KTM 250 EXC, Owner'S Manual

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6-14E
Repair manual KTM 250-610 Racing
Art.-Nr
. 3.206.023-E
1
2
3
4
4
5
5
Mounting the flywheel (400/520 models up to 2002)
– Check the Woodruff key in the crankshaft for proper fit and slip the
flywheel onto the crankshaft.
– Mount wave washer and collar nut, tighten to 60 Nm.
NOTE: When ordering a new part, a forged rotor will be supplied, this
part is produced without rivets and is interchangeable.
– Unscrew the crankshaft fixing bolt, mount the sealing ring
1
and
tighten the crankshaft fixing bolt again to 25 Nm.
Mounting the flywheel (250 EXC models after 2002, all
models after 2003)
– Unscrew the crankshaft fixing screw, mount the seal ring
1
and
tighten the crankshaft fixing screw to 25 Nm (see above).
– Check the Woodruff key in the crankshaft for proper fit and slip the
flywheel onto the crankshaft.
– Mount the shaft disk and collar nut. Counteracting with the clutch
holder, tighten the and collar nut to 60 Nm.
Mounting the pulse generator and the ignition cover
– Position the pulse generator in the engine casing and insert the
cable grommet
2
into the aperture of the casing.
– Degrease the threads of the 2 bolts
3
(M5x16), coat them with
Loctite 243 and tighten to 6 Nm.
NOTE:
– For the 400 SX engines equipped with the 4K-3A ignition, 2 spacer
bushings must be added behind the pulse generator.
– The gap between rotor and pulse generator must be 0.55 - 0.85 mm,
but is only adjustable on 400 SX engines (measurement 0.7 mm).
– Apply a new gasket and fix the ignition cover with the 4 bolts (
4
and
5
), tightening torque 10 Nm.
NOTE: The 2 longer bolts
4
(M6x35) are mounted at the dowels.