KTM 250 300 380 400 520 525 540 560 610 Workshop Repair Service Manual 1983-2010 PDF - MKTM250610OPES.zip

A full service and repair guide featuring Electrical Wiring Diagrams covering 1983-2010 KTM 250, 300, 380, 400, 520, 525, 540, 560, and 610 models, packed with everything needed to service, troubleshoot, fix, and rebuild these machines the way expert technicians do.

Inside the KTM 250, 300, 380, 400, 520, 525, 540, 560, 610 workshop service and repair guide, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

MAKE: KTM

YEAR: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

MODEL: 250 EGS, 250 EXC, 250 EXC, 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 EXC SIX DAYS, 250 EXC-USA, 250GS, 250 MX, 250 MXC, 250 SX, 250 SX-F, 250 SXS, 250 SXS-F, 250 XC, 250 XC-F, 250 XCF-W, 250 XC-W, 300 EGS, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 SXS, 300 XC, 300 XC-W, 380 EGS, 380 SX, 380 MXC, 380 EXC, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 450 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE

"'04-'10 250-300.pdf"

229 pages; 2004-2007 Repair Manual for 250 EXC, 250 EXC, 250 EXC SIX DAYS, 250 EXC-USA, 250 MXC, 250 SX, 250 SXS, 250 XC, 250 XC-W, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 XC, 300 XC-W

"'05-'10 250"

55 MB, 700+ pages PDF; 2005-2010 Service Manual for 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 SX-F, 250 SXS-F, 250 XC-F, 250 XCF-W

"'05-'08 250"

177 MB, 3,000+ pages PDF, EN/DE/FR/IT/ES; 2005-2008 Service Manual (Repair Manual. Owner's Manual...) for 250 SX-F, 250 EXC-F (USA/EU), 250 EXC-F SIX DAYS, 250 XCF-W, 250 XC-F, 250 SXS-F

"'00-'06 250-610"

35 MB, 600+ PDF, 2000-2006 Service Manual (Repair Manual. Owner's Manual...) for 250 EXC RACING

400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 450 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE

"'04-'06 250-300.pdf"

159 pages; Repair Manual 2004-2006 for 250 SX, 250 SXS, 250 MXC, 250 EXC, 250 EXC SIX DAYS, 250 XC, 250 XC-W, 300 SX, 300 SXS, 300 MXC, 300 EXC, 300 EXC SIX DAYS, 300 XC, 300 XC-W

"'05-'06 250 SX-F.pdf"

125 pages; Repair Manual for 2005-2006 250 SX-F

"'99-'03 250-300-380 SX, MXC, EXC.pdf"

153 pages; Repair Manual 1999-2003 for 250 EGS, 250 SX, 250 MXC, 250 EXC, 300 EGS, 300 SX, 300 MXC, 300 EXC, 380 EGS, 380 SX, 380 MXC, 380 EXC

"'00-'03 250-525 SX_MXC_EXC Racing.pdf"

167 pages; Repair Manual Engine for 250-400-520-525 SX, MXC, EXC RACING

"250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) (EN-DE).pdf"

63 pages, EN/DE; 250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) Owners Repair Manual

PRODUCT DETAILS:

Total Pages: 613 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

KTM 200-300 Series Repair Manual 2004-2010...2

HOME...0

NOTES AND PREFACE...0

Important information...4

Updating instructions...4

Explanation updating...6

Introduction...8

Reply fax for repair manuals...10

TABLE OF CONTENTS...2

GENERAL INFORMATION...12

SPECIAL TOOLS - ENGINE...14

CHECKING THE SETTING OF THE TVC SYSTEM...15

ENGINE CHARACTERISTIC...15

BLEEDING THE HYDRAULIC CLUTCH (UP TO MODEL 2005)...16

BLEEDING THE HYDRAULIC CLUTCH (AS OF MODEL 2006)...17

CHANGING THE FRONT BRAKE FLUID...18

CHANGING THE REAR BRAKE FLUID...19

CHECKING BRAKE PADS AND BRAKE DISCS...19

REMOVING AND REFITTING ENGINE...20

REMOVING THE ENGINE...22

REFITTING THE ENGINE...24

DISASSEMBLING THE ENGINE...28

PREPARATION...30

DRAINING THE GEAR OIL...30

DISMOUNTING THE SPROCKET AND SHIFT LEVER...30

DISMOUNTING THE CYLINDER HEAD, CYLINDER AND PISTON...30

DISMOUNTING THE CLUTCH COVER...31

DISMOUNTING THE PRESSURE CAP AND THE CLUTCH DISCS...32

DISMOUNTING THE PRIMARY DRIVE...32

DISMOUNTING THE KICKSTARTER SHAFT...33

DISMOUNTING THE SHIFT LOCK...33

DISMOUNTING THE IGNITION COVER...33

DISMOUNTING THE IGNITION...34

DISMOUNTING THE REED VALVE HOUSING...35

PARTING THE ENGINE HOUSING HALVES...35

DISMOUNTING THE GEARSHIFT MECHANISM AND TRANSMISSION...35

DISMOUNTING THE CRANKSHAFT...36

SERVICING INDIVIDUAL COMPONENTS...38

SERVICING THE RIGHT ENGINE HOUSING HALF...40

SERVICING THE LEFT ENGINE HOUSING HALF...41

CRANKSHAFT...42

CRANKSHAFT WEBS - MEASURE OUTER DIMENSION...42

CHECK THE PISTON...42

PISTON RING END GAP...42

MEASURING PISTONS AND CYLINDERS - ESTABLISHING THE PISTON MOUNTING CLEARANCE...43

RECOATED CYLINDER...43

NIKASIL COATING OF CYLINDER...43

CYLINDER EXHAUST CONTROL SYSTEM...44

CYLINDER PREASSEMBLY...44

EXHAUST CONTROL, CLUTCH COVER...46

PREASSEMBLY OF CLUTCH COVER...46

REED VALVE HOUSING...47

CLUTCH...48

REPLACE OUTER CLUTCH HUB...49

SHIFT MECHANISM...50

PREASSEMBLY THE SHIFT SHAFT...50

ASSEMBLY MAINSHAFT...51

ASSEMBLY COUNTERSHAFT...52

CHECKING THE KICKSTARTER FOR WEAR...53

ASSEMBLING THE KICKSTARTER SHAFT...53

CHECKING THE ELECTRIC STARTER MOTOR FOR WEAR...54

ELECTRIC STARTER MOTOR - CHECKING FOR AND ADJUSTING PLAY...54

ASSEMBLING THE ENGINE...56

CRANKSHAFT...58

TRANSMISSION...58

ASSEMBLING THE ENGINE HOUSING...59

MOUNTING THE SHIFT MECHANISM...60

MOUNTING THE KICKSTARTER SHAFT...60

MOUNTING THE PRIMARY DRIVE AND CLUTCH...61

MOUNTING THE CLUTCH DISCS AND PRESSURE CAP...62

MOUNTING THE CLUTCH COVER...62

MOUNTING THE PISTON AND CYLINDER...63

ADJUSTING DIMENSION “X“...63

ADJUSTING THE CONTROL FLAP (DIMENSION “Z“)...64

MOUNTING THE STEERING COVERS...65

MOUNTING THE CYLINDER HEAD...65

MOUNTING THE REED VALVE HOUSING...65

MOUNTING THE ENGINE SPROCKET...66

MOUNTING THE IGNITION (WITHOUT ELECTRIC STARTER)...66

MOUNTING THE IGNITION COVER (WITHOUT ELECTRIC STARTER)...67

MOUNTING THE IGNITION (WITH ELECTRIC STARTER)...67

MOUNTING THE IGNITION COVER (WITH ELECTRIC STARTER)...67

MOUNTING THE OUTER IGNITION COVER (WITH ELECTRIC STARTER)...67

MOUNTING THE ELECTRIC STARTER...67

FIXING THE STARTER DRIVE COVER (WITH ELECTRIC STARTER)...67

FITTING THE PUSH ROD...68

MOUNTING THE STARTING LEVER AND SHIFT LEVER...68

FILLING UP THE TRANSMISSION OIL...68

CHECK THE TRANSMISSION OIL LEVEL...68

ELECTRICAL...70

IGNITION COIL...72

CDI UNIT...72

CHECKING THE VOLTAGE REGULATOR...72

CHECKING THE CAPACITOR...73

SPARK PLUG...73

IGNITION...73

CHECK THE STATOR AND PULSE GENERATOR (PICK UP)...74

MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...70

MODEL 2004...70

STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC...75

STATIC GENERATOR VALUES 250/300 MXC/EXC...77

STATIC IGNITION AND GENERATOR VALUES 250 EXC USA...79

MODEL 2005...70

STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC...81

STATIC GENERATOR VALUES 250/300 MXC/EXC...83

STATIC IGNITION AND GENERATOR VALUES 250 EXC USA...85

MODEL 2006...70

STATIC IGNITION VALUES 250 SX/SXS, 250/300 EXC/EXC SIX DAYS, 300 XC/XC-W...81

STATIC GENERATOR VALUES 250/300 EXC/EXC SIX DAYS, 300 XC-W...83

STATIC IGNITION AND GENERATOR VALUES 250 XC/XC-W...85

MODEL 2007-...70

STATIC IGNITION VALUES 250/300 EXC-E FROM 2007...87

STATIC GENERATOR VALUES 250/300 EXC-E FROM 2007...89

DYNAMIC GENERATOR VALUES 250/300 EXC-E FROM 2007...91

FUEL SYSTEM...92

OPERATING RANGES OF THE CARBURETOR...94

CARBURETOR ADJUSTMENT...95

DISMOUNTING AND INSTALLING THE CARBURETOR...97

DISASSEMBLING THE CARBURETOR...98

CHECKING THE JET NEEDLE AND THROTTLE SLIDE...99

CHECKING THE STARTING PISTON...99

CHECKING THE FLOAT NEEDLE VALVE...99

CHECKING THE CARBURETOR JETS AND GASKETS...99

ASSEMBLING THE CARBURETOR...100

DRAINING THE CARBURETOR FLOAT CHAMBER...101

CHECKING THE FLOAT LEVEL...101

TROUBLE SHOOTING...102

TROUBLE SHOOTING 250 / 300...104

TECHNICAL SPECIFICATIONS...106

MODEL 2004...106

ENGINE...110

CHASSIS...111

MODEL 2005...106

ENGINE...112

CHASSIS...113

MODEL 2006...106

ENGINE 250...114

ENGINE 300...115

CHASSIS SX / SXS / EXC / EXC SIX DAYS...116

CHASSIS XC / XC-W...117

MODEL 2007...106

ENGINE 250 SX...118

ENGINE 250/300 XC / XC-W / EXC / EXC SIX DAYS...120

CHASSIS 250 SX...119

CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...121

MODEL 2008...106

ENGINE 250 SX...123

ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS...124

ENGINE 300 XC / XC-W / EXC / EXC SIX DAYS...125

CHASSIS 250 SX...126

CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...127

MODEL 2009...106

ENGINE 250 SX...129

ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS...130

ENGINE 300 XC / XC-W / EXC / EXC SIX DAYS...131

CHASSIS 250 SX...132

CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...133

MODEL 2010...108

ENGINE 250 SX...135

ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS...136

ENGINE 300 XC / XC-W / EXC / EXC SIX DAYS...137

CHASSIS 250 SX...138

CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...139

TIGHTENING TORQUES - ENGINE...141

TOLERANCES AND FITTING CLEARANCES / GASKET THICKNESSES...141

TIGHTENING TORQUES - CHASSIS...142

CARBURATOR SPECIFICATION...106

MODEL 2004...143

MODEL 2005...145

MODEL 2006...147

MODEL 2007...150

MODEL 2008...153

MODEL 2009...157

MODEL 2010...157

PERIODIC MAINTENANCE SCHEDULE...162

MODEL 2004 / 2005...164

MODEL 2006...167

MODEL 2007...169

MODEL 2008...173

MODEL 2009...173

MODEL 2010...177

WIRING DIAGRAM...182

MODEL 2004...186

MODEL 2005...193

MODEL 2006...194

MODEL 2007...212

MODEL 2008/2009...216

MODEL 2010...223

KTM 250 SX-F Repair Manual 2005-2006...231

HOME...0

NOTES AND PREFACE...231

Title page and file spine...231

Explanation update...237

Introduction...239

Reply fax for repair manuals...241

TABLE OF CONTENTS...235

SERVICE-INFORMATIONS...231

GENERAL INFORMATION...243

BLEEDING THE COOLING SYSTEM...245

CHANGING THE OIL FILTER...245

OIL CIRCUIT...246

BLEEDING OF THE HYDRAULIC CLUTCH...247

ADJUSTING THE THROTTLE CABLES...247

SPECIAL TOOLS ENGINE...248

REMOVING AND REFITTING ENGINE...251

DISMOUNTING THE ENGINE...253

MOUNTING THE ENGINE...257

DISASSEMBLING THE ENGINE...261

PREPARATORY WORK...263

MOVING THE ENGINE INTO THE TDC POSITION...264

REMOVING THE CAMSHAFTS...265

REMOVING THE CYLINDER HEAD AND PISTON...266

REMOVING THE CLUTCH COVER...268

DISMANTLING THE CLUTCH...269

REMOVING THE CHAIN DRIVE AND PRIMARY GEAR...270

DISMANTLING THE SHIFT MECHANISM...271

REMOVING THE OIL PUMPS...272

SEPARATING THE CASING HALVES, REMOVING THE CRANKSHAFT AND TRANSMISSION SHAFTS...273

SERVICING INDIVIDUAL COMPONENTS...275

LEFT CASING HALF...277

RIGHT CASING HALF...278

BYPASS VALVE...279

CLUTCH COVER...279

CRANKSHAFT...280

MEASURING THE OUTSIDE DIMENSION OF THE CRANKSHAFT WEBS...281

CRANKSHAFT BEARINGS...281

AXIAL CLEARANCE OF THE CRANKSHAFT...281

CYLINDER...282

MEASURING THE PISTON AND CYLINDER, MOUNTING CLEARANCE...282

PISTON...283

PISTON RING END GAP...283

CHECKING THE OIL PUMPS FOR WEAR...283

LUBRICATING SYSTEM...284

CAMSHAFT BEARING...285

CAMSHAFTS...286

AUTOMATIC DECOMPRESSION...286

CAMSHAFT BEARING BRIDGES...287

TIMING CHAIN TENSIONER...288

TIMING TRAIN...289

CYLINDER HEAD...290

CLUTCH...292

KICKSTARTER...293

PRE-MOUNTING THE KICKSTARTER SHAFT...293

SHIFT MECHANISM...295

PRE-MOUNTING THE SHIFT SHAFT...295

GENERAL INFORMATION ON SERVICING THE TRANSMISSION...296

ASSEMBLING THE MAIN SHAFT...296

ASSEMBLING THE COUNTERSHAFT...297

ASSEMBLING THE ENGINE...299

INSTALLING THE TRANSMISSION SHAFTS AND CRANKSHAFT, ASSEMBLING THE CASING HALVES...301

MOUNTING THE OIL PUMPS...303

MOUNTING THE SHIFT MECHANISM...305

MOUNTING THE PRIMARY PINION AND THE CHAIN DRIVE...306

MOUNTING THE CLUTCH...307

MOUNTING THE CLUTCH COVER...308

MOUNTING THE PISTON AND CYLINDER HEAD...309

MOUNTING THE CAMSHAFTS...312

MOUNTING THE CHAIN TENSIONER...313

CHECKING THE VALVE CLEARANCE...313

ASSEMBLING THE ENGINE...314

ELECTRICAL...315

CDI UNIT...317

CHECKING THE IGNITION COIL...317