250/300/380 Sx,Mxc,Exc Repair Manual Engine

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 250/300/380 SX,MXC,EXC REPAIR MANUAL www.ktm.at Austria 5230 Mattighofen KTM SPORTMOTORCYCLEAG ENGINE

250 - 380 SX,MXC,EXC

REPAIR MANUAL ENGINE

1 SERVICE-INFORMATIONS

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING THE ENGINE

5 SERVICING ON INDIVIDUAL COMPONENTS

6 ASSEMBLING THE ENGINE

7 ELECTRICAL

8 TROUBLE SHOOTING

9 TECHNICAL SPECIFICATIONS

10 PERIODIC MAINTENANCE SCHEDULE

11 WIRING DIAGRAMS

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E pages andinsertthemintheexistingrepairinstructions: To – – – – – – STORING THEREPAIR MANUALINTHEBINDER I xml: aen.353=catr35=page The respective headings canbeentered inthelistofcontents. 3=chapter Index sheetsthathave not beenmarkedwithacertainchapterare foryourpersonalconvenience. index heading„Chapter 3“. All pageswithapagenumberthatbegins thedigit3,forexample,mustbeputunder Example: pageno.3-5 the pagenumberprintedinrightbottom cornerofeachpage. Then inserttheindividualchaptersofmanual betweenthesheetsofindexaccording to purpose ontheinsideofbinderorinsert this pageonthebeginningofmanual. Put thesummarylistofcontents(150x297 mm) intothetransparent pocketprovided forthis spine ofthebinder. Put thespinelabel(170x45mm)intotransparent pocketprovided forthispurposeonthe this purposeontheoutsideofbinder. Put thefront pageoftherepair manual(210x297mm)intothetransparent pocket provided for Put theindexintobinder. beabletocontinueusingtheexistingloose-leafrepairinstructions,simplyprintfollowing MPORTANT 14-20, 26,28-36,37,41,42,50,51,67,72-77,83,121-126,127,134-136, eoepg s elc ypg s netpg s afterpage Insertpage(s) Replacebypage(s) Remove page(s) -3t -45-13Cto5-14C 5-13 to5-14 - o242-1Cto2-6C 2-1 to2-4 - o494-1Cto4-8C 4-1 to4-9 111-C11-14Cto11-16C 10-6Cto10-8C 11-1C 10-1C 11-1 10-1 - -C9-37Cto9-42C 7-5Cto7-10C 9-1C 7-1C 5-4C/5-5C 5-1C 9-1 3-4C 7-1 5-4 5-1 3-4 KTM REPAIR MANUALINLOOSE-LEAFFORM I NFORMATION 137, 151-153 /U DTN INSTRUCTIONS PDATING

EXPLANATION - UPDATING

3.205.63-E Repair Manual 250 / 300 / 380 SX, MXC, EXC Basicversion Modelyear 1999 (Engine number with first digit “9“) 11/1998

3.205.87-E Updating of Rep.Manual 3.205.63-E Modelyear 2000 (Engine number with first digit “0“) 2/2000

3.210.02-E Updating of Rep.Manual 3.205.63-E Modelyear 2001/2002 (Engine number with first digit “1“) (Engine number with first digit “2“) 3/2001 Art No 3206004 -E

3.206.004-E Updating of Rep.Manual 3.205.63-E Modelyear 2003 (Engine number with first digit “3“) 11/2002

Modification / Updating: Technical Specification, Periodic Maintenance Schedule, Wiring Diagrams Repair manual KTM 250 / 300 380

Edition 11/2002

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 on going total reengineered quality plan for a brighter tomorrow.

KTM Sportmotorcycle AG 5230 Mattighofen, Austria

All design and assembly modification rights reserved.

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To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows:

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Name mechanic/shop foreman Company/work shop Repair manual 250 / 300 / 380 Art Nr 3206004 -E TRG ..2-6 STORAGE . .2-6 CLEANING ..2-5 SPECIAL TOOLS-ENGINE ..2-4 BLEEDING OFTHEHYDRAULICCLUTCH ..2-4 CHECKING OFTHESETTINGTVCSYSTEM ..2-3 CARBURETOR ADJUSTMENT ..2-2 OPERATING RANGESOFTHECARBURETOR GENERAL INFORMATION INDEX 2-1C 2

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E main jetisrequired. Iftheporcelain isdarkbrown orblack with sootthemainjetmustbe replaced byasmallerone. new sparkplug isfoundtohaveaverybright orwhitecoatingiftheengine rings,afterashortdistance ofridingflatou Operation withthethrottle fullyopen(flatout).Thisrangeisinfluencedbythemain jetandtheneedle.Ifporcelai Full throttlerange engine pings,adjusttheidling rangericher. If thesefaultsshouldoccurat the lowerendofpartthrottle rangeatafour-stroke running, maketheidlingrangeleaner be raised. one notch.Ifthentheenginepings,especiallywhenaccelerating underfullpoweratmaximumenginerevs, thejetneedleshoul on afour-stroke cycleorwithreduced powerwhenitisaccelerated withthethrottle partlyopen,thejetneedlemustbelower part-throttle settingiscontrolled bytheidlingsetting inthelowerrangeandbymainjetupperrange.Ifeng Operation withpartlyopenthrottle valve.Thisrange is onlyinfluencedbythejetneedle(shapeandposition).Theoptimum Part-throttle range needle isleaking. not smoothlybutsuddenlyathighenginespeeds,themixture tothecarburetor willbetoorich,thefuellevelhighor idling-speed andpart-throttle setting,theenginesputters andsmokeswhenthethrottle isfullyopenedanddevelopsitsfull Engine behaviorwhenthethrottle opens.Theidlejetand theshapeofthrottle valveinfluencesthisrange.If,despitego Opening up 2 Operation withclosedthrottle valve.Thisrangeisinfluencedbythepositionofaircontrol screw Idling range To means oftheidleadjustingscrew. using theaircontrol screw (basicpositionoftheaircontrol screw =openby1.5turns).Thenadjusttothe normalidlingspe higher idlingspeedandturningthescrew counterclockwise produces aloweridlingspeed.Create around andstableenginespee too muchfuelinproportion toair mixture toorich: not enoughfuelinproportion toair mixture toolean: . Onlymakeadjustmentswhentheengineishot.

this end,slightlyincrease theidlingspeedofenginebymeansidleadjustingscrew. Turning itclockwiseproduc B A D C OPERATING RANGESOFTHECARBURETOR idle adjustingscrew air controlscrew throttle valve idle jet jet needle jet needle main jet 2 1 and theidleadjustingscrew t, alarger n ofthe ine runs 1 2-2C ; ifthe power ed by ed by

float es a od d d 2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60.

Basic information on a change of the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures ➞ choose leaner carburetor adjustment low altitude or low temperatures ➞ choose richer carburetor adjustment WARNING –ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE, AND USE OF SAME WILL VOID YOUR WARRANTY. –ONLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS. –NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. USING TOO MUCH OIL, THE ENGINE CAN START SMOKING AND FOUL THE SPARK PLUG. –IN THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY. ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID OVERHEATING AND PISTON SEIZURE.

NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system.

Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles).

jet needle throttle valve open effect Explanation - Example N 85 A 1 N 85 B 0 – /4 – Compared to the needle N 85 A, the jet needle N 85 C is two steps leaner 1 in the range from the closed position of the throttle to 1/4 throttle. N 85 C 0 – /4 – – Otherwise, there are not differences. 1 N 85 D 0 – /4 – – –

1 N 85 E 0 – /4 – – – – 1 N 85 C 0 – /4 – – NOZ C

1 NOZ D 0 – /4 –

1 NOZ E 0 – /4 – – ! CAUTION !

1 WHEN CHANGING THE JET NEEDLE, MAKE SURE THAT YOU USE THE CORRECT NEEDLE NOZ F 0 – /4 – – – TYPE (N 85 ,NOZ OR N3). THE TECHNICAL DATASHEET TELLS YOU WHICH JET 1 NOZ G 0 – /4 – – – – NEEDLE CAN BE USED FOR WHICH MODEL.

1 NOZ H 0 – /4 – – – – –

1 NOZ I 0 – /4 – – – – – –

1 NOZ J 0 – /4 – – – – – – –

N3CG

1 N3CH 0 – /4 –

1 N3CW 0 – /4 – – Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 4 2 3 1 that theTVCsystemwillperformadjustmentearlier. adjustment bytheTVCsystem,twistingadjustingscrew outmeans Twisting theadjustingscrew indelaysthecommencementof NOTE: –A – – – This testchecksthestartofadvanceandendadvance. The functionoftheTVCsystemischeckedwithenginerunning. Checking thesettingofTVCsystem – –T Bleeding ofthehydraulicclutch – – – –H 8 20Umn7200U/min 5200U/min 7750U/min 7550 U/min 7750U/min 5900U/min 5400U/min 5300U/min 7000U/min 380 300 from Modell2001on 5000U/min 300 uptoModell2000 250 from Modell2000on 250 Model1999 in abubble-free state.Makesure thattheoildoesnot overflow. At theslavecylinderofclutch,remove thebleedernipple If necessary, turntheadjustingscrew starts toadvance(toothsegmentcreeps upwards). Start engine,accelerategentlyandobservewhentheTVCsystem cable intheelectronics box,dependingontherev counterdesign). Connect arev counter(eithertotheignitioncableorblue/white For this,remove theleftcontrol cover. KTM hydraulic oil. Refill oil,untiloilisdischarged from thebore CYLINDER I EE NTEMSE YIDRI CORRECT IS CYLINDER MASTER THE IN LEVEL OIL CONTROL place, mountthebleedersyringe ake off cover togetherwithrubberbellows. LW A IGCMLTDTEBEDN PROCEDURE BLEEDING THE COMPLETED VING AY S SSBOERDBEHDALCOLFRTEHDALCCLUTCH HYDRAULIC THE FOR OIL HYDRAULIC BIODEGRADABLE USES S IDGAAL YRUI OIL HYDRAULIC BIODEGRADABLE USE . N . N VRRFL IHMNRLHDALCOLO RK FLUID BRAKE OR OIL HYDRAULIC MINERAL WITH REFILL EVER ! VRMXBOERDBEHDALCOL IHMNRLOILS MINERAL WITH OILS HYDRAULIC BIODEGRADABLE MIX EVER CAUTION tr favneendofadvance start ofadvance 3 1 . which isfilledwithSAE10 SAE 10 . , O AET EIYTA THE THAT VERIFY TO HAVE YOU 4 of themastercylinder OFL PTEMASTER THE UP FILL TO ! 2 . 2-4C . Itits . 2-5C SPECIAL TOOLS – ENGINE 250 / 300 / 380

13 10 6 17 5 14 1 16

4 19 18

7 26

8 25

9 3

Fig. Part no. Description 1 560.12.001.000 Universal engine work stand 3 546.29.003.000 Clutch holder 4 560.12.004.000 Gear wheel segment 5 546.29.009.044 Magneto extractor M 27x1 Kokusan 66 276 807 Magneto extractor M 26x1,5 SEM 7 510.12.011.000 Circlip plier 8 544.12.012.000 Holding spanner for flywheel SEM 9 584.29.037.040 Mounting tool inner ring NJ 207 9 584.29.037.043 Mounting tool inner ring NJ 207 10 510.12.016.000 Protection cap 11 546.29.012.100 Holding spanner for flywheel Kokusan 13 501.12.013.000 Dial gauge 0-10 mm 14 501.12.030.000 Dial gauge support 16 6 899 785 Loctite 243 blue 6 ccm 17 151.12.017.000 Bearing puller 18 151.12.018.100 Internal bearing puller 18-23 mm 18 151.12.018.000 Internal bearing puller 12-16 mm 18 151.12.018.200 Internal bearing puller 5-7 mm 19 546.29.027.000 Clutch rivetting tool 25 0276 179 000 Extractor primary gear 26 503.29.050.000 Vent springe for hydraulic clutch Repair manual KTM 250 / 300 / 380 Art No 3206004 -E ETUTO FTEEPARTS THESE OF DESTRUCTION N The hard dirtcanberemoved before washingwiththehelpofasoftwaterjet. The bestmannerwouldbetousewarmwaterthathasbeenmixedwithanormalbrand-namewashingdetergent andasponge. Clean yourmotorcycle regularly inorder tomaintainthebeautyofitsplasticsurfaces. shops). Thisway, youcanavoid thelongwaitingtimesatyourshopbeginningof thenextbikingseason. jobs, repairs, oranyrefitting benecessary, youshouldhavethemcarried outduringtheoff-season (lowerworkloadatmechani NOTE: Before youputyour motorcycle awayforthewinter, you should checkallpartsfortheirfunctionandwear. Shouldanyse –T – – USE AFTERAPERIODOFSTORAGE I – – – – – Should youwishtomakeapauseoverlongerspaceoftime,pleaseobservethefollowinginstructions: A K –t – precautions againsttheaggressive road salt. In theeventthatmotorcycle isalsousedinwinterandonroads where onehastoexpectsalt spraying, youwillhavetota –Y – COMPONENTS ELECTRICAL H HSDVLPDSEMWUDCNES UIGTECMUTO RCS N AS H AVSADEHUTT RUST TO EXHAUST AND VALVES THE CAUSE AND PROCESS COMBUSTION THE DURING CONDENSE WOULD STEAM DEVELOPED THUS THE – – – – – –A –T –A – T E H ANTI THE EEP TRRDSO ATDROADS SALTED ON RIDES FTER VRCENYU OOCCEWT HIGH A WITH MOTORCYCLE YOUR CLEAN EVER Check themotorcycle asbefore eachstart(seedrivinginstructions) Fill upthetankwithfresh fuel. Remove sparkplugandfillinapprox. 5ccmofengineoilintothecylinderthrough theopening.Actuatekick-starter 10times from becomingresin- cloggedbytheoldfuel. Let theenginewarmupagain,closefuelcockandwaituntildiesoff byitself.Inthiswaythecarburetor jets ar Check antifreeze andamountofcoolingliquid. Change engineoil(oldcontainsaggressive contaminants). Clean motorcycle thoroughly (seechapter:CLEANING) able toescapeandthereby causecorrosion. Cover themotorcycle withanairpermeatedtarporblanket. Donotusenonairtightmaterialsasapossiblehumiditymight The storageplaceshouldbedryandnotsubjectedtotoo bigtemperature fluctuations. Lubricate bearingpointsofthecontrol levers,footrests, etc.aswellthechain. Correct tire pressure. Let fuelflowoutoftankintoanappropriate container. to distributetheoilontocylinderwallsandmountsparkplug. OL EVR A OLTTEEGN U O HR IEDRN H TRG PERIOD STORAGE THE DURING TIME SHORT A FOR RUN ENGINE THE LET TO BAD VERY BE WOULD clean themotorcycle thoroughly andletitdryaftereachride Before cleaningwithwater, plugtheexhaustpipetoprevent wateringress. sion agent. of apaintbrush. motorcycle isallowedtoevaporate. light switchandthesocketconnectorswithcontactspray. Slide backtheprotective coversonthehandlebar-mounted instrumentssothatanywatermayhaveseepedintothispartof evaporate from inaccessablepartsoftheengineandbrakes. the enginehasreached theworkingtemperature andalsousethebrakes.Bywarmingthesecomponents,residual watercan ake ashort,careful testride first. r o prevent failures intheelectricsystem,youshouldtreat theignitionlock,emergency OFFswitch,theshortcircuit bu ou shouldusenormalbrand-namedetergents tocleanthemotorcycle. Especiallydirtypartsshouldalsobecleanedwiththehe eat theengine,carburetor, swingarm,andallotherbare orgalvanizedparts(exceptforbrakediscs)withawax-basedanti fter themotorcycle hasbeenrinsedwithasoftwaterjet,itshouldbedriedbyairpressure andacloth.Then takeashort fter themotorcycle hascooleddown,oilandgrease alltheglidingbearingparts.Treat thechainwithaspray. - ORSO GN RMGTIGIT OTC IHTEBAEDISCS BRAKE THE WITH CONTACT INTO GETTING FROM AGENT CORROSION ! ! ! , CONNECTORS . , LA OOCCETOOGL IHCL AE N E TDYWELL DRY IT LET AND WATER COLD WITH THOROUGHLY MOTORCYCLE CLEAN CONSERVATION FORWINTEROPERATION , HAHDCABLES SHEATHED - RSUE LAE RAHIGH A OR CLEANER PRESSURED , W BEARINGS CAUTION CAUTION CAUTION ARNING CLEANING STORAGE , CARBURETOR - RSUE AE JET WATER PRESSURED , , TEWS HSWL INFCNL EUETEBAIGPOWER BRAKING THE REDUCE SIGNIFICANTLY WILL THIS OTHERWISE ETC . N AS ITRACSO EDT PREMATURE A TO LEAD OR DISTURBANCES CAUSE AND . T EEGN OL O E AMDU NUHAND ENOUGH UP WARMED GET NOT WOULD ENGINE HE . T EWTRCUDOHRIERNIT THE INTO RUN OTHERWISE COULD WATER HE . ! ! ! . e prevented drive until tton, the

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Repair manual 250 / 300 / 380 Art No 3206004 -E REMOVING ANDREFITTINGENGINE EITN H NIE..3-4 REFITTING THEENGINE ..3-2 REMOVING THEENGINE INDEX 3-1C 3

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 3 1 2 4 – – – –P – Dismounting theengine – – – – – Disengage andremove spring Dismount enginestrut Drain coolant,anddisconnectradiatorhosesfrom engine. Dismount exhaustsystem. Remove seat,rightsidepaneling,andtankwithspoilers. Clean motorcycle thoroughly. Remove sprocket cover plug connector. Disconnect plug-and-socketconnectorofignitionsystemandspark- Remove footbrakecylindercover r op upmotorcycle onanappropriate stand. 1 2 . and chain. 4 . 3 . 3-2C 3-3C – Loosen the 3 screws, and remove intermediate flange chamber 1 of KTC system together with O-ring. – Remove engine fastening screw 2. – Remove cable ties and loose the cable of ignition from frame.

– Loosen both hose clamps, and pull caburetor out of carburetor connection boot and intake flange.

– Remove transmission-oil drain plug 3 together with sealing ring, and 4 drain the transmission oil. – Remove the 2 screws 4, and dismount clutch slave cylinder. 4 ! CAUTION ! DO NOT ACTUATE THE CLUTCH LEVER WITH THE CLUTCH SLAVE CYLINDER 5 DISMOUNTED. – Remove engine fastening screw 5. – Remove hexagon nut of swingarm pivot 6. 6 – Remove swingarm pivot, and pull swing arm backward out of the frame so as to make lifting the engine out of the frame easier. 3 – Lift engine out of frame. NOTE: Cylinder head and cylinder can be dismounted even if the engine remains mounted. Likewise, work on clutch, primary drive, gearshift mechanism, and ignition system can be carried out. Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 3 4 1 2 T S O ITEO O RD OIL GRADE LOW OR LITTLE TOO USE – – – Filling inofcoolingliquid: TOP SPEED4T). – Filling inoftransmissionoil: –T Refitting theengine – – – ASISO N LTHWL ESBETT XESV ERADTEAR AND WEAR AXCESSIVE TO SUBJECT BE WILL CLUTCH AND RANSMISSION inspection openingwhenthemotorcycle isinanuprightposition. clutch coveristoberemoved. Oilshouldjustbarely escapefrom the the radiatorfins. radiator untilthecoolantcan be seenapprox. 10mm(0.4in)above Return themotorcycle to itsoriginalpositionandtopuptheleft enter therightradiator. radiator. Thenimmediatelymountthe screw sothatnomore aircan Now addcoolingliquiduntilitemerges free ofbubblesattheright the rightapprox. 30degree angle. Make sure thatthedrainscrew Remove theplug In order tocheckthetransmissionoillevelcontrol screw MOTOREX TOPSPEED4T). Remove thescrew gallons)coolantintothesystem. Pour approx. 0.50litres (0.13US o installtheengine,reverse thestepsforremoving theengine. ! 4 1 40% coolant:60%water on therightradiatorandtiltmotorcycle to and topupwithengineoil15W-50 (i.e. CAUTION . U EOL HIGH ONLY SE 3 is fastened. - RD OIL GRADE ( I . E . MOTOREX ! 2 , 3-4C on the FYOU IF

Repair manual 250 / 300 / 380 Art No 3206004 -E DISASSEMBLING THEENGINE IMUTN FTECAKHF ..4-8 DISMOUNTING OFTHECRANKSHAFT ..4-7 DISMOUNTING OFGEARSHIFTMECHANISMANDTRANSMISSION PA ..4-7 DISMOUNTING OFINTAKE FLANGEANDREEDVALVE HOUSING ..4-6 DISMOUNTING OFTHEIGNITION(SEM) . ..4-6 DISMOUNTING OFTHEIGNITION(KOKUSAN) . ..4-5 DISMOUNTING OFIGNITIONCOVER ..4-5 DISMOUNTING OFTHESHIFTLOCK ..4-5 DISMOUNTING OFKICKSTARTER ..4-4 DISMOUNTING OFTHEPRIMARY DRIVE ..4-4 DISMOUNTING OFPRESSURECAPANDCLUTCHDISCS ..4-3 DISMOUNTING OFCLUTCHCOVER ..4-2 DISMOUNTING OFCYLINDERHEAD,ANDPISTON ..4-2 DISMOUNTING OFSPROCKETANDSHIFTLEVER ..4-2 DRAINING GEAROIL R TING OFENGINEHOUSINGHALVES ..4-7 INDEX 4-1C 4

4-2C – Cleaning the engine thoroughly. – Clamp the engine into the workstand. – Remove the kickstarter together with the distance bushing behind.

Draining gear oil

NOTE: The transmission oil should already be drained when the engine is dismounted. Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch.

– Unscrew plug 1, allowing oil to drain.

Dismounting of sprocket and shift lever – Remove circlip 2 from countershaft using circlip pliers. Slide off engine sprocket, distance bushing and O-ring. – Undo the screw 3 and remove the shift lever. – Pull out the clutch push rod 4 from drive shaft.

2 4 Art No 3206004 -E 3

Dismounting of cylinder head, cylinder and piston – Unscrew the 6 collar screws 5 and remove cylinder head and the two O-rings.

– Undo the screws 6 and remove the left control cover together with the gasket. Repair manual KTM 250 / 300 380

6 4-3C – Undo the screws 1 and remove the right control cover.

– Remove the securing clip of the ball socket 2 and unhook the ball socket 3 from the adjusting lever. 3 – Remove gasket of the control cover.

– Remove the 4 collar nuts 4 on cylinder base and remove cylinder.

– Cover the crankcase. – Place piston on wooden jig and remove both piston pin locking pins. – Expel piston pin from piston without exerting undue force. Use a suitable mandrel if necessary. – Remove piston and piston pin needle-bearing from conrod eye. – Remove the cylinder base gaskets. ! CAUTION ! THE PISTON PIN MUST NEVER BE FORCED OUT WITH A PUNCH. THIS WOULD DAMAGE THE CONROD BEARING.

Dismounting of clutch cover 6 – Remove collar screws and clutch cover including gasket. NOTE: The water pump cover 6, the outer cover 5 and the cover lid 7 do not need to be removed. The water pump and the centrifugal timer remain in the clutch cover.

5 7 4-4C Dismounting of pressure cap and clutch discs – Loosen collar screws 1 in diagonally opposite sequence to prevent 1 wedging of discs as springs expand. – Remove collar screws, springs and spring retainers.

–Take pressure cap and disc package out of outer clutch hub. –Take thrust bearing 2 off the drive shaft. 2

Dismounting of the primary drive – Block the primary gear with the gear wheel segment 3 (see illustration). – Undo the hexagon nut (LH thread) and remove it together with the detent edged ring. Art No 3206004 -E 3

– Release the lock washer of the inner clutch hub. – Connect clutch holder 4 to inner clutch hub and loosen hexagon nut 4 (see illustration). – Remove clutch holder. – Remove inner clutch hub and outer clutch hub together with bearing from main shaft.

– Pulling the primary gear 5 and the distance bushing 6 off the crankshaft.

5 NOTE: The primary gear and the outer clutch hub belong together. Always replace both together! Repair manual KTM 250 / 300 380

6 4-5C Dismounting of kickstarter – Remove circlip 1 and kickstarter intermediate gear. – Carefully release collar screw 2 kickstarter spring is tensioned, release tension on kickstarter spring and unhook spring hanger. 2 ! CAUTION ! CAREFULLY RELEASE THE KICKSTARTER SPRING! DANGER OF INJURY!

–Take the complete kickstarter shaft out of the housing. –Take care of the stop disc, which could stay in the housing.

Dismounting of the shift lock –Press the sliding plate 3 back with a screw driver so it no longer 3 engages with the driver for the shaft roller, at the same time remove shift shaft from the housing.

NOTE: Watch the stop disc which remains in the housing.

– Remove allan head screw 4 and take driver for roller 5 and locking piece 6 from the shift roller.

NOTE: From model 2002 driver for roller 5 and locking piece 6 are 5 made of aluminium.

4 6

NOTE: Disassemble locating lever only if the engine case must be replaced.

7 – Remove screw 7 and locking lever with spring and bush.

Dismounting of ignition cover – Undo the 5 screws and remove the ignition cover together with the gasket. 4-6C Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner 1 and undo the collar nut.

– Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel.

– Undo the 3 screws 2 and remove the stator together with the base plate.

Art No 3206004 -E 2

Dismounting of the ignition (SEM) – Hold the flywheel with the special tool and undo the collar nut. – Place protective cap on crankshaft thread. –Twist in the flywheel extractor and remove the flywheel.

– Loosen the 3 collar screws 3, and take base plate with stator out of the casing. 3 Repair manual KTM 250 / 300 380 4-7C Dismounting of intake flange and reed valve housing – Remove the 5 collar screws 1. – Remove intake flange and reed valve housing.

Parting of engine housing halves –Top ignition-gear upwards and remove all 11 housing screws. – Loosen the 2 engine fixtures on the engine work stand.

– Lift left-hand housing half with suitable tools by on the bosses provided, or part with a few light plastic mallet blows against the countershaft from the right-hand housing half. ! CAUTION ! LEVERING APART WITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED, SINCE THE SEAL FACES ARE EASILY DAMAGED.

NOTE: Watch gear shaft stop discs 2 to prevent them sticking to inside of housing.

Dismounting of gearshift mechanism and transmission –Take the two stop discs 2 off the transmission shafts. – Pull the 2 pressure springs 3 out of the shift rails.

2 3 4-8C – Pull out the shift rails and swing the shift forks aside. – Pull the shift roller out of the bearing seat. – Remove the shift forks. 1 NOTE: During disassembly, watch out for the shift rollers 1 on the driving pins of the shift forks. They may remain in the shift roller. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. Therefore mark accordingly upon removal.

– Remove the 2 pressure springs 2 from the engine case.

2 2

– Pull the drive shaft together with the countershaft out of the bearing seats. Art No 3206004 -E

– Remove 1st-gear idler gear 3 with needle cage and the two stop discs from the engine case.

Dismounting the crankshaft – Pull crankshaft from the bearing seat (if necessary, use a plastic hammer and tap carefully on the crankshaft journal).

– Remove O-ring from crankshaft. Repair manual KTM 250 / 300 380

– Clean all parts and check for wear, replace if necessary.

NOTE: When an engine is completely overhauled it is recommended that all gaskets, shaft seal rings and O-rings are renewed. Repair manual 250 / 300 / 380 Art No 3206004 -E SERVICING ONINDIVIDUALCOMPONENTS Bearings orshaftsealringsshould notbehammered intotheirseats.Ifnosuitablepress isavailable,useasuitablemandrel used asabase. placed onasuitablylarge planesurface,supportingthe wholeofthesealingsurfacewithoutdamagingit.Awooden panelisbe Having firstremoved thedowels, inorder toexpelthebearingsorremove them withlightmalletblows,thehousinghalvesmust housing halvesonlyneedtobeheateduponcebefore replacing thebearings. NOTE: Readthrough thefollowingsectionbefore commencing work.Thendeterminetheassemblysequencesothatengine Engine housing be replaced. After cooling,should thebearingsfailtolock inthebore, theyare bound torotate afterwarming. Inthateventthehousing C. 150° hammer theminwithgreat care. Coldbearingswillpracticallydrop intotheir seatsatanenginehousingtemperature ofapprox SEBEO IKTRE HF ..5-17 ASSEMBLE OFKICKSTARTER SHAFT ..5-17 KICKSTARTER ASSEMBLY ..5-16 COUNTERSHAFT ..5-15 ASSEMBLY MAINSHAFT ..5-15 TRANSMISSION ..5-14 CHECK STATOR (SEM) ..5-14 IGNITION (SEM) CHECK STATOR ANDPULSEGENERATOR ..5-13 (KOKUSAN) . ..5-13 SPARK PLUG ..5-13 IGNITION (KOKUSAN) . .5-12 PREASSEMBLY OFSHIFTSHAFT . ..5-12 SHIFT MECHANISM ..5-11 REPLACE OUTERCLUTCHHUB ..5-10 CLUTCH ..5-9 REED VALVE HOUSING,INTAKE FLANGE ..5-8 PREASSEMBLY OFCLUTCHCOVER ..5-8 EXHAUST CONTROL,CLUTCHCOVER . ..5-6 CYLINDER PREASSEMBLY ..5-6 CYLINDER EXHAUSTCONTROLSYSTEM ..5-5 NIKASIL COATING OFCYLINDER ..5-5 RECOATED CYLINDER ..5-5 CHECKING CYLINDERFORWEAR ..5-4 PISTON RINGENDGAP ..5-4 PISTON ..5-4 CRANKSHAFT WEBS–MEASUREOUTERDIMENSION . ..5-4 CRANKSHAFT WORKING ONTHELEFT-HAND ..5-3 HOUSINGHALF ..5-2 WORKING ONTHERIGHT-HAND HOUSINGHALF INDEX 5-1C must

and be st 5 .

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 9 A A 6 1 8 S 3 2 5 7 4 10 11 7 Grooved ballbearingofcountershaft Bearing boltkickstarterintermediategear the stop. and guidehammer(seeillustration).Press innewgrooved ballbearingto C.Ifnecessaryusea6mminternal bearingextractor temperature of150° the housinqhalfonaplanepieceofwoodwhenhousinghas The bearingsusuallyfalloutoftheirseatownaccord byknocking Grooved ballbearingofcentrifugaltimer the outside. Press oldneedlebushinginwards, press innewneedlebushingflushfrom Remove retaining screws Grooved ballbearingoftheshiftroller side oftheballcagemustbefaceinwards. Press innewgrooved ballbearingfrom downward tothestop.Theopen Press innewballbearingfrom insideuptothestop. Grooved ballbearingofmainshaft (outside) ofthecase. stop. Theopensideoftheballcagemustbetowards thebottom Press oldgrooved ball-bearinginwards. Press innewballbearingtothe – W – secured withLoctite243. When replacing theretaining bracket,thetwocollar screws are tobe Retaining bracket not forget newcoppersealring. When mountingthestopscrew, itmustbesecured withLoctite243.Do Stop screw kickstarter inward, untilflush. Press innewshaftsealringfrom theoutside,withsealinglipfacing Crankshaft sealring 243. When replacing therelease plate,secure theflat-headscrews withLoctite Kickstarter release plate damage. housing half,asitispracticallyimpossibletoremove itwithoutcausing bolt. Itisnotrecommended tomountausedbearingboltinnew Experience hasshownthatitisnevernecessarytoreplace thebearing Grooved ballbearingofcrankshaft NECSIEAILPA FTEMAINSHAFT THE OF PLAY AXIAL EXCESSIVE IN Needle bushingoftheshiftshaft 243. bearing from insidetothestopandsecure retaining screws withLoctite D EANN BRACKET RETAINING O orking ontheright-handhousinghalf bore Finally checkclearpassageofthecrankshaftballbearinglubrication approx. 150°C. Remove allshaftsealringsanduseanoventoheatthecasinghalf O S OC HNPESN H ROE ALBAIGAANTTHE AGAINST BEARING BALL GROOVED THE PRESSING WHEN FORCE USE NOT S . ! 3 3 OAODABNIGO H BRACKET THE OF BENDING A AVOID TO bk bl 9 A CAUTION and press bearinginwards. Press innewball 6 1 2 4 . 5 7 8 , HC OL RESULT WOULD WHICH ! 5-2C 5-3C Working on the left-hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. 7

Crankshaft roller bearing 1 Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside). The inner ring on the crankshaft must also be renewed (see paragraph about crankshaft).

6 Needle bearing of drive shaft 2 8 Press old grooved ball bearing inward, press new grooved ball bearing from the inside up to the stop.

Grooved ball bearing of countershaft 3 Press old ball bearing inwards, press in new ball bearing to the stop from 2 inside.

3 4 Grooved ball bearing of shift roller 4 Ball bearing falls out of its seat of its own accord when housing half has been heated to approx. 150° C. If necessary, knock housing half on a plane piece of wood. Press in new grooved ball bearing to the stop.

5 1 Needle bushing of shift shaft 5 Remove shaft seal ring and press old needle bushing inwards. Press in new needle bushing from the outside to the collar D.

D Crankshaft seal ring 6 Press in new crankshaft seal ring from the outside, with sealing lip facing inwards. The seal ring is 1 mm (0.04 in) lower than the upper edge ot the collar (see sketch).

Counter shaft seal ring 7 5 Press in the new shaft seal ring, until it is flush with machined surface.

Shift shaft seal ring 8 Press in the new shaft seal ring, until it is flush with machined surface.

When housing half has cooled off, check to see that the bearings are 6 tight. 1 mm (0.04 in.)

– Finally check clear passage of the crankshaft roller bearing lubrication bore S.

S Repair manual KTM 250 / 300 / 380 Art No 3206004 -E OE Distanceadjustmentofthemainbearingsisnotrequested. NOTE: OPESDADTECNO LGADBAIGMYB DAMAGES BE MAY BEARING AND PLUG CONROD THE AND COMPRESSED the pistonring. piston andcylinderwearare withinthepermittedtolerancelimits,replace Iftheendgapisgreater check pistonandcylinderforwear. If NOTE: N OKOKTEBAIGINRRN FREE RING INNER BEARING THE KNOCK TO – Checkpistonringsforwearandcheck endgap. 4. Thepistonringlocatingpinsmust befirmlyseatedinthepistonand 3. Pistonringgrooves: Thepistonringsmustnotgetjammedinthe 2. illustrated. Crankshaft webs–measure outerdimensionwithaslidingcaliperas Crankshaft webs–measureouterdimension –T – – Crankshaft – Piston ringendgap Pistonrunningsurface:Checkforpressure marks(seizingmarks)minor 1. checked: If ausedpistonistoremain inservicethenthefollowingshouldbe Piston AIGTECAKHF UNUSABLE CRANKSHAFT THE MAKING VRCAPTECAKHF IHASU RWBI H VICE THE IN WEB OR STUD A WITH CRANKSHAFT THE CLAMP EVER The endgap approx. 10mm(1/2inch)from topofcylinder. Insert pistonringintothecylinderandadjust.Piston mustbe must notbewornout. paper (grainsize400). grooves. Forcleaningthegrooves, useanoldpistonringorabrasive friction markscanberemoved withafineabrasivestick. immediately. 150°C, engagetheinnerringandslipitoncrankshaftjournal ring off thecrankshaft. together tightlysoastoobtainagoodheattransferandpulltheinner 150°C andslipitontheinnerringimmediately. Press thespecialtool Heat specialtool584.29.037.040onaheatingpaduptoapprox. be renewed. When replacing theroller bearing,theinnercrankshaftringmustalso o mountthenewinnerring,heatspecialtoolagaintoapprox. rnsatwb ue ieso 0m 0.05mm Crankshaft webs–outerdimension=60mm± ! Piston ringendgap:max.0.40 mm(0.015in) B can nowbecheckedwithafeelergauge. CAUTION . . T ECAKHF ESMYBE MAY WEBS CRANKSHAFT HE , N EE TRY NEVER AND ! , THEREBY 5-4C 5-5C Checking cylinder for wear Measure diameter of cylinder approx. 10 mm (0.4 in.) below top of 10mm cylinder edge. Check diameter in several corresponding places to see if

x cylinder in worn oval. y

Engine Cylinder Ø Piston size 67,500 - 67,512 1 250 67,513 - 67,525 2 72,000 - 72,012 1 300 72,013 - 72,025 2 78,000 - 78,012 1 380 78,013 - 78,025 2 250 66,340 - 66,350 1 starting with the 2000 mod 66,351 - 66,360 2 300 71,940 - 71,950 1 starting with the 2000 mod 71,951 - 71,960 2

Recoated cylinder NOTE: If the cylinder diameter is larger than e.g. 66.360 mm the cylinder 1 must be regenerated or replaced. For reconditioning of the old cylinder all exhaust control components must be removed. The intermediate flange 1 remains with the cylinder. The piston size is stamped into the bottom of the piston.

Nikasil coating of cylinder 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 inbedded.

The main advantages of the Nikasil coating are: ● excellent heat dissipation and thus better power output ● low wear ● low weight of the cylinder.

NOTE: The worn coating can be regenerated at low cost provided that the cylinders running surface is flawless. Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Bearing sleeves Silicon O-rings Control rollers Dismantle andcleanallexhaustcontrol components,checkforsignsofwearanddamage. Cylinder exhaustcontrolsystem Gear segments Check toothingofcontrol rollers forsignsofwear. Control flap only 250 14 6 13 7 4 1 5 – Cleanthecontrol flap.Thecontrol flapmustnotgraze insidetheexhaustport. 2 3 , – Checkclearanceofbearings.Removeoil-deriveddeposits. 12 – Checktoothingofgearsegmentsandcontrol rollers forsignsofwear. – Checkbearingsleevesofthecontrol flapforplayandeasyoperation. 8 + 9 11 – ChecksiliconO-ringsofcontrol flapandcontrol rollers forsignsofwear. Renewifnecessary. 10 2 5 7 6 6 3 7 9 1 19 – – Cylinder preassembly secure flat-headscrews Place control rollers Mount siliconO-rings(16x2mm) 18 8 4 9 1 7 in cylinderandmountretaining brackets 3 with Loctite243. 2 5 on control rollers andgrease. 1 8 16 5 6 17 7 5-6C 6 ; 5-7C

14 13 12 11 10 2 3 9 4

9 3 2 17 8 16

–Mount and grease silicon O-rings (15x1,50 mm) 9 on control flap and grease. – Slightly grease the bearing sleeves 3 and plug them on the control flap. – Mount toothed segments 2 (the toothed segment with the cylindrical pin has to be mounted on the right side).

– On the right-hand side, mount bearing bushing bk with collar outside, adjusting lever bl with ball head on outside, overload spring bm with short leg on outside and spring sleeve bn to control flap. – Coat allan head screw bo with Loctite 243 and screw up about 5 revolutions, hook the short leg of the overload spring on to the cylinder pin (see illustration) and tighten the allan head screw.

– On the left side, mount the stop plate 8. Apply Loctite 243 to the threads of the two screws bq + br, and mount them.

–Turn control rollers 1 in cylinder in such a way that ports are completely open and no edges protrude.

– Place preassembled control flap in cylinder, engage gear segments in control rollers in such a manner that, when the control flap is ,open (pivoted right to the top), the markings of the gear segments and the gear rollers coincide. Please check that the two control rollers do not block the cross-section of the port when the control flap is open. – Coat sealing surface thinly with silicon and mount intermediate flange bs with 4 O-rings (11,3x2,4 mm). – Mount exhaust flange bt and spring hangers. If you are dealing with a throttled version, do not forget the exhaust throttle.

– Finally check smooth running of exhaust control system.

NOTE: It must be possible to push adjusting lever bl further upwards against the spring force.

17 11 16 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 6 1 LOCTITE 243 1 7 4 6 LOCTITE 243 3 13 7 –T Check linkageballheads – – Check playandeasyoperatabilityoftheadjustingleverinbearing – Exhaust control,clutchcover –G Preassembly ofclutchcover If thewaterpumpshaftsealring wear. – – – Check pin Remove circlip Check grooved ballbearing Loctite 243ontheoutside. – –T – 2 Mount waterpumpwheel Clean allpartsandcheckforsignsofwear. Remove screws copper gasket. two screws mountedatthe dowelsmusteachbeprovided withone Position gasketandfixwater pumpcoverwith5collarscrews. The Mount dowelsofthewaterpumpcover. mount withwasher. Fit adjustingspring 1 The centrifugaltimer clutch cover. clutch cover. Fit bearingsupportwithcontrol leverandlinkage.Secure bothscrews water pumpwheel ake cuptappet ake off water pumpcover, remove allenheadscrew 14 r ease waterpumpshaftsealring with Loctite243. A 10 of adjustingleverforwear. bl and checkaxialbearings 1 2 and takeoff thebearingsupport. , adjustingspring 7 12 3 8 . , auxiliaryspring bk 9 can bepulledoutofthebearing. bo for clearance. for clearance. 7 8 bn , coatscrew is replaced, itshouldbecoatedwith bn 11 3 and mountcentrifugaltimer 4 and auxiliaryspring bm 1 and cuptappet 6 and washersforsignsof with Loctite243and LOCTITE 243 6 and takeoff A 2 4 5-8C out of in the 8 9 . . 5-9C Reed valve housing, intake flange NOTE: Reed paddles 1 gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced. If the reed sealing surfaces 2 of the reed valve housing are also damaged, replace the complete reed valve housing. ! CAUTION ! SECURE ALL SCREWS OF THE REED VALVE HOUSING WITH LOCTITE 243.

Velocity insert 3 Check for firm mounting and for signs of damage. LOCTITE 243 Intake flange 4 Check for cracks and other signs of damage. 3 1 4

1 LOCTITE 243 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Push rod Outer clutchhub Check innerring Check startsurfaces ofclutchdiscsonforwear. Ifindentations exceed0.50mm(0.02in), replace outerclutchhub (seebelow Check contactsurfaces Pressure cap Check contactsurfacesofsteel discsontheinnerclutchhub,maximum0.50mm(0.02in) indentations. Inner clutchhub Must beplane,checkformechanicaldamage. 8 Steeldiscs 13.50 mm(0.531in)betweenstartingsurfaces. Minimum thickness2.60mm(0.102in)/newdisc2.70 (0.106in).Discsmustbeplane;there mustbeminimumspacingof 9 Liningdiscs New springlength42,5mm/1.7in(new431.73in). Replaceall6springsifapplicable. Thrust bearing Clutch Clutch springs 2 Check forwear. Minimumlength:199 mm(new:199.80mm) 5 7 4 3 1 6 9 8 check forwear 1 3 and needlecage LOCTITE 242 A between liningdiscandpressure capforsignsofmechanicaldamageandscore marks. 7 2 bk A for wear. 6 B 8 11 13 5 14 4 10 12 9 13,5 mm 5-10C ). 5-11C Replace outer clutch hub – Drill open the clutch rivets bl in area of retaining bracket bm and remove parts. – Check 8 absorbing elements bn for signs of mechanical damage, replace all 8 where applicable. ! CAUTION ! THE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN. TO ENSURE THAT THE OUTER CLUTCH HUB 8 AND RETAINING BRACKET ARE POSITIONED DIRECTLY ON THE PRIMARY GEAR CROWN bo, THE PARTS MUST BE HELD IN POSITION UNDER 12 11 TENSION WITH THE CLUTCH RIVETTING TOOL C WHILE RIVETING.

8 11 14 13 12

C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 0,80 mm 0,40 - 9 LOCTITE 243 LOCTITE 243 5 3 LOCTITE 243 D 2 C 1 4 Shift roller Grooved ballbearings be more than0.7mm/0.03in). Check slidingguides(excessbetweenguidepinandshiftquadrantnotto Sliding guides Check thatguidepin Check return surface Slide plate – – Preassembly ofshiftshaft plate Assemble shiftmechanism(seebelow)andcheckfree play betweenslide Shift mechanism Check grooved ballbearingsforeasymovement. Check slideplateatmeshingpoints Check positionofshiftroller ingrooved ballbearings Check shiftgrooves forwear. Check shiftforkblades Shift forks Shift mechanism - 0.032in). – – –M E 1 Mount slideplate Fix shiftshaftinviceatshorterend(usecovered clamps). shift quadrant Slide onspringguide Mount pressure spring illustration). upwards overthespring guide andliftoffset endoverbolt ount thestopdisc 4 7 3 and shiftquadrant 6 8 1 2 4 A 10 5 . 4 D E B 3 A with guidepinsdownwards, hookguidepinsinto 1 bk for wear(renew, ifstrongly notched). is securely fixedandcheckforwear. 7 6 and shiftroller drivingpin (14x30x1 mm). 5 , slideonreturn spring . . Free playshouldbe0.40-0.80mm(0.016 C for wear. LOCTITE 243 B 8 3 for signsofwear. . with offset end 5-12C 9 (see 5-13C Ignition (Kokusan) 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. 2K-1 Make sure to select the correct measuring range when performing measurements.

Spark plug – Set the electrode distance. 2K-2 Electrode distance: 0.60 mm (0.024 in)

Insulator Check for cracks and fissures. ! CAUTION !

2K-3 ALWAYS USE A SPARK PLUG WITH RESISTOR. OTHERWISE PROBLEMS CAN OCCUR IN THE CDI UNIT.

2K-4

Check stator and pulse generator (Kokusan) Use an ohmmeter to perform the following measurements:

Ignition Measure Cable colours Resistance 15%ע 2K-1 Pulser coil red – green 100 Ω 15%ע Exciter black/red – red/white 24 Ω 15%ע 2K-2 Pulser coil red – green 100 Ω 15%ע Exciter black/red – red/white 24 Ω 15%ע Charge coil ground – yellow 0,74 Ω 15%ע Kokusan 2K-1/2K-4 2K-3 Pulser coil red – green 100 Ω 15%ע Exciter black/red – red/white 12.7 Ω 15%ע Charge coil ground – yellow 0.65 Ω 15%ע white – yellow 0.16 Ω 15%ע 2K-4 Pulser coil red – green 100 Ω 15%ע Exciter black/red – red/white 24 Ω 15%ע Charge coil yellow – yellow 0.65 Ω

NOTE: The measuring must be performed at a temperature of 20° C. Otherwise significant deviations must be expected. Replace the stator if the measured values deviate significantly from the Kokusan 2K-2 setpoint values.

Kokusan 2K-3 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

110 mm SEM K11 LOCTITE 243 Check forcracksandfissures. Insulator setpoint values. Replace thestatorifmeasured valuesdeviatesignificantlyfrom the Otherwise significantdeviationsmustbeexpected. C. Themeasuringmustbeperformedatatemperature of20° NOTE: Perform thefollowingmeasurements withanohmmeter. Check stator(SEM) – Spark plug measurements. Make sure toselectthecorrect measuringrangewhenperforming socket connectionsoftheignitionsystemfirst. In thecaseofmalfunctionalwayscheckcablesandplug r short circuits leadingtoweakignitionsparksorlowgeneratoroutput, The measurements describedbelowwillonlyreveal severe problems. Coil General information Ignition (SEM) THE A espectively, canonlybedetectedwiththehelpofanignitiontestbench. LW Set theelectrode distance. CDI AY S elwylo 1,0 yellow yellow + S PR LGWT RESISTOR WITH PLUG SPARK A USE re e 1,7k red green lc e 1,7k 165 red black green black UNIT oe–Pl Resistance –Pole Pole . ! Electrode distance:0.60mm(0.024in) CAUTION . O HRIEPOLM A CU IN OCCUR CAN PROBLEMS THERWISE Ω ! ע Ω Ω Ω 20 5-14C Ω 5-15C Transmission Secure mainshaft or countershaft in the vice (using soft jaw-covers). Remove gears and check the following for wear: 11 – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels –Tooth faces of all gears –Tooth profile of mainshaft and countershaft and correspondending 10 gears – Easy operation of gear-change

Carefully clean components and replace damaged components.

NOTE: Always place circlips with sharp edge facing the components 9 secured, ensuring that they are not overexpanded (use special pliers). Check that after any repair of the transmission, circlips should axially not move more than 0.20 mm (0.006 in) and must not seize between stop discs.

Assembly mainshaft – Fix mainshaft in vice with toothed end upwards (use covered clamps). 5 – Oil all parts before assembly. – Mount the split needle cage 1 on mainshaft, push 5th idler gear 2 over it with collar downwards. – Place internally toothed stop disc 3 (22.4x25.7x32.0x1.5 mm) in position and mount circlip 4 (25x1.64 mm) with sharp edge upwards. – Place 3rd sliding gear 5 in position with shift groove downwards, 4 mount circlip 6 (25x1.64 mm) with sharp edge downwards and internally toothed stop disc 7 (22.4x25.7x32.0x1.5 mm) – Mount the split needle cage 8, 4th idler gear 9 with shift dogs 3 downwards 2nd gear bk with collar downwards and stop disc bl (20.2x33x1.5 mm). – Finally check all gears for easy running.

1 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 3 5 6 8 10 11 13 1 4 2 9 12 7 –Mou – – – – Assembly countershaft – –T –T – – – Remove gearsandcheckthefollowingforwear: Secure mainshaftorcountershaftinthevice(usingsoftjaw-covers). T discs. move more than0.20mm(0.006in)andmustnotseizebetweenstop Check thatafteranyrepair ofthetransmission,circlips shouldaxiallynot secured, ensuringthattheyare notoverexpanded (usespecialpliers). Alwaysplacecirclips withsharpedgefacingthecomponents NOTE: Carefully cleancomponentsandreplace damagedcomponents. –Mou – –Mou ransmission Finally checkallgearsforeasyrunning. Push stopdisc Oil allpartsbefore assembly. Fix countershaftinvicewithtoothedend(usecovered clamps). Easy operationofgear-change gears Shift dogsandgearwheels Mainshaft andcountershaftpivotpointsincludingidlergears Needle bearing r r (28,2x40x1,5 mm),needlecage upwards. Remove countershaftfrom viceandfixagainwithtoothedend upwards onthecountershaft. (22,2x33x1,5 mm),needlecage (25x2 mm)withsharpedgeupwards. ecesses downwards andstopdisc ecesses downwards andstopdisc ooth profile ofmainshaftandcountershaftcorrespondending ooth facesofallgears nt 3 nt 4 nt 5 rd th th idler gear sliding gear sliding gear 1 (26x40x1,5 mm)ontocountershaft. 2 4 with shiftdogrecesses upwards andcirclip 9 with shiftgroove downwards, stopdisc with shiftdogupwards, stopdisc bl 6 bn 8 , 2 , 1 (25,7x40x1,5 mm). (17,2x34x1,5 mm)withcollar nd st free gear idler gear 7 bm with shiftdog with shiftdog 5-16C bk 5 3 5-17C

LOCTITE 243 7 8 1 LOCTITE 243 9 6 3

4 10 2 LOCTITE 648

Kickstarter 1 A Starter gear Check clearance of starter gear.

Starter intermediate gear 2 Check clearance of starter intermediate gear.

Locking pawl 3 Check for signs of wear and damage.

Kickstarter shaft 4 Check for signs of wear and damage. 3 5 For changing the locking pawl, press bearing needle 9 out of the kickstarter shaft.

Assemble of kickstarter shaft – Fix the kickstarter shaft 4 in a vice with the toothed end upwards (use covered vice clamps). – Mount ratchet spring 5 on kickstarter shaft as shown in the illustration. – Place needle cage 6 in position, push starter gear 1 over it, pressing locking pawl 3 inwards so that starter gear passes smoothly over it. – Hook legs of the starter spring 7 into driving hub 8, push both together on the starter shaft, hook starter spring leg into kickstarter shaft bore A. – Release kickstarter shaft, and fix stop disc bk with a small amount of grease on the kickstarter shaft. Repair manual 250 / 300 / 380 Art No 3206004 -E ONIGSATN EE N HF EE ..6-11 MOUNTING STARTING LEVERANDSHIFT ..6-11 MOUNTING IGNITIONCOVER ..6-11 ADJUSTING IGNITIONPOINT(SEM) ..6-11 MOUNTING THEIGNITION(SEM) ..6-10 MOUNTING THEIGNITION(KOKUSAN) ..6-10 MOUNTING ENGINESPROCKET ..6-9 MOUNTING REEDVALVE HOUSING ANDINTAKE FLANGE ..6-9 MOUNTING CYLINDERHEAD ..6-9 MOUNTING STEERINGCOVERS ..6-8 ADJUSTING CONTROLFLAP(DIMENSION„Z“) ..6-7 ADJUSTING DIMENSION„X“ ..6-7 MOUNTING PISTONANDCYLINDER ..6-6 MOUNTING CLUTCHCOVER ..6-6 MOUNTING CLUTCHDISCSANDPRESSURECAP ..6-5 MOUNT PRIMARY DRIVEANDCLUTCH ..6-4 MOUNTING KICKSTARTER ..6-4 MOUNTING SHIFTMECHANISM ..6-3 ASSEMBLING THEENGINEHOUSING ..6-2 TRANSMISSION . ..6-2 CRANKSHAFT ASSEMBLING THEENGINE INDEX 6-1C 6

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2 A 1 3 LD F H HF FORKS SHIFT THE OFF SLIDE –G T – Crankshaft – –M – – – –A – W W U W ransmission E HF OK HUDB ONE NTESM LDN ERA BEFORE AS GEAR SLIDING SAME THE IN MOUNTED BE SHOULD FORKS SHIFT SED A E UHN NCRANKSHAFT IN PUSHING HEN E TAHN H HF FORKS SHIFT THE ATTACHING HEN carefully asfarstop. Insert crankshaftfrom abovethrough grooved ballbearingandpush Secure theright-handhousinghalfinengineworkstand. Shift fork bearings asfartheywillgo. Mount driveshafttogetherwithcountershaft,andinsertthemintothe grease. Fix thelowerstopdisconcountershaftwithasmallamountof grooved ballbearing. Attach theshiftforkstoslidinggears,andinsertroller intothe marks appliedbefore disassemblyforbetterorientation. C TTEMRIG RMDISMANTLING FROM MARKINGS THE AT TCH ttach theshiftforkstoroller. r ount thetwoothershiftforks ease thedrivingpinsofshiftforksandmountrollers 2 ! ! ! with drivingpin . , CAUTION CAUTION CAUTION AESR ORDI AIGCYLINDER FACING IS CONROD SURE MAKE A , AESR HTTESITDUSD NOT DO DRUMS SHIFT THE THAT SURE MAKE in themiddlebelongstomainshaft. 3 . at thecountershaft,using ! ! ! . 6-2C 1 . . 6-3C – Fix the 4 pressure springs 1 with ample amounts of grease in the 1 gearshift rails.

– Oil gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft). Insert gearshift rails into the casing bores as far as they will go. 2 NOTE: It must now be possible to gently turn gear shafts. – Slide stop disc 2 (20.2x 33x1.5 mm) on the drive shaft, and stop disc 3 3 (25.7x40 x1.5 mm) on the countershaft.

Assembling the engine housing – Remove engine fastener from engine work stand. – Check that both dowels are in proper place in right-hand housing and that transmission shaft stop discs have been mounted. – Apply light coat of grease to sealing surfaces of the housing and position new gasket. –Grease shaft seal rings in left-hand half and place left-hand half in position. – Position screws and tighten with 8 Nm (6 ft.lb). – Gently knock crankshaft with plastic hammer and check easy running of shafts. – Fix engine in work stand.

60 60

45 45

M6 x ...

45 60

45 45 45 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E A 7 5 4 2 9 6 3 8 1 B – OE From model2002ondriverforroller NOTE: – – – – – – Mounting shiftmechanism – starter springmustpointforward (seephoto). Ifthekickstartershaftismountedcorrectly, thevisibleendof NOTE: – Mounting kickstarter –M – – – – – –G made ofaluminium. – Insert locatinglever Coat allanheadscrew must abutthecasingnose edge showingupwards. Slip onstopdisc(17.2x25x1 mm) andmountcirclip withthesharp showing towards theengine casingontothebearing. Hook springhanger outside therelease plate. kickstarter shaftinbearingbore insuchawaythatthelockingpawlis Place spacingwasheronthestopfaceanplacepreassembled Mount roller lockingdevice Coat collarscrew Insert collarsleeveintospringwithupwards. Place locatingspringwithbentlegupwards intoenginehousing. Mount driverforshiftroller the flatpartsare notinthemiddle.Pulllockingleverfrom shiftroller. Place starterintermediategear same allaround. Adjust starterspringsothatthedistancetokickstartershaft isthe spring pawlwithallanheadscrew. clock-wise andfix Loctite 243,tightenstarterspringapprox. 90° housing nose Check thatlegsofreturn springsurround bothleftandrightsideof Now squeeze,andpushshiftshaftintothestop. stop discuntilslideplatecontactsdriverforshaftroller. screw. Hook lockingspring lever. through thegears,turncountershaft.Thenremove thefootshift r ount thefootshiftleverandthrough allgears.Whenshifting ease assembledshiftshaftandpushintobearingstogetherwith A . 1 3 2 with Loctite243. 6 7 to lever. Theotherendoftheretaining spring with roll upwards andfixallpartswithcollar with Loctite243andmount. B to starterspring,coatscrew 5 4 . LOCTITE 243 . (plastic part)toshiftroller. Ensure that 8 with thehighcollar(seesketch) 5 and lockingpiece 9 4 6-4C with are 6-5C Mount primary drive and clutch –Grease crankshaft seal ring. 1 – Put the oiled O-ring (25x1.50 mm) onto the crankshaft and mount the distance bushing with the chamfer facing the crank web. – Insert woodruff key into crankshaft. – Place primary gear 1 onto crankshaft with collar downwards. – Put the inner ring onto the main shaft with the collar facing downwards, then mount the oiled needle cage 2. 2

– Mount outer clutch hub and stop disc 3.

– Apply Loctite 243 to the thread of the main shaft. – Mount inner clutch hub, new lock washer and hexagon nut to main 4 shaft. – Position clutch holder 4 and tighten hexagon nut with 100 Nm (74 ft.lb.). – Remove the clutch holder and secure the hexagon nut by bending both brackets of the lock washer upwards.

– Apply Loctite 243 to thread of the crankshaft. – Fit locking washer and hexagon nut (left hand thread) by hand. 5 – Block primary drive with gear segment 5 and tighten primary gear hexagon nut with 150 Nm (110 ft.lb.). – Remove gear segment and check easy running of primary drive by turning crankshaft. Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 30 30 30 70 1 30 70 M6x ... –T – – – – – – –G – Mounting clutchcover –O Mounting clutchdiscsandpressurecap kickstarter springhasbeenpositionedcorrectly. Iftheclutchcovercannotbemounted,verifywhetherornot NOTE: ft.lb.) toprevent damagingofthethreads intheinnerclutchhub. collar screws. Place pressure capintoposition;fitclutchsprings,springretainer and a liningdiscformingthefinallayerupwards. mm /0.10in)and8intermediatediscs( Beginning withoneliningdisc,mountalternately9discs( Oil liningdiscsbefore mounting. Then checkeasyrunningofallshafts. (6 ft.lb.). Fit collarscrews (seesketchforscrew lengths)andtightenwith8Nm gear. turning crankshaftsothatcentrifugaltimercanengageintheprimary Carefully positionpreassembled clutchcoverandpress intoplace, Secure gasketwithalittlegrease. housing. Check whetherbothdowelsare mountedinclutchcoverorengine ighten thecollarscrews crosswise. Donotapplymore than6Nm(4.5 r 30 il thethrustbearing ease kickstartershaftsealringandpositionclutchcovergasket. 70 70 30 1 , andslideitoverthedriveshaft. ≠ 1.20 mm/0.047in),with 30 45 6-6C ≠ 2.70 6-7C Mounting piston and cylinder – Before assembly, oil all parts thoroughly at the sliding points. – Insert needle bearing in conrod eye, mount piston (arrow on piston head shows direction for exhaust duct). – Mount piston pin and wire circlips with open side showing downwards (see sketch). – Mount cylinder base gaskets. – Place piston on selfmade wooden stand and position piston ring.

– Place on preassembled cylinder, remove wooden stand and tighten cylinder down crosswise, using two nuts.

Adjusting dimension „X“ X Dimension „X“ is the dimension from upper edge of piston to upper edge of cylinder with cylinder under low tension and piston in TDC position. The dimension „X“ should be adjusted extremely carefully by inserting cylinder base gaskets of suitable thicknesses. ! CAUTION ! IF THE DIMENSION „X“ IS TOO LARGE, THE COMPRESSION RATIO WILL BE REDUCED AND THE ENGINE LOOSES POWER. ON THE OTHER HAND, IF THE DIMENSION „X“ IS TOO SMALL, THE ENGINE WILL PING AND OVERHEAT.

– Set the piston to TDC, and apply a sliding gage or straight-edge to the cylinder. Now, check the distance between the piston's upper edge and the sliding gage. This distance should be from 0 mm to 0.10 mm at the most. It can be corrected, if necessary, by adding or removing of cylinder-base gaskets. ! CAUTION ! THE PISTON MUST NOT PROTRUDE BEYOND THE CYLINDER'S UPPER EDGE.

Dimension „X“ = 0 mm + 0,1 mm

– Mount the 2 remaining collar nuts at the cylinder base, and tighten each of the 4 collar nuts to 35 Nm (27 ft.lb.). Repair manual KTM 250 / 300 / 380 Art No 3206004 -E flap control 5 7 2 6 8 3 1 4 – – –T ● – exhaust port. flap totheupperedgeofcylinder, asmeasured inthecentre ofthe Note: Dimension“Z“isthedistancefrom theloweredgeofcontrol Adjusting controlflap(dimension“Z“) – ● When pressing ballsocketdonot: – – – – –P – –S – – Having tightenedthescrews Remove depthgauge. Adjust linkagelengthifnecessary. swivel control flapupwards. pull thelinkagetoofarup(max.1mm/0.04in). Secure bumpplatefasteningscrews Undo thescrews ofthestopplate(leftsidecylinder) Refit ballsocketandfitsafetydevice fit gasketforcontrol cover. Once adjustmentsare completed,remove ballsocket onceagainand Retighten counternut. "Z" againandcorrect it,ifnecessary. not tightenthemyet. and applyLoctite243tothethreads. Thenmountbothscrews butdo Allow bumpplate Control flapmustrest againstdepthgauge. shown intheillustration. Set preselected valueondepthgaugeandfix. ball socket o doso,loosencounternut wifel control flapupwards andholddepthgaugeintocylinderas r ess linkageofcontrol flap 380 :50,5mm 300 :46,0mm 250 abModel2001:49,5mm 250 Model2000:50,5mm 250 Model1999:48,0mm 6 onto ballofadjustinglever. 3 to rest againstretaining bracket 1 5 + 0,2/-0,6mm + 0,2/-0,6mm 7 + down-wards asfarstopandpress and turnballsocketaccordingly. 2 , youhavetocheckthedimension 1 8 and . + 0,2/-0,6mm + 0,2/-0,6mm 2 . + 0,2/-0,6mm 4 . 1 and 6-8C 2 6-9C Mounting steering covers –Mount the right-hand control cover 1, and fix it with 3 screws.

– Place gasket in position and fix left-hand steering cover 2 on cylinder.

Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O-rings in grooves. – Mount cylinder head with water nozzle on the exhaust side.

– Oil the collar nuts at threads and contact faces. –Mount the collar screws with new copper gaskets and tighten them crosswise, taking three turns to achieve the total tightening torque of 35 Nm (25 ft.lb.). – In first stage, only tighten until slight resistance is felt.

Mounting reed valve housing and intake flange – Place reed valve housing with velocity insert in inlet duct and fix intake flange with the 5 collar screws. Repair manual KTM 250 / 300 / 380 Art No 3206004 -E B 2 A C 3 1 4 – – Mounting theignition(Kokusan) – Mounting enginesprocket – – –T – – – – – At engineswithignitiontype2K-4themarking in thecasing,andtighten3screws ofthestator. Apply Loctite243to3screws Insert thewoodruff keyintothecrankshaft. Lubricate O-ring Slide distancebushing the 3screws alltheway). coincide withthemarkingonstator. Nm (45ft.lb.). Hold therotor withtheholdingspannerandtighten nutwith60 Mount thedetentedgedringandnut. Mount therotor. fix itwiththecirclip Slide sprocket ontothecountershaftwithcollarfacinginward, and position. the markingonstator. At engineswithallotherignitions(notSEM)themarking urn statorsuchthatthemark 1 with oilandslideovercountershaft. 3 (sharp edgefacingoutward). 2 in positionsothatO-ringiscorrect 4 A and fixthestator(donotyettighten on thestatorcoincideswithmark C must coincidewith 6-10C B must 6-11C Mounting the ignition (SEM) 1 2 – Insert woodruff key into crankshaft. – Apply Loctite 243 to the threads of the 3 screws 2. – Mount base plate 1 together with stator, and tighten the 3 screws. – Mount the cable guide 3 into the cutaway portion of the casing. – Mount the rotor. – Mount the detent edged ring and the nut. – Hold the rotor with the holding spanner and tighten the nut with 60 3 4 Nm (45 ft.lb.).

Adjusting ignition point (SEM) – Make sure that the stator can be turned on the intermediate plate. Otherwise, loosen the 3 screws 4. – Mount flywheel. – Screw dial gauge into spark plug thread. – Place adjusting pin 5 in flywheel bore (“91“) 2 mm (0.08 in) and turn flywheel until pin slots into recess 6 in stator. 5 –Turn flywheel and stator jointly to TDC. –Turn dial gauge scale to 0 and turn flywheel with stator clockwise accordingly to preignition.

Ignition point:

– Carefully remove flywheel to prevent further turning of stator. –Tighten the three stator cylinder screws. – Mount flywheel and tighten collar nut with 60 Nm (45 ft.lb). – Check ignition point once more. – Remove dial gauge and fit spark plug with OR. 6

Mounting ignition cover – Put on a new gasket, and fix the ignition cover by means of the 5 screws.

Mounting starting lever and shift lever – Push distance bushing onto kickstarter shaft and mount kickstarter. – Mount shift lever. – Operate the kickstarter a few times and check if the engine turns freely. – Oil the push rod, and insert it into the drive shaft.

NOTE: The transmission oil should be filled in only after the engine has been mounted. Otherwise, a part of the transmission oil would leak out through the drive shaft. Repair manual 250 / 300 / 380 Art No 3206004 -E TTCINTO N EEAO AUS20MC X UA ..7-9 STATIC IGNITIONANDGENERATOR VALUES 250MXC,EXC(USA) STATIC . . .7-7 GENERATOR VALUES 250-380EXC ..7-5 STATIC IGNITIONVALUES 250-380SX,EXC ..7-4 CHECKING THECAPACITOR (MOD.2000) ..7-4 CHECKING THEVOLTAGE REGULATOR (MOD.2000) ..7-3 CDI UNIT ..7-3 IGNITION COIL(KOKUSAN) ..7-3 IGNITION COIL(SEM) ..7-3 CHECKING THECAPACITOR ..7-2 CHECKING THEVOLTAGE REGULATOR (TYMPANIUM) ..7-2 CHECKING THEVOLTAGE REGULATOR (KOKUSAN) CHECKING THEVOLTAGE ..7-2 REGULATOR-RECTIFIER (SHINDENGEN) ELECTRICAL INDEX 7-1C 7

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E ● ● A defectvoltageregulator cancausedifferent kindsoftrouble: speedometer illuminationandthehorn. circuit, theotherregulates thecircuit fortheheadlight,tail switches. Oneofthevoltageregulators regulates onlythebrakelight Thevoltageregulators are connecteddownstream ofthe NOTE: Checking thevoltageregulator(Tympanium) ● ● A defectvoltageregulator cancausedifferent kindsoftrouble: Checking thevoltageregulator(Kokusan) – – – – – – Checking thevoltageregulator-rectifier (Shindengen) voltage regulator. If thereading significantlydeviatesfrom thenominal value,replace the V shouldnotbeexceededeither. voltage of12.0-14.0VA.C.Athigherenginespeeds,thelimit At anenginespeedof3000r.p.m, thevoltageregulator mustsupplya – In thecaseofasignificantdeviationfrom thenominalvalue: consumers. to checkthevoltage.Startengineandswitchonpower Connect avoltmeter(yellowcable=positive,brown cable=negative) The bulbsburnout. Excessive voltageinthecircuit the wiringharnessorignitionsystemmustbecheckedfordefects. If thepowerconsumersare stillnotsuppliedwithpower, theswitch, properly. The voltageregulator isdefectifthepowerconsumersnowwork In thiscase,thevoltageregulator mustbedisconnectedatidlespeed. No voltageinthecircuit r The bulbsburnout.Inthiscasethevoltageregulator mustbe Excessive voltageinthecircuit the wiringharnessorignitionsystemmustbecheckedfordefects. If thepowerconsumersare stillnotsuppliedwithpower, theswitch, properly. The voltageregulator isdefectifthepowerconsumersnowwork In thiscase,thevoltageregulator mustbedisconnectedatidlespeed. No voltageinthecircuit Replace thevoltageregulator-rectifier. Check thestator. the cabletree. r Check theconnectorbetweenstatorandvoltageregulator- Check thecapacitor voltage. Accelerate theenginetoaspeedof5000r.p.m. andread off the cable =positive,brown cable=negative). Connect avoltmetertothetwoterminalsofcapacitor(red/white Start theengineandswitchonlowbeam. eplaced. ectifier andtheconnectorbetweenvoltageregulator-rectifier and Nominal value:14.0–15.0V 7-2C 7-3C Checking the capacitor – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – 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 (marked +) is made with a test lamp 1. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. ! CAUTION ! DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS (CONNECT RED/WHITE CABLE TO + 1 TERMINAL).

Ignition coil (SEM) As this ignition coil uses electronic components, you are advised not to use conventional measuring instruments. An accurate function test can only be carried out on an ignition test bench.

Ignition coil (Kokusan) – 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.

Measurement Cable colours Resistance Primary coil blue/white – ground 0,425 - 0,575 Ω Secondary coil blue/white – ignition wire 10,8 - 16,2 kΩ

CDI unit Check the cables and plug and socket connections of the CDI unit 2. The CDI unit function can only be checked on an ignition test bench. ! CAUTION ! NEVER USE A COMMERCIAL MEASURING DEVICE TO CHECK THE CDI UNIT. COMMERCIAL MEASURING DEVICES CAN DESTROY HIGHLY SENSITIVE ELECTRONIC COMPONENTS. 2 Repair manual KTM 250 / 300 / 380 Art No 3206004 -E + 1 – – – – – Checking thecapacitor – – – – In thecaseofasignificantdeviationfrom thenominalvalue: – – – Checking thevoltageregulator – – – – In thecaseofasignificantdeviationfrom thenominalvalue: – – – Checking thevoltageregulator capacitor isfaulty. If thetestlampdoesnotgooutorlightupatall, and return toitsdarkstateafter1secondatthelatest. When thepowercircuit isclosed,thetestlampmustlightupbriefly lamp battery andthepositiveterminalofcapacitorismadewithatest of thecapacitor. Theconnectionbetweenthepositivepoleof Connect thenegativepoleofa12Vbatterywithterminal bridge anddismountit. Discharge thecapacitorbybridgingtwoconnectionswithacable Replace thevoltageregulator-rectifier. Check thestator. r Check theconnectorbetweenstatorandvoltageregulator- Check thecapacitor voltage. Accelerate theenginetoaspeedof5000r.p.m. andread off the Connect avoltmetertothetwoterminalsofcapacitor. Start theengine. Replace thevoltageregulator-rectifier. Check thestator. r Check theconnectorbetweenstatorandvoltageregulator- Check thecapacitor voltage. Accelerate theenginetoaspeedof5000r.p.m. andread off the Connect avoltmetertothetwoterminalsofcapacitor. Start theengineandswitchonlowbeam. ectifier andbetweenthevoltageregulator andthecabletree. ectifier andbetweenthevoltageregulator andthecabletree. 1 . Nominal value:14.0-15.0V Nominal value:14.0-15.0V 7-4C 7-5C STATIC IGNITION VALUES 250-380 SX, EXC (KOKUSAN 2K-1, 2K-3, 2K-4) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground – light switch turned off – the gap between the rotor and pulse generator must be set to 0.75 mm – kick the kick starter forcefully at least 5 times for each measurement

Static ignition values 250-380 SX, EXC (except 250 USA) Check the pulse generator for an output signal – two-pin connector 1 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 1 cable and the black measuring lead to the red cable, disconnect both connectors 1 to disconnect the CDI unit 2

3 Multimeter display: 6 volts +/- 1 volt (250 SX model 2000/2001: 5 volts +/- 1 volt)

– Same measurement with CDI unit connected

Multimeter display: 3 volts +/- 1 volt (250 SX model 2000/2001: 9 volts +/- 1 volt)

Check the generator charging coil for ignition capacitor charge for output voltage – 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 3 to disconnect the CDI unit 2

Multimeter display: 35 volts +/- 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 cir- S cuit diagram on opposite page) for output voltage (blue/white cable 4 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

R Multimeter display: 200 volts +/- 10 volts

NOTE: the ignition coil does not need to be removed to measure. 5 7-6C

SPORTMOTORCYCLES 250-380 EXC 2000

4 1 5 Art No 3206004 -E 3

2 Repair manual KTM 250 / 300 380 7-7C STATIC GENERATOR VALUES 250-380 EXC (KOKUSAN 2K-3) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off – kick the kick starter forcefully at least 5 times for each measurement

Static generator values 250-380 EXC (except 250 USA) 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 (250): 19 volts +/- 2 volts 7 (300-380): 15 volts +/- 1 volt – between white and brown (ground), connector 8 disconnected

Multimeter display (250): 24 volts +/- 2 volts 8 (300-380): 19 volts +/- 1 volt – Repeat both measurements with connector 7 and 8 connected. The measured values should be the same. NOTE: the black measuring lead 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:

– between yellow/red and brown (ground)

Multimeter display: 14 volts +/- 1 volt

NOTE: S S – the black measuring lead of the peak voltage adapter must be 10 applied to the ground. – 300/380 USA corresponds to 300/380 EXC Europe but with less accessories (blinkers, horn, no capacitor installed). Features no rectifi- cation, only an over-voltage regulation. 7-8C

SPORTMOTORCYCLES 250-380 EXC 2000 Art No 3206004 -E

10 9

Repair manual KTM 250 / 300 380 11 7-9C STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC USA (KOKUSAN 2K-2) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground – light switch turned off – the gap between the rotor and pulse generator must be set to 0.75 mm – kick the kick starter forcefully at least 5 times for each measurement

Static ignition values 250 MXC, EXC USA Check the pulse generator for an output signal – two one-pin connectors 1 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 1 cable and the black measuring lead to the red cable, disconnect both connectors 1 to disconnect the CDI unit 2

3 Multimeter display: 3.5 volts +/- 1 volt – Same measurement with CDI unit connected

Multimeter display: 2 volts +/- 0.5 volt

Check the generator charging coil for ignition capacitor charge for output voltage – 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 3 to disconnect the CDI unit 2

Multimeter display: 45 volts +/- 5 volts

– Same measurement with connectors CDI unit connected

Multimeter display: 220 volts +/- 10 volts

Check the primary voltage output 4 for ignition coil control (also see cir- S cuit diagram on opposite page) for output voltage (blue/white cable 4 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 R Multimeter display: 210 volts +/- 10 volts

NOTE: the ignition coil does not need to be removed to measure. 5 Static generator values 250 MXC, EXC USA Check the generator output 6 for the lighting system (also see circuit diagram on opposite page) for voltage:

– between yellow and brown (ground), connector disconnected

Multimeter display: 10.5 volts +/- 1 volt 7-10C

250 EXC 2001

4 3 6 Art No 3206004 -E

2 1 Repair manual KTM 250 / 300 380

Repair manual 250 / 300 / 380 Art No 3206004 -E RUL HOIG20-30..8-2 TROUBLE SHOOTING250-380 TROUBLE SHOOTING INDEX 8-1C 8

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Should anerror occurnevertheless,weadviseyoutousethetrouble shootingchartinorder tofindthecauseoferror. If youletthespecifiedmaintenanceworkonyourmotorcycle becarriedout,disturbancescanhardly beexpected. power Engine hasnotenough running Engine withoutidle Engine failstostart TROUBLE Engine hasnotenoughpreignition Exhaust systemdamaged spark plug Loss ofcompression through loose blocked Fuel supplypartlyinterruptedor Control flapdoesnotwork Air filterobstructed Charred glass fiberyarninsilencer W Ignition systemdamaged adjustment Idle adjustingscrew outof blocked W Spark tooweak Loose ignitioncableconnectors short-circuit switchfaulty Kill buttonwire or damaged Ignition wire orsparkplugconnector Plug fouledbyoil,wetorbridged Electrode distancetoogreat Fuel supplyinterrupted Operating error ear ater inthecarburetor andjets CAUSE TROUBLE SHOOTING Check andadjustignition Check exhaustsystemfordamage T Blow through fuelpipeandcleancarburetor Check control flap,jointrod andcentrifugaltimer Clean orrenew airfilter Renew filling Overhaul engine Examine ignitionsystem Readjust idlerunningorreplace idleadjustingscrew Dismantle andcleancarburetor Examine ignitionsystem Inspect cableconnectors cable, ignitionlockorswitch ignition spark.IfthesparkisO.K.repair defectivepartof Disconnect yellow-blackcoloured cablefrom CDIandcheck – – – must beproduced atthesparkplug (blank placeonengine)andactuatekickstarter, astrong spark Dismount sparkplug,connectignitioncable,holdtoground Clean sparkplugorrenew Reduce electrode distance(0.60mm) – – basin andopenfueltap, Close fueltap,loosenhoseatcarburettor, leadintoa Open fueltap,switchoignition,replenish fuel,donotusechoke ighten sparkplug If nosparkisproduced, checkignitionsystem If asparknowoccurs,replace sparkplugcap cable, holdabout5mmfrom ground andactuatekickstarter If nosparkisproduced, loosensparkplugcapfrom ignition if fuelleaksout,cleancarburettor if nofuelleaksout,checktankventilation,i.e.cleantap REMEDY 8-2C 8-3C

TROUBLE CAUSE REMEDY

Engine has not enough Reed paddles tensionless or dama- Replace reed paddles or reed valve housing power ged, surface of reed valve housing damaged

Wear Overhaul engine

Electronical ignition timing faulty Check ignition system

Engine revs not high and Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and adjust running with four stroke too high, float needle seating is level cycle dirty or enlarged

Loose carburetor jets Tighten jets

High rpm misfiring Incorrect heat range spark plug or Refer to technical data section low quality spark plug

Incorrect or faulty spark plug connector Test and/or replace spark plug connectors correct type

Loose, corroded or non conductive Check and seal with silicon ignition socket connector

Engine spluters into the Lack of fuel Clean fuel pipes, examine tank aeration and clean carburetor Spark plug with incorrect heat value Fit correct spark plug (Ignition by incandescence)

Engine takes air out of control Check intake flange and carburettor if firmly setted

Engine overheating Insufficient liquid in cooling system Top up coolant and bleed cooling system check cooling system for leaks

Cooling system not or insufficiently Bleed cooling system (see operating instructions) bleeded

Radiator fins clogged Clean radiator fins with water jet

Frothing in cooling system Renew coolant using branded anti-freeze/anti-corrosive

Pinched or kinked water hoses Replace with correct routed hoses

Incorrect ignition timing because of Readjust to correct ignition timing specifications, secure loose stator bolts screws properly with Loctite 243

Incorrect dimension ,,X“ Measure and adjust to correct specification

Emission of white smoke Cylinder head or O-ring of cylinder Check cylinder head, replace O-ring (steam) head gasket leaks

Excessive oil escapes from Excessive oil quantity in trans- Correct transmission oil level transmission breather tube mission

Water pump shaft seal ring or right- Replace shaft seal ring and change gear oil, check coolant hand crankshaft seal ring defect

Silicon O-rings of control roller or of control flap leaks Replace O-rings

All switched on lamps Voltage regulator faulty Control connections of voltage regulator. Check voltage blown out regulator Repair manual 250 / 300 / 380 Art No 3206004 -E ABRTRSTIG . . .9-41 CARBURETOR SETTINGS ..9-39 CHASSIS 250-300 ..9-37 ENGINE 250-300 MODEL 2003 . . .9-33 CARBURETOR SETTINGS . ..9-32 CHASSIS 250-380 ..9-30 ENGINE 250-380 ..9-28 ENGINE 250-380USA MODEL 2002 ..9-24 CARBURETOR SETTINGS . ..9-23 CHASSIS 250-380 ..9-21 ENGINE 250-380 ..9-19 ENGINE 250-380USA MODEL 2001 ..9-15 CARBURETOR SETTINGS . ..9-14 CHASSIS 250-380 ..9-12 ENGINE 250-380 ..9-10 ENGINE 250-380USA MODEL 2000 ..9-7 CARBURETOR SETTINGS . .9-6 CHASSIS 250-380 ..9-4 ENGINE 250-380 ..9-2 ENGINE 250-380USA MODEL 1999 TECHNICAL SPECIFICATIONS INDEX 9-1C 9

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

TECHNICAL SPECIFICATIONS - ENGINE 250/300/380 SX/MXC/EXC ‘99 (only for USA)

Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC 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 67.5 / 69.5 mm (2.66 / 2.74 in) 72 / 73 mm (2.84 / 2.88 in) 78 / 77 mm (3 / 2.98 in) Fuel SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X) Oil / gasolin ratio 1:50 - 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 two plain compression rings (upper edge piston - +0.1 mm + 0.004 in Dimension "X"upper edge cylinder) 0 mm (0 in ) Ignition timing 1.8 mm (0.07 in) (17 °) BTDC 2.0 mm (0.08 in) (17°) BTDC 2.2 mm (0.09 in) (17 °) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) (height of the Dimension "Z"control flap) 48 mm (1.9 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open 5400/min 5300/min 5200/min TVC fully open 7550/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 EXC M-XC EXC MXC 1st Gear 15:29 15:29 15:29 15:29 15:29 15:29 15:29 2nd Gear 17:27 18:26 18:26 18:26 18:26 18:26 18:26 3rd Gear 19.25 19:22 19:22 19:24 19:24 19:22 19:24 4th Gear 21:23 21:20 21:20 21:23 21:23 21:20 21:23 5th Gear 23:21 23:18 23:18 23:21 23:21 23:18 23:21 Gear lubrication 0.8 l engine oil 20W-40 (Shell Advance VSX4) 5 1 Available chain sprockets 13t / 14t / 15t for chain /8 x /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-1 KOKUSAN 2K-2 KOKUSAN 2K-1 KOKUSAN 2K-2 Generator output no generator 12V 40W no generator 12V 40W Carburetor flat-slide carburetor, carburetor setting see table 3 Air-filter wet foam type air filter insert 9-2C 9-3C 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 0.05 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 0.2/0.4/0.5/0.7 mm Cylinder-head gasket O-rings

BASIC CARBURETOR SETTING

250 MXC, EXC 250 SX 380 SX, MXC, EXC 300 MXC, EXC

Carburetor Keihin PWK 38 Keihin PWK 38 Keihin PWK 38 Carburetor setting number 090598 100598 070598 Main jet 172(168,170,175) 175(170,172,178) 170(168,172,175) Idling jet 45(48,50) 45(42,48) 48(45,50) Starting jet 85 85 85 TABLE 3 Jet needle NOZ G(NOZ H,NOZ I) N85 C(N85 D) NOZ H(NOZ G,NOZ I) Needle position from top II III II Throttle valve 6 6 6 Air adjustment screw open 1,5 1,5 Umdr. 1,5 Umdr. Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

TECHNICAL SPECIFICATIONS - ENGINE 250/300/380 SX/EXC/EGS ‘99 (all models out of USA)

Engine 250 SX 250 EXC, EGS 300 EXC, EGS 380 SX 380 EXC, EGS 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 67.5 / 69.5 mm (2.66 / 2.74 in) 72 / 73 mm (2.84 / 2.88 in) 78 / 77 mm (3 / 2.98 in) Fuel SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X) Oil / gasoline ratio 1:50 - 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 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) (17 °) BTDC 1.2 mm (0.05 in) (13.5 °) BTDC 1.2 mm (0.05 in) (13.5 °) BTDC 2.1 mm (0.08 in) (17 °) BTDC 1.4 mm (0.06 in) (14,5°) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) (height of the Dimension "Z"control flap) 48 mm (1.9 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open 5400/min 5300/min 5200/min TVC fully open 7550/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)

5 1 ailable chain sprockets 13t / 14t / 15t for chain /8 x /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-1 SEM K11 KOKUSAN 2K-1 SEM K11 Generator output no generator 12V 130W no generator 12V 130W 9-4C Carburetor flat-slide carburetor, carburetor setting see table 4 Air-filter wet foam type air filter insert 9-5C 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)

GASKET THICKNESSES Crankcase 0.5 mm Clutch cover 0.5 mm Cylinder bottom gasket as required Available cylinder bottom gaskets 0.2/0.4/0.5/0.7 mm Cylinder-head gasket O-rings

BASIC CARBURETOR SETTING

250 MXC, EXC 250/300 EGS 380 EGS 250 SX 300 MXC, EXC AUSTRALIA 380 SX, MXC, EXC AUSTRALIA

Carburetor Keihin PWK 38 Keihin PWK 38 Keihin PWK 38 Keihin PWK 38 Keihin PWK 38 Carburetor setting number 090598 100598 100598 070598 060598 Main jet 172(168,170,175) 175(170,172,178) 175(170,172,178) 170(168,172,175) 175(168,170,172) Idling jet 45(48,50) 45(42,48) 45(42,48) 48(45,50) 45(48,50) Starting jet 85 85 85 85 85

TABLE 4 Jet needle NOZ G(NOZ H,NOZ I) N85 C(N85 D) N85 C(N85 D) NOZ H(NOZ G,NOZ I) NOZ G(NOZ H,NOZ I) Needle position from top II III III II II Throttle valve 6 6 6 6 6 Air adjustment screw open 1,5 1,5 Umdr. 1,5 Umdr. 1,5 Umdr. 1,5 Umdr. Performance restrictor – – slide stop 31mm – slide stop 36mm Repair manual KTM 250 / 300 / 380 Art No 3206004 -E ia rv ai 45 45 45 45 14:50/15:48 0.4 in) 10mm(58.3± 63.5° 1481± 925mm(36.4in) 9.5or12liter 14:50/14:52 9.5or12liter 14:52 1.0 bar(14psi) 140/80-18“70R 12liter 1.0 bar(14psi) 1.0bar(14psi) 90/90 -21“54R 140/80-18“70R Dead-weight withoutfuel 14:50 Ground clearance,unloaded Extreme Ø50mm WP 1.0bar(14psi) Seat height,unloaded 1.0bar(14psi) 90/90-21“54R Wheel base 110/100-18“64M 7.5liter Steering headangle Centralchrome-moly-steel frame 1.0bar(14psi) Chain 110/90-19“62M 280/320mm(11.012.6in) 80/100-21“51M Discbrakewithcarbon-steeldiscØ220mm(8.7in),caliperfloated 1.0bar(14psi) Final driveratio Discbrakewithcarbon-steeldiscØ260mm(10.2in),caliperfloated Fuel tankcapacity 80/100-21“51M Air press. road driveronly 1.0bar(14psi) Air pressure offroad Rear tires Air press. road driveronly Air pressure offroad Front tires Rear brake Front brake Rear suspension Wheel travelfront/rear Fork Frame A te ot ncassM61 m(7 ft.lb) 10Nm (44 ft.lb) (30ft.lb) 60Nm 40Nm M6 M12 M12 (11ft.lb) 15Nm (74ft.lb) 100Nm (59ft.lb) 80Nm Other boltsonchassis (19ft.lb) M14x1,5 25Nm M8 Shock absorberbottom (15ft.lb) M20x1,5 20Nm Shock absorbertop (11ft.lb) 15Nm M8 Hexagon nutswingarmbolt M8 Collar nutrear wheelspindle (30ft.lb) M8 Clamping boltsforkstubs 40Nm Clamping boltslowerforkbridge Clamping boltsupperforkbridge M10 SAE5 Brake caliperfront Collar boltfront wheel spindle 5 SAE 4.0N/mm 12 5mm (0.2in) 12 4.2N/mm approx. 750ccm 155mm(6.1in) 5mm(0.2in) Fork oil approx. 750ccm 150mm(5.9in) Capacity perforkleg 12 Air chamberlength Spring preload 12 Spring Rebound adjuster Compression adjuster TORQUES STANDARD ADJUSTMENT-FORK TECHNICAL SPECIFICATIONS CHASSIS250/300380SXMXCEXCEGS‘99 r different design.Makesure nottomixthemupincaseof The dampingunitsintheleftandrightforklegare of NOTE: albefnlsrces38,40,42,45,48,50,52 vailable finalsprockets epair orservicejobs. P9878W 918T769 WP 918T768 WP 0 g(2 b)125k 263ls 0. g(2 b)109kg(240.6Ibs) 103.7kg(229lbs) 102.5kg(226.3lbs) 101 kg(223lbs) 2U aln)(. Sglos 25o . Sglos 25o . Sgallons) (2.5or3.2US gallons) (2.5or3.2US gallons) (3.2US gallons) (2 US 5/8S 5/0/8 X 5/0/8 X 250/300/380EGS 250/300/380EXC 250/300/380MXC 250/380SX 04 m(33ft.lb) 45 Nm M 10 –– –– –– –– 5N (19ft.lb) 25Nm M 8 PP WP r + Loctite243 ogressive D amping S ystem shockabsorber, aluminiumswingarm 385 mm(15in) pigPS–5 PDS2–250 12 6 6mm(0.23in) PDS3–250 5mm (0.20in) 14 Spring preload 5 Spring Rebound adjuster Compression adjuster STANDARD-ADJUSTMENT -SHOCKABSORBER might comeloose. tightened inseveral(3)steps.Otherwise,thebolts The clampingboltsoftheforkplatesmustbe 5/8 x1/4" 1/0 8 4 – 110/100 -18“64M 010-2“5M– 80/100 -21“51M . a 2 s)2.0bar(28psi) 1.5bar(21psi) 2.0 bar(28psi) 1.5 bar(21psi) P11T1 WP1218T714 WP 1218T712 9-6C 9-7C NICHT FÜR STRASSENBETRIEB ROZ 95 Super bleifrei Kraftstoff: NOT FOR HIGHWAY USE Fuel: Super unleaded ROZ 95 1/4 1 1/2 1 3/4 2 2 1/4 AS =IJ Air screw open from fully-seated POS = = Clip position from top Idling jet MJ = Main jet 2. 4. 71 322211 71 333221 322222 321111 433211 5050 48 48 45 45 45 45 45 42 42 42 48 45 45 45 45 42 45 42 40 40 40 38 48 45 42 42 42 40 3/41/2 1 3/4 1 1/4 1 1 1/2 1 3/4 1 1/4 1 1/2 2 1 3/4 178180 175182 178 172 180 175 170 178 172 168 175 170 165 172 168 170 175 172 170 168185 165 182 165 180 178 175 172 N85BN85B N85CN85B N85B N85C N85B N85C N85C N85C N85C N85D N85C N85D N85C N85C N85D N85D 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 N85C N85C N85C N85DN85A N85D N85B N85D N85B N85C N85C N85D 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ MJ AS IJ MJ AS MJ AS POS POS POS AS IJ IJ POS MJ AS POS MJ NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38 TEMPERATUR LD NADEL LD NADEL NADEL HD LSCHR LD HD LSCHR HD LSCHR POS POS POS LSCHR LD NADEL LD NADEL POS HD LSCHR POS HD 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTITUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOS =HD Leerlaufdüse = Clip Position von oben = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTING KTM 250 SX EUROPA, USA ‘99 KEIHIN PWK 38

MEERESHÖHE TEMPERATUR -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C ALTITUDE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

3000 m LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 10000 ft LD IJ 45 42 40 40 40 38 NADEL NEEDLE NOZH NOZH NOZH NOZI NOZI NOZI 2301 m POS POS 321111 7501 ft HD MJ 170 168 165 162 160 160 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 7500 ft LD IJ 48 45 42 42 42 40 NADEL NEEDLE NOZG NOZH NOZH NOZI NOZI NOZI 1501 m POS POS 321111 5001 ft HD MJ 172 170 168 165 162 160 1500 m LSCHR AS 11 1/4 1 1/2 1 3/4 2 2 1/4 5000 ft LD IJ 48 45 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZH NOZI 751 m POS POS 332222 2501 ft HD MJ 175 172 170 168 165 162 750 m LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 2500 ft LD IJ 50 48 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZI NOZI 301 m POS POS 322222 1001 ft HD MJ 178 175 172 170 168 165 300 m LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 50 48 45 45 42 42 NADEL NEEDLE NOZF NOZG NOZG NOZH NOZH NOZI Meeresniveau POS POS 433211 Sea level HD MJ 180 178 180 172 170 168 1. LSCHR = Luftregulierschraube offen 2. AS = Air screw open from fully-seated NICHT FÜR STRASSENBETRIEB 3. Kraftstoff: Super bleifrei ROZ 95 LD = Leerlaufdüse 4. IJ = Idling jet 9-8C POS = Clip Position von oben 5. POS = Clip position from top NOT FOR HIGHWAY USE HD = Hauptdüse MJ = Main jet Fuel: Super unleaded ROZ 95 9-9C NICHT FÜR STRASSENBETRIEB ROZ 95 Super bleifrei Kraftstoff: NOT FOR HIGHWAY USE Fuel: Super unleaded ROZ 95 N0ZH NOZI NOZI H 1/4 1 1/2 1 3/4 2 2 1/4 AS =IJ Air screw open from fully-seated POS = = Clip position from top Idling jet MJ = Main jet 2. 4. FGGHHI 322222 321111 321111 11 332222 433211 HHH I I I GHH I I I GGHHH I GG 52 50 48 48 48 45 52 50 48 48 48 45 5050 48 48 45 48 45 48 45 48 42 45 48 45 45 42 42 40 1/2 3/4 1 1 1/4 1 1/2 1 3/4 3/4 1 1 1/4 1 1/2 1 3/4 2 180 178 175 172 170 168 172175 170178 172 168 175 170 165 172 168 162 170 165 162 168 162 165 182 180 178 175 172 170 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F 1. 3. 5. -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ POS MJ AS IJ POS MJ AS POS MJ AS IJ POS MJ AS AS IJ NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE MJ POS KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38 TEMPERATUR LD NADEL LD NADEL POS HD LSCHR LD NADEL NADEL POS HD LSCHR POS HD LSCHR LD POS HD LSCHR LSCHR LD NADEL HD POS 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTITUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOS =HD Leerlaufdüse = Clip Position von oben = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

TECHNICAL DATA - ENGINE 250/300/380 SX / MXC / EXC 2000 (only USA)

Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC 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 / gasolin 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 rings two plain compression rings (upper edge piston - Dimension "X"upper edge cylinder) 0 +0.1 mm (0 + 0.004 in) Ignition timing 2.0 mm (0.07 in) (17 °) BTDC 2.2 mm (0.09 in) (17 °) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) (height of the Dimension "Z"control flap) 50,5 mm (1.99 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open 5000/min 5300/min 5200/min TVC fully open 7500/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 EXC MXC EXC MXC EXC MXC 1st Gear 15:29 15:29 15:29 15:29 15:29 15:29 15:29 15:29 2nd Gear 17:27 18:26 17:27 18:26 18:26 18:26 18:26 18:26 3rd Gear 19:25 19:22 19:25 19:22 19:24 19:24 19:22 19:24 4th Gear 21:23 21:20 21:23 21:20 21:23 21:23 21:20 21:23 5th Gear 23:21 23:18 23:21 23:18 23:21 23:21 23:18 23:21 Gear lubrication 0.8 l engine oil 20W-40 (Shell Advance VSX4) 5 1 Available chain sprockets 13t / 14t / 15t for chain /8 x /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-4 KOKUSAN 2K-2 KOKUSAN 2K-1 KOKUSAN 2K-3 Generator output no generator 12V 40W no generator 12V 110W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert 9-10C 9-11C TIGHTENING TORQUES - ENGINE 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)

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

250 SX 250 MXC, EXC 300 MXC, EXC 380 SX, MXC, EXC

Carburetor Keihin PWK 38 AG PJ Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 110499 130499 140499 150499 Main jet 172 (170,175) 180 (178,182) 175 (172,178) 170 (168,172) Idling jet 48 (45,50) 45 (48) 45 (48) 45 (48) Starting jet 85 85 85 85 Jet needle NOZ E (NOZ F) NOZ G (NOZ H) NOZ H (NOZ I) NOZ H (NOZ I) Needle position from top III III III III Slide 7 6 6 6 Air adjustment screw open 1,5 1,5 1,5 1,5 Performance restrictor – – – – Power jet jet 55 – – – Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2000 (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 2.0 mm (0.07 in) (17 °) BTDC 2.2 mm (0.08 in) (17 °) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) (height of the Dimension "Z"control flap) 50,5 mm (1.99 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open 5000/min 5300/min 5200/min TVC fully open 7500/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) 5 1 ailable chain sprockets 13t / 14t / 15t for chain /8 x /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-4 KOKUSAN 2K-3 KOKUSAN 2K-1 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 9-12C 9-13C 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)

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

250/300 EXC 250 SX 250 MXC, EXC 300 MXC, EXC 380 SX, MXC, EXC throttled

Carburetor Keihin PWK 38 AG PJ Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 110499 130499 140499 150499 050799 Main jet 172 (170,175) 180 (178,182) 175 (172,178) 170 (168,172) 175 Idling jet 48 (45,50) 45 (48) 45 (48) 45 (48) 35 Starting jet 85 85 85 85 85 Jet needle NOZ E (NOZ F) NOZ G (NOZ H) NOZ H (NOZ I) NOZ H (NOZ I) R 1475 J Needle position from top III III III III III Throttle valve 7 6 6 6 6 Air adjustment screw open 1,5 1,5 1,5 1,5 1,5 Performance restrictor – – – – slide stop 34mm Power jet jet 55 – – – – Repair manual KTM 250 / 300 / 380 Art No 3206004 -E * Dead-weightwithoutfuel edwih S 0 g(2 b)125k 263ls 103,7kg(229 lbs) 140/80-18“70R 102,5kg(226,3lbs) 1,0bar(14psi) 100/100-18“64M 101kg(223lbs) – 1,0bar(14psi) Dead-weight USA* Dead-weight 100/100-18“64M 100/90-19“62M 1,0bar(14psi) 100/90-19“62M Air pressure offroad Rear tires USA Rear tires ia rv ai S 45t1:2 14:52t 90/90-21“54R 14:52t 1,0bar(14psi) 80/100-21“51M – Wear limitmax.0,4mm(0,016in) 14:50t 1,0bar(14psi) 80/100-21“51M Chain Final driveratioUSA Discbrakewithcarbon-steeldiscØ220mm(8.7in),caliperfloated 80/100-21“51M Fuel tankcapacity 1,0bar(14psi) 80/100-21“51M Discbrakewithcarbon-steeldiscØ260mm(10.2in),caliperfloated Air pressure road driveronly WP Air pressure road driveronly Air pressure offroad Front tires USA Front tires Brake discs Rear brake Front brake Rear suspension Fork pigPS–5 PDS2-250 20 5 5mm (0.2in) PDS3–250 5mm(0.2in) SAE5 18 4 Spring preload Spring 5 SAE Rebound adjuster 4,0N/mm Compression adjuster 12 15:48t/14:50t 14 6,5mm(0.26in) approx. 830ccm 150mm(5.9in) 4,0N/mm 6mm(0.24in) approx. 840ccm 140mm(5.5in) Fork oil 12 0,4 in) 10mm(58,3± 63,5° 1481± Capacity perforkleg Air chamberlength 14 Spring preload Spring – Rebound adjuster Compression adjuster 14:50t Ground clearance,unloaded S Wheel base Steering headangle A Final driveratio rm Centralchrome-moly-steel frame 295/320mm(11,3/12,6in) Wheel travelfront/rear Frame S S eat height,unloaded vailable finalsprockets T T ANDARD ANDARD * TECHNICAL SPECIFICATIONS CHASSIS250/300/380SX,MXC,EXC2000 A A DJUSTMENT DJUSTMENT P01U8 WP0518U787 WP 0518U785 P11U1 WP1218U720 WP 1218U718 -F , ie 2U aln)1 ie 32U aln)9,5/12liter(2,5/3,2USGallons) 12liter(3,2USGallons) 7,5 liter(2USGallons) - S ORK 0 g(2 b)–109kg(240,6lbs) – 101 kg(223lbs) HOCK 5/8 X203030MC250/300/380EXC 250/300/380MXC 250/380 SX – – A BSORBER P r ogressive D W amping hite 38t, 40t,42t,45t,48t,50t,52t P ower – hc bobrtpM1 0N (44 ft.lb) (44ft.lb) 60Nm 60Nm M12 M12 (15ft.lb) 20 Nm (30ft.lb) 40Nm (7ft.lb) Screw adjustingring springpreload 10Nm M8 (74ft.lb) Shock absorberbottom 100Nm M 10 (59ft.lb) 80Nm Shock absorbertop (19ft.lb) M14x1.5 25Nm M8 Allen headbolthandlebarsupport (11ft.lb) M20x1.5 15Nm Collar bolthandlebarclamp (15ft.lb) 20Nm M8 Hexagon nutswingarmbolt M8 Collar nutrear wheelspindle M8 Clamping boltsforkstubs (30ft.lb) Clamping boltslowerforkbridge 40Nm Clamping boltsupperforkbridge M16x1,5 Brake caliperfront Collar nutfront wheelspindle te ot ncassM61 m(7 ft.lb) 10Nm M6 Other boltsonchassis S T 925 mm(36,5in) 385 mm(15,2in) ystem shockabsorber, aluminiumswingarm , a 2pi 1,5bar(21psi) 2,0 bar 1,5 bar(21psi) GEIGTORQUES IGHENING 5/8 x1/4" U p S (28psi) ide D own 43MA - CHASSIS 04 m(33ft.lb) 45Nm M 10 m(6ft.lb) Nm 8 M 6 5N (19ft.lb) 25Nm M 8 2,0 bar (28psi) + Loctite243 9-14C 9-15C 21.06.99 NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 1/2 1 3/4 2 2 1/4

AS =IJ Air screw open from fully-seated POS = = Clip position from top Idling jet MJ = Main jet 2. 4. 332211 1/41 332222 11 433222 443332 443332 52 50 48 48 48 45 52 50 48 48 48 45 50 48 48 48 48 45 50 48 45 45 45 42 48 45 45 42 42 40 3/4 1 1 1/4 1 1/2 1 3/4 2 1/2 3/4 1 1 1/4 1 1/2 1 3/4 170172 168175 170 165 172 168 161628 170 160 165 168 160 162 165 160 162 178180 175 178 172 180 170 172 168 170 165 168 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 NOZC NOZDNOZC NOZE NOZC NOZD NOZE NOZD NOZE NOZE NOZF NOZE NOZD NOZENOZD NOZDNOZD NOZE NOZE NOZD NOZF NOZE NOZE NOZG NOZE NOZH NOZF NOZG NOZF NOZF 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ IJ IJ POS MJ AS POS MJ AS POS MJ AS IJ AS NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE POS MJ AS POS MJ KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ TEMPERATUR LD NADEL LD NADEL NADEL LD LD NADEL POS HD LSCHR POS HD LSCHR POS HD LSCHR LD NADEL LSCHR POS HD LSCHR POS HD 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOS =HD Leerlaufdüse = Clip Position von oben = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTINGKTM 250 MXC/EXC EUR/USA 2000 KEIHINAG PWK 38

MEERESHÖHE TEMPERATUR -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C ALTIDUDE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

3000 m LSCHR AS 1 3/4 1 3/4 1 3/4 2 2 1/2 1 3/4 10000 ft LD IJ 40 40 40 38 38 38 NADEL NEEDLE NOZH NOZH NOZH NOZI NOZI NOZI 2301 m POS POS 332222 7501 ft HD MJ 178 175 172 170 170 168 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 1 3/4 2 2 7500 ft LD IJ 42 42 40 40 40 40 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZI NOZI 1501 m POS POS 332222 5001 ft HD MJ 180 178 175 172 170 168 1500 m LSCHR AS 1 1/4 1 1/2 1 1/2 1 3/4 1 3/4 2 5000 ft LD IJ 45 45 42 42 42 40 NADEL NEEDLE NOZG NOZG NOZG NOZH NOZI NOZI 751 m POS POS 433222 2501 ft HD MJ 182 180 178 175 172 170 750 m LSCHR AS 1 1/4 1 1/4 1 1/4 1 1/2 1 3/4 1 3/4 2500 ft LD IJ 45 45 45 42 42 42 NADEL NEEDLE NOZF NOZG NOZG NOZG NOZH NOZH 301 m POS POS 443332 1001 ft HD MJ 185 182 180 178 175 172 300 m LSCHR AS 11 1/41 1/2 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 50 48 45 45 42 42 NADEL NEEDLE NOZE NOZF NOZG NOZG NOZH NOZH Meeresniveau POS POS 543332 Sea level HD MJ 188 185 182 180 178 175

LSCHR = Luftregulierschraube offen 1. AS = Air screw open from fully-seated NICHT FÜR STRASSENBETRIEB 21.06.99 LD = Leerlaufdüse 2. IJ = Idling jet Kraftstoff: Euro-Super bleifrei ROZ 95 3. 9-16C POS = Clip Position von oben 4. POS = Clip position from top NOT FOR HIGHWAY USE 5. HD = Hauptdüse MJ = Main jet Fuel: Euro-Super unleaded ROZ 95 9-17C 21.06.99 AG NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 1/4 1 1/2 1 3/4 2 2 1/4 AS =IJ Air screw open from fully-seated POS = = Clip position from top Idling jet MJ = Main jet 2. 4. 321111 321111 11 3322222 322222 433211 5050 48 48 45 45 45 45 45 42 42 42 4848 45 45 42 45 42 45 42 45 40 42 45 42 40 40 40 38 3/41/2 1 3/4 1 1/4 1 1 1/2 1 3/4 1 1/4 1 1/2 2 1 3/4 172175 170178 172 168180 175 170 165 178 172 168 162 175 170 165 162 172 168 162 170 165 168 182 180 178 175 172 170 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 NOZF NOZG NOZG NOZH NOZH NOZI NOZH NOZHNOZG NOZH NOZHNOZG NOZH NOZI NOZGNOZG NOZH NOZI NOZG NOZI NOZH NOZH NOZI NOZI NOZH NOZH NOZI NOZI NOZI NOZI 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ IJ POS MJ AS POS MJ AS IJ POS MJ AS POS MJ AS AS IJ NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE MJ POS KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 TEMPERATUR LD NADEL LD NADEL LD NADEL NADEL POS HD LSCHR POS HD LSCHR LD POS HD LSCHR POS HD LSCHR LSCHR LD NADEL HD POS 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOS =HD Leerlaufdüse = Clip Position von oben = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTING KTM 380 SX / MXC / EXC EUR / USA 2000KEIHIN PWK 38 AG

3000 m LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 10000 ft LD IJ 45 45 40 40 40 38 NADEL NEEDLE NOZH NOZH NOZH NOZI NOZI NOZI 2301 m POS POS 321111 7501 ft HD MJ 172 170 168 165 162 162 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 7500 ft LD IJ 48 45 42 42 42 40 NADEL NEEDLE NOZG NOZH NOZH NOZI NOZI NOZI 1501 m POS POS 321111 5001 ft HD MJ 175 172 170 168 165 162 1500 m LSCHR AS 11 1/4 1 1/2 1 3/4 2 2 1/4 5000 ft LD IJ 48 45 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZH NOZI 751 m POS POS 3322222 2501 ft HD MJ 178 175 172 170 168 165 750 m LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 2500 ft LD IJ 50 48 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZI NOZI 301 m POS POS 322222 1001 ft HD MJ 180 178 175 172 170 168 300 m LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 50 48 45 45 42 42 NADEL NEEDLE NOZF NOZG NOZG NOZH NOZH NOZI Meeresniveau POS POS 433211 Sea level HD MJ 182 180 178 175 172 170

LSCHR = Luftregulierschraube offen 1. AS = Air screw open from fully-seated NICHT FÜR STRASSENBETRIEB 21.06.99

2. 9-18C LD = Leerlaufdüse 3. IJ = Idling jet Kraftstoff: Euro-Super bleifrei ROZ 95 POS = Clip Position von oben 4. POS = Clip position from top NOT FOR HIGHWAY USE 5. HD = Hauptdüse MJ = Main jet Fuel: Euro-Super unleaded ROZ 95

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

TECHNICAL DATA - ENGINE 250/300/380 SX / MXC / EXC 2001 (only USA)

(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 2.4 mm (0.095 in) BTDC 2.43 mm (0.096 in) BTDC 2.6 mm (0.1 in) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) (height of the Dimension "Z"control flap) 49,5 mm (1.95 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open 5000/min 5900/min 5200/min 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 EXC MXC EXC MXC EXC MXC 1st Gear 15:29 15:29 15:29 15:29 15:29 15:29 15:29 15:29 2nd Gear 17:27 18:26 17:27 18:26 18:26 18:26 18:26 18:26 3rd Gear 19:25 19:22 19:25 19:22 19:24 19:24 19:22 19:24 4th Gear 21:23 21:20 21:23 21:20 21:23 21:23 21:20 21:23 5th Gear 23:21 23:18 23:21 23:18 23:21 23:21 23:18 23:21 Gear lubrication SX 0.8 l engine oil 20W-40 (Shell Advance VSX4) MXC/EXC 0,8 l gear oil 80W (Shell Gear EP 80) 5 1 Available chain sprockets 13t / 14t / 15t for chain /8 x /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-4 KOKUSAN 2K-2 KOKUSAN 2K-3 KOKUSAN 2K-3 Generator output no generator 12V 40W no generator 12V 110W Carburetor flat-slide carburetor, carburetor setting see table Air-filter wet foam type air filter insert 9-19C 9-20C TIGHTENING TORQUES - ENGINE 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

250 SX 250 MXC, EXC 300 MXC, EXC 380 SX, MXC, EXC

Carburetor Keihin PWK 38 AG PJ Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 010300 030300 050300 070300 Main jet 172 (170,175) 178 (175,180) 175 (172,178) 170 (168,172) Idling jet 48 (45,50) 45 (48) 45 (48) 45 (48) Starting jet 85 85 85 85 Jet needle NOZ E (NOZ F) NOZ G (NOZ H) NOZ H (NOZ I) NOZ G (NOZ I/NOZ H) Needle position from top III IV III III Slide 7 6,5 6,5 6,5 Air adjustment screw open 1,5 1,5 1,5 1,5 Performance restrictor – – – – Power jet jet 55 – – – Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2001 (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 2.4 mm (0.095 in) BTDC 2.43 mm (0.096 in) BTDC 2.6 mm (0.1 in) 17 °) BTDC Spark plug NGK BR 8 ECM Electrode gap 0.6 mm (0.024 in) (height of the Dimension "Z"control flap) 49,5 mm (1.94 in) 46 mm (1.7 in) 50.5 mm (1.99 in) TVC start open 5000/min 5900/min 5200/min 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 gear oil 80W (Shell Gear EP 80) 0,8 l engine oil 20W-40 (Shell Advance0,8 lVSX4) gear oil 80W (Shell Gear EP 80) 5 1 ailable chain sprockets 13t / 14t / 15t for chain /8 x /4" Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F) Ignition system KOKUSAN 2K-4 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 9-21C 9-22C 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)

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

250 EXC AUS 300 EXC AUS 380 EXC throttled throttled throttled

Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 040300 060300 080300 Main jet 178 (175,180) 175 (172,178) 170 (168,172) Idling jet 45 (48) 45 (48) 45 (48) Starting jet 85 85 85 Jet needle NOZ G (NOZ H) NOZ H (NOZ I) NOZ G (NOZ I/NOZ H) Needle position from top IV III III Slide 6,5 6,5 6,5 Air adjustment screw open 1,5 1,5 1,5 Performance restrictor slide stop 34mm slide stop 34mm slide stop 36mm Power jet jet – – –

BASIC CARBURETOR SETTING

250/300 EXC 250 SX 380 SX throttled

Carburetor Keihin PWK 38 AG PJ Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 010300 070300 020300 Main jet 172 (170,175) 170 (168,172) 175 (172,178,180) Idling jet 48 (45,50) 45 (48) 35 Starting jet 85 85 85 Jet needle NOZ E (NOZ F) NOZ G (NOZ I/NOZ H) R 1475 J Needle position from top III III III Throttle valve 7 6,5 6,5 Air adjustment screw open 1,5 1,5 1,5 Performance restrictor – – slide stop 34mm Power jet jet 55 – – Repair manual KTM 250 / 300 / 380 Art No 3206004 -E * Dead-weightwithoutfuel rm Centralchrome-moly-steel frame 295/320mm(11,3/12,6in) Wheel travelfront/rear Frame edwih S 0 g(2 b)125k 263ls 103,7kg(229 lbs) 140/80-18“70R 102,5kg(226,3lbs) 1,0bar(14psi) 100/100-18“64M 101kg(223lbs) – 1,0bar(14psi) Dead-weight USA* Dead-weight 100/100-18“64M 100/90-19“62M 1,0bar(14psi) 100/90-19“62M Air pressure offroad Rear tires USA Rear tires ia rv ai S 45t1:2 14:52t 90/90-21“54R 14:52t 1,0bar(14psi) 80/100-21“51M – Wear limitmax.0,4mm(0,016in) 14:50t 1,0bar(14psi) 80/100-21“51M Chain Final driveratioUSA Discbrakewithcarbon-steeldiscØ220mm(8.7in),caliperfloated 80/100-21“51M Fuel tankcapacity 1,0bar(14psi) 80/100-21“51M Discbrakewithcarbon-steeldiscØ260mm(10.2in),caliperfloated Air pressure road driveronly WP Air pressure road driveronly Air pressure offroad Front tires USA Front tires Brake discs Rear brake Front brake Rear suspension Fork pigPS–6 PDS2-250 25 5 6mm (0.24in) PDS7–265 5mm(0.2in) 25 SAE5 5 Spring preload Spring Rebound adjuster 4,0N/mm 5 SAE Compression adjuster 12 15:48t/14:50t 5mm(0.20in) 14 150mm(5.9in) 4,0N/mm 5mm(0.20in) 130mm(5.1in) 12 0,4 in) 10mm(58,3± 63,5° 1481± Fork oil Air chamberlength 14 Spring preload Spring – Rebound adjuster Compression adjuster 14:50t Ground clearance,unloaded S Wheel base Steering headangle A Final driveratio eat height,unloaded vailable finalsprockets TECHNICAL SPECIFICATIONS CHASSIS250/300/380SX,MXC,EXC2001 S T ANDARD * S T ANDARD A DJUSTMENT P01V0 WP 0518V704 WP 0518V703 P11V3 WP1218V731 WP 1218V730 A DJUSTMENT , ie 2U aln)1 ie 29U aln)8,5/11liter(2,2/2,9USGallons) 11liter(2,9USGallons) 7,5 liter(2USGallons) 0 g(2 b)–109kg(240,6lbs) – 101 kg(223lbs) 5/8 X203030MC250/300/380EXC 250/300/380MXC 250/380 SX - S HOCK – – -F ORK A BSORBER P r ogressive D W amping hite 38t, 40t,42t,45t,48t,50t,52t P ower – hc bobrtpM1 0N (44 ft.lb) (44ft.lb) 60Nm 60Nm M12 M12 (15ft.lb) 20 Nm Screw adjustingring spring preload (7ft.lb) Shock absorberbottom 10Nm M8 (74ft.lb) Shock absorbertop 100Nm (59ft.lb) 80Nm (19ft.lb) M14x1.5 25Nm M8 Allen headbolthandlebarsupport M20x1.5 Collar bolthandlebarclamp M8 Hexagon nutswingarmbolt Collar nutrear wheelspindle Clamping boltsforkstubs (30ft.lb) Clamping boltslowerforkbridge 40Nm Clamping screws upperforkbridge M16x1,5 Brake caliperfront Collar nutfront wheelspindle te ot ncassM61 m(7 ft.lb) 10Nm M6 Other boltsonchassis S 925 mm(36,5in) 385 mm(15,2in) ystem shockabsorber, aluminiumswingarm , a 2pi 1,5bar(21psi) 2,0 bar 1,5 bar(21psi) 5/8 x1/4" U p S (28psi) ide T GEIGTORQUES IGHENING D own 43MA 04 m(33ft.lb) 45Nm M 10 04 m(30ft.lb) 40Nm M 10 m(6ft.lb) Nm 8 M 6 (11ft.lb) 15Nm (15ft.lb) 20Nm M 8 M 8 5N (19ft.lb) 25Nm M 8 2,0 bar - CHASSIS (28psi) + Loctite243 + Loctite 243 9-23C 9-24C NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 = 6 mm 1/4 1 1/2 1 3/4 2 2 1/4 ASIJ = Air screw open from fully-seated POS = = Clip position from top MJ Idling jet Slide = = Main jet 7 Atomizer 2. 4. 332211 332222 11 433222 443332 543332 52 50 48 48 48 45 52 50 48 48 48 45 5050 48 48 45 48 45 48 45 48 42 45 48 45 45 42 42 40 3/4 1 1 1/4 1 1/2 1 3/4 2 1/2 3/4 1 1 1/4 1 1/2 1 3/4 170172 168175 170 165 172 168 162 170 165 160 168 162 160 165 160 162 178180 175 178 172 175 170 172 168 170 165 168 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 NOZC NOZDNOZC NOZE NOZC NOZD NOZE NOZD NOZE NOZE NOZF NOZE NOZD NOZENOZD NOZDNOZD NOZE NOZE NOZD NOZF NOZE NOZE NOZG NOZE NOZH NOZF NOZG NOZF NOZF 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ IJ POS MJ AS POS MJ AS IJ POS MJ AS AS IJ NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE POS MJ AS POS MJ KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ TEMPERATUR LD NADEL LD NADEL LD NADEL NADEL POS HD LSCHR POS HD LSCHR LD POS HD LSCHR LSCHR LD NADEL POS HD LSCHR POS HD 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOSHD = = Leerlaufdüse Clip Position von oben Schieber= 7 Zerstäuber= 6 mm = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTINGKTM 250 MXC/EXC EUR/USA 2001 KEIHINAG PWK 38

3000 m LSCHR AS 1 3/4 1 3/4 1 3/4 2 2 1/2 1 3/4 10000 ft LD IJ 42 42 42 40 40 40 NADEL NEEDLE NOZH NOZH NOZH NOZI NOZI NOZI 2301 m POS POS 332221 7501 ft HD MJ 178 175 172 170 170 168 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 1 3/4 2 2 7500 ft LD IJ 45 45 42 42 42 42 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZI NOZI 1501 m POS POS 332222 5001 ft HD MJ 180 178 175 172 170 168 1500 m LSCHR AS 1 1/4 1 1/2 1 1/2 1 3/4 1 3/4 2 5000 ft LD IJ 48 48 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZG NOZH NOZI NOZI 751 m POS POS 433322 2501 ft HD MJ 182 180 178 175 172 170 750 m LSCHR AS 1 1/4 1 1/4 1 1/4 1 1/2 1 3/4 1 3/4 2500 ft LD IJ 48 48 48 45 45 45 NADEL NEEDLE NOZF NOZF NOZG NOZG NOZH NOZH 301 m POS POS 544332 1001 ft HD MJ 185 182 180 178 175 172 300 m LSCHR AS 11 1/4 1 1/2 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 52 50 48 48 45 45 NADEL NEEDLE NOZE NOZF NOZG NOZG NOZH NOZH Meeresniveau POS POS 554332 Sea level HD MJ 188 185 182 180 178 175 LSCHR = Luftregulierschraube offen AS = Air screw open from fully-seated LD = Leerlaufdüse 1. IJ = Idling jet NICHT FÜR STRASSENBETRIEB

POS = Clip Position von oben 2. POS = Clip position from top Kraftstoff: Euro-Super bleifrei ROZ 95 9-25C 3. MJ = Main jet HD = Hauptdüse 4. NOT FOR HIGHWAY USE Schieber= 6,5 5. Slide = 6,5 Zerstäuber= 6 mm Atomizer= 6 mm Fuel: Euro-Super unleaded ROZ 95 9-26C AG NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 = 6 mm 1/4 1 1/2 1 3/4 2 2 1/4 ASIJ = Air screw open from fully-seated POS = = position from top Clip MJ Idling jet Slide = = Main jet 6,5 Atomizer 2. 4. 332221 332222 11 433322 544332 554332 5050 48 48 45 45 45 45 45 42 42 42 4848 45 45 42 45 42 45 42 45 40 42 45 42 40 40 40 38 3/41/2 1 3/4 1 1/4 1 1 1/2 1 3/4 1 1/4 1 1/2 2 1 3/4 175178 172180 175 170182 178 172 168 180 175 170 165 178 172 168 162 175 170 165 172 168 170 185 182 180 172 170 168 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 NOZF NOZG NOZG NOZH NOZH NOZI NOZH NOZHNOZG NOZH NOZHNOZG NOZH NOZI NOZGNOZG NOZH NOZI NOZG NOZI NOZH NOZH NOZI NOZI NOZH NOZH NOZI NOZI NOZI NOZI 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ IJ POS MJ AS POS MJ AS IJ POS MJ AS POS MJ AS AS IJ NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE MJ POS KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 TEMPERATUR LD NADEL LD NADEL LD NADEL NADEL POS HD LSCHR POS HD LSCHR LD POS HD LSCHR POS HD LSCHR LSCHR LD NADEL HD POS 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOSHD = = Leerlaufdüse Clip Position von oben Schieber= 6,5 Zerstäuber= 6 mm = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTING KTM 380 SX / MXC / EXC EUR / USA 2001KEIHIN PWK 38 AG

3000 m LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 10000 ft LD IJ 45 45 40 40 40 38 NADEL NEEDLE NOZH NOZH NOZH NOZI NOZI NOZI 2301 m POS POS 332221 7501 ft HD MJ 170 168 165 162 160 158 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 7500 ft LD IJ 48 45 42 42 42 40 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZI NOZI 1501 m POS POS 332222 5001 ft HD MJ 172 170 168 165 162 160 1500 m LSCHR AS 11 1/4 1 1/2 1 3/4 2 2 1/4 5000 ft LD IJ 48 45 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZG NOZH NOZI NOZI 751 m POS POS 433322 2501 ft HD MJ 175 172 170 168 165 162 750 m LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 2500 ft LD IJ 50 48 45 45 45 42 NADEL NEEDLE NOZF NOZF NOZG NOZG NOZH NOZH 301 m POS POS 544322 1001 ft HD MJ 178 175 172 170 168 165 300 m LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 50 48 45 45 42 42 NADEL NEEDLE NOZE NOZF NOZG NOZG NOZH NOZH Meeresniveau POS POS 554332 Sea level HD MJ 180 178 175 172 170 168 LSCHR = Luftregulierschraube offen AS = Air screw open from fully-seated LD = Leerlaufdüse 1. IJ = Idling jet NICHT FÜR STRASSENBETRIEB

POS = Clip Position von oben 2. POS = Clip position from top Kraftstoff: Euro-Super bleifrei ROZ 95 9-27C 3. MJ = Main jet HD = Hauptdüse 4. NOT FOR HIGHWAY USE Schieber= 6,5 5. Slide = 6,5 Zerstäuber= 6 mm Atomizer= 6 mm Fuel: Euro-Super unleaded ROZ 95 9-28C hamber C orque orque T x ratio to be on the safe side TM K " 4 / 1 x 8 ontrol exhaust system and ontrol / 5 C alve V win needle bearing needle bearing KTM T NGK BR 8 ECM 0.6 mm (0.024 in) 5 speed, claw actuated 0 +0.1 mm (0 + 0.004 in) wet foam type air filter insert 13t / 14t 15t for chain flat-slide carburetor, carburetor setting see table carburetor flat-slide carburetor, 0.8 l engine oil 20W-40 (Shell Advance VSX4) 0.8 l engine oil 20W-40 MXC/EXC 0,8 l engine oil 10W-40 (Shell Advance Ultra 4) MXC/EXC 0,8 l engine oil 10W-40 49,5 mm (1.95 in) 46 mm (1.7 in) 50.5 mm (1.99 in) 250 SX 250 MXC/EXC 300 MXC/EXC 380 SX 380 MXC/EXC TECHNICAL DATA - ENGINE 250/300/380 SX / MXC EXC 2002 (only USA) TECHNICAL DATA control flap) control upper edge cylinder) (height of the (upper edge piston - Gear 17:27 18:26 17:27 18:26 18:26 18:26 18:26 18:26 GearGear 21:23 23:21 21:20 23:18 21:23 23:21 21:20 23:18 21:23 23:21 21:23 23:21 21:20 23:18 21:23 23:21 Gear 19:25 19:22 19:25 19:22 19:24 19:24 19:22 19:24 Gear 15:29 15:29 15:29 15:29 15:29 15:29 15:29 15:29 vailable chain sprockets st nd rd th th ransmission 3 TVC start open 5000/min 5900/min 5200/min Air-filter Engine DesignPiston displacement / strokeBore FuelOil / gasolin ratioCrankshaft bearing bearing Connecting rod Piston pin bearing PistonPiston ringDimension "X" oil. When in doupt, please contact your importer or use 1:40 mi 1:40 – 1:60 when using high grade two stroke Ignition timing 66.4 / 72 mm (2.62 2.84 in) 249 ccmSpark plug engine with Liquid-cooled single-cylinder two-stroke gap Electrode Dimension "Z" rings one plain compression TVC fully openPrimary drive 72 / 73 mm (2.84 2.88 in)Clutch oil (Shell Advance Racing X) octane no 95, mixed with high-grade two stroke unleaded SUPER fuel, research T 1,9 mm (0,07 in) BTDC cast piston5 297 ccm bearing ball bearing / 1 cylinder roller 1 deep-groove 78 / 77 mm (3 2.98 in) rings two plain compression A 7000/minCoolantIgnition system 1,94 mm (0,08 in) BTDC straight cut spur gears, primary ratio 25:72Generator outputCarburetor piston forged KOKUSAN 2K-1 no generator 2.1 mm (0,09 in) BTDC 368 ccm multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15) 7750/min straight cut spur gears, primary ratio 26:72 KOKUSAN 2K-2 cast piston 12V 40W at least -25 °C (-13 °F) 60% water, 40% anti freeze, 1.3 litres, 7200/min KOKUSAN 2K-3 no generator KOKUSAN 2K-3 12V 110W Gear ratio1 EXC MXC EXC MXC EXC MXC 4 2 Gear lubrication SX Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Carburetor Power jet Performance restrictor Air adjustmentscrew open Slide Needle positionfrom top Jet needle Starting jet Idling jet Main jet Carburetor settingnumber BASIC CARBURETORSETTING lthsrns-lnt Ø2.5new=43mm,minimumlength42mm mm 0.3–0.4 0.06mm(250)(300)0.08(380) Clutch springs-length mm 0.021–0.032 T Connecting rod bearing-radialclearance Piston ringendgap Piston fittingclearance TOLERANCES ANDFITTINGCLEARANCES yidrha aktO-rings 0.5mm 0.5mm asrequired Cylinder-head gasket A Cylinder bottomgasket Clutch cover Crankcase GASKET THICKNESSES te ot 0N (7ft.lb) 10Nm (74ft.lb) 100 Nm (6ft.lb) 8Nm M6 (44ft.lb) (25ft.lb) 60Nm 35Nm M14 (14ft.lb) (25ft.lb) (74ft.lb) Loctite64819Nm 35Nm Loctite243100Nm M6 M18x1.5 M12x1 M6x16 M10 (110ft.lb) Loctite243150Nm Other bolts M18x1.5 M8 Flat headboltrelease platekickstarter Swingarm pivot Crankcase andcoverbolts Nut forinnerclutchhub Nut forprimarysprocket (LHthread) Flywheel collarnut Nuts-cylinder base Flange bolts-cylinder-head TIGHTENING TORQUES-ENGINE ransmission shafts end float 0.1–0.2 mm 0.1–0.2 ransmission shaftsendfloat vailable cylinder bottom gaskets 0.2/0.4/0.5/0.75 mm 0.2/0.4/0.5/0.75 vailable cylinderbottomgaskets Keihin PWK38AG NOZ E(NOZF/D) 170 (168,172) 48 (45,50) 061200 250 SX 1,5 6,5 85 III – – Keihin PWK38AG NOZ E(NOZF) 178 (175,180) 250 MXC,EXC 030201 45 (48) 1,5 6,5 85 IV – – 04 m(33ft.lb) (19ft.lb) 45Nm 25Nm M 10 M 8 Keihin PWK38AG NOZ H(NOZI) 175 (172,178) 300 MXC,EXC 040201 45 (48) 1,5 6,5 85 III – – Keihin PWK38AG 380 SX,MXC,EXC O NZH) NOZ G(NOZ 170 (168,172) 050201 45 (48) 1,5 6,5 85 III – – 9-29C 9-30C hamber 0,8 l engine oil 10W-40 (Advance Ultra 0,8 l engine oil 10W-40 C orque orque T ix ratio to be on the safe side TM K 0,8 l engine oil 20W-40 (Shell Advance VSX4) 0,8 l engine oil 20W-40 " 4 / 1 x 8 ontrol exhaust system and ontrol / 5 C alve V win needle bearing needle bearing KTM T NGK BR 8 ECM 0.6 mm (0.024 in) 5 speed, claw actuated 0 + 0.1 mm (0 0.004 in) wet foam type air filter insert flat-slide carburetor, carburetor setting see table carburetor flat-slide carburetor, 0,8 l engine oil 10W-40 (Shell Advance Ultra 4) 0,8 l engine oil 10W-40 49,5 mm (1.94 in) 46 mm (1.7 in) 50.5 mm (1.99 in) 250 SX 250 EXC 300 EXC 380 SX 380 EXC 0,8 l engine oil 20W-40 (Shell Advance VSX4) 0,8 l engine oil 20W-40 TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2002 (all models out of USA) TECHNICAL DATA control flap) control (height of the upper edge cylinder) (upper edge piston - Gear 17:27 18:26 18:26 18:26 GearGear 21:23 23:21 21:20 23:18 21:23 23:21 21:20 23:18 Gear 19.25 19:22 19:24 19:22 Gear 15:29 15:29 15:29 15:29 st nd rd th th ransmission 3 TVC start open 5000/minAir-filter 5900/min 5200/min Engine DesignPiston displacement / strokeBore FuelOil / gasoline ratioCrankshaft bearing bearing Connecting rod Piston pin bearing PistonPiston ringDimension "X" oil. When in doupt, please contact your importer or use 1:40 m 1:40 – 1:60 when using high grade two stroke Ignition timing 66.4 / 72 mm (2.62 2.84 in) 249 ccmSpark plug engine with Liquid-cooled single-cylinder two-stroke gap Electrode Dimension "Z" ring one plain compression TVC fully openPrimary drive 72 / 73 mm (2.84 2.88 in)Clutch oil (Shell Advance Racing X) octane no 95, mixed with high-grade two stroke unleaded SUPER fuel, research T 1,9 mm (0,07 in) BTDC cast piston5 297 ccm bearing ball bearing / 1 cylinder roller 1 deep-groove 78 / 77 mm (3 2.98 in) 4) ailable chain sprockets rings two plain compression 7000/minCoolantIgnition system 1,94 mm (0.075 in) BTDC straight cut spur gears, primary ratio 25:72Generator outputCarburetor piston forged KOKUSAN 2K-1 no generator 2.1 mm (0.08 in) BTDC 368 ccm multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15) 7750/min straight cut spur gears, primary ratio 26:72 KOKUSAN 2K-3 cast piston 12V 110W 13t / 14t 15t for chain at least -25 °C (-13 °F) 60% water, 40% anti freeze, 1.3 litres, 7200/min KOKUSAN 2K-3 no generator KOKUSAN 2K-3 12V 110W Gear ratio 1 4 2 Gear lubrication Repair manual KTM 250 / 300 / 380 Art No 3206004 -E te ot 0N (7ft.lb) 10Nm (74ft.lb) 100 Nm (6ft.lb) M6 8Nm (44ft.lb) (25ft.lb) 60Nm 35Nm M14 (25ft.lb) 35Nm (74ft.lb) (14ft.lb) Loctite243100Nm Loctite64819Nm M6 M18x1.5 M12x1 M10 M6x16 (110ft.lb) Loctite243150Nm Other bolts Flat headboltrelease platekickstarter M8 M18x1.5 Swingarm pivot Crankcase andcoverbolts Nut forinnerclutchhub Nut forprimarysprocket (LHthread) Flywheel collarnut Nuts-cylinder base Flange bolts-cylinder-head TIGHTENING TORQUES yidrha aktO-rings 0.5mm 0.5mm asrequired Cylinder-head gasket A Cylinder bottomgasket Ø2.5new=43mm,minimumlength42mm Clutch cover Crankcase mm 0.3–0.4 GASKET THICKNESSES 0.06mm(250)(300)0.08(380) Clutch springs-length T Connecting rod bearing-radialclearance Piston ringendgap Piston fittingclearance TOLERANCES ANDFITTINGCLEARANCES ransmission shafts end float 0.1–0.2 mm 0.1–0.2 ransmission shaftsendfloat vailable cylinder bottom gaskets 0.2/0.4/0.5/0.75 mm 0.2/0.4/0.5/0.75 vailable cylinderbottomgaskets Power jet Performance restrictor Air adjustmentscrew open Slide Needle positionfrom top Jet needle Starting jet Idling jet Main jet Carburetor settingnumber Carburetor Power jet Performance restrictor Air adjustmentscrew open Slide Needle positionfrom top Jet needle Starting jet Idling jet Main jet Carburetor settingnumber Carburetor BASIC CARBURETORSETTING BASIC CARBURETORSETTING Keihin PWK38AG NOZ E(NOZF/D) Keihin PWK38AG 170 (168,172) O NZF) E (NOZ NOZ 178 (175,180) 48 (45,50) 5 X USA 250 EXC 061200 250 SX 030201 45 (48) 1,5 6,5 85 III 1,5 6,5 – – 85 IV – – 0.021–0.032 mm 0.021–0.032 Keihin PWK38AG 04 m(33ft.lb) 45Nm M 10 Keihin PWK38AG 5N (19ft.lb) 25Nm M 8 O NZH) NOZ G(NOZ O NZH) (NOZ G NOZ slide stop36mm 170 (168,172) 170 (172,168) 300 EXCAUS 380 SXUSA 050201 throttled 45 (48) 070201 45 (48) 380 SX 1,5 6,5 1,5 6,5 85 85 II – – II – R 1475J(NOZE/H) Keihin PWK38AG Keihin PWK38AG 175 (172,178,180) slide stop34mm O NZI) H(NOZ NOZ 175 (178,172) 300 MXC/EXC 250/300 EXC 35 (45/48) throttled 061200 040201 45 (48) USA 1,5 6,5 1,5 6,5 85 85 III III – – – 9-31C 9-32C

TECHNICAL SPECIFICATIONS CHASSIS 250/300/380 SX, MXC, EXC 2002

250/380 SX 250/300/380 MXC 250/300/380 EXC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 48 MA White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm (11,3/12,6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated Brake discs Wear limit max. 0,4 mm (0,016 in) Front tires 80/100 - 21“51M – 90/90 - 21“ 54R Front tires USA 80/100 - 21“51M 80/100 - 21“51M 80/100 - 21“51M Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi) Air pressure road driver only – 1,5 bar (21psi) 1,5 bar (21psi) Rear tires 100/90 - 19“ 62M – 140/80 - 18“ 70R Rear tires USA 100/90 - 19“ 62M 100/100 - 18“ 64M 100/100 - 18“ 64M Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi) Air pressure road driver only – 2,0 bar (28psi) 2,0 bar (28psi) Fuel tank capacity 7,5 liter (2 US Gallons) 11 liter (2,9 US Gallons) 8,5/11 liter (2,2/2,9 US Gallons) Final drive ratio 14:50t – 15:48t / 14:50t Final drive ratio USA 14:50t 14:52t 14:52t Chain 5/8 x 1/4 " Available final sprockets 38t, 40t, 42t, 45t, 48t, 50t, 52t Steering head angle 63,5° Wheel base 1481 ± 10 mm (58,3 ± 0,4 in) Seat height, unloaded 925 mm (36,5 in) Ground clearance, unloaded 385 mm (15,2 in) Dead-weight * 101 kg (223 lbs) – 109 kg (240,6 lbs) Dead-weight USA * 101 kg (223 lbs) 102,5 kg (226,3 lbs) 103,7 kg (229 lbs)

* Dead-weight without fuel

STANDARD ADJUSTMENT-FORK TIGHENING TORQUES - CHASSIS WP 1418W709 WP 0518W711 Collar nut front wheel spindle M 16/20x1,5 40 Nm (30 ft.lb) Compression adjuster 20 20 Brake caliper front M 8 25 Nm (19 ft.lb) Rebound adjuster 16 12 + Loctite 243 Spring 4,2 N/mm 4,0 N/mm Clamping bolts upper fork bridge M 8 20 Nm (15 ft.lb) Spring preload 5 mm (0.20in) 5 mm (0.20in) Clamping bolts lower fork bridge M 8 15 Nm (11 ft.lb) Air chamber length 100 mm (4,0 in) 140 mm (5.9in) Clamping bolts fork stubs M8 10 Nm (7 ft.lb) Fork oil SAE 5 SAE 5 Collar nut rear wheel spindle M 20x1.5 80 Nm (59 ft.lb) Hexagon nut swing arm bolt M 14x1.5 100 Nm (74 ft.lb) Collar bolt handlebar clamp M 8 20 Nm (15 ft.lb) STANDARD ADJUSTMENT - SHOCK ABSORBER Allen head bolt handlebar support M 10 40 Nm (30 ft.lb) + Loctite 243 WP 1218V736 WP 1218V737 Shock absorber top M 12 60 Nm (44 ft.lb) Compression adjuster 15 LS (low speed) 15 Shock absorber bottom M 12 60 Nm (44 ft.lb) 2 HS (high speed) Screw adjusting ring spring preload M 6 8 Nm (6 ft.lb) Rebound adjuster 25 25 Other bolts on chassis M 6 10 Nm (7 ft.lb) Spring PDS7–260 PDS6–260 M 8 25 Nm (19 ft.lb) Spring preload 4 mm (0.16 in) 5 mm (0.19 in) M 10 45 Nm (33 ft.lb) Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTINGKTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG

3000 m LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 10000 ft LD IJ 48 45 45 42 42 40 NADEL NEEDLE NOZE NOZE NOZF NOZG NOZH NOZI 2301 m POS POS 332211 7501 ft HD MJ 170 168 165 162 160 158 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 7500 ft LD IJ 48 48 45 45 42 42 NADEL NEEDLE NOZD NOZE NOZE NOZF NOZG NOZH 1501 m POS POS 332221 5001 ft HD MJ 172 170 168 165 162 160 1500 m LSCHR AS 11 1/4 1 1/2 1 3/4 2 2 1/4 5000 ft LD IJ 50 48 48 45 45 42 NADEL NEEDLE NOZD NOZD NOZE NOZE NOZF NOZG 751 m POS POS 433222 2501 ft HD MJ 175 172 170 168 165 162 750 m LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 2500 ft LD IJ 50 50 48 48 45 45 NADEL NEEDLE NOZC NOZD NOZD NOZE NOZE NOZF 301 m POS POS 443332 1001 ft HD MJ 178 175 172 170 168 165 300 m LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 52 50 50 48 48 45 NADEL NEEDLE NOZC NOZC NOZD NOZD NOZE NOZE Meeresniveau POS POS 543332 Sea level HD MJ 180 178 175 172 170 168 LSCHR = Luftregulierschraube offen AS = Air screw open from fully-seated LD = Leerlaufdüse 1. IJ = Idling jet NICHT FÜR STRASSENBETRIEB POS = Clip Position von oben 2. POS = Clip position from top Kraftstoff: Euro-Super bleifrei ROZ 95 9-33C HD = Hauptdüse 3. MJ = Main jet 4. NOT FOR HIGHWAY USE Schieber= 6,5 5. Slide = 6,5 Zerstäuber= 5 mm Atomizer= 5 mm Fuel: Euro-Super unleaded ROZ 95 9-34C AG NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 1/2 1 1/4 1 1/2 1 3/4 ASIJ = Air screw open from fully-seated POS = = Clip position from top MJ Idling jet Slide = = Main jet 6,5 Atomizer= 5 mm 2. 4. 332222 433322 11 1/41 1/41 544332 11 554332 332221 45 45 42 42 40 40 4848 45 48 45 45 45 45 42 45 42 42 50 48 48 45 45 45 45 45 45 42 42 40 180182 178 180 175 178 172 175 170 172 168 170 185188 182 185 180 182 178 180 175 178 172 175 178 175 172 170 168 165 1 3/4 1 3/4 1 3/4 2 2 1/2 1 3/4 1 1/41 1/4 1 1/2 1 1/4 1 1/2 1 1/4 1 3/4 1 1/2 1 3/4 1 3/4 2 1 3/4 1 1/4 1 1/2 1 3/4 1 3/4 2 2 NOZE NOZF NOZG NOZH NOZI NOZI NOZC NOZDNOZC NOZD NOZC NOZE NOZD NOZD NOZF NOZE NOZG NOZF NOZD NOZENOZD NOZD NOZF NOZE NOZG NOZH NOZF NOZG NOZI NOZH 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ AS IJ IJ POS MJ AS POS MJ AS NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE POS MJ AS IJ POS MJ IJ MJ AS POS KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 TEMPERATUR LD NADEL LSCHR LD NADEL LD NADEL POS HD LSCHR POS HD LSCHR NADEL POS HD LSCHR LD POS HD LD NADEL HD LSCHR POS 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOSHD = = Leerlaufdüse Clip Position von oben Schieber= 6,5 Zerstäuber= 5 mm = Hauptdüse Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

VERGASERREGULIERUNG CARBURETOR SETTINGKTM 300 MXC/EXC EUR/USA 2002 KEIHINAG PWK 38

3000 m LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 10000 ft LD IJ 45 45 42 42 40 40 NADEL NEEDLE NOZH NOZH NOZI NOZI NOZJ NOZJ 2301 m POS POS 332221 7501 ft HD MJ 175 172 170 168 165 162 2300 m LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 7500 ft LD IJ 45 45 45 42 42 40 NADEL NEEDLE NOZH NOZH NOZH NOZI NOZI NOZJ 1501 m POS POS 332221 5001 ft HD MJ 178 175 172 170 168 165 1500 m LSCHR AS 11 1/4 1 1/2 1 3/4 2 2 1/4 5000 ft LD IJ 48 45 45 45 42 42 NADEL NEEDLE NOZG NOZH NOZH NOZH NOZI NOZI 751 m POS POS 433322 2501 ft HD MJ 180 178 175 172 170 168 750 m LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2 2500 ft LD IJ 48 48 45 45 45 42 NADEL NEEDLE NOZG NOZG NOZH NOZH NOZH NOZI 301 m POS POS 544332 1001 ft HD MJ 182 180 178 175 172 170 300 m LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4 1000 ft LD IJ 50 48 48 45 45 45 NADEL NEEDLE NOZF NOZG NOZG NOZH NOZH NOZH Meeresniveau POS POS 554332 Sea level HD MJ 185 182 180 178 175 172 LSCHR = Luftregulierschraube offen AS = Air screw open from fully-seated LD = Leerlaufdüse 1. IJ = Idling jet NICHT FÜR STRASSENBETRIEB

POS = Clip Position von oben 2. POS = Clip position from top Kraftstoff: Euro-Super bleifrei ROZ 95 9-35C 3. MJ = Main jet HD = Hauptdüse 4. NOT FOR HIGHWAY USE Schieber= 6,5 5. Slide = 6,5 Zerstäuber= 5 mm Atomizer= 5 mm Fuel: Euro-Super unleaded ROZ 95 9-36C PWK 38 AG KEIHIN NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 1/4 1 1/2 1 3/4 2 2 1/4 ASIJ = Air screw open from fully-seated POS = = position from top Clip MJ Idling jet Slide = = Main jet 6,5 Atomizer= 5 mm 2. 4. 332221 332222 11 433322 544322 554332 4850 48 48 45 48 45 45 45 45 42 45 4548 45 45 45 45 42 45 42 42 40 42 45 45 42 42 40 40 3/41/2 1 3/4 1 1/4 1 1 1/2 1 3/4 1 1/4 1 1/2 2 1 3/4 170172 168 170 165 168 162 165 160 162 158 160 175178 172180 175 170 178 172 168 175 170 165 172 168 162 170 165 168 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 NOZF NOZGNOZF NOZGNOZE NOZF NOZH NOZG NOZF NOZH NOZG NOZF NOZI NOZH NOZG NOZH NOGH NOZH NOZG NOZHNOZG NOZH NOZG NOZH NOZI NOZH NOZI NOZI NOZI NOZI 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ IJ POS MJ AS POS MJ AS IJ AS IJ NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE MJ AS MJ AS MJ POS POS POS KTM 380 SX / MXC EXC EUR USA 2002 TEMPERATUR LD NADEL LD NADEL LD NADEL NADEL POS HD LSCHR POS HD LSCHR LD LSCHR LD NADEL HD LSCHR HD LSCHR HD POS POS POS 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOSHD = = Leerlaufdüse Clip Position von oben Schieber= 6,5 Zerstäuber =5 mm = Hauptdüse 9-37C hamber C orque orque T TM mix ratio to be on the safe side 297 ccm K 7750/min 5900/min forged piston forged " 4 / 1 x 8 ontrol exhaust system and ontrol / 5 C alve V win 0,60 mm 12V 40W 12V 110W NGK BR 7 ES needle bearing needle bearing KTM T KOKUSAN 2K-2 KOKUSAN 2K-3 5 speed, claw actuated 0,8 l engine oil 10W-40 0 + 0,1 mm (0 0.004 in) two plain compression rings two plain compression wet foam type air filter insert straight cut spur gears, primary ratio 25:72 Art No 3206004 -E flat-slide carburetor, carburetor setting see table carburetor flat-slide carburetor, 250 MXC/EXC 300 MXC/EXC 49,5 mm (0.024 in) 46 mm (1.7 in) TECHNICAL DATA - ENGINE 250/300 MXC / EXC 2003 TECHNICAL DATA Repair manual KTM 250 / 300 380 control flap) control upper edge cylinder) (height of the (upper edge piston - gear 18:26 17:27 18:26 18:26 geargear 21:20 23:18 21:23 23:21 21:20 23:18 21:23 23:21 gear 19:22 19:25 19:22 19:24 gear 15:29 15:29 15:29 15:29 st nd rd th th ransmission 3 Gear ratio1 EXC MXC EXC MXC Engine DesginPiston displacement / strokeBore FuelOil / gasolino ratioCrankshaft bearing bearing Connecting rod Piston pin bearing PistonPiston ring Dimension “X“ oil. When in dout, please contact your importer or use 1:40 1:40 – 1:60 when using high grade, two- stroke Ingition timingSpark plug engine with Liquid-cooled single-cylinder two-stroke gap Electrode 66,4 / 72 mm (2.62 2.84 in) 249 ccm Dimension “Z“ TVC fully openPrimary drive ClutchT oil octane no 95, mixed with high-grade, two- stroke unleaded SUPER fuel, research 5 bearing ball bearing / 1 cylinder roller 1 deep-groove 1,9 mm vor OT Gear lubrication cast piston ailable chain sprocketsCoolantIgnition system Generator output Ignition system USA (MXC) 7000/min Generator output 72 / 73 mm (2.84 2.88 in) Carburetor filter Air- multiple disc clutch in oil bath, hydraulically operated (Shell HF-E15 1,94 mm vor OT 13Z / 14Z 15Z for chain at least -25 °C (-13 °F) 60% water, 1.3 liters, 40% antifreeze, TVC start open4 5000/min 2 9-38C 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) Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm (14 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) Other screws 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 / 300) 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 minimum length = 42 mm, new = 43 mm Crankshaft webs – outer dimension 60 mm ± 0,05 mm Runout Crankshaft journal Crankshaft max 0,06 (neu 0,03)

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

250/300 EXC 250 EXC USA 300 EXC AUS 300 MXC / EXC throttled throttled USA

Carburetor Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 120202 140202 130202 150202 Main jet 175 (182,185) 182 (185) 175 (172,178) 175 (172,178) Idling jet 35 (48) 48 35 (45,48) 45 (48) Starting jet 85 85 85 85 Jet needle R 1475 J N3CH (N3CW) R1475J (NOZ H/NOZ NOZ H (NOZ I) Needle position from top (N3CH/N3CW) IV I) III Slide III 6.5 II 6.5 Air adjustment screw open 6.5 1.5 6.5 1.5 Performance restrictor 1.5 – 1.5 – Power jet nozzle slide stop 34mm – slide stop 34mm – 9-39C

TECHNICAL SPECIFICATIONS CHASSIS 250/300 MXC, EXC 2003

250/300 MXC 250/300 EXC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated Brake discs Wear limit max. 0,4 mm (0,016 in) Front tires – 90/90 - 21“ 54R Front tires USA 80/100 - 21“51M 80/100 - 21“51M Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) Air pressure road driver only 1,5 bar (21psi) 1,5 bar (21psi) Rear tires – 140/80 - 18“ 70R Rear tires USA 100/100 - 18“ 64M 100/100 - 18“ 64M Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) Air pressure road driver only 2,0 bar (28psi) 2,0 bar (28psi) Fuel tank capacity 11 liter (2,9 US Gallons) 9/11 liter (2,3/2,9 US Gallons) Final drive ratio – 15:48t / 14:50t Final drive ratio USA 14:52t 14:52t Chain 5/8 x 1/4 " Available final sprockets 38t, 40t, 42t, 45t, 48t, 50t, 52t Bulbs headlight HS1 12V 35/35W parking light 12V 5W (base W2, 1x9,5d) instrument light 12V 1,2W (base W2, 1x4,6d) brake- rear light 12V 21/5W (base BaY15d) flasher light 12V 10W (basel Ba15s) license plate illumination 12V 1,2W (base 1x4,6d) Steering head angle 63,5° Wheel base 1481 ± 10 mm (58,3 ± 0,4 in) Seat height, unloaded 925 mm (36,5 in)

Art No 3206004 -E Ground clearance, unloaded 385 mm (15,2 in)

STANDARD ADJUSTMENT-FORK STANDARD ADJUSTMENT - SHOCK ABSORBER WP 4860 MXMA WP 5018-MCC 1418X736 1218X759 Compression adjuster 20 Compression adjuster 17 Rebound adjuster 20 Rebound adjuster 26 Spring 4,0 N/mm Spring 71-90/260 Spring preload 5 mm (0.20in) Spring preload 7 mm (0.27 in) Air chamber length 110 mm (4,3 in) Fork oil SAE 5 Repair manual KTM 250 / 300 380 9-40C

TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle M 24x1,5 40 Nm Brake caliper, front M 8 Loctite 243 + 25 Nm Brake disk, front M 6 10.9 Loctite 243 + 15 Nm Brake disk, rear M 6 Loctite 243 + 15 Nm Clamping screws, upper fork bridge M 8 20 Nm Clamping screws, lower fork bridge M 8 15 Nm Clamping screws, fork stubs M 8 10 Nm Collar nut, rear wheel spindle M 20x1,5 80 Nm Hexagon nut, swing arm bolt M 14x1,5 100 Nm Hexagon collar screw, handlebar clamp M 8 20 Nm Allan head screw, handlebar support M 10 Loctite 243 + 40 Nm Shock absorber, top M 12 60 Nm Shock absorber, bottom M 12 60 Nm Sprocket screws M 8 Loctite 243 + 35 Nm Ball joint for push rod M 6 Loctite 243 + 10 Nm Engine mounting bolt M 10 45 Nm Engine brace M 8 33 Nm Screw adjusting ring spring preload shock abs. M6 8 Nm Spoke nipple M4,5 /M5 5 Nm Other screws on chassis M 6 10 Nm M 8 25 Nm M 10 45 Nm Other collar nuts on chassis M 6 15 Nm M 8 30 Nm M 10 50 Nm 9-41C AG 1,5 NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 11 111 1,5 1,5 1,5 2 Art No 3206004 -E ASIJ = Air screw open from fully-seated POS = = Clip position from top MJ Idling jet Slide = = Main jet 6,5 Atomizer= 5 mm 2. 4. 11 433332 1 443333 1 1444333 1 1 1,5544433 1 554443 1 1,5 1,5 1,5 1,5 4848 4848 48 48 48 48 45 48 48 45 48 45 45 48 45 45 5052 48 50 48 48 48 48 48 48 48 48 3/4 1 1 182185 182188 182 180188 185 182 178190 188 182 180 175 188 185 182 178 172 188 182 180 175 185 182 178 182 180 182 N3CHN2CH N3CHN3CG N3CH N3CH N3CWN3CG N3CH N3CH N3CW N3CGN3CG N3CH N3CH N3CW N3CW N3CH N3CG N3CH N3CW N3CH N3CG N3CH N3CW N3CH N3CH N3CH N3CH N3CH 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ POS MJ AS IJ POS MJ AS IJ POS MJ AS POS MJ AS POS MJ AS NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE IJ IJ KTM 250 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 TEMPERATUR NADEL NADEL NADEL LD POS HD LSCHR LD POS HD LSCHR LD POS HD LSCHR POS HD LSCHR POS HD LSCHR NADEL NADEL LD LD Repair manual KTM 250 / 300 380 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOSHD = = Leerlaufdüse Clip Position von oben Schieber= 6,5 Zerstäuber= 5 mm = Hauptdüse 9-42C AG NICHT FÜR STRASSENBETRIEB ROZ 95 bleifrei Euro-Super Kraftstoff: NOT FOR HIGHWAY USE Fuel: Euro-Super unleaded ROZ 95 1/2 1 3/4 2 2 1/4

ASIJ = Air screw open from fully-seated POS = = position from top Clip MJ Idling jet Slide = = Main jet 6,5 Atomizer= 5 mm 2. 4. 332221 1/41 332221 11 433322 544332 554332 48 45 45 45 42 42 45 4548 4550 48 42 48 45 42 48 45 40 45 45 45 42 45 45 45 42 42 40 40 3/41/2 1 3/4 1 1/4 1 1 1/2 1 3/4 1 1/4 1 1/2 2 1 3/4 175178 172180 175 170182 178 172 168 180 175 170 165 178 172 168 162 175 170 165 172 168 170 185 182 180 178 175 172 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 NOZF NOZG NOZG NOZH NOZH NOZH NOZH NOZHNOZH NOZH NOZINOZG NOZH NOZHNOZG NOZI NOZH NOZI NOZG NOZJ NOZH NOZH NOZI NOZJ NOZH NOZI NOZJ NOZH NOZI NOZI 1. 3. 5. -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C IJ IJ IJ IJ POS MJ AS POS MJ AS POS MJ AS POS MJ AS IJ AS NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE MJ POS KTM 300 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 TEMPERATUR NADEL LD LD NADEL LD NADEL LD NADEL POS HD LSCHR POS HD LSCHR POS HD LSCHR POS HD LSCHR LD NADEL LSCHR HD POS 751 m 750 m 301 m 300 m 7501 ft 7500 ft 5001 ft 5000 ft 2501 ft 2500 ft 1001 ft 1000 ft 3000 m 2301 m 2300 m 1501 m 1500 m 10000 ft Sea level ALTIDUDE Meeresniveau MEERESHÖHE VERGASERREGULIERUNG CARBURETOR SETTING LSCHR = offen Luftregulierschraube LDPOSHD = = Leerlaufdüse Clip Position von oben Schieber= 6,5 Zerstäuber= 5 mm = Hauptdüse Repair manual 250 / 300 / 380 Art No 3206004 -E LUBRICATION ANDMAINTENANCESCHEDULE URCTO N ANEAC CEUE 5 0 ..10-6 LUBRICATION ANDMAINTENANCESCHEDULE250-300 MODEL 2003 ..10-4 LUBRICATION ANDMAINTENANCESCHEDULE250-380 MODEL 2001/2002 ..10-3 LUBRICATION ANDMAINTENANCESCHEDULE250-380 MODEL 2000 ..10-2 LUBRICATION ANDMAINTENANCESCHEDULE250-380 MODEL 1999 INDEX 10-1C 10

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Clean andlubricate control leverpivotpoints Check allbolts, nuts,screws andclampsfor proper tightness Apply contactspraytolightswitches, flasherswitchesandignitionlock Check adjustmentofheadlight Check batteryholderandconnections (CH,Singapore) Check electricalsystem Adjust andoilcontrol cables Check cablesfordamageandfree movement Check tires forcutsandairpressure Check wheelbearings Check forevenspoketensionandrimalignment Grease swingarmneedlebearings Service shockabsorbercompletely Check settinganddampingofshockabsorber Clean andregrease steeringheadbearing Check steeringheadbearingfree play Service telescopicforkcompletely Change oiloftelescopicfork Undo thebleederscrews attheforklegs Clean thedustscrabbersoftelescopicforce Push uptheprotective bellowsandremove thedirt;drainholesmustbefree ofobstructions Check telescopicforkforleaks Check telescopicforkaction Change theoilofhydraulicclutch Check theoillevelinmastercylinderofhydraulicclutch Check free travelandfree movabilityofhandbrakeleverandfoot Inspect conditionandinstallationoffront andrear brakehoses Check brakediscs Check thicknessofdiscbrakepads Change brakefluid Check brakefluidlevelfront andrear Check oftheexhaustsuspensionsystem Replace glassfiberyarnofsilencer Check exhaustsystemforcracksandleaks Check coolingsystemforleaks-visualinspection Check qualityofantifreeze Check coolantlevel Check chaintension Clean andoilchain Check chain,sprockets, guidesandchainwear Clean andcheckairfilterelement,boxcarburetor connectionboot Check breather hosesofenginecaseandgastankforcorrect positionwithoutbuckles Adjust idling Drain andcleancarburetor floatchamber Check intakemanifoldforleaksandcracks Functional testingoftheexhaustcontrol system Change sparkplug Check sparkplugandelectrode gap Change transmissionoil Check transmissionoillevel PERIODIC LUBRICATION ANDMAINTENANCESCHEDULE AT

A REGULARCOMPETITIONUSEOFTHEBIKE,4000KM(2500MILES) SERVICE ISTOBEDONEAFTEREVERY RACE (don’t grease thepivotbearingforshockabsorber) 125-380 6.98 ●●● ●●● ●● ●● ●● ●●● ●● ●● ●●● ●●● ●● ●●● ●●● ●●● ●●● ●● ●●● ●● ● KTM before each start rider ●●●● ●● ● ●● ●●● ●●●●● ●●●● after washing ●● ●● ●●● ● 1st service after 1000 km (600 miles) or 10 hours

●● ●●● after 2000 km dealer (1250 miles) or 20 hours KTM

after 4000 km ● ● ●● ● ● ● ● ● ● ●

(2500 miles) or once a year 10-2C ● ● ● ● ● ● ● ● at least once a year

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E PERIODIC LUBRICATION ANDMAINTENANCESCHEDULE Grease swingarmneedlebearings Service shockabsorbercompletely Check settinganddampingofshockabsorber Clean andregrease steeringheadbearing Check steeringheadbearingfree play Service telescopicforkcompletely Change oiloftelescopicfork Undo thebleederscrews attheforklegs Clean thedustscrabbersoftelescopicforce Check telescopicforkforleaks Check telescopicforkaction Change theoilofhydraulicclutch Check theoillevelinmastercylinderofhydraulicclutch Check free travelandfree movabilityofhandbrakeleverandfoot Inspect conditionandinstallationoffront andrear brakehoses Check brakedisksforwearandwobbling Check thicknessofdiscbrakepads Change brakefluid Check brakefluidlevelfront andrear Check oftheexhaustsuspensionsystem Replace glassfiberyarnofsilencer Check exhaustsystemforcracksandleaks Check coolingsystemforleaks-visualinspection Check qualityofantifreeze Check coolantlevel Check chaintension Clean andoilchain Check chain,sprockets, guidesandchainwear Clean andcheckairfilterelement,boxcarburetor connectionboot Check breather hosesofenginecaseandgastankforcorrect positionwithoutbuckles Adjust idling Drain andcleancarburetor floatchamber Check intakemanifoldforleaksandcracks Functional testingoftheexhaustcontrol system Change sparkplug Check sparkplugandelectrode gap Change transmissionoil Check transmissionoillevel Clean andlubricate control leverpivotpoints Check allbolts, nuts,screws andclampsfor proper tightness Apply contactspraytolightswitches, flasherswitchesandemergency off switch Check adjustmentofheadlight Check electricalsystem Adjust andoilcontrol cables Check cablesfordamageand free movement Check tires forcutsandairpressure Check wheelbearings Check forevenspoketensionandrimalignment AT

A REGULARCOMPETITIONUSEOFTHEBIKE,4000KM(2500MILES) SERVICE ISTOBEDONEAFTEREVERY RACE (dont grease thepivotbearingforshockabsorber) 125-380 6.99 ●● ●● ●●● ●●● ●● ●●● ●● ●●● ●●● ●●● ●● ●●● ●● ● ●●● ●●● ●● ●● ●● ●●● KTM before each start rider ●●● ●●●●● ●●●● ●● ● ●● after washing ●● ●● ●●● ● 1st service after 1000 km (600 miles) or 10 hours

●● ●●● after 2000 km dealer (1250 miles) or 20 hours KTM

after 4000 km ●● ● ● ● ●● ● ● ●

(2500 miles) or once a year 10-3C ● ● ● ● ● ● ● ● at least once a year 10-4C

PERIODIC MAINTENANCE SCHEDULE 2001/02 250/300/380 SX/MXC/EXC 1. service after after after 10 hours 4000 kilometer A washed motorcycle can be checked more quickly which saves money! 20 hours or or or 1000 kilometer 2000 kilometer once a year Check gear box oil level ● Change gear box oil ●● Check spark plugs, adjust distance between electrodes ●● ENGINE Renew spark plugs ● Check the carburettor connection boot for cracks and leaks ● Check idle speed setting ●● ●● CARBURETOR Check that vent hoses are not damaged or bent Check cooling system for leaks, check quantity of anti freeze ●● Check exhaust system for leaks and fitment ● Check cables for damage, smooth operation, bends; adjust and lubricate ●● Check oil level of the clutch master cylinder ●●● Clean air filter and filter box ● Check electric wires for damage and bends ● Check headlamp setting ● Check function of electric systems (low-, high beam, break light, indicator, ●● indicator lamps, speedometer illumination, horn, emergency OFF switch or button Check brake fluid level, lining thickness, break lining ●● Check brake lines for damage and leaks ●● Check/adjust smooth operation and free travel of handbrake/foot brake lever ●● Check tightness of brake system screws ●● Check shock absorber and fork for leaks and function ●● Clean fork dust bellows ● Bleed fork legs ● Check swing arm bearings ● Check/adjust steering head bearings ●● Check tightness of all chassis screws (triple clamps, fork leg axle passage ●● axle nuts and screws, swing arm bearings, shock absorber) Check spoke tension and rim joint ● Check tyres and air pressure ●● Check chain, rear sprockets and chain guides for wear, fitment and tension ●● Lubricate chain ●● WHEELS CHASSIS BRAKES ADD-ON-PARTS Check clearance of wheel bearings ●●

IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least every 2 years once a year or 20000 km Check function of exhaust control ● Complete maintenance of shock absorber ● Complete maintenance of fork ● Clean and grease steering head bearings and gasket elements ● Clean and adjust carburetor ● Replace glass fibre yarn filling of the exhaust main silencer ● Treat electric contacts and switches with contact grease ● Change hydraulic clutch fluid ● Change break fluid ●

IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 5 HOURS OR 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! Repair manual KTM 250 / 300 / 380 Art No 3206004 -E Check tightnessofscrews, nutsandhoseclampsregular Tr with wax-basedanticorrosion agent Tr Check brakeperformance Check allcontrol elementsforsmoothoperation Drain andcleanfloatchamber Check fuellinesforleaks Check coolingliquidlevel Check tires forpressure andwear Clean airfilterandbox Clean andlubricatechain,checktensionadjustifnecessary Remove andcleanforkdustbellowsregulary Bleed forklegsregulary Lubricate andadjustcablesnipples Check hornforfunction Check lightsforfunction Check brakepadsforwear Check brakefluidlevel Check gearboxoillevel eat ignitionandsteeringlockslightswitcheswithcontactspray eat blankmetalparts(withtheexceptionofbrakeandexhaustsystems) I MPORTANT C EK AND HECKS M ITNNET BE TO AINTENANCE C RIDOTB THE BY OUT ARRIED

●● ● ● ● ● ● ● ● ● ● Before each start

● ● ● ●● ● After every cleaning

● ● ● For cross-

country use R IDER 10-5C

● Once a year 10-6C

PERIODIC MAINTENANCE SCHEDULE 2003 250/300 MXC/EXC 1st service after after after 10 hours 4000 kilometer A clean motorcycle can be checked more quickly which saves money! 20 hours or or or 1000 kilometers 2000 kilometers once a year Check gear box oil level ● Change gear box oil ●● Check spark plugs, adjust distance between electrodes ●● ENGINE Renew spark plugs ● Check the carburetor connection boot for cracks and leaks ● Check idle speed setting ●● ●● CARBURETOR Check that vent hoses are not damaged or bent Check cooling system for leaks, check quantity of antifreeze ●● Check exhaust system for leaks and fitment ● Check cables for damage, smooth operation, bends; adjust and lubricate ●● Check oil level of the clutch master cylinder ●●● Clean air filter and filter box ● Check electric wires for damage and bends ● Check headlamp setting ● Check function of electric systems (low beam, high beam, break light, indicator, ●● indicator lamps, speedometer illumination, horn, emergency OFF switch or button Check brake fluid level, lining thickness, brake lining ●● Check brake lines for damage and leaks ●● Check/adjust smooth operation and free travel of handbrake/foot brake lever ●● Check tightness of brake system screws ●● Check shock absorber and fork for leaks and function ●● Clean dust bellows ● Bleed fork legs ● Check swing arm bearings ● Check/adjust steering head bearings ●● Check tightness of all chassis screws (triple clamps, fork leg axle passage ●● axle nuts and screws, swing arm bearings, shock absorber) Check spoke tension and rim joint ● Check tires and air pressure ●● Check chain, rear sprockets and chain guides for wear, fitment and tension ●● Lubricate chain ●● WHEELS CHASSIS BRAKES ADD-ON-PARTS Check clearance of wheel bearings ●●

IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least every 2 years once a year or 20000 km Check function of exhaust control ● Complete maintenance of shock absorber ● Complete maintenance of fork ● Clean and grease steering head bearings and gasket elements ● Clean and adjust carburetor ● Replace glass fibre- yarn filling of the exhaust main silencer ● Treat electric contacts and switches with contact grease ● Change hydraulic clutch fluid ● Change break fluid ●

IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER! 10-7C

IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER After every cleaning For cross- country use Once a year Before each Before start Check gear box oil level ● Check brake fluid level ● Check brake pads for wear ● Check lights for function ● Check horn for function ● Lubricate and adjust cables and nipples ● Bleed fork legs regulary ● Remove and clean dust bellows regularly ● Clean and lubricate chain, check tension and adjust if necessary ●● Clean air filter and filter box ● Check tires for pressure and wear ● Check cooling liquid level ● Check fuel lines for leaks ● Empty and clean float chamber ● Check all control elements for smooth operation ● Check brake performance ●● Treat blank metal parts (with the exception of brake and exhaust systems) ● with wax-based anti corrosion agent Treat ignition and steering locks and light switches with contact spray ● Check tightness of screws, nuts and hose clamps regularly ● Art No 3206004 -E Repair manual KTM 250 / 300 380 10-8C

RECOMMENDED INSPECTION OF THE 250/300 EXC AND MXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) 30 45 60 90 120 135 hours hours hours hours hours hours Check the reed-type intake valve for wear ●●●●●● Check the clutch shoes for wear ●●●●●● Check the length of the clutch springs ●●●●●● Check the cylinder and piston for wear ●●●●●● Check the exhaust control for proper functioning and smooth running ●●●●●● Check the eccentricity of the crankshaft journal ●●●●●● Check the radial clearance of the conrod bearings ●●● Check the radial clearance of the piston pin main bearing ●●● Check the crankshaft main bearing for wear ●●● Replace the crankshaft bearings and conrod bearings ●●● Check the entire transmission including roller and bearings for wear ●●●

RECOMMENDED INSPECTION OF THE 250/300 EXC AND MXC ENGINE USED FOR HOBBY- ENDURO BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) 60 90 120 180 240 270 hours hours hours hours hours hours Check the reed-type intake valve for wear ●●●●●● Check the clutch shoes for wear ●●●●●● Check the length of the clutch springs ●●●●●● Check the cylinder and piston for wear ●●●●●● Check the exhaust control for proper functioning and smooth running ●●●●●● Check the eccentricity of the crankshaft journal ●●●●●● Check the radial clearance of the conrod bearings ●●● Check the radial clearance of the piston pin main bearing ●●● Check the crankshaft main bearing for wear ●●● Replace the crankshaft bearings and conrod bearings ●●● Check the entire transmission including roller and bearings for wear ●●●

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED. Repair manual 250 / 300 / 380 Art No 3206004 -E IIGDARM20-30EC(S)..11-16 250-300EXC(USA) WIRING DIAGRAM ..11-14 250-300EXC(EU/AUS) WIRING DIAGRAM 2003 MODEL ..11-13 300-380EXC(USA) WIRING DIAGRAM ..11-11 250-380EXC WIRING DIAGRAM ..11-10 250EXC(USA) WIRING DIAGRAM 2001/2002 MODEL . ..11-9 380EXCUSA WIRING DIAGRAM ..11-7 250-380EXC WIRING DIAGRAM ..11-6 250-300EXCUSA WIRING DIAGRAM 2000 MODEL ..11-5 250-380EXC(USA) WIRING DIAGRAM 11-3 . 250-380EGS WIRING DIAGRAM ..11-2 250-380EXC WIRING DIAGRAM 1999 MODEL WIRING DIAGRAMS INDEX 11-1C 11

Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-2C 11-3C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-4C 11-5C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E

SPORTMOTORCYCLES 11-6C 11-7C

SPORTMOTORCYCLES Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-8C 11-9C

SPORTMOTORCYCLES Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-10C 11-11C Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 11-12C 11-13C Art No 3206004 -E Repair manual KTM 250 / 300 380 11-14C

250-300 EXC 2003 11-15C KTM 250-300 EXC 2003 Art No 3206004 -E Repair manual KTM 250 / 300 380 11-16C 250/300 EXC 2003