KTM250525SXMXCEXC2003RepairManual

250-525SX,MXC,EXCRACINGREPAIRMANUALENGINEKTMSPORTMOTORCYCLEAG5230MattighofenAustria:14,21-24,30-47,50-52,56-76,79-92,97-124,134-140,142,150-154,165-167KTMREPAIRMANUALINLOOSE-LEAFFORMSTORINGTHEREPAIRMANUALINTHEBINDER–Puttheindexintothebinder.–Putthefrontpageoftherepairmanual(210x297mm)intothetransparentpocketprovidedforthispurposeontheoutsideofthebinder.–Putthespinelabel(170x45mm)intothetransparentpocketprovidedforthispurposeonthespineofthebinder.–Putthesummarylistofcontents(150x297mm)intothetransparentpocketprovidedforthispurposeontheinsideofthebinderorinsertthispageonthebeginningofthemanual.–Theninserttheindividualchaptersofthemanualbetweenthesheetsoftheindexaccordingtothepagenumberprintedintherightbottomcornerofeachpage.Example:pageno.3-53=chapter35=page5Allpageswithapagenumberthatbeginswiththedigit3,forexample,mustbeputundertheindexheading„Chapter3“.–Indexsheetsthathavenotbeenmarkedwithacertainchapterareforyourpersonalconvenience.Therespectiveheadingscanbeenteredinthelistofcontents.Removepage(s)Replacebypage(s)Insertpage(s)afterpage2-1/2-72-1C2-7Cto2-9C3-13-1C4-1to4-144-1Cto4-13C5-1/5-35-1C/5-3C5-6to5-85-6Cto5-8C5-12to5-265-12Cto5-27C6-1/6-46-1C/6-4C6-7to6-166-7Cto6-17C7-1to7-27-1Cto7-2C7-7to7-117-7Cto7-11C8-1to8-138-1Cto8-21C9-19-1C9-10to9-139-10Cto9-16C10-110-1C10-8Cto10-11C11-111-1C11-11Cto11-13CRepairmanualKTM250-525SX,MXC,EXCRACINGArt.-No.3206007-EEXPLANATION-UPDATINGEdition01/20033.205.85-ERepairManual400/520SX,MXC,EXCRACINGBasicversionModelyear2000(Enginenumberwithfirstdigit“0“)2/20003.210.01-EUpdatingofRep.Manual3.205.85-EModelyear2001(Enginenumberwithfirstdigit“1“)1/20013.210.44-EUpdatingofRep.Manual3.205.85-EModelyear2002(Enginenumberwithfirstdigit“2“)2/20023.206.007-EUpdatingofRep.Manual3.205.85-EModelyear2003(Enginenumberwithfirstdigit“3“)1/2003Modification/Updating:TechnicalDetailsModel2003(clutch,valvespring,camshaftgear,carburetor)TechnicalSpecifications,PeriodicMaintenanceSchedule,WiringDiagramsINTRODUCTIONThisrepairmanualoffersextensivrepair-instructionsandisanup-to-dateversionthatdescribesthelatestmodelsoftheseries.However,therighttomodificationsintheinterestoftechnicalimprovementisreservedwithoutupdatingthecurrentissueofthismanual.Adescriptionofgeneralworkingmodescommoninworkshopshasnotbeenincluded.Safetyrulescommonintheworkshophavealsonotbeenlisted.Wetakeitforgrantedthattherepairsaremadebyqualifiedprofesionallytrainedmechanics.Readthroughtherepairmanualbeforebeginningwiththerepairwork.
WARNING
STRICTCOMPLIANCEWITHTHESEINSTRUCTIONSISESSENTIALTOAVOIDDANGERTOLIFEANDLIMB.!CAUTION!NON-COMPLIANCEWITHTHESEINSTRUCTIONSCANLEADTODAMAGEOFMOTORCYCLECOMPONENTSORRENDERMOTORCYCLESUNFITFORTRAFFIC!„NOTE”POINTSOUTUSEFULTIPS.UseonlyORIGINALKTMSPAREPARTSwhenreplacingparts.TheKTMhighperformanceengineisonlyabletomeetuserexpectationsifthemaintenanceworkisperformedregularlyandprofessionally.KTMAustria’scertificateofachievementforitsqualitysystemISO9001isthebeginningofanongoingtotalreengineeredqualityplanforabrightertomorrow.KTMSportmotorcycleAG5230Mattighofen,AustriaAlldesignandassemblymodificationrightsreserved.CbyKTMSPORTMOTORCYCLEAG,AUSTRIAAllrightsreservedREPLYFAXFORREPAIRMANUALSWehavemadeeveryefforttomakeourrepairmanualsasaccurateaspossiblebutitisalwayspossibleforamistakeortwotocreepin.Tokeepimprovingthequalityofourrepairmanuals,werequestmechanicsandshopforementoassistusasfollows:Ifyoufindanyerrorsorinaccuraciesinoneofourrepairmanual–whetherthesearetechnicalerrors,incorrectorunclearrepairprocedures,toolproblems,missingtechnicaldataortorques,inaccurateorincorrecttranslationsorwording,etc.–pleaseentertheerror(s)inthetablebelowandfaxthecompletedformtousat0043/7742/6000/5349.NOTEtotable:–Enterthecompleteitemno.fortherepairmanualincolumn1(e.g.:3.210.66-E).Youwillfindthenumberonthecoverpageorintheleftmarginoneachrightpageofthemanual.–Enterthecorrespondingpagenumberintherepairmanual(e.g.:5-7c)incolumn2.–Enterthecurrenttext(inaccurateorincomplete)incolumn3byquotingordescribingtherespectivepassageofthetext.Ifyourtextdeviatesfromthetextcontainedintherepairmanual,pleasewriteyourtextinGermanorEnglishifpossible.–Enterthecorrecttextincolumn4.Yourcorrectionswillbereviewedandincorporatedinthenextissueofourrepairmanual.Itemno.ofrepairmanualPageCurrenttextCorrecttextAdditionalsuggestions,requestsorcommentsonourRepairManuals(inGermanorEnglish):Namemechanic/shopforemanCompany/workshopGENERALINFORMATIONRepairmanualKTM250-525SX,MXC,EXCRACINGArt.-No.3206007-EOILCIRCUIT..............................................2-2EN