250/300/380 sx,mxc,exc repair manual engine - Tanga Moteurs

More documents

Recommendations

Info

9-30C TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2002 (all models out of USA) Engine 250 SX 250 EXC 300 EXC 380 SX 380 EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm 297 ccm 368 ccm Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in) 72 / 73 mm (2.84 / 2.88 in) 78 / 77 mm (3 / 2.98 in) Fuel unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X) Oil / gasoline ratio 1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side Crankshaft bearing 1 deep-groove ball bearing / 1 cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston cast piston forged piston cast piston Piston ring one plain compression ring two plain compression rings (upper edge piston - Dimension "X" upper edge cylinder) 0 + 0.1 mm (0 + 0.004 in) Ignition timing 1,9 mm (0,07 in) BTDC 1,94 mm (0.075 in) BTDC 2.1 mm (0.08 in) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) Dimension "Z" 49,5 mm (1.94 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open (height of the 5000/min 5900/min 5200/min control flap) TVC fully open 7000/min 7750/min 7200/min Primary drive straight cut spur gears, primary ratio 25:72 straight cut spur gears, primary ratio 26:72 Clutch multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15) Transmission 5 speed, claw actuated Gear ratio 1st Gear 15:29 15:29 15:29 15:29 2nd Gear 17:27 18:26 18:26 18:26 3rd Gear 19.25 19:22 19:24 19:22 4th Gear 21:23 21:20 21:23 21:20 5th Gear 23:21 23:18 23:21 23:18 Gear lubrication 0,8 l engine oil 20W-40 (Shell Advance VSX4) 0,8 l engine oil 10W-40 (Shell Advance Ultra 4) 0,8 l engine oil 20W-40 (Shell Advance VSX4) 0,8 l engine oil 10W-40 (Advance Ultra 4) ailable chain sprockets 13t / 14t / 15t for chain 5 /8 x 1 /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-1 KOKUSAN 2K-3 KOKUSAN 2K-3 KOKUSAN 2K-3 Generator output no generator 12V 110W no generator 12V 110W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert
Repair manual KTM 250 / 300 / 380 Art No 3206004 -E TIGHTENING TORQUES Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb) Crankcase and cover bolts M 6 8 Nm (6 ft.lb) Swingarm pivot M 14 100 Nm (74 ft.lb) Flat head bolt release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb) Other bolts M 6 10 Nm (7 ft.lb) M 8 25 Nm (19 ft.lb) M 10 45 Nm (33 ft.lb) TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 0.06 mm (250) 0.06 mm (300) 0.08 mm (380) Piston ring end gap 0.3–0.4 mm Connecting rod bearing - radial clearance 0.021–0.032 mm Transmission shafts end float 0.1–0.2 mm Clutch springs - length Ø 2.5 new = 43 mm, minimum length = 42 mm GASKET THICKNESSES Crankcase 0.5 mm Clutch cover 0.5 mm Cylinder bottom gasket as required Available cylinder bottom gaskets 0.2/0.4/0.5/0.75 mm Cylinder-head gasket O-rings BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Idling jet Starting jet Jet needle Needle position from top Slide Air adjustment screw open Performance restrictor Power jet jet BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Idling jet Starting jet Jet needle Needle position from top Slide Air adjustment screw open Performance restrictor Power jet jet 250 SX 380 SX 380 SX USA Keihin PWK 38 AG 061200 170 (168,172) 48 (45,50) 85 NOZ E (NOZ F/D) III 6,5 1,5 – – 250 EXC USA Keihin PWK 38 AG 030201 178 (175,180) 45 (48) 85 NOZ E (NOZ F) IV 6,5 1,5 – – Keihin PWK 38 AG 050201 170 (168,172) 45 (48) 85 NOZ G (NOZ H) II 6,5 1,5 – – 300 EXC AUS throttled Keihin PWK 38 AG 070201 170 (172,168) 45 (48) 85 NOZ G (NOZ H) II 6,5 1,5 slide stop 36mm – 250/300 EXC throttled Keihin PWK 38 AG 061200 175 (172,178,180) 35 (45/48) 85 R 1475 J (NOZ E/H) III 6,5 1,5 slide stop 34mm – 300 MXC/EXC USA Keihin PWK 38 AG 040201 175 (178,172) 45 (48) 85 NOZ H (NOZ I) III 6,5 1,5 – – 9-31C
Page 1:
Repair manual KTM 250 / 300 / 380 A
Page 5:
1 SERVICE-INFORMATIONS 2 GENERAL IN
Page 9:
Page 13 and 14:
REPLY FAX FOR REPAIR MANUALS We hav
Page 16 and 17:
Page 18 and 19:
Page 20:
Page 24 and 25:
Page 26:
Page 30 and 31:
Page 32 and 33:
Page 34 and 35:
Page 36 and 37:
Page 39 and 40:
Page 41 and 42:
Page 43 and 44:
Page 45 and 46:
Page 47 and 48:
Page 49 and 50:
Page 51 and 52:
Page 53 and 54:
Page 55:
Repair manual 250 / 300 / 380 Art N
Page 58 and 59:
6-3C 2 45 45 M6 x ... 45 3 45 1 45
Page 60 and 61:
6-5C 4 2 3 5 1 Mount primary drive
Page 62 and 63:
6-7C X Mounting piston and cylinder
Page 64 and 65: 6-9C 2 1 Mounting steering covers -
Page 66 and 67: 6-11C 1 2 3 4 6 5 Mounting the igni
Page 69 and 70: Repair manual KTM 250 / 300 / 380 A
Page 77: Repair manual KTM 250 / 300 / 380 A
Page 83: Repair manual 250 / 300 / 380 Art N
Page 86 and 87: 9-3C Flange bolts - cylinder-head M
Page 88 and 89: TABLE 4 9-5C Carburetor Carburetor
Page 90 and 91: 9-7C KTM 250/300 MXC/EXC EU, USA‘
Page 92 and 93: 9-9C KTM 380 SX/MXC/EXC EU, USA ‘
Page 94 and 95: 9-11C TIGHTENING TORQUES - ENGINE F
Page 96 and 97: 9-13C TIGHTENING TORQUES Flange bol
Page 98 and 99: 9-15C KTM 250 SX EUR/USA 2000 KEIHI
Page 100 and 101: 9-17C KTM 300 MXC/EXC EUR/USA 2000
Page 113: Repair manual KTM 250 / 300 / 380 A
Page 140 and 141: 11-3C
Page 142 and 143: 11-5C
Page 144 and 145: 11-7C SPORTMOTORCYCLES
Page 146 and 147: 11-9C SPORTMOTORCYCLES
Page 148 and 149: 11-11C
show all

250/300/380 sx,mxc,exc repair manual engine - Tanga Moteurs

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?