburetor cover and unhitch both throttle cables.

– Detach the return spring

1 of the footbrake pedal.

– Remove the 2 screws

2 and take off the frame cover.

– Open the radiator cap. – Remove the screw

3 at the cylinder together with the sealing ring and

drain the coolant into a receptacle.

– Disconnect the water hoses

4 and 5.

– Disconnect the hose of the engine ventilation system

– Disconnect the plug-in connection from the throttle-valve sensor. – Loosen the front and rear hose clamps of the carburetor, pull the

carburetor backward and pivot it out of the rubber sleeve at the front.

–Take the carburetor off the vehicle.

– Disconnect the cable

7 from the E-starter motor.

– Disconnect the plug-and-socket connection

– Remove the screw

9 and swing the brake-fluid container sideward.

3-3C

7 8

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

– Remove the bolts 1 and take off the sprocket cover. – Remove the 2 bolts

2 of the clutch slave cylinder and pull the clutch

slave cylinder off the casing.

– Swing the chain damper plate backwards. – Open the chain joint and remove the chain from the vehicle.

– Remove the bolt

3 and take off the cable clip.

NOTE: From Model 2001 onwards a cable tie is mounted instead of the the cable clip.

– Disconnect the radiator hose

4 and dismount the tank roller 5.

– Dismount the front engine mounting bolt

– Remove the engine mounting bolt

7 and the hex nut 8.

– Dismount the swing arm pivot and pull the swing arm backwards. – Lift the engine out of the frame.

3-4C

Mounting the engine

– The engine is mounted exactly the reverse order. Be sure to use the

correct fastening torques (see technical specifications).

– After a short, careful test ride, check engine oil and coolant level once

more.

Bleeding the cooling system

To bleed the cooling system, fill in approx. 0.8 liters (0.2 US gallons) of coolant and remove the bleeder bolt

1. Do not reinstall the bleeder bolt

until coolant escapes at the bore without any bubbles. Then, fill in the coolant until it reaches a level about 10 mm above the radiator fins. After a short ride, check the coolant level once more.

Checking the adjustment of the hand decompression release cable

Start the engine and, at idling speed, slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever. The backlash until said thumping should be approx. 10 mm, measured at the lever's outer end. If necessary, correct this backlash. To adjust move back the protective cover

2, loosen the counter nut 3

and correct the adjustment screw 4 accordingly. Tighten counter nut and push back protective cover.

CAUTION

IF THERE IS NO PLAY IN THE DECO

-LEVER, THIS CAN RESULT IN ENGINE DAMAGE.

Adjusting the throttle cables

The throttle grip should always provide for a backlash of 3-5 mm. Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. To adjust the throttle cables, dismount the seat and the tank together with spoilers. Slide back the protection cover

5. Loosen the counter nut

6 and turn the adjusting screw 7 accordingly. Turning the adjusting

screw counterclockwise will reduce the backlash, turning the adjusting screw clockwise will increase the backlash. Tighten the counter nut and check whether the throttle grip can be actuated smoothly. Mount tank and seat.

3-5C

10 mm

Repair manual KTM 250-525 SX, MXC, EXC RACING

Art.-No. 3206007 -E

DISMANTLING THE ENGINE

DRAINING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

DISMOUNTING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

DISMOUNTING THE CHAIN WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

DISASSEMBLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

DISMOUNTING THE IGNITION SYSTEM (400/520 MODELS UNTIL 2002)

. .4-3 DISMOUNTING THE IGNITION SYSTEM AND LOOSENING THE PRIMARY GEAR (250 EXC MODELS FROM 2002, 450/525 MODELS FROM 2003) . .4-4

REMOVING THE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

REMOVING THE CLUTCH DRIVE AND THE OUTER CLUCH HUB . . . . . . .4-5

DISMOUNTING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

DISMOUNTING THE UPPER CYLINDER HEAD PORTION . . . . . . . . . . . . . .4-7

DISMOUNTING CYLINDER HEAD, CYLINDER AND PISTON . . . . . . . . . . .4-7

DISMOUNTING THE TIMING CHAIN AND THE TIMING GEAR . . . . . . . . .4-9

DISMOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER . . . . . .4-10

DISMOUNTING THE PRIMARY GEAR AND FREEWHEEL . . . . . . . . . . . . .4-11

DISMOUNTING THE SHIFT MECHANISM AND TRANSMISSION . . . . . . .4-12

DISMOUNTING THE BALANCER SHAFT AND CRANKSHAFT . . . . . . . . . .4-13

4-1C

INDEX

4-2C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Draining the engine oil

– Remove the bolts 1, 2, and 3, and drain the engine oil into a

receptacle.

– Remove kickstart and shift lever.

Dismounting the oil filter

– Unfasten the 4 bolts and remove both oil filter covers 4.

– Pull the 2 oil filters out of the housing.

NOTE: To pull out the oil filters, you should use circlip pliers (see photo).

Dismounting the chain wheel

– Remove collar bolt 5 and disc spring. –Take the chain wheel off the countershaft. – Pull the spacer bushing off the countershaft.

NOTE: If the transmission and clutch of the engine are okay, you can engage a gear in order to block the countershaft (force transmission to the blocked crankshaft does exist). If the countershaft cannot be blocked as described above, you have to use a holding spanner to steady the chain-wheel in order to unfasten the collar bolt.

– Pull push rod

6 out of the main shaft.

– Loosen the 2 bolts

7 and dismount the E-starter motor.

4-3C

Disassembling the clutch

– Loosen all bolts of the clutch cover and dismount clutch cover together

with gasket.

– Pull the 2 dowels out of the engine casing.

– Loosen the bolts in a crosswise order to prevent the clutch discs from

getting jammed when the clutch springs are released.

– Dismount the pressure cap together with bolts, spring retainer, and

clutch springs.

– Remove the pressure piece

–Take all lining and steel discs out of the outer clutch hub. – Remove all 12 driving pin sleeves

2 (from model 2002 on).

Up to the 2002 model: – Remove the circlip

From 2003 model: – Bend up the lock washer

4 with a flat chisel, position the clutch holder

5 with 6 driving sleeves as shown and loosen the nut 6.

NOTE: Do not remove the clutch holder to allow the flywheel nut to be removed later.

Dismounting the ignition system (models 400/520 until 2002 only)

– Unfasten the 4 bolts 7 and take the ignition cover together with the

seal off the engine casing.

4-4C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

–Turn crankshaft to TDC.

NOTE: In the TDC position, the guidepiece

A will be above the pulser coil

(see photo).

–Turn out the crankshaft fixing bolts

1 and remove the sealing ring 2.

–Turn in the crankshaft fixing bolt by hand. – If you feel any resistance, move the flywheel slightly back and forth so

that the crankshaft fixing bolt may engage the recess of the crankshaft.

–Tighten the crankshaft fixing bolt to 10 Nm/8 ft.lb.

– Loosen the collar nut

3 and remove the spring washer.

NOTE: When ordering a new part, a forged rotor will be supplied, this part is produced without rivets and is interchangeable.

Dismounting the ignition system and loosening the primary gear (model 250 EXC from 2002, models 450/525 from 2003)

– Unfasten the 4 bolts 4 and take the ignition cover together with the

seal off the engine casing.

– Holding the clutch holder mounted earlier, unscrew the nut

– Remove the clutch holder.

CAUTION

INCE A LONGER CRANKSHAFT LOCATING SCREW IS MOUNTED ON THE 250 EXC

MODELS

, IT IS IMPERATIVE THAT YOU HOLD THE CLUTCH HOLDER WHILE UNSCREWING

THE NUT

OTHERWISE YOU MAY BEND THE LOCATING SCREW AND DAMAGE THE

ENGINE HOUSING

4-5C

– Apply the special tool as shown, loosen the collar nut from the primary

gear and remove.

– Remove the special tool.

CAUTION

OLLAR NUTS WITH LEFT-HAND THREAD AND WITH RIGHT-HAND THREAD WERE USED

RESPECTIVELY

. COLLAR NUTS LABELED AS "LEFT" HAVE A LEFT-HAND THREAD.

OLLAR NUTS WITHOUT LABELING HAVE A RIGHT-HAND THREAD.

–

Turn the crankshaft to the TDC position (see illustration on page 4-4C).

–Turn out the crankshaft fixing bolts 1 and remove the sealing ring 2. –Turn in the crankshaft fixing bolt by hand. – If you feel any resistance, move the flywheel slightly back and forth so

that the crankshaft fixing bolt may engage the recess of the crankshaft.

–Tighten the crankshaft fixing bolt to 10 Nm/8 ft.lb.

Pulling off the flywheel

– Loosen the 2 bolts 3 and take the pulse generator out of the engine

casing.

– Mount the puller tool and pull off the flywheel. For the pull-off step,

use the protection cover.

– Remove the Woodruff key from the crankshaft.

CAUTION

–N

EVER USE A HAMMER OR OTHER TOOLS TO HIT AGAINST THE FLYWHEEL

. THIS

MIGHT CAUSE THE MAGNETS TO COME OFF THE FLYWHEEL AND THE CRANKSHAFT TO BE DAMAGED

–H

OLD THE PULLER TOOL TO PREVENT THE LOCATING SCREW FROM BEING BENT

(250 EXC MODEL

Removing the clutch drive and the outer clutch hub

– Insert the protection cover into the main shaft and mount the puller

tool. – Pull the inner clutch hub off the main shaft. –Take the outer clutch hub

4 together with the bearing bush and the

2 stop discs off the main shaft.

NOTE: In the 2001/2002 models, disk

5 is replaced by a stepped disk

and the bushing by 2 needle bearings 6 (see illustration).

4-6C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

From the 2003 model: – Remove the outer clutch hub

1 together with the stepped disk 2

and both half disks 3 from the main shaft.

– Remove both needle bearings

4 and the supporting plate.

Dismounting the oil pump

– Loosen the 2 bolts 5 and remove the oil pump cover.

– Pull needle roller 6, inner rotor 7 and outer rotor 8 out of the oil

pump casing.

– Remove banjo bolt

9 and jet bolt bk together with their sealing rings

and dismount the oil line.

4-7C

Dismounting the upper cylinder-head portion

– Loosen each of the 6 bolts together with their sealing rings and

dismount both valve covers

1 together with their gaskets.

– Unscrew the spark plug.

– Unfasten 4 bolts and dismount the water pump cover

2 together with

its gasket.

– Loosen all bolts

3 of the upper cylinder head part.

– Use a plastic hammer to carefully tap upwards in area

A and lift off

the upper cylinder head part.

Dismounting cylinder head, cylinder and piston

– Dismount the bolt 4 together with the sealing ring and the pressure

spring. – Unfasten the 2 bolts and pull the timing-chain tensioner out of the

cylinder.

4-8C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

– Apply the timing chain separating tool and open the timing chain by

turning the spindle (see photo).

CAUTION

–M

AKE SURE THAT THE PUSHED-OUT BOLTS DO NOT FALL INTO THE ENGINE.

–P

REVENT THE TIMING CHAIN FROM FALLING INTO THE CHAIN TUNNEL.

–T

HE OPENED RIVET LINK IS TO BE DISCARDED.

NOTE: Every rivet link of the timing chain can be opened.

–To keep the timing chain from falling into the chain tunnel, you should

insert a cable tie through the ends of the timing chain.

– Extract the camshaft from the cylinder head.

– Remove the 3 bolts

NOTE: – If no repairs to the cylinder and cylinder head are necessary, these 3

bolts need not be removed. You can dismount the cylinder and the cylinder head as one. In this case, the cylinder head gasket need not be replaced.

–from Model 2001 onwards the bolt outside the chain tunnel is moun-

ted with a copper seal ring (6x10x1)

– Remove the 4 cylinder-head bolts

2 together with washers and

dismount the cylinder head together with the cylinder head gasket.

– Pull the cylinder upward while holding the piston.

4-9C

– Remove the wire circlip and the push piston bolt from the piston.

Dismount the piston.

Dismounting timing chain and timing gear

– Loosen the 2 bolts 1 and dismount the fall-out protection element 2. – Remove the timing chain.

– Remove the bolts

3 and 4. Pull timing chain tensioner and timing

chain guide upward out of the engine casing.

– Remove circlip

– Apply the puller tool and pull the timing gear off the crankshaft.

4-10C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Dismounting E-starter drive gear and kickstarter

– Remove the 2 circlips 1 and the stop discs. Pull the kickstarter idler

gear

2 and the E-starter idler gear 3 off the bearing bolts.

– Pull the reduction gear and the needle bearing off the bearing bolt.

Take the bearing bolt out of the engine casing.

– Carefully loosen the collar bolt

4 while holding down the kickstarter

spring. Release the kickstarter spring and unhitch the spring shackle.

CAUTION

E CAREFUL WHEN RELEASING THE KICKSTARTER SPRING, AS THE RECOILING

KICKSTARTER SPRING MAY CAUSE INJURY

– Pull the kickstarter shaft together with ratchet gear, spring, and disc

out of the engine casing.

– Slide back the sliding plate and pull the shift shaft together with the

stop disc

5 out of the engine casing.

– Remove the bolt

6 and dismount the shift arrester.

– Remove the bolt

7, dismount the arrester lever together with bushing

and spring.

NOTE: The arrester lever only needs to be dismounted if the engine casing is exchanged.

– Remove the tab washer

8. Pull stop disc, oil pump wheel, and needle

roller off the oil pump shaft.

4-11C

Dismounting primary gear and free wheel

– Remove the collar nut 1.

CAUTION

OLLAR NUTS WITH LEFT

-HAND THREAD AND WITH RIGHT-HAND THREAD WERE USED

RESPECTIVELY

. COLLAR NUTS LABELED AS "LEFT" HAVE A LEFT-HAND THREAD.

OLLAR NUTS WITHOUT LABELING HAVE A RIGHT-HAND THREAD.

NOTE: The collar nut

1 was already removed from the 250 EXC models

from 2002 and the 450/525 models from 2003 as described on page 4-5.

– Loosen the 2 bolts 2 and dismount the oil pump cover.

–Take the oil pump shaft together with needle roller, inner rotor

3 and

outer rotor

4 out of the engine casing.

– Remove 2 bolts

5 opposite located.

– Mount the puller tool and pull the primary gear off the crankshaft.

– Loosen the crankshaft fixing bolt. – Loosen each of the 13 casing bolts.

4-12C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Dismounting shift mechanism and transmission

–Turn the engine sideward. – Unfasten the engine fixture at the engine work stand – Applying a suitable tool to the cast-on members on the casing, lift off

the left half of the casing, or separate it from the right half by slightly tapping on the countershaft with a plastic hammer.

CAUTION

RY TO AVOID PRYING THE HALVES APART WITH A SCREWDRIVER OR A SIMILAR TOOL

AS THIS IS APT TO INFLICT DAMAGE ON THE SEALING SURFACES

– Dismount the left casing half and the gasket. – Pull the 2 dowels out of the engine casing and secure the right half of

the casing in the work stand.

– Remove the stop disc

1, O-ring 2, and inner ring 3.

– Pull both shift rails

4 together with the 4 springs out of the engine

casing and swing the shift forks sideward.

– Pull the shift roller

5 out of the bearing seat.

– Remove the shift forks

NOTE: During disassembly, watch out for the shift rolls

A on the driving

pins of the shift forks. They may remain in the shift roller.

– Pull main shaft and countershaft out of the bearing seats

simultaneously.

–Take 1st speed idler gear

7 together with needle cage and the two

stop discs out of the engine casing.

4-13C

Dismounting balancer shaft and crankshaft

–Turn the crankshaft until the marks on the balancer shaft and

crankshaft match. – In this position, the balancer shaft can be pulled out of the bearing

seat.

– Pull the crankshaft out of the bearing seat.

– Clean all components, check them for wear and, if necessary, replace

them with new ones.

NOTE: For a complete engine overhaul procedure, we recommend that you replace all gaskets, shaft seal rings, O-rings, and bearings.

Repair manual KTM 250-525 SX, MXC, EXC RACING

Art.-No. 3206007 -E

SERVICING INDIVIDUAL COMPONENTS

LEFT CASING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

RIGHT CASING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

CRANKSHAFT WEBS - MEASURE OUTER DIMENSION . . . . . . . . . . . . . . .5-7

DRIVING GEAR OF BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

COMPENSATING THE AXIAL CLEARANCE OF THE CRANKSHAFT . . . . . . .5-7

CYLINDER - NICASIL COATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

MEASURING PISTON AND CYLINDER, PISTON FITTING CLEARANCE . . . .5-8

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

MEASURING PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

CHECKING THE OIL PUMPS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

UPPER PORTION OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

PREASSEMBLING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

TIMING TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

CHECKING THE CLUTCH FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

CHECKING THE KICKSTARTER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . .5-19

PREASSEMBLING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . .5-19

SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

PREASSEMBLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

ASSEMBLING THE MAIN SHAFT (4-SPEED) . . . . . . . . . . . . . . . . . . . . . . .5-22

ASSEMBLING THE MAIN SHAFT (6-SPEED) . . . . . . . . . . . . . . . . . . . . . . .5-23

ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

REPLACING THE STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

E-STARTER DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

CHECKING THE FREE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27

REPLACING THE FREE WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27

INDEX

5-1C

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. A wooden panel is best used as a base.

Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx. 150° C.

After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must be replaced.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-2C

Left casing half

Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C.

Cylindrical roller bearing of crankshaft

Use a suitable punch to press the cylindrical roller bearing from the outside to the inside. From the inside, press in a new cylindrical roller bearing up to the stop.

Grooved ball bearing of main shaft

Use a suitable punch to press the grooved ball bearing from the outside to the inside. From the inside, press in a new grooved ball bearing up to the stop.

Cylindrical roller bearing of countershaft

Use a suitable punch to press the cylindrical roller bearing from the outside to the inside. From the inside, press in a new cylindrical roller bearing up to the stop.

Shaft seal ring of shift shaft

From the outside, press in new shaft seal ring up to a flush position, its open side facing inward.

Shaft seal ring of countershaft

From the outside, press in new shaft seal ring up to a flush position, its open side facing inward.

Grooved ball bearing of balancer shaft

Use a bearing extractor to pull the grooved ball bearing out of the casing half. Press a new grooved ball bearing in up to the stop.

Grooved ball bearing of shift roller

At a casing temperature of approx. 150°C, the grooved ball bearing will fall out from the bearing seat almost by itself. If necessary, knock the casing half lightly on a planar wooden board. Press a new grooved ball bearing in to a flush position.

Needle bearing of shift shaft

Press needle bearing from the outside to the inside. Press a new needle bearing in from the inside and up to a flush position.

– Once the casing half has cooled down, check the bearings for tight fit.

5-3C

The oil pump housing must not have any score marks or seizing marks.

Blow compressed air through all oil ducts and check them for unobstructed passage.

Check the 2 dowels

1 for tight fit and, if necessary, adhere them by

means of Loctite 243.

Right casing half

Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C.

Cylindrical-roller bearing of crankshaft

Use a suitable punch to press the cylindrical-roller bearing from the outside to the inside. From the inside, press in a new cylindrical-roller bearing up to the stop.

Grooved ball bearing of main shaft

Use a suitable punch to press the grooved ball bearing from the outside to the inside. From the inside, press in a new grooved ball bearing up to the stop. NOTE: The grooved ball bearing on the main shaft

3 is secured with a

screw from the 2003 models. Apply Loctite 243 to the thread of the screw and tighten to 5 Nm.

Grooved ball bearing of countershaft

Use a suitable punch to press the grooved ball bearing from the outside to the inside. From the inside, press in a new grooved ball bearing up to the stop.

Shaft seal ring of crankshaft

Press in new shaft seal ring to a flush position, its open side facing inward.

Bearing bolt of the kickstarter idler gear

Bearing bolt of the E-starter idler gear 7 By experience, no wear occurs on the bearing bolts. Exchanging of bearing bolts is possible only to a limited extent because, in most cases, this will cause damage to the casing.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-4C

Grooved ball bearing 1 and seal ring 2 of balancer shaft. Use a bearing extractor to pull the grooved ball bearing out of the casing half and remove the seal ring. Press a new shaft seal ring in to a flush position, its open side facing downward. Press new grooved ball bearing in up to the stop.

Grooved ball bearing of shift roller

Remove the screw A. At a casing temperature of approx. 150°C, the grooved ball bearing will fall out from the bearing seat almost by itself. If necessary, knock the casing half lightly on a planar wooden board. Press new grooved ball bearing in to a flush position. Coat the thread of the screw

A with Loctite 243 and tighten the screw to 5 Nm/4 ft.lb.

Needle bearing of shift shaft

Press needle bearing from the outside to the inside. Press new needle bearing in from the outside and up to a flush position.

– Once the casing half has cooled down, check if the fit of the bearings

is tight.

Kickstarter release plate

When exchanging the release plate, secure both bolts with Loctite 243 and tighten to 8 Nm/6 ft.lb.

The oil pump casing

6 must not have any score marks or seizing marks.

Check oil ducts

7 for unobstructed passage.

NOTE: In order to clean all oil ducts and check them for unhindered passage you should dismantle both jets and the bypass valve (see below).

Oil jet "60"

Dismount the oil jet and blow compressed air through the oil duct. Degrease the thread of the oil jet, apply Loctite 243 and mount the oil jet.

NOTE: Through this jet, engine oil is sprayed to the piston bottom in order to cool the piston.

5-5C

Oil jet "100" 1 Dismount the oil jet and clean with compressed air. Degrease the thread of the oil jet, apply Loctite 243 and mount the oil jet.

NOTE: This jet is used to dose the amount of oil for the conrod bearing.

Bypass valve Check valve plunger, sealing seat, and pressure spring for damage.

Minimum length of pressure spring

2: 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 decrease. This causes a decrease in oil pressure and subsequently increased wear.

Clean all oil ducts with compressed air and check them for unobstructed passage.

Clutch cover

Shaft seal ring of kickstarter shaft 3 Remove the old shaft seal ring by levering it out with a screwdriver. Press a new shaft seal ring in up to the stop.

Shaft seal ring of crankshaft

Remove the old shaft seal ring by levering it out with a screwdriver. Press a new shaft seal ring in up to the stop, its open side facing downward.

Oil duct

Clean with compressed air and check for unobstructed passage.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-6C

Crankshaft

If the conrod bearing is replaced, take care to properly position the crankpin. The bores of the crank web

A and crank pin B must coincide.

CAUTION

IF THE CRANK PIN IS PRESSED IN THE WRONG POSITION, THE CONROD BEARING IS

SUPPLIED INSUFFICIENTLY OR NOT AT ALL WITH ENGINE OIL

, WHICH RESULTS IN

BEARING DAMAGE

If the crankshaft will continue to be used, check crankshaft journals for run out. Place crankshaft on a roller block or a similar device and check the outer end of the journals for run out with a dial gauge.

Run out of crankshaft journals: max. 0.08 mm (0.0032 in)

Run out of crankshaft journals (Modelle 2003): max. 0,12 mm (0.0048 in)

The radial play and axial play on the conrod bearing must be checked.

radial clearance: max. 0.05 mm (0.0019 in)

axial clearance: max. 1.10 mm (0.0476 in)

NOTE: From Model 2001 onwards the conrod

2 is mounted without

thrust washers

1, but the conrod overhaul set (see drawing below) is the

same for both Model 2000 and 2001. The trust washers included in the set are not used for Model 2001 engines.

5-7C

Crankshaft webs – measure outer dimension

Crankshaft webs – measure outer dimension with a sliding caliper as illustrated.

Crankshaft webs – outer dimension = 65 mm ± 0.05 mm

Driving gear of balancer shaft

– Before pulling the driving gear off the balancer shaft you have to

remove the inner ring of the crankshaft bearing: – For this purpose, secure the crankshaft with the crankshaft web

carrying the inner ring to be replaced in a vise. – Heat the special tool 584.29.037.037 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.

– Remove both screws on the drive wheel. – Insert 2 screws

1 in the M6 thread 2.

– Pull off the driving gear by turning in the bolts equally.

–To mount the drive gear, heat it to approx. 100°C. – Degrease the 2 retaining bolts of the drive gear and coat the threads

with Loctite 243. – Slip the drive wheel on the crankshaft such that the mark

C is

disposed in the region of the crank pin. – Mount the retaining bolts and tighten them to 8 Nm (6 ft.lb).

–To mount the new inner ring, heat the special tool again to approx.

150°C, engage the inner ring and slip it on the crankshaft journal

immediately. – Allow the inner ring to cool for about 30 seconds and hammer the

inner ring in once more by means of a suitable tube so as to ensure its

proper fit. – Having exchanged the inner rings, measure the axial clearance of the

crankshaft.

CAUTION

EVER CLAMP THE CRANKSHAFT IN A VISE WITH A CRANKSHAFT JOURNAL AND TRY TO

HAMMER THE INNER BEARING RING APART

. THIS WOULD CAUSE THE CRANKSHAFT

WEBS TO BE COMPRESSED

, MAKING THE CRANKSHAFT UNSUITABLE FOR FURTHER USE.

Compensating the axial clearance of the crankshaft

– Insert the crankshaft into the right casing half and apply the casing

gasket. – Mount and tighten the casing bolts in the region of the crankcase. – Mount the dial gauge holder on the engine casing and measure the

crankshaft's axial clearance.

Axial clearance: 0.1 - 0.2 mm (0.0039 - 0.0078)

– If the value measured does not correspond to the desired value,

correct the axial clearance. – For this purpose, dismantle the crankshaft and use the special tool to

pull the inner ring on the side of the ignition off the crankshaft. Now,

add or remove compensating washers.

NOTE: If the axial clearance is too large, you have to add compensating washers. If axial clearance is too small, you have to remove compensating washers. These compensating washers may be added only on the ignition side.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-8C

Cylinder – Nikasil coating

Nikasil is the brand name for a cylinder coating process, developed by the piston manufacturer Mahle. The name is derived from the two materials used in this process - a nickel layer into which the particularly hard silicon carbide is embedded. The main advantages of the Nikasil coating are excellent heat dissipation and thus better power output, low wear and low weight of the cylinder. The worn coating can be regenerated at low cost provided that the running surface of cylinder is flawless.

Measuring piston and cylinder, determining the piston fitting clearance

– In order to determine the wear of the cylinder, measure the cylinder

center of the running area with a micrometer.

– Measure the diameter of the x-axis and the y-axis in order to check for

oval wear, if any.

Cylinder diameter 250 size I: 75.000 - 75.012 mm

size II: 75.013 - 75.025 mm

Cylinder diameter 400/ size I: 89.000 - 89.012 mm 450 EXC/MXC size II: 89.013 - 89.025 mm

Cylinder diameter 520/ size I: 95.000 - 95.012 mm 450 SX / 525 size II: 95.013 - 95.025 mm

NOTE: The size of the cylinder 1 is marked on the cylinder, the size of the piston is marked at the top of the piston 2. – The piston is measured on the piston skirt across to the piston pin as

shown in the illustration.

Diameter of piston 250 size I: 74.960 - 74.970 mm

size II: 74.971 - 74.980 mm

Diameter of piston 400 size I: 88.930 - 88.940 mm

size II: 88.941 - 88.950 mm

Diameter of piston 450 EXC/MXC

size I: 88.916 - 88.946 mm size II: 88.926 - 88.956 mm

Diameter of piston 520 size I: 94.942 - 94.950 mm

size II: 94.951 - 94.958 mm

Diameter of piston 450 SX / 525

size I: 94.932 - 94.960 mm size II: 94.940 - 94.968 mm

– The cylinder diameter minus the piston diameter yields the piston

assembly clearance.

Piston assembly clearance 250 piston size I: 0.030 - 0.052 mm

piston size II: 0.032 - 0.055 mm wear limit: 0.12 mm

Piston assembly clearance 400 piston size I: 0.060 - 0.082 mm

piston size II: 0.062 - 0.085 mm wear limit: 0.12 mm

Piston assembly clearance size I: 0.054 - 0.096 mm 450 EXC/MXC piston size II: 0.056 - 0.099 mm

wear limit: 0.12 mm

Piston assembly clearance 520 piston size I: 0.050 - 0.070 mm

piston size II: 0.054 - 0.075 mm wear limit: 0.12 mm

Piston assembly clearance piston size I: 0.040 - 0.080 mm 450SX/525 piston size II: 0.044 - 0.085 mm

wear limit: 0.12 mm

NOTE: Dimensions in Inch see Technical Specification.

Checking the oil pumps for wear

– Place inner and outer rotors into the engine casing such that the marks

are adjacent to one another. – Now, carry out the following wear measurements with a feeler

gauge

outer rotor - oil pump housing: max. 0.20 mm (0.0078 in)

outer rotor - inner rotor: max. 0.20 mm (0.0078 in)

5-9C

Checking the piston

– Replace the piston in the case of excessive oil consumption or grooves

in the piston skirt. – If reinstalling the old piston perform the following steps:

1. Piston bearing surface - check for damage.

2. Piston ring grooves - the piston rings must move easily in the groove.

Old piston rings or sandpaper (400 grit) may be used to clean the

piston ring grooves.

3. Piston rings - check for damage and end gap (see below).

Mount the oil scraper ring with the labeling "TOP" facing upwards.

Mount the rectangular ring with the labeling "O" facing upwards.

4. Piston pin: If the piston pin is heavily discolored or has score marks it

must be replaced. Also insert the piston pin into conrod and check its

bearing for play.

NOTE: When in place, the piston pin may not have any play. It must be possible to shift it with slight counterpressure.

Piston ring end gap

– Insert piston ring into the cylinder and adjust. Piston ring must be

approx. 10 mm (0.4 in) from top of cylinder. – The end gap can now be checked which a feeler gauge

Compression rings: max. 0.80 mm (0.0315 in)

Oil scraper ring: max. 1.00 mm (0.0393 in)

If the end gap is larger, check piston and cylinder for wear. If piston and cylinder wear are within the permitted tolerance limits, replace the piston ring.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-10C

Lubrication system

Oil line

Check for hairline cracking at the soldering joints, blow compressed air through the oil line and, while doing that, check it for unobstructed passage. In addition, check the oil line for possible scuff marks and replace the copper seal rings (8x12x1)

O-rings

Replace the O-rings during every oil filter change.

Oil pump cover

Check for score marks caused by the oil pump rotors on its inner side and, if necessary, replace it.

Oil pump shaft

Place it on a planar surface and check it for eccentricity.

Oil pump wheel

Check toothing for wear. The recess for the needle roller must not be worn out.

Oil screen

Clean the two oil screens with compressed air and petroleum.

O-rings

Check them for brittleness and, if necessary, replace them.

Oil pump rotors

Place the oil pump rotors into the engine casing and check them as shown on page 5-9. No particles must adhere to the oil pump rotors.

5-11C

Upper portion of cylinder head

– Remove circlip 1 and pull the decompressor shaft 2 together with

spring

3 out of the bore.

– Pull the two end pieces

4 together with the rocker arm pins 5 + 6

out of the cylinder head's upper portion. Withdraw the rocker arms 7.

– Clean all components and check them for wear.

Rocker arm pins

5 + 6

The rocker arm pins must not have any score marks and turning them in the rocker arms

7 must be easy.

Rocker arm rollers

Check if they move smoothly; if you detect any radial play, you have to replace the rocker arm.

Adjusting bolts

The seating surfaces of the adjusting bolts must be planar.

Decompressor shaft

Check for smooth movability and play in the bearing bore. Replace the O-ring

bl.

Replace the O-rings

– Prior to assembly, oil all components thoroughly. – Position rocker arms in the cylinder head's upper portion and mount

the rocker arm pins.

NOTE: The shorter rocker arm pin

6 must be mounted in the back.

– Mount the end pieces

4 and turn them such that later on the bolts of

the cylinder head's upper portion can be mounted. – Mount the decompressor shaft

2 and preload the spring.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-12C

Cylinder head

– Loosen the 3 bolts 1 and dismount the exhaust flange 2 together

with its gasket.

– Dismount the 4 valves with the aid of a special tool.

NOTE: – Conical springs are mounted on the 250 EXC and 450/525 SX models

from 2003.

– When being mounted again, used valves must be mounted in the

same valve guide as before. For this purpose, place the valves in a cardboard box in the same position they were mounted in the cylinder head (see photo).

Model 2003 250/450, 525 SX

5-13C

–Take the valve spring retainer 1 and the valve springs 2 out of the

cylinder head. – Pull the valve stem gaskets off the valve guides and remove the spring

seats

NOTE: Conical springs are mounted on the 250 EXC and 450/525 SX models from 2003.

Sealing surface Check the spark plug thread and the valve seats for damage and cracks. Use a ruler and a feeler gauge to check the sealing surface of the cylinder head for distortion. Max. distortion: 0.10 mm (0.0039 in).

Valve guides The valve guides are checked with a limit plug gauge

4 (Ø 6.05 mm). If

the limit plug gauge can be easily inserted into the valve guide, the guide must be replaced in a specialized workshop.

Valve seats The valve seats must not be "battered". Sealing seat width: inlet: 1.50 mm max. (0.0590 in); outlet: 2.00 mm max. (0.0787 in). If necessary, the valves must be reseated.

Valves Check the valve disc for wear and eccentricity. Max. eccentricity at valve disc: 0.03mm. The valve seat must not be "battered". The sealing surface should be in the middle of the valve seat. The valve stem is chromehardened; by experience, wear occurs at the valve guide.

Valve springs Check the valve springs for fractures or wear (visual check); use a sliding caliper to measure the length. The minimum length may not be less than

39.20 mm/1.4252 in (outer valve spring) and 36.45 mm/1.435 in (inner valve spring). Replace the spring if it is shorter – also see Technical Information 0003/30/02.

Valve springs (250 EXC, 450/525 SX from the 2003 model) Check the valve springs for fractures or wear (visual check); use a sliding caliper to measure the length. The minimum length of the valve springs may not be less than 37.70 mm for the 250 EXC and 38.30 mm for the 450/ 525 SX model. Replace the spring if it is shorter.

Valve stem gaskets Every time the valves are dismounted you should replace the valve stem gaskets.

– Place the 4 spring seats

3 into the cylinder head.

– Slip the valve stem gaskets onto the valve guides and oil them. – Thoroughly oil the valves at the stem and insert them into the valve

guides. When mounting them, watch for the correct position of the

valves.

– Position the valve springs

2, place the valve spring retainer 1 into the

valve springs.

NOTE: The outer valve springs must be mounted with the more narrowly wound end facing downward (up to model 2001).

–Preload the valve springs with the special tool and mount the valve

keys.

NOTE: When mounting the valve keys ensure their proper fit. It is best to secure the valve keys to the valve by means of some grease.

– Finally, use a plastic hammer to tap several times onto the valve spring

retainers.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Camshaft

– Dismount circlip 1 and water pump wheel 2. – Pull the needle roller

3 out of the hole in the camshaft and pull the

gasket carrier

4 off of the camshaft.

– Use the puller tool to extract the grooved ball bearing

5 from the

camshaft (see photo).

CAUTION

NEVER CLAMP THE CAMS OF THE CAMSHAFT INTO A VISE.

– Unhitch the spring

6 at the automatic decompressor shaft 7 and at

the same time pull the autodecompressor shaft out of the camshaft.

– Loosen the 2 bolts

8 and take off the camshaft wheel 9.

– Use the puller tool to pull the grooved ball bearing

bk off the camshaft.

Clean all components, check them and if necessary replace them with new components.

Camshaft Check bearing seats and cams for wear.

Renew grooved ball bearings

5 and bk

Autodecompressor shaft 7 Check bearing for play and contact surface to the rocker arm for wear.

Camshaft wheel

Check teeth for wear.

Check the bolt

bl for tight fit.

NOTE: The self-locking nut

bm was replaced by a normal nut starting with

the 2002 model. Secure the nut with Loctite 222 and tighten to 8 Nm – see Technical Information 0111/36/02 for models up to 2001.

5-14C

–Press the shaft seal rings 1 out of the gasket carrier 2. –Press the new shaft seal rings in up to a flush position, with the open

side facing outwards. Thoroughly grease the sealing lips.

–Take the 2 O-rings

3 off the gasket carrier and remove the gasket

residues with a wire brush. – Mount 2 new O-rings.

NOTE: – The two O-rings

3 have different sizes starting with the 2002 model.

The smaller O-ring is mounted on the outside, i.e. facing the water

pump wheel. – The flat marks of the rear side of the gaskets carrier are neccesary only

if the gasket carrier is to be taken out with the timing chain mounted,

the flat marks make the fitment of the gasket carrier easier. – Starting with the 2002 model, the gasket carrier can be pulled out of

the cylinder head with the two M3 threads

4 without having to

remove the top part of the cylinder head.

Preassembling the camshaft

– Coat the threads of the 2 bolts 6 with Loctite 243 and mount the

camshaft wheel

7. Tighten bolts to 28 Nm (21 ft.lb).

– For preassembly, press on the grooved ball bearing

5 by means of a

hollow punch. – Mount the autodecompressor shaft

8 and the spring 9. Preload the

spring by approx. 1/2 turn and insert the end of the spring into the

groove

Now, check whether the autodecompressor shaft turns back into its

initial position by itself. If not, increase the preloading of the spring. – Slide on the washer

bk (only applies to the 2002 model).

The following steps only apply to models up to 2001

(see page 6-12 for models from 2002 onwards) – Slide on the mounting sleeve A and mount the gasket carrier 2 with

the collar

bl facing the camshaft wheel.

CAUTION

TISIMPERATIVE THAT YOU USE THE MOUNTING SLEEVE. OTHERWISE YOU WILL

DAMAGE THE SHAFT SEAL RING

– Dismount the mounting sleeve, insert the needle roller

bm into the

camshaft and mount the water pump wheel

bn with the circlip bo.

NOTE: From Model 2001 onwards the length of the needle roller is

17.8 mm (0.7007 in); Model 2000: 13.8 mm (0.5433 in). The needle roller and water pump wheel are only changeable as a set.

5-15C

Model 2002

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-16C

Timing chain tensioner

– Pull the pressure pin of the timing chain tensioner out all the way and

check whether or not it moves smoothly.

– Check the toothing on the pressure pin and the ratcheting pawl for

wear.

– For mounting, push the ratchet in the direction of the arrow so that

the pressure pin will no longer be locked and push the pressure pin all the way into the tensioner housing.

Timing train

Clean all components thoroughly and check them for wear.

Timing gear

Check the toothing for broken-off parts and wear.

Timing chain tensioner rail

Check for seizing marks at the contact surface.

Timing chain guide

Check for seizing marks at the contact surface.

Rivet link

The opened rivet link of the timing chain must be replaced.

Modell 450 SX

LOCTITE 243

5-17C

Checking the clutch for wear

Thrust bearing 1 Check it for seizing marks and unobstructed movability.

Push rod 2 Place it on a planar surface and check it for eccentricity.

Clutch springs 3 Minimum length: 42 mm (1.6535 in) - new: 43 mm (1.6929 in); if necessary, replace all 6 springs.

7 lining discs

Minimum thickness: 1.7 mm (0.0669 in) - new: 1.8 mm (0.0708 in). The lining discs must be planar.

8 intermediate discs

5 (up to model 2001)

They must be planar. Check them for mechanical damage. In the case of punctual broken-off portions, you have to replace the intermediate discs.

Four 1.4 mm (0.0551 in)

6 clutch disks (models from 2002 onwards)

Must be planar. Check for mechanical damage. Replace clutch disks if localized points are broken off.

Four 1.0 mm (0,03937 in)

7 clutch disks (models from 2002 onwards)

Must be planar. Check for mechanical damage. Replace clutch disks if localized points are broken off.

Inner clutch hub

Check the outer toothing A on the inner clutch hub. If the depressions are greater than 0.5mm (0.0196 in), the inner clutch hub must be replaced. A modified driver with sleeves

9 is installed starting with the 2002 model.

Pressure cap bk Check the seating surface B of the steel disc for damage.

Outer clutch hub bl Check the stop surfaces C of the lining disk and the clutch cage for wear. If the depressions are greater than 0.5 mm (0.0196 in) the lining disk and clutch hub must be replaced.

Bearing bush

Slip the bearing bush and the outer clutch hub on the main shaft and check the bearing for clearance. If necessary, replace the bearing bush.

NOTE: – Every time the inner clutch hub is replaced, the bearing bush should be exchanged as well (Model 2000). –from Model 2001 onwards two needle bearings

bm are mounted instead of the bearing bush bo, the outer clutch hub is replaced

with a hardened version, the support washer

bn is replaced with a step washer bp and the mesh of the shaft is different.

Modification - Model 2001

Modification - Model 2002

5-18C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Modell 2003

Checking the clutch for wear

Pressure piece 1 Check it for seizing marks and unobstructed movability.

Axial needle bearing

Check for damage.

Push rod

Place it on a planar surface and check it for eccentricity.

Clutch springs 4 Minimum length: 42 mm (1.6535 in) - new: 43 mm (1.6929 in); if necessary, replace all 6 springs.

7 lining discs

Minimum thickness: 1.7 mm (0.0669 in) - new: 1.8 mm (0.0708 in). The lining discs must be planar.

Four 1.4 mm (0.0551 in)

6 clutch disks

Must be planar. Check for mechanical damage. Replace clutch disks if localized points are broken off.

Four 1.0 mm (0,03937 in)

7 clutch disks

Must be planar. Check for mechanical damage. Replace clutch disks if localized points are broken off.

Inner clutch hub

Check for seizing marks and damage.

Pressure cap

Check the seating surface A of the steel disc for damage.

Outer clutch hub

Check the stop surfaces B of the lining disk and the clutch cage for wear. If the depressions are greater than 0.5 mm (0.0196 in) the lining disk and clutch hub must be replaced.

Needle bearing

Check for seizing marks and damage.

LOCTITE 243

5-19C

Checking the kickstarter for wear

Take all components off the kickstarter shaft and clean them.

Kickstarter gear

Check the toothing for wear and the bearing for clearance.

Kickstarter idler gear

Check the bearing for clearance and seizing marks. Check the toothing for wear. It is constantly engaged with the outer clutch hub.

Kickstarter ratchet gear

Check the inclined surface and the toothings for wear.

Kickstarter shaft

Check bearing positions and toothings for wear and damage. Check the oil bore for the kickstarter gear for unobstructed passage.

Preassembling the kickstarter shaft

– Clamp the kickstarter shaft 4 with the toothed end facing upward

into a vise (use protection jaws).

– Mount stop disc

5, needle bearing 6 and kickstarter gear 1 with the

locking teeth facing downward.

– Slip on the stop disc

7 and mount the circlip 8 with the sharp edge

facing upward.

– Mount the driving hub

9 such that the recess is located above the

bore in the kickstarter shaft.

– Mount kickstarter spring

bk and hook starter spring leg into kickstarter

shaft bore.

– Unclamp the kickstarter shaft. – Slip the kickstarter ratchet gear

3 on the kickstarter shaft such that

the marks A mates with the oil duct B in the kickstarter shaft.

– Mount the ratchet gear spring

bl and the stop disc bm on the

kickstarter shaft.

5-20C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

5-21C

Shift mechanism

Shift forks 1 Check plate A for wear. The forks are 4.8mm - 4.9 mm (0.1889 in -

0.1929 in) thick in a new condition. The wear limit is at 4.6 mm (0.1811 in).

Shift roller 2 Check the shift grooves B for wear. Check the fit of the shift roller in the grooved ball bearing

Grooved ball bearing

Check it for smooth movability.

Shift rolls

Check the shift rolls for pressure marks and cracks.

Shift rails

Check the shift rails for eccentricity on a planar surface. Check the shift rails for score and seizing marks. The smooth movability of the shift forks on the shift rails must be ensured.

Sliding plate

Check it for wear at the points of engagement C. Check the return surface

D on the sliding plate for wear (replace it in case

of severe notching). Check the guide bolts

E for tight fit and wear.

Shift mechanism Preassemble the shift shaft and check the clearance

F between the

sliding plate

6 and the shift element. The clearance must be 0.40 -

0.80 mm (0.0157 - 0.0315 in).

Preassembling the shift shaft

– Secure the short end of the shift shaft in a vise (use

protection jaws).

– Mount the sliding plate

6 with the guide bolt facing

downward and engage the guide bolt at the shift element.

– Mount the pressure spring

– Slide on the spring guide

8, slide the return spring 9

with its dropped end facing upward over the spring guide and lift the dropped end over the counterbearing bolt

bl (see photo).

– Mount the stop disc

bk.

5-22C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Transmission

Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following parts for wear and grooves:

● Bearings

● Pivot points of the main shaft and countershaft and pivot points of the idler gears

● Shift dogs of the gears

● Tooth faces of all gears

● Tooth profiles of the main shaft and countershaft as well as of the corresponding gears

● Check the profiles of all control gears for smooth operation

Thoroughly clean all parts, exchange damaged components. New axial securing elements should be mounted whenever repair work is performed.

Assembling the main shaft (4-speed)

– Secure the main shaft with the toothed end facing downward in a vise (use protection

jaws). – Prior to assembly, oil all components thoroughly. – Mount the spacer bushing

1 and the 3

rd/4th

speed sliding gear 2 with the small gear

facing downward. – Mount the spacer bushing

3 and the 2

speed fixed gear 4 with the collar facing

downward. – Slip on the stop disc

5 (17.2x30x1 mm).

– Then, check all gear wheels for smooth movability.

NOTE: From Model 2001 onwards the spacer bushings

1 and 3 are made of steel (before

they were made of aluminium), the steel version can be used in Model 2000 gearboxes.

5-23C

Transmission

Clamp the main shaft or counter shaft, respectively, into the vise (use protective jaws). Remove the gears and check the following parts for wear and grooves:

● Bearings

● Pivot points of the main shaft and countershaft and pivot points of the idler gears

● Shift dogs of the gears

● Tooth faces of all gears

● Tooth profiles of the main shaft and countershaft as well as of the corresponding gears

● Check the profiles of all control gears for smooth operation

Thoroughly clean all parts, exchange damaged components. New axial securing elements should be mounted whenever repair work is performed.

Assembling the main shaft (6-speed)

– Secure the main shaft with the toothed end facing downward in a vise (use protection

jaws). – Prior to assembly, oil all components thoroughly. – Mount the split needle bearing

2, slip on the 5

speed idler gear 1 with the shift dogs

facing upward. – Mount the stop disc

3 (25.2x32x1.5 mm) and the circlip 4 with the sharp edge pointing

upward. – Slip on the 3

rd/4th

speed sliding gear 5 with the small gear facing downward and mount

the circlip 6. – Slip on the stop disc

7 (25.2x32x1.5 mm) and the split needle bearing 8.

– Slip on the 6

speed idler gear 9 with the recess pointing upward.

– Slip on the 2ndspeed fixed gear bk with the collar facing downward and the stop disc bl

(17.2x30x1 mm).

– Then, check all gear wheels for smooth movability.

5-24C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Transmission

Clamp the main shaft or countershaft, respectively, into the vise (use protective jaws). Remove the gears and check the following parts for wear and grooves:

● Bearings

● Pivot points of the main shaft and countershaft and pivot points of the idler gears

● Shift dogs of the gears

● Tooth faces of all gears

● Tooth profiles of the main shaft and countershaft as well as of the corresponding gears

● Check the profiles of all control gears for smooth operation

Thoroughly clean all parts, exchange damaged components. New axial securing elements should be mounted whenever repair work is performed.

Assembling the countershaft (4 and 6-speed)

– Secure the countershaft with the toothed end facing downward in a vise (use protection

jaws). – Prior to assembly, oil all components thoroughly. – Mount the split needle bearing

and the 2ndspeed idler gear 1- with the recess for shift

dogs facing upward - on the countershaft. – Mount the stop disc

(25.2x32x1.5mm) and circlip 4with the sharp edge facing

upward. – Mount the 6

speed sliding gear 5with the shift groove facing upward.

– Mount the circlip

and the stop disc 7(25.2x32x1.5mm).

– Mount the 2 split needle bearings

9+ bl

and the 4thspeed idler gear 8with the recess

for shift dogs facing downward. – Mount the 3

speed idler gear bkwith the recess for shift dogs facing upward.

– Mount the stop disc

(25.2x32x1.5mm) and the circlip bn.

– Slip on the 5

speed sliding gear bowith the shift groove facing downward and the stop

disc

(20x32x1mm).

– Mount the needle bearing

, the 1stspeed idler gear brwith the recess facing downward

and the stop disc

(17.2x30x1.5mm).

1011

5-25C

Ignition

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.

Make sure to select the correct measuring range when performing measurements. The CDI unit can only be checked on the ignition test bench.

Check stator and pulse generator

Use an ohmmeter to perform the following measurements:

NOTE: The measuring must be performed at a temperature of 20° C. Otherwise significant deviations must be expected. Replace the stator and/or the pulse generator if the measured values deviate significantly from the setpoint values.

Replacing the stator 400/450/525 SX (4K-3A)

– Remove the bolt 1 and dismount the retaining plate. – Remove the 2 bolts

2 and take the stator out from the ignition cover.

– Place a new stator in the ignition cover. Degrease the threads of all 3

bolts and apply Loctite 243. – Mount the bolts and tighten them to 6 Nm/5 ft.lb. – Place the wire harness in a non-energized condition and secure it with

the retaining plate. Do not forget the cable socket

Replacing the stator 250/400/450 MXC, EXC, 520 SX, MXC, EXC, 525 MXC, EXC (4K-3B)

– Remove the bolt 4 and dismount the retaining plate. – Remove the 2 bolts

5 and take the stator out from the ignition cover.

– Place a new stator in the ignition cover. Degrease the threads of all 3

bolts and apply Loctite 243. – Mount the bolts and tighten them to 8 Nm/6 ft.lb. – Place the wire harness in a non-energized condition and secure it with

the retaining plate.

Ignition Measure cable colours Resistance

Pulser coil red – green 100 Ω  20%

4K-3A Exciter black/red– red/white 24,8 Ω  20%

Charge coil ground – yellow 0,74 Ω  20%

Pulser coil red – green 100 Ω  20%

4K-3B Exciter black/red – red/white 12,7 Ω  20%

Charge coil ground – yellow 0,65 Ω  20%

white – yellow 0,16 Ω  20%

5-26C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

E-starter drive gear

Idler gear 1 Check toothing and bearing position of the idler gear for wear. Check the bearing bolts of the idler gear for score marks, as well.

Reduction gear

Check toothing and bearing position of the idler gear for wear. Check the bearing bolts of the idler gear for score marks, as well. Slip the reduction gear together with the needle cage onto the bearing bolt and check the clearance.

Free wheel hub

Take the free wheel out of the free wheel hub and check the contact surface A for pressure marks. Clean the free wheel hub thoroughly.

Free wheel

Thoroughly clean the free wheel with petroleum and compressed air. Check the segments of the free wheel for wear. Then, oil the free wheel thoroughly.

Free wheel gear

Slip the free wheel gear onto the crankshaft and check for clearance. If necessary, replace the needle bush. Check the contact surface to the free wheel for pressure marks.

NOTE: If damage is found on the reduction gear

2 or on the free wheel gear 5 forcing you to change parts, then 2 and 5 are

only available as a set.

E-starter motor

Renew the O-ring 7 at the flange.

5-27C

Checking the free wheel

– Insert the free wheel gear 1 into the free wheel 2. – It must be possible to turn the free wheel gear clockwise. – Counterclockwise, the free wheel gear must be blocked without

backlash.

Replacing the free wheel hub

– Use the circlip pliers to compress the spreader ring 3 and remove it

together with the free wheel

– Remove the 6 bolts

– Use a plastic hammer to tap on the free wheel hub

5 from the side

and dismount the free wheel hub. – Mount the new free wheel hub on the primary wheel. – Degrease the threads of the bolts, apply Loctite 648 and tighten the

bolts in a crosswise order to 16 Nm/12 ft.lb.

– Oil the free wheel

2 thoroughly and insert it into the free wheel

hub

– Use circlip pliers to insert the spreader ring into the groove and check

its proper fit. It is best to use a punch to carefully tap on the mounted

spreader ring.

NOTE: The noses

A on the spreader ring must engage the groove of the

free wheel hub.

Repair manual KTM 250-525 SX, MXC, EXC RACING

Art.-No. 3206007 -E

ASSEMBLING THE ENGINE

MOUNTING THE CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . .6-2

MOUNTING THE SHIFT MECHANSIM AND TRANSMISSION . . . . . . . . . . .6-2

ASSEMBLING THE ENGINE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

MOUNTING THE PRIMARY GEAR AND FREE WHEEL . . . . . . . . . . . . . . . .6-4

MOUNTING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

MOUNTING THE SHIFT ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

MOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER . . . . . . . . .6-6

MOUNTING THE OUTER CLUTCH HUB AND THE DRIVER . . . . . . . . . . . .6-7

MOUNTING THE PRIMARY GEAR NUT (250 EXC AND ALL MOD. FROM 2003)

. .6-8

MOUNTING THE TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

MOUNTING THE PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . .6-10

MOUNTING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

MOUNTING THE CYLINDER HEAD TOP PORTION . . . . . . . . . . . . . . . . .6-12

MOUNTING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . .6-13

ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

MOUNTING THE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

MOUNTING THE PULSE GENERATOR AND THE IGNITION COVER . . . . .6-14

MOUNTING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

MOUNTING THE OIL LINE AND THE ELECTRIC STARTER . . . . . . . . . . . .6-16

MOUNTING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

HOW TO FILL IN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

INDEX

6-1C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

6-2C

Mounting the crankshaft and balancer shaft

– Secure the right half of the casing in the work stand. – Thoroughly oil the cylinder roller bearings of the crankshaft and grea-

se the shaft seal ring of the crankshaft.

– Carefully, insert the crankshaft into the bearing seat.

–Turn the crankshaft such that the mark

A is in front and insert the

balancer shaft into the bearing seat. Make sure that the mark

A on

the crankshaft is between the 2 marks

B on the balancer shaft.

Mounting the shift mechanism and transmission

–Turn the engine sideward. – Insert main shaft

1 and countershaft 2 into the bearing seats simul-

taneously.

– Apply grease to secure the shift rolls

3 to the shift forks.

– Apply grease to secure the 4 springs

4 in the shift rails.

6-3C

– Oil the shift forks at their flat sides and engage them in the sliding

gears.

ONLY ENGINES WITH 4-SPEED-SHIFTING:

NOTE: The shift fork

1 and the short shift rail is not mounted in these

engines.

– Insert shift roller into bearing seat.

ONLY ENGINES WITH 4-SPEED-SHIFTING:

NOTE: The shift roller must be turned with the shift roller mounted such that the pin

A faces vertically downward.

– Engage the shift forks in the shift roller and mount the two shift rails

2 together with the springs.

– Make sure that the following parts were mounted:

inner bearing ring

O-ring 4 stop disc 5 2 dowels in the engine casing

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

6-4C

Assembling the engine casing

– Remove the engine fixture at the work stand. – Slightly coat the casing sealing surface with grease and apply a new

gasket to it.

– Put on the left half of the casing and tap on it lightly with a plastic

hammer until it reaches its proper fit. – Check the casing gasket for proper fit. –Grease the casing bolts in the area of their threads and at the seating

surfaces of their heads. Insert the bolts and tighten them (the bolt

length is indicated in the drawing). – Prior to and after tightening the casing bolts to 10 Nm/7 ft.lb, check

whether all shafts move smoothly. – Fix the engine to the work stand. – Cut the projecting casing gasket at the cylinder base away neatly at

the sealing surfaces.

Mounting the primary gear and the freewheel

400/520 models until 2002:

–Turn the crankshaft to TDC and mount the crankshaft fixing bolt

without a sealing ring. – Check if the Woodruff key has been mounted in the crankshaft. – Thoroughly oil the free wheel and the needle cage in the free wheel

gear. – Insert the free wheel gear

1 into the free wheel hub and push all parts

onto the crankshaft simultaneously. – Degrease the thread of the crankshaft and coat it with Loctite 243.

Mount the collar nut and tighten to 150 Nm/110 ft.lb.

250 EXC models from 2002 and all models after 2003:

– Check if the Woodruff key has been mounted in the crankshaft. – Thoroughly oil the free wheel and the needle cage in the free wheel

gear. – Insert the free wheel gear

1 into the free wheel hub and push all parts

onto the crankshaft simultaneously.

NOTE: The collar nut on the primary gear will be mounted later.

M6x...

6-5C

Mounting the oil pumps

– Thoroughly clean the seating surface of the oil pump cover. – Insert the needle roller into the oil pump shaft. – Slide inner rotor and outer rotor onto the oil pump shaft such that the

2 center points

A and B are located next to one another and insert

all components into the engine casing.

NOTE: The inner and outer rotor must be mounted with the center points facing the casing.

– Fill the oil pump casing with engine oil. – Degrease the threads of the 2 bolts

1 (M5x12), apply Loctite 222

mount the oil pump cover and tighten the bolts to 6 Nm/5 ft.lb.

– Insert the needle roller

2 into the bore of the oil pump shaft.

NOTE: If the shift lock has been removed, it can easily be mounted at this point (see page 6-6).

– Slide on the oil pump wheel

3, mount the stop disc 4 and the tab

washer

– By turning the oil pump wheel, check whether the oil pump shaft

moves smoothly.

–Wipe the seating surface of the oil pump cover clean. – Insert the outer and inner rotors into the engine casing such that the

two marks

A and B are located adjacent to one another.

NOTE: The inner and outer rotor must be mounted with the center points facing the casing.

– Mount the needle roller

– Degrease the threads of the 2 bolts (M5x16) and coat them with

Loctite 222. – Fill the oil pump casing with engine oil. – Use the 2 bolts to fix the oil pump cover and tighten to 6 Nm/5 ft.lb. – After mounting check the oil pumps for easy operation. For this

purpose turn the oil pump wheel.

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

6-6C

Mounting the shift arrester

– Slip the disc 2, the locking lever 3, the locking spring sleeve 4 and

the locking lever spring

5 onto the bolt 1 (M5x20).

– Apply Loctite 243 to the bolt's thread and tighten the bolt to

6 Nm/5 ft.lb.

– Slide the shift locating drum

6 onto the shift roller. Please note that

the flat portions are eccentric. Here, the locking lever has be drawn away from the shift roller.

– Apply Loctite 243 to the thread of the bolt 7 (M6x30) and tighten the

bolt to 10 Nm/7 ft.lb.

–Grease the preassembled shift shaft and, together with the stop disc,

slide it into the bearings until the sliding plate abuts the roller driving pin.

– Push back the sliding plate and push the shift shaft in up to the stop.

– Check whether the legs

A of the return spring abut the casing nose

B on both the left and right sides.

– Slip on the shift lever and shift through all gears. Turn the main shaft

as you shift through the gears. Then, dismount the shift lever again.

Mounting E-starter drive gear and kickstarter

– Oil the kickstarter idler gear 8 and the E-starter idler gear 9 at the

bearing positions and slide them onto the bearing bolts.

– Mount stop discs and circlips with the sharp edge facing outwards.

6-7C

– Insert the bearing bolt into the casing bore. Mount the needle bearing

1 and the reduction gear 2.

– Insert the preassembled kickstarter shaft into the bearing bore such

that the ratchet gear is positioned behind the release plate.

– Mount the spring shackle to the starter spring, coat the thread of the

bolt

3 (M6x12) with Loctite 243, tighten to 10 Nm/7 ft.lb, preload

the starter spring around approx. 45° clockwise and fix the spring

shackle by means of the bolt. – Align the starter spring such that the distance to the kickstarter shaft

is the same all around.

Mounting the outer clutch hub and driver up to the 2002 model

– Mount the stop disc and the bearing bush. – Oil the bearing bush, slip the outer clutch hub and the stop disc

onto the main shaft.

NOTE: From Model 2001 onwards the support washer

4 is replaced by

a step washer and two needle bearings

5 are mounted instead of the

bearing bush (see drawing below).

These parts cannot be used for Model 2000 engines.

– Heat the driving pin to approx. 150°C and slide it onto the main shaft. – Mount the circlip

6 with its sharp edge facing upwards.

NOTE: A used driving pin can usually be mounted without being heated.

6-8C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Mounting the outer clutch hub and driver from the 2003 model onwards

– Mount the supporting plate and the oiled needle bearing 1. – Mount the outer clutch hub

2 together with the half disks 3 and

stepped disk

4 on the main shaft.

– Heat the driver to approx. 150°C and mount on the main shaft. – Mount a new lock washer. – Degrease the main shaft thread and apply Loctite 243. – Apply the special tool (see dismounting), mount the collar nut 5 and

tighten to 150 Nm.

– Secure the collar nut with the lock washer

5 as illustrated.

NOTE: A used driving pin can usually be mounted without being heated.

Mounting the primary gear nut (250 EXC models after 2002 and all models after 2003)

– Apply the special tool as illustrated. – Degrease the thread of the crankshaft and coat it with Loctite 243.

Mount the collar nut

7 and tighten to 150 Nm/110 ft.lb.

NOTE: The nut was already mounted on the models up to 2002.

–Turn the crankshaft to TDC and mount the crankshaft fixing bolt

without a sealing ring.

6-9C

Mounting the timing gear

– Check the Woodruff key in the crankshaft for its correct fit. –Warm the timing gear

1 and position on the crankshaft with the high

collar facing inwards. Tap carefully with a suitable pipe if necessary. – Mount circlip

2 with the sharp edge facing outwards.

– Degrease the threads of the 2 bolts and apply Loctite 243. Use the 2

bolts

5 (M6x25) to fix the timing chain guide 3 and the

tensioning rail

4 , tighten the bolts to 8 Nm/6 ft.lb. Do not forget the

2 bushings.

NOTE: 2 mounting points for the tensioning rail are provided for models from 2003. The tensioning rail is attached to point

A on the 450 SX

model. The tensioning rail is attached to point

B on all other models.

CAUTION

FTER TIGHTENING

, CHECK THE TENSIONING RAIL FOR SMOOTH OPERATION

– Place the timing chain such that both ends are of equal length.

NOTE: The timing chain can also be pulled in after the cylinder and cylinder head are mounted.

– Degrease the threads of the 2 bolts (M5x16) and coat them with

Loctite 243. Mount the fall-out protection element

6 and tighten the

bolts

7 to 6 Nm/5 ft.lb.

– Stick one cable strap each through the 2 ends of the timing chain (see

photo).

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

6-10C

Mounting piston and cylinder

– Apply a new cylinder-base gasket. – Oil the piston pin boss in the conrod and the piston pin. – Mount the piston and secure the piston pin with 2 new wire circlips.

CAUTION

THE ARROW AT THE PISTON HEAD MUST POINT IN THE TRAVEL DIRECTION.

– Oil the piston and align the piston rings.

NOTE: The open end of the oil scraper ring must be in the back. The open end of the compression ring must be offset from it around 90°.

– Pull the timing chain upward through the chain tunnel. – Slide the cylinder over the piston and remove the piston mounting

ring.

CAUTION

EXERCISE EXTREME CAUTION WHEN MOUNTING THE CYLINDER

! THE OIL SCRAPER RING

CAN BREAK EASILY

Mounting the cylinder head

– Check the two dowels in the cylinder for perfect fit. – Apply a new cylinder-head gasket (the labeling "ALTO" facing

upward) and mount the cylinder head. At the same time, insert the timing chain.

– Oil the 4 collar bolts at their threads and their seating surfaces and

mount them together with the washers. –Tighten the collar bolts in a crosswise order as follows. – At first, tighten them only until you feel a light resistance. – The second time around, tighten the bolts to 40 Nm/30 ft.lb. – The third time, tighten them to 50 Nm/38 ft.lb.

– Mount and tighten bolts

1 (M6x45) and 2 (M6x40) and tighten to

10 Nm/7 ft.lb.

NOTE: The shorter bolt

2 (M6x40) must be mounted on the left, in the

region of the water pump with a new copper seal ring(6x10x1).

6-11C

NOTE: The gasket carrier has a drain bore A from the 2003 model. Make sure the bore faces up when mounting.

– Place the camshaft into the cylinder head such that the marks

B at the

camshaft gear are aligned with the upper edge of the cylinder head (see photo). The stop bolt of the automatic decompressor must be on top.

NOTE: When mounting the camshaft, you have to use the crankshaft fixing bolt to block the crankshaft in the TDC position.

– Place the timing chain onto the camshaft gear and mount a new rivet

link

– At first, mount the socket of the special tool as shown and then

compress the rivet link.

– Mount the socket of the special tool as shown and rivet on the rivet

link.

NOTE: The rivet member must be riveted on so tightly that the ends of the inserting member have a trapezoid-shaped cross-section (see drawing).

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Mounting cylinder head top portion

– Clean and degrease the sealing surface. – Fit dowels. – Apply a thin layer of sealing compound (Three Bond). – Carefully position cylinder head top section and tighten bolts to

10 Nm/7 ft.lb.

NOTE: – The bolt M6x75 is to be mounted with a new copper seal ring

(6x10x1)

– Prior to fastening the bolts, it is necessary to check and, if necessary,

adjust the clearance play of the rocker arms. – For this purpose, insert a feeler gauge

1 ( 0.05 mm) between the end

piece and rocker arm. Press the end piece inwards and tighten the bolt

in the area of the end piece. –Tighten the remaining bolts in a crosswise order to 10 Nm/7 ft.lb.

Axial clearance rocker arms 0.02 - 0.10 mm / 0.0008 - 0.0039 in

The following steps only apply to models from 2002 onwards:

– Slip on the assembling sleeve

A. Grease the O-rings and mount the

gasket carrier

2 without canting, the collar facing the camshaft gear.

CAUTION

LWAYS USE THE ASSEMBLING SLEEVE TO PREVENT THE SHAFT SEALING RINGS FROM

BEING DAMAGED

NOTE: The gasket carrier has a drain bore from the 2003 model (see page 6-11). Make sure the bore faces up when mounting.

– Remove the assembling sleeve, insert the needle roller in the camshaft

and mount the water pump wheel with the Seeger circlip ring.

– Mount the water pump cover with a new gasket. Tighten the bolts

(M6x20) crosswise to 8 Nm/6 ft.lb.

6-12C

M6x...

5045

6-13C

Mounting the timing chain tensioner

– Mount the preassembled timing chain tensioner 1 with a new gasket. – Mount the 2 bolts (M6x20) with copper seal rings 6x10x1 and tighten

to 8 Nm/6 ft.lb.

– Use a screwdriver to push the pressure pin in until you feel a slight

resistance. Then, push it in one notch further.

– Mount the pressure spring and the plug with a new sealing ring and

tighten to 10 Nm/7 ft.lb.

Adjusting the valve clearance

– The valve clearance A is measured on a cold engine between the

valve stem and the adjusting screw.

Valve clearance: 0.12 mm (0.0047 in)

CAUTION

IF THE PISTON IS NOT IN THE IGNITION TDC POSITION THE VALVES WILL BE ACTUATED

BY THE ROCKER ARMS AND IT WILL NOT BE POSSIBLE TO ADJUST THE VALVE CLEARANCE CORRECTLY

. IN THIS CASE THE ENGINE MUST BE TURNED ONE REVOLUTION FURTHER

AND BLOCKED AGAIN

NOTE: The feeler gauge must be pointed and bent slightly to adjust the valve clearance for the 450/525 SX 2003 models.

– Having set the clearance, tighten the counter nuts to 11 Nm/8 ft.lb

and check valve clearance once again.

– Mount 2 valve covers

with new gaskets and bolts (M6x20) together with new copper seal rings (6x10x1). Tighten the bolts to 8 Nm/6 ft.lb.

– Screw in the spark plug and tighten to 12 Nm/10 ft.lb.

6-14C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

Mounting the flywheel (400/520 models up to 2002)

– Check the Woodruff key in the crankshaft for proper fit and slip the

flywheel onto the crankshaft.

– Mount wave washer and collar nut, tighten to 60 Nm/44 ft.lb.

NOTE: When ordering a new part, a forged rotor will be supplied, this part is produced without rivets and is interchangeable.

– Unscrew the crankshaft fixing bolt, mount the sealing ring

1 and

tighten the crankshaft fixing bolt again to 25 Nm/18 ft.lb.

Mounting the flywheel (250 EXC models after 2002, all models after 2003)

– Unscrew the crankshaft fixing screw, mount the seal ring 1 and

tighten the crankshaft fixing screw to 25 Nm (see above).

– Check the Woodruff key in the crankshaft for proper fit and slip the

flywheel onto the crankshaft.

– Mount the shaft disk and collar nut. Counteracting with the clutch

holder, tighten the and collar nut to 60 Nm.

Mounting the pulse generator and the ignition cover

– Position the pulse generator in the engine casing and insert the cable

grommet

2 into the aperture of the casing.

– Degrease the threads of the 2 bolts

3 (M5x16), coat them with

Loctite 243 and tighten to 6 Nm/5 ft.lb.

NOTE: – For the 400 SX engines equipped with the 4K-3A ignition, 2 spacer

bushings must be added behind the pulse generator.

– The gap between rotor and pulse generator must be 0.55 - 0.85 mm

(0.022 - 0.033) in, but is only adjustable on 400 SX engines (measurement 0.7 mm / 0.027 in).

– Apply a new gasket and fix the ignition cover with the 4 bolts (

4 and

5), tightening torque 10 Nm/7 ft.lb.

NOTE: The 2 longer bolts

4 (M6x35) are mounted at the dowels.

6-15C

Mounting the clutch

– Prior to assembly, thoroughly oil all lining discs.

Clutch disks up to the 2001 model:

– Starting with an intermediate disc

1, alternatingly insert a total of 8

intermediate discs and 7 lining discs

2. An intermediate disc must be

on top.

Clutch disks from the 2002 model onwards:

– Position the 12 driving pin sleeves

on the

driver; fix with grease if necessary.

– Starting with a thin clutch disk

, alternately insert 8 clutch disks and 6 lining disks

, finishing with a thin clutch disk

on top.

NOTE: the two outer clutch disks

are 1 mm (0.03937 in) thick, the thicker clutch disks

(1.4 mm/0.00551 in) are positioned on

the inside (see drawing).

– Mounting the pressure piece. – Apply the pressure cap and mount the clutch springs, the spring

retainers, and the collar bolts.

– Fasten the collar bolts

7 in a crosswise order to 10 Nm/7 ft.lb.

–Verify that the two dowels have been mounted in the engine casing. –Grease all shaft seal rings in the clutch cover and fix the clutch cover

gasket with some grease.

– Pay special attention to ensuring that the gasket does not close off the

oil jet

8 in the engine casing.

– Fill in app. 30 ml engine oil into the bore of the crankshaft.

– Carefully mount the preassembled clutch cover and press it on. – Mount the bolts (bolt lengths M6x30 and M6x35 – see drawing) and

tighten them to 10 Nm//7 ft.lb.

NOTE: If the clutch cover cannot be mounted, check whether the kickstarter spring has been positioned correctly.

M6x35

M6x30

M6x35

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

6-16C

Mounting the oil line

– Position the oil line 3and secure it with the jet screw 1and the

hollow screw

. Use new sealing rings, tighten the screws to 10 Nm/8

ft.lb.

NOTE: Place the oil line such that it does not touch the engine. The oil line must not be twisted during tightening.

Mounting the electric starter

– Oil the O-ring of the E-starter motor and insert the E-starter motor

into the engine casing. Mount the 2 screws

(M6x20) and tighten to

8 Nm/6 ft.lb.

– Oil the spacer bushing 5and slip it onto the countershaft with the

recess for the O-ring facing inward. – Slide the sprocket on with the high collar facing inward. – Degrease the thread of the collar screw, coat it with Loctite 243 and

mount it together with the spring retainer, tighten to 60 Nm/45 ft.lb.

NOTE: To tighten the screw, shift into 1

gear with the crankshaft being

blocked.

6-17C

Mounting the oil filters

– Fill the oil filter housing with engine oil to approx. 1/4 of its capacity. – Insert both oil filters

1 into the engine casing.

– Oil the O-rings at the oil filter cover and secure the oil filter cover

by means of the 4 bolts (M5x16), tighten to 6 Nm/5 ft.lb..

– Mount kickstart and shift lever.

How to fill in engine oil

– Mount the plugs 3 and 4 and the oil drain plug 5 and tighten them.

NOTE: Tightening torque

3 10 Nm/0.4 ft.lb, 4 15 Nm/0.6 ft.lb and

5 20 Nm/0.78 ft.lb.

– Remove the oil dipstick at the clutch cover and fill in 1.20 liter of

synthetic 10W-50 engine oil (e.g. Motorex Power Synt. 4T).

– Reattach the plug and check the engine for leaks.

NOTE: The engine oil level must be checked once more after the engine has been mounted on the vehicle.

CAUTION

–U

SE ONLY BRAND SYNTHETIC OILS MEETING OR SURPASSING THE QUALITY

REQUIREMENTS OF

API CLASSES SG OR SH (SPECIFICATIONS ON THE

CONTAINER

–I

NSUFFICIENT AMOUNTS OR LOW-GRADE ENGINE OIL WILL LEAD TO PREMATURE

WEAR IN THE ENGINE

 

–

0°C

32°F

15W 40 15W 50

10W 40 10W 50

API: SG, SH

TEMPERATUR

Repair manual KTM 250-525 SX, MXC, EXC RACING

Art.-No. 3206007 -E

ELECTRICAL SYSTEM

LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

FILLING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

CHECKING THE VOLTAGE REGULATOR-RECTIFIER . . . . . . . . . . . . . . . . . .7-4

CHECKING THE CHARGING VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

TROUBLESHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . . .7-5

MAIN FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . .7-6

CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

MEASUREMENTS WITH PEAK VOLTAGE ADAPTER

STATIC IGNITION VALUES 250-525 SX, MXC, EXC RACING . . . . . . . . . . .7-7

STATIC GENERATOR VALUES 250-525 SX, MXC, EXC RACING . . . . . . . . .7-9

DYNAMIC GENERATOR VALUES 250-525 SX, MXC, EXC RACING . . . . . .7-11

THROTTLE VALVE SENSOR

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19

INDEX

7-1C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

7-2C

Leakage inspection

The drop test must be performed before checking the voltage regulator/rectifier –Turn off the ignition and disconnect the ground wire from the battery. – Insert an amperemeter between the ground wire and the negative

pole of the battery.

Setpoint value: max. 1 mA

– Check for power consumers, should the measured value exceed the

indicated maximum value.

Example:

● defective voltage regulator-rectifier

● defective capacitor

● leak currents in the socket connectors, in the ignition lock or in the

starter relay.

Removing the battery

– Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Unhitch the two rubber fixtures

1 and lift the battery out of the bat-

tery holder. – When reinstalling the battery, connect the negative pole last.

CAUTION

THE BATTERY POLES MUST FACE THE FRONT, OTHERWISE ACID MAY ESCAPE.

Charging the battery

– Remove the battery and check the charging level. Use a voltmeter to

measure the voltage between the battery poles (off-load voltage). – Accurate results can only be obtained if the battery has neither been

charged nor discharged during a period of 30 minutes preceding the

measuring. – If the battery is empty, it can be recharged for a maximum period of

10 hours at 0.5 A and a maximum of 14.4 V.

CAUTION

–T

OAVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR

–ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE

CHARGING UNIT ON

–WHEN RECHARGING THE BATTERY IN CLOSED ROOMS PROVIDE SUFFICIENT

VENTILATION

. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING

PROCESS

–CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED

VALUES

. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY

VALVES

–A

VOID QUICK CHARGING IF POSSIBLE.

0,00

off-load voltage charging level charging time charging voltage

Volt % 0.5 A

>12.7 100 –– ~12.5 75 4 h

max.

~12.2 50 7 h

14.4 V

~12.0 25 11 h ~11.8 0 14 h

7-3C

Filling the battery

–Take the battery and the electrolyte container out of the packaging.

Before you start filling the battery, please read the enclosed instructions carefully.

–Take the cover off the electrolyte container. – Apply the electrolyte container to the filling apertures of the battery

and push it down tight.

– Once all chambers of the electrolyte container are empty, withdraw it

from the battery.

– Close the filling apertures tightly by means of the cover.

NOTE: After filling, let the battery sit for at least another 30 minutes without charging or loading it.

CAUTION

OLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW BATTERY

HE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL

SUPPLIED WITH THE BATTERY

. FAILURE TO OBSERVE THESE INSTRUCTIONS CAN RESULT

IN SEVERE INJURIES

Checking the capacitor

– Discharge the capacitor by bridging the two connections with a cable

bridge and dismount it.

– 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 is made with a test lamp

– When the power circuit is closed, the test lamp must light up briefly

and return to its dark state after 1 second at the latest.

– If the test lamp does not go out or does not light up at all, the

capacitor is faulty.

–

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

7-4C

Checking the voltage regulator-rectifier

A defect voltage regulator can cause different kinds of trouble:

● No voltage in the circuit

In this case, the voltage regulator must be disconnected at idle speed.

The voltage regulator is defect if the power consumers now work

properly.

If the power consumers are still not supplied with power, the switch,

the wiring harness or the ignition system must be checked for defects.

● Excessive voltage in the circuit

The bulbs burn out. In this case the voltage regulator must be

replaced.

Checking the charging voltage

NOTE: The values stated below only apply to fully charged batteries (minimum charging level 90%).

– Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. – Accelerate the engine to a speed of 5000 rpm and read the voltage.

Nominal value: 14.0 - 15.0 V

In the case of a significant deviation from the nominal value: – Check the connector between the stator and the voltage regulator-

rectifier and the connector between the voltage regulator-rectifier and

the cable tree. – Check the stator. – Replace the voltage regulator-rectifier.

7-5C

CDI unit

Check the cables and plug and socket connections of the CDI unit. The CDI unit function can only be checked on an ignition test bench.

CAUTION

EVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE CDI UNIT.

OMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC

COMPONENTS

Ignition coil

– Disconnect all cables and remove the spark plug connector. – Use an ohmmeter to measure the following values.

NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values.

Troubleshooting in the ignition system

Before checking the ignition system check:

● if the emergency off switch is switched on

● if the battery is charged

● the main fuse

Check if an ignition spark is produced when the starter is operated. Proceed as follows: – Pull off the spark plug connector. – Disconnect the spark plug connector from the ignition cable. – Hold the free end of the ignition cable approximately 5 mm

(0.1968 in) from the ground.

–A strong spark should be visible when the electric starter is operated.

If the battery level is low, turn off the light, and use the kick starter.

– If a spark is visible, replace the spark plug connector. –Twist out the spark plug and insert it into the spark plug connector. – Connect the spark plug to the ground. A strong spark should be visible

at the electrode when the electric starter is operated. If this is not the case, the spark plug connector or the spark plug is defective.

– If no spark is produced during the first test, perform the following

checks:

● emergency off switch and

● corresponding parts of the cable tree

– If the ignition is sufficiently supplied with power and no spark is

produced, check:

● the ground connection of CDI unit and ignition coil

● the cable between the CDI unit and the ignition coil

● the pulse generator

● the stator

● the ignition coil

● the short circuit button

NOTE: The CDI unit cannot be tested with simple devices. It can only be replaced. It can only be tested on an ignition test bench.

Measure Cable colours Resistance

primary coil blue/white – ground 0.30 Ω ±15%

secondary coil blue/white – ignition wire 6.30 kΩ ±20%

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

7-6C

Main fuse

NOTE: The fuse 1 is positioned in the starter relay of the E-starter underneath the left side paneling.

The following loads are connected to it: – E-starter system – horn – flasher lights The fuse

serves as a spare fuse.

–To replace it, remove the left trim panel and pull the cover off the start

relay. – Pull out the fuse and replace it with a new one.

CAUTION

EVER INSERT A STRONGER FUSE OR

"MEND" THE FUSE. I

MPROPER HANDLING MAY

DESTROY THE ENTIRE ELECTRIC SYSTEM

– In case you use the spare fuse to replace the installed one while using

your motorcycle, you should remember to replace it as soon as

possible.

Checking the electric starter motor

– Disconnect the negative pole of the battery and remove the electric

starter motor. – Connect the negative pole of a 12 V battery to the housing of the

E-starter motor and briefly connect the positive pole of the battery to

connection

of the electric starter motor (use thick cables). – The starter must turn as soon as the circuit is closed. – If this is not the case, replace the starter motor.

Checking the starter relay

– Remove the seat and the left side cover and disconnect the

combination connector of the starter relay.

– Disconnect the negative terminal at the battery and the two cables at

the starter relay.

– Connect the starter relay to a 12 V battery as indicated in the diagram. – Check continuity between terminals Cand Dusing an ohmmeter.

Reading: 0 Ω OK

Reading: ∞Ω defective

NOTE: The response of the starter relay is accompanied by a faint clicking sound.

Check the pulse generator for an output signal – two-pin connector 1 with green and red cable colors (also see circuit diagram on opposite page):

– Apply the red measuring lead of the peak voltage adapter to the green

cable and the black measuring lead to the red cable, disconnect connector

1 to disconnect the CDI unit

Multimeter display: 4.5 volts +/- 0.5 volt

– Same measurement with CDI unit connected

Multimeter display: 3 volts +/- 0.5 volt

Check the generator charging coil for ignition capacitor charge – two-pin connector

3 with black/red and red/white cable colors (also see circuit

diagram on opposite page):

–

Apply the red measuring lead of the peak voltage adapter to the black/red cable and the black measuring lead to the red/white cable, disconnect connector

to disconnect the CDI unit

Multimeter display: 30 volts (35 volts for 400 SX) +/- 5 volts

– Same measurement with connectors CDI unit connected

Multimeter display: 200 volts +/- 10 volts

Check the primary voltage output 4 for ignition coil control (also see circuit diagram on opposite page) for output voltage (blue/white cable color):

– Apply the red measuring lead

R of the peak voltage adapter to the

black/white cable (ground) and the black measuring lead

S to the

blue/white cable, CDI unit

2 and ignition coil 5 connected

Multimeter display: 200 volts +/- 10 volts

STATIC IGNITION VALUES 250-525 SX, MXC, EXC RACING (KOKUSAN 4K-3A, B)

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 – the gap between the rotor and pulse generator must be set to 0.75 mm – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement

7-7C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

7-8C

250/400/520 EXC RACING

STATIC GENERATOR VALUES 250-525 MXC, EXC RACING (KOKUSAN 4K-3B)

Check the generator output 6 (also see circuit diagram on opposite page) for voltage between the following cable colors:

– between yellow and brown (ground), connector

7 disconnected

Multimeter display: 15 volts +/- 1 volt

– same measurement with connector

7 connected

Multimeter display: 12 volts +/- 1 volt

– between white and brown (ground), connector

8 disconnected

Multimeter display: 19 volts +/- 1 volt

– same measurement with connector

8 connected

Multimeter display: 14 volts +/- 1 volt

NOTE: the black measuring lead

8 of the peak voltage adapter must be

applied to the ground.

Check regulator rectifier output voltage

9 (also see circuit diagram on

opposite page) cable colors yellow/red, regulator rectifier

bk connected,

capacitor

bl disconnected (if installed) and fuse bm removed:

– between yellow/red and brown (ground)

Multimeter display: 14 volts +/- 1 volt

NOTE:

– the black measuring lead

S of the peak voltage adapter must be

applied to the ground.

– for facilitation of work, the regulator rectifier

bk can be detached from

the frame.

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 – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement

7-9C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E

7-10C

250/400/520 EXC RACING

KTM 250 SX-MXC-EXC, 525 SX-MXC-EXC 2003 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 SERVICE-INFORMATIONS

INTRODUCTION

REPLY FAX FOR REPAIR MANUALS

GENERAL INFORMATION

Oil circuit

Engine oil

Checking the engine oil level

Changing the engine oil

Changing the oil filters

Checking the oil level of the hydraulic clutch

Bleeding of the hydraulic clutch

SPECIAL TOOLS

Dismounting the engine

Mounting the engine

Bleeding the cooling system

Checking the adjustment of the hand decompression release cable

Draining the engine oil

Dismounting the oil filter

Dismounting the chain wheel

Disassembling the clutch

Dismounting the oil pump

Dismounting cylinder head, cylinder and piston

SERVICING INDIVIDUAL COMPONENTS

Left casing half

Right casing half

Clutch cover

Crankshaft

Driving gear of balancer shaft

Compensating the axial clearance of the crankshaft

Checking the oil pumps for wear

Lubrication system

Upper portion of cylinder head

Cylinder head

Camshaft

Preassembling the camshaft

Timing chain tensioner

Timing train

Checking the clutch for wear

Checking the kickstarter for wear

Preassembling the kickstarter shaft

Shift mechanism

Preassembling the shift shaft

Assembling the main shaft (4-speed)

Assembling the main shaft (6-speed)

Ignition

E-starter drive gear

Checking the free wheel

Replacing the free wheel hub

Mounting the crankshaft and balancer shaft

Mounting the oil pumps

Mounting the shift arrester

Mounting the timing gear

Mounting the cylinder head

Mounting the timing chain tensioner

Adjusting the valve clearance

Mounting the pulse generator and the ignition cover

Mounting the clutch

How to fill in engine oil

Leakage inspection

Removing the battery

Charging the battery

Filling the battery

Checking the capacitor

Checking the voltage regulator-rectifier

Checking the charging voltage

CDI unit

Troubleshooting in the ignition system

Main fuse

Checking the electric starter motor

Checking the starter relay