2011r 250-300 Repair manual.pdf

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REPAIR MANUAL

2011

250 SX

250 XC EU/USA

300 XC EU/USA

Art. no. 3206102en

INTRODUCTION

Read this repair manual carefully and thoroughly before beginning work.

INTRODUCTION

Only use

ORIGINAL KTM SPARE PARTS.

The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.

This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of

technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that the repair work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

TABLE OF CONTENTS

Checking the riding sag of the shock absorber ..................

Adjusting the spring preload of the shock absorber ...........

Adjusting the riding sag .................................................

Removing the shock absorber .........................................

Installing the shock absorber ..........................................

Servicing the shock absorber ..........................................

Removing the spring ......................................................

Disassembling the damper .............................................

Disassembling the piston rod ..........................................

Disassembling the seal ring retainer ................................

Replacing the pilot bushing ............................................

Checking the damper .....................................................

Disassembling the rebound adjuster ................................

Removing the heim joint ................................................

Installing the heim joint .................................................

Assembling the rebound adjuster ....................................

Assembling the seal ring retainer ....................................

Assembling the piston rod ..............................................

Assembling the damper..................................................

Bleeding and filling the damper ......................................

Filling the damper with nitrogen .....................................

Installing the spring (SX)................................................

Installing the spring (XC)................................................

Changing the heim joint .................................................

05/EXHAUST ....................................................................

Removing the main silencer............................................

Installing the main silencer ............................................

Changing the glass fiber yarn filling of the main silencer ...

06/AIR FILTER..................................................................

Removing the air filter box lid.........................................

Installing the air filter box lid..........................................

Removing the air filter ...................................................

Installing the air filter ....................................................

Cleaning the air filter and air filter box ............................

07/FUEL TANK, SEAT, TRIM..............................................

Opening the filler cap ....................................................

Closing the filler cap......................................................

Removing the seat .........................................................

Mounting the seat .........................................................

Removing the fuel tank ..................................................

Installing the fuel tank ...................................................

Fuel tap (XC).................................................................

Fuel tap (SX).................................................................

08/MASK, FENDER ...........................................................

Removing the front fender ..............................................

Installing the front fender...............................................

Removing the start number plate ....................................

Installing the start number plate .....................................

09/FRONT WHEEL ............................................................

Removing the front wheel ...............................................

Installing the front wheel................................................

Checking the brake discs................................................

Removing the brake disc of the front brake ......................

Installing the brake disc of the front brake .......................

Checking the tire condition.............................................

Checking the tire air pressure .........................................

Checking the spoke tension ............................................

10/REAR WHEEL ..............................................................

Removing the rear wheel ................................................

Installing the rear wheel .................................................

Removing the brake disc of the rear brake........................

MEANS OF REPRESENTATION ............................................ 6

IMPORTANT NOTES ............................................................ 7

SERIAL NUMBERS.............................................................. 8

Chassis number............................................................... 8

Type label....................................................................... 8

Engine number................................................................ 8

Fork part number............................................................. 8

Shock absorber part number............................................. 8

MOTORCYCLE..................................................................... 9

Raising the motorcycle with the lift stand .......................... 9

Removing the motorcycle from the lift stand ...................... 9

Starting .......................................................................... 9

Starting the motorcycle for checking ............................... 10

01/FORK, TRIPLE CLAMP.................................................. 11

Adjusting the compression damping of the fork ................ 11

Adjusting the rebound damping of the fork....................... 11

Bleeding the fork legs .................................................... 12

Cleaning the dust boots of the fork legs ........................... 12

Loosening the fork protection.......................................... 12

Positioning the fork protection ........................................ 12

Removing the fork legs................................................... 13

Installing the fork legs ................................................... 13

Removing the fork protector............................................ 14

Installing the fork protector ............................................ 14

Conducting major fork service......................................... 14

Conducting minor fork service......................................... 15

Disassembling the fork legs ............................................ 15

Disassembling the cartridge............................................ 18

Disassembling the piston rod .......................................... 20

Disassembling the screw cap with the membrane holder ... 21

Disassembling the screw sleeve ...................................... 22

Checking the fork legs.................................................... 22

Checking the fork legs - during a minor fork service .......... 24

Changing the pilot bushing............................................. 25

Assembling the screw sleeve........................................... 26

Assembling the screw cap with the membrane holder........ 26

Assembling the piston rod .............................................. 27

Assembling the cartridge ................................................ 28

Assembling the fork legs (SX) ......................................... 30

Assembling the fork legs (XC) ......................................... 33

Bleeding and filling the cartridge .................................... 36

Filling the cartridge with nitrogen.................................... 37

Greasing the steering head bearing.................................. 38

Removing the lower triple clamp ..................................... 38

Installing the lower triple clamp...................................... 39

Checking the play of the steering head bearing................. 40

Adjusting the play of the steering head bearing ................ 41

02/HANDLEBAR, INSTRUMENTS....................................... 42

Handlebar position ........................................................ 42

Adjusting the handlebar position..................................... 42

Adjusting the basic position of the clutch lever................. 42

Checking the throttle cable routing.................................. 43

Checking the play in the throttle cable............................. 43

Adjusting the play in the throttle cable ............................ 44

04/SHOCK ABSORBER, SWINGARM................................... 45

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 45

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 45

Adjusting the rebound damping of the shock absorber....... 46

Measuring the sag of the unloaded rear wheel .................. 46

Checking the static sag of the shock absorber .................. 47

TABLE OF CONTENTS

Installing the brake disc of the rear brake ........................ 82

Checking the chain tension ............................................ 82

Adjusting the chain tension ............................................ 83

Adjusting the chain guide............................................... 84

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 84

Checking the chain for dirt ............................................. 86

Cleaning the chain......................................................... 86

11/WIRING HARNESS, BATTERY ....................................... 87

Ignition curve plug connection ........................................ 87

Removing the main fuse (XC).......................................... 87

Installing the main fuse (XC) .......................................... 87

Recharging the battery (XC) ............................................ 88

Disconnecting the negative cable of the battery (XC) ......... 89

Connecting the negative cable of the battery (XC) ............. 89

Removing the battery (XC) .............................................. 89

Installing the battery (XC)............................................... 89

Checking the charging voltage (XC) ................................. 90

Checking the closed current (XC) .................................... 90

Checking the starter relay (XC) ........................................ 90

13/BRAKE SYSTEM........................................................... 91

Checking the front brake linings...................................... 91

Changing the front brake linings ..................................... 91

Checking the free travel of the hand brake lever ............... 93

Adjusting the basic position of the hand brake lever.......... 93

Checking the front brake fluid level ................................. 93

Adding front brake fluid ................................................. 94

Changing the front brake fluid ........................................ 94

Checking the rear brake linings ....................................... 95

Removing the rear brake linings ...................................... 96

Installing the rear brake linings....................................... 96

Changing the rear brake linings....................................... 97

Checking the free travel of foot brake lever....................... 98

Adjusting basic position of foot brake lever ...................... 98

Checking the rear brake fluid level .................................. 99

Adding brake fluid for the rear brake ............................... 99

Changing the rear brake fluid........................................ 100

30/ENGINE..................................................................... 101

Removing the engine ................................................... 101

Installing the engine .................................................... 109

30/DISASSEMBLING THE ENGINE................................... 118

SX.............................................................................. 118

Clamping the engine into the engine work stand ............. 118

Draining the gear oil .................................................... 118

Removing the clutch push rod ...................................... 118

Removing the shift lever............................................... 118

Removing the engine sprocket ...................................... 118

Removing the spacer ................................................... 119

Removing the alternator cover....................................... 119

Removing the kick starter ............................................. 119

Removing the cylinder head.......................................... 119

Removing the cylinder ................................................. 120

Removing the piston .................................................... 121

Removing the water pump cover ................................... 121

Removing the clutch cover ........................................... 121

Removing the clutch discs............................................ 122

Removing the outer clutch hub ..................................... 122

Removing the kick starter shaft..................................... 123

Removing the intermediate kick starter gear................... 123

Removing the shift shaft .............................................. 123

Removing the shift drum locating unit ........................... 123

Removing the locking lever ........................................... 124

Removing the rotor ......................................................

Removing the reed valve housing ..................................

Removing the left engine case section ...........................

Removing the shift rails ...............................................

Removing the shift drum ..............................................

Removing the shift forks ..............................................

Removing the transmission shafts .................................

Removing the crankshaft ..............................................

XC..............................................................................

Clamping the engine into the engine work stand .............

Draining the gear oil ....................................................

Removing the clutch push rod ......................................

Removing the shift lever...............................................

Removing the engine sprocket ......................................

Removing the spacer ...................................................

Removing the starter motor ..........................................

Removing the kick starter .............................................

Removing the cylinder head..........................................

Removing the cylinder .................................................

Removing the piston ....................................................

Removing the water pump cover ...................................

Removing the clutch cover ...........................................

Removing the clutch discs............................................

Removing the outer clutch hub .....................................

Removing the kick starter shaft.....................................

Removing the intermediate kick starter gear...................

Removing the shift shaft ..............................................

Removing the shift drum locating unit ...........................

Removing the locking lever...........................................