Checking the clutch for wear
Thrust bearing
1
Check it for seizing marks and unobstructed movability.
Push rod
2
Place it on a planar surface and check it for eccentricity.
Clutch springs
3
Minimum length: 42 mm, new: 43 mm; if necessary,
replace all 6 springs.
7 lining discs
4
Minimum thickness: 1.7 mm, new: 1.8 mm. The lining
discs must be planar.
8 intermediate discs
5
(up to model 2001)
They must be planar. Check them for mechanical damage. In the case of punctual broken-off portions, you have to replace the
intermediate discs.
Four 1.4 mm
6
clutch disks (models from 2002 onwards)
Must be planar. Check for mechanical damage. Replace clutch disks if localized points are broken off.
Four 1.0 mm
7
clutch disks (models from 2002 onwards)
Must be planar. Check for mechanical damage. Replace clutch disks if localized points are broken off.
Inner clutch hub
8
Check the outer toothing
A
on the inner clutch hub. If the depressions are greater than 0.5mm, the inner clutch hub must be
replaced. A modified driver with sleeves
9
is installed starting with the 2002 model.
Pressure cap
bk
Check the seating surface
B
of the steel disc for damage.
Outer clutch hub
bl
Check the stop surfaces
C
of the lining disk and the clutch cage for wear. If the depressions are greater than 0.5 mm the lining
disk and clutch hub must be replaced.
Bearing bush
bm
Slip the bearing bush and the outer clutch hub on the main shaft and check the bearing for clearance. If necessary, replace the
bearing bush.
NOTE:
– Every time the inner clutch hub is replaced, the bearing bush should be exchanged as well (Model 2000).
– from Model 2001 onwards two needle bearings
bm
are mounted instead of the bearing bush
bo
, the outer clutch hub is
replaced with a hardened version, the support washer
bn
is replaced with a step washer
bp
and the mesh of the shaft is
different.
5-17E
1
A
C
B
2
3
4
8
10
11
12
13
5
Modification - Model 2001
15
14
Modification - Model 2002
9
8
Modification - Model 2002
6
7
7
4
Summary of Contents for 250 EXC
Page 59: ...ENGLISH 58 ...
Page 60: ...ANHANG APPENDICE APPENDIX APÉNDICE 1 SCHALTPLAN WIRING DIAGRAMM ...
Page 61: ...ANHANG APPENDICE APPENDIX APÉNDICE 2 SCHALTPLAN WIRING DIAGRAMM ...
Page 62: ...ANHANG APPENDICE APPENDIX APÉNDICE 3 SCHALTPLAN WIRING DIAGRAMM ...
Page 92: ...2 7E 1 2 3 4 21 23 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 22 24 ...
Page 172: ...8 3E CARBURETOR KEIHIN FCR MX 37 39 41 ...
Page 242: ...Repair manual KTM 250 610 Racing Art Nr 3 206 023 E 12 2E ...
Page 243: ...12 3E ...
Page 244: ...12 4E Repair manual KTM 250 610 Racing Art Nr 3 206 023 E ...
Page 245: ...12 5E ...
Page 246: ...Repair manual KTM 250 610 Racing Art Nr 3 206 023 E 12 6E ...
Page 247: ...12 7E ...
Page 248: ...Repair manual KTM 250 610 Racing Art Nr 3 206 023 E 12 8E 250 400 520 MXC EXC RACING 2002 ...
Page 249: ...12 9E Modell 250 400 520 EXC RACING ...
Page 250: ...Repair manual KTM 250 610 Racing Art Nr 3 206 023 E 12 10E 250 400 520 EXC RACING 2002 ...
Page 251: ...250 450 525 MXC EXC 01 02 03 12 11E ...
Page 252: ...12 12E Repair manual KTM 250 610 Racing Art Nr 3 206 023 E ...
Page 253: ...12 13E 250 450 525 EXC Racing 2003 ...
Page 257: ...12 17E ...
Page 258: ...12 18E Repair manual KTM 250 610 Racing Art Nr 3 206 023 E ...