KTM 250 400 450 520 525 SX MXC EXC RACING 2000 2001 2002 2003 FACTORY SERVICE REPAIR MANUAL + WIRINGS

KTM 250 400 450 520 525 SX MXC EXC RACING 2000 2001 2002 2003 FACTORY SERVICE REPAIR MANUAL + WIRINGS

2000-2003 

Model: KTM 250, 400, 450, 520, 525, SX, MXC, EXC RACING

Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your motorbike. 

 

 

 

TABLE OF CONTENTS:

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

 

MANUALS COVER:

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

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

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

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

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

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

DISMOUNTING AND INSTALLING THE CARBURETOR . . . . . . . . . . . .8-4

DISASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39) . . . . . . . . .8-5

DISASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41) . . . .8-8

CHOKE SLIDE AND HOT START KNOB . . . . . . . . . . . . . . . . . . . . . .8-11

CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . .8-11

CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . .8-11

CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . .8-11

ASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39) . . . . . . . . . . .8-12

ASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41) . . . . .8-15

ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . .8-18

CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . .8-19

DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . .8-19

CARBURETOR ADJUSTING IDLING (KEIHIN FCR 35/39) . . . . . . . . . .8-20

CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . .8-20

CARBURETOR ADJUSTING IDLING (KEIHIN FCR-MX 37/39/41) . . . .8-21

CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . .8-21

MODEL 2000

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

 

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

TIGHTENING TORQUES – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3

ASSEMBLY CLEARANCE, WEAR LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

STANDARD ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . .9-5

TIGHTENING TORQUES – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

 

MODEL 2001

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

 

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . .9-7

STANDARD ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . .9-7

 

MODEL 2002

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .9-8

 

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9

MOUNTING CLEARANCES, WEAR LIMITS FOR MODELS UP TO 2002 . .9-10

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . .9-11

STANDARD ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . .9-11

 

MODEL 2003

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . .9-12

 

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13

TIGHTENING TORQUES – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14

MOUNTING CLEARANCES, WEAR LIMITS FOR MODELS FROM 2003 . .9-15

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . .9-16

STANDARD ADJUSTMENT FORK / SHOCK ABSORBER . . . . . . . . . . . . . .9-16

TIGHTENING TORQUES – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16

MODEL 2000

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

MODEL 2001

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .10-4

MODEL 2002

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .10-6

MODEL 2003

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .10-8

MODEL 2000

WIRING DIAGRAM USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2

WIRING DIAGRAM EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3

 

MODEL 2001

WIRING DIAGRAM EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5

WIRING DIAGRAM USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

 

MODEL 2002

WIRING DIAGRAM USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8

WIRING DIAGRAM EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

 

MODEL 2003

WIRING DIAGRAM USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11

WIRING DIAGRAM EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

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