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DISASSEMBLING THE ENGINE

Repair manual KTM 250 SX-F

Art.-No. 3.206.027-E

PREPARATORY WORK  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
MOVING THE ENGINE INTO THE TDC POSITION  . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE CAMSHAFTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
REMOVING THE CYLINDER HEAD AND PISTON  . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE CLUTCH COVER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
DISMANTLING THE CLUTCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
REMOVING THE CHAIN DRIVE AND PRIMARY GEAR  . . . . . . . . . . . . . . . . . . . . . .4-9
DISMANTLING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING THE OIL PUMPS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
SEPARATING THE CASING HALVES, REMOVING THE CRANKSHAFT AND TRANSMISSION SHAFTS . . .4-12

INDEX

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4

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Summary of Contents for 250 SX-F 2005

Page 1: ...250 SX F REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE R PARATION MANUAL DE REPARACI N ART NR 3 206 027 E REPAIRMANUAL2005 2006...

Page 2: ......

Page 3: ...REPAIRMANUAL2005 2006 250 SX F KTM Group Partner...

Page 4: ......

Page 5: ...REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTE...

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Page 7: ...EXPLANATION UPDATING Edition 05 2005 3 206 027 E Repair Manual 250 SX F Basicversion Modelyear 2005 5 2005...

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Page 9: ...TS 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 prof...

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Page 11: ...missing technical data or torques inaccurate or incorrect translations or wording etc please enter the error s in the table below and fax the completed form to us at 0043 7742 6000 5349 NOTE to table...

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Page 13: ...r manual KTM 250 SX F Art No 3 206 027 E 2 1 2 BLEEDING THE COOLING SYSTEM 2 2 CHANGING THE OIL FILTER 2 2 OIL CIRCUIT 2 3 BLEEDING OF THE HYDRAULIC CLUTCH 2 4 ADJUSTING THE THROTTLE CABLES 2 4 SPECIA...

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Page 15: ...filter insert 4 out of the case Clean the oil filter cover the sealing area on the O ring and the engine case Check the O ring in the oil filter cover for damage and replace if necessary Lay the moto...

Page 16: ...o the conrod bearing 6 and sprayed onto the piston 8 from below through a jet 7 Two other oil ducts lead into the cylinder head One duct supplies the hydraulic chain tensioner 9 the other duct leads t...

Page 17: ...is discharged from the bore A of the master cylinder in a bubble free state Make sure that the oil does not overflow CAUTION HAVING COMPLETED THE BLEEDING PROCEDURE YOU HAVE TO VERIFY THAT THE OIL LEV...

Page 18: ...2 5 SPECIAL TOOLS ENGINE 250 SX F 4 2 bk bl bm bn bo bp bq br bs 1 3 5 6 7 8 9 25 20 30 15 10 12 5 3 5 bt ck...

Page 19: ...screw 8 580 12 009 000 Magneto extractor 9 600 29 015 000 Piston ring mounting tool 10 584 29 037 037 Mounting tool for inner rings of crankshaft bearings 11 510 12 012 000 Chain sprocket holder 12 5...

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Page 21: ...REMOVING AND REFITTING ENGINE Repair manual KTM 250 SX F Art NO 3 206 027 E DISMOUNTING THE ENGINE 3 2 MOUNTING THE ENGINE 3 6 INDEX 3 1 3...

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Page 23: ...n the chain and remove Dismount the foot brake cylinder 1 you do not need to loosen the line to the rear wheel brake Detach the return spring on the foot brake lever Remove the upper shock absorber sc...

Page 24: ...el Loosen the hose clamp 1 and pull the radiator hoses off of the engine Disconnect the spark plug connector 2 Unscrew the chain securing guide 3 on the clutch slave cylinder and tilt up Unscrew the c...

Page 25: ...t 5 and remove from the motorcycle together with the hose NOTE only pull the connection upwards otherwise it can easily break Loosen the carburetor connection boots 6 Dismount the carburetor towards t...

Page 26: ...en the chain guide 1 and tilt upwards Remove the front 2 and lower 3 engine fixing screws and lift the engine out of the frame from the left side CAUTION MAKE SURE THE MOTORCYCLE CANNOT TIP OVER 3 5 1...

Page 27: ...and screw in the lower 1 and the front 2 engine fixing screws but do not tighten them yet Mount the chain guide 3 and tighten the screw Place the carburetor into the boots Tighten the carburetor conne...

Page 28: ...to the carburetor Connect the generator connector 4 and throttle potentiometer connector 5 Attach the wiring harnesses with cable clips Mount the clutch slave cylinder 6 screw in both front screws M6x...

Page 29: ...leeve 4 Attach the exhaust springs 5 Position the rear wheel with the swing arm and shock absorber in the frame Insert the swing arm pivot and tighten the nut Tighten the upper shock absorber screw 6...

Page 30: ...oot brake lever Mount the chain and chain joint CAUTION WHEN YOU MOUNT THE CHAIN JOINT MAKE SURE THE CLOSED SIDE OF THE GUIDE POINTS IN THE RUNNING DIRECTION To adjust the chain tensioning see Owner s...

Page 31: ...ON 4 3 REMOVING THE CAMSHAFTS 4 4 REMOVING THE CYLINDER HEAD AND PISTON 4 5 REMOVING THE CLUTCH COVER 4 7 DISMANTLING THE CLUTCH 4 8 REMOVING THE CHAIN DRIVE AND PRIMARY GEAR 4 9 DISMANTLING THE SHIFT...

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Page 33: ...the oil filter cover and the seal ring on the oil drain plug Use suitable pliers circlip pliers 510 12 011 000 to pull out the oil filter and discard Unscrew the spark plug Dismount the ignition cove...

Page 34: ...kshaft until the two marks 1 on the camshaft gears are aligned and precisely above the dividing line 2 between the two camshaft bearing bridges Unscrew the engine locking screw 3 remove the seal ring...

Page 35: ...ridge 4 and carefully remove the camshaft bearing bridge NOTE the screws on the timing chain guide rail 5 have distance bushings 6 be careful not to lose them Turn the exhaust camshaft up along the ti...

Page 36: ...d to check the valve clearance after assembling if valves or other parts in the valve control or replaced the valve clearance will need to be readjusted Remove the screws from the chain guide 2 the cy...

Page 37: ...on to the chain tensioning rail Discard the cylinder base gasket remove the dowels Carefully remove the piston pin retainer from the groove NOTE for easier demounting mounting remove the piston pin re...

Page 38: ...jector screw Remove the special tool from the rotor again Remove the water pump cover 1 Use a suitable wrench 510 12 011 000 to remove the lock ring 2 pull the water pump wheel off the shaft and take...

Page 39: ...outer clutch hub Remove the pressure piece 1 and bend up the lock washer on the driving nut Hold the driver with the special tool 503 29 003 000 and unscrew the driving nut A F 27 Remove the driving...

Page 40: ...stop disk and remove the woodruff key 3 Slip off the timing chain NOTE mark the running direction if you plan to use the timing chain again Remove the timing chain tensioning rail and the chain securi...

Page 41: ...of the locking lever Remove the locking lever Detach the kickstarter spring 5 and pull the kickstarter shaft all the way out being careful not to lose the washer and spring underneath NOTE slightly t...

Page 42: ...l out the oil pump shaft and remove the needle roller Take both pressure pump rotors 4 out of the engine case Remove the screws and lift the pump cover off the suction pump 5 discarding the O ring Rem...

Page 43: ...ing NOTE the main shaft has a stop disk which usually adheres to the bearing be careful not to lose it Lift the crankshaft out of the bearing First pull out the upper springs 2 in the shift rails and...

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Page 45: ...ER MOUNTING CLEARANCE 5 7 PISTON 5 8 PISTON RING END GAP 5 8 CHECKING THE OIL PUMPS FOR WEAR 5 8 LUBRICATING SYSTEM 5 9 CAMSHAFT BEARING 5 10 CAMSHAFTS 5 11 AUTOMATIC DECOMPRESSION 5 11 CAMSHAFT BEARI...

Page 46: ...es must be placed on a suitably large plane surface supporting the whole of the sealing surface without damaging it A wooden panel is best used as a base Bearings or shaft seal rings should not be ham...

Page 47: ...iver from the outside Press in a new bearing from the inside up to the stop Needle bearing for the shift shaft 4 Press in the needle bearing from the outside Press in a new needle bearing from the ins...

Page 48: ...side with a suitable driver Press in a new grooved ball bearing from the inside up to the stop Needle bearing for the shift shaft 5 Press in the needle bearing from the outside Press in a new needle b...

Page 49: ...of the kickstarter shaft 2 press in a new shaft seal ring open side on the inside up to the stop Pry the shaft seal ring 3 out of the water pump Press the grooved ball bearing 4 out of the timing tra...

Page 50: ...EARING WILL NOT BE SUPPLIED WITH ENGINE OIL WHICH WILL RESULT IN DAMAGE TO THE BEARINGS If you will continue to use the crankshaft check the crankshaft journal for runout Place the crankshaft on a rol...

Page 51: ...ring measure the axial clearance of the crankshaft CAUTION NEVER CLAMP THE CRANKSHAFT INTO A VISE WITH THE CRANKSHAFT JOURNAL AND TRY TO STRIKE THE INNER BEARING RING THE CRANKSHAFT WEB WILL BE PRESSE...

Page 52: ...ablishing the mounting clearance of the piston To establish the wear to the cylinder use a micrometer to measure the cylinder in the middle of the bearing surface Measure the diameter of the cylinder...

Page 53: ...red or have visible running marks Place the piston pin in the conrod and check for clearance Piston ring end gap Insert the piston ring in the cylinder and align with the piston approx 10 mm under the...

Page 54: ...aged Thoroughly clean the magnet on the oil drain plug 5 each time you change the oil filter Check the oil pump rotors 6 see pages 5 8 Thoroughly clean the oil pump rotors before remounting Check the...

Page 55: ...ositioning pin The positioning pin can be knocked out through this hole with a suitable driver Pull off the camshaft bearing using the extractor 590 29 033 000 and pressure tool 770 29 035 000 Slide o...

Page 56: ...n spring 6 and automatic decompression weight 7 Check all parts for damage and wear Assemble in the reverse order Perform a function test The spring should turn the automatic decompression shaft back...

Page 57: ...e installation position Check the cam lever shafts and cam lever 2 for wear seizing marks and damage Blow into the oil bore 3 with compressed air or a cleansing spray to make sure the oil jets 4 are n...

Page 58: ...again it may not be mounted in this state since the locking mechanism will not function Press down on the timing chain tensioner to ensure smooth operation To prepare the timing chain tensioner for i...

Page 59: ...timing chain guide 3 for seizing marks and damage Check the timing chain clip 4 for seizing marks and damage Check the timing chain 5 for damage and wear make sure the chain links operate smoothly NOT...

Page 60: ...iners if still mounted Dismount the valve keys using the special tools 590 29 019 000 and 770 29 041 000 and relieve the valve springs NOTE Used valves must be remounted in the same valve guide as bef...

Page 61: ...should be in the center of the valve seat The valve stem is hard plated wear usually appears at the valve guide Check the valve springs for ruptures or wear visual check measure the length with a sli...

Page 62: ...es 5 minimum thickness 2 9 mm The lining disks must be flat Clutch disks 7 pieces 6 must be flat check for mechanical damage Replace the clutch disks if they have score shaped breakout Check the drive...

Page 63: ...mounting the kickstarter shaft Clamp the kickstarter shaft in a vise with the toothed end facing up use protective jaws Mount the stop disk 5 and kickstarter pinion with the lock toothing facing down...

Page 64: ...5 19 1 2 3 4 4 5 5 4 A D 6 7 8 9 C E B 1 1...

Page 65: ...ft rails Check the shift rail 6 at the contact areas C for wear Check the return surface D on the shift rail for wear replace in case of severe indentation Check the guide bolt E for a tight fit and w...

Page 66: ...er you repair the transmission Assembling the main shaft Clamp the main shaft in the vise with the toothed end facing down use protective jaws Carefully oil all parts before mounting Mount the split n...

Page 67: ...wn use protective jaws Carefully oil all parts before mounting Mount the idler gear sleeve 25x28x9 7mm 1 and the 2nd gear idler gear 2 on the countershaft with the recess for the shift dogs facing up...

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Page 69: ...6 2 MOUNTING THE OIL PUMPS 6 4 MOUNTING THE SHIFT MECHANISM 6 6 MOUNTING THE PRIMARY PINION AND THE CHAIN DRIVE 6 7 MOUNTING THE CLUTCH 6 8 MOUNTING THE CLUTCH COVER 6 9 MOUNTING THE PISTON AND CYLIND...

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Page 71: ...aft The one sided shift fork 2 is inserted on the bottom the symmetrical shift fork 3 on top The needle rollers on the shift forks must point towards the shift drum Mount the shift drum and allow the...

Page 72: ...th a plastic hammer if necessary Turn in the screws as illustrated and tighten to 10 Nm CAUTION DO NOT PULL THE CASING HALVES TOGETHER BY TIGHTENING THE SCREWS NOTE use the M6x40 screw to fasten the h...

Page 73: ...be visible Fill the oil pump with engine oil Mount the pressure pump cover Apply Loctite 222 to the screws and tighten to 6 Nm Insert the needle roller 2 in the oil pump shaft and mount the oil pump...

Page 74: ...otor Fill the oil pump with engine oil Insert a new O ring 3 and mount the oil pump cover 4 Apply Loctite 222 to the screws and tighten to 6 Nm Insert the preassembled kickstarter shaft in the seat of...

Page 75: ...OTE the flat surfaces on the shift lock are not symmetrical Apply Loctite 243 to the shift lock and tighten to 10 Nm Mount the preassembled shift shaft in the case do not forget the stop disk press th...

Page 76: ...pply Loctite 243 to the screws and tighten to 10 Nm NOTE Make sure you only apply Loctite 243 to the screw thread otherwise the timing chain tensioning rail will block and can break The chain securing...

Page 77: ...to the driving nut 5 and mount with a new lock washer 6 Hold the driver with special tool 503 29 003 000 and tighten the driving nut to 120 Nm A F 27 Turn down the lock washer the driving nut Insert t...

Page 78: ...t a new gasket and the clutch cover do not forget the dowels Turn in the screws as illustrated and tighten to 10 Nm Insert the needle roller in the shaft mount the water pump wheel and lock ring Mount...

Page 79: ...ER YOU WILL BE ABLE TO PUSH THE PISTON INTO THE CYLINDER BY TAPPING LIGHTLY WITH THE HAMMER HANDLE EXCESSIVE FORCE USUALLY DAMAGES THE PISTON RINGS Mount a new cylinder base gasket and thrust bushing...

Page 80: ...oiled cylinder head screws and washers and tighten crosswise to 40 Nm in the first stage Tighten crosswise to 50 Nm in the second stage Tighten the 3 screws to 10 Nm Insert the guide rail with the no...

Page 81: ...ing adjust the valve clearance if valves or other parts in the valve control were replaced Mount the thrust bushings and pull the timing chain up Fold all 4 cam levers 1 up and mount the lower camshaf...

Page 82: ...Run the timing chain over the rear sprocket of the exhaust camshaft and press the exhaust camshaft into the bearing seat NOTE The lock ring on the camshaft ball bearing must engage in the groove in t...

Page 83: ...oil pressure has been built up yet CAUTION IF THE CHAIN TENSIONER IS NOT LOCKED AND RELIEVED AFTER ASSEMBLY AS DESCRIBED IN CHAPTER 5 THE TIMING CHAIN WILL SKIP WHEN THE ENGINE IS STARTED RESULTING IN...

Page 84: ...CT AND LEAD TO EXCESSIVE ENGINE WEAR Push in the pushrod Mount the pulse generator 2 apply Loctite 243 to the screws and tighten to 6 Nm Press the cable guide into the recess in the case Mount the ign...

Page 85: ...E IGNITION COIL 7 2 TROUBLESHOOTING IN THE IGNITION SYSTEM 7 2 IGNITION SYSTEM 7 3 CHECKING THE STATOR AND PULSE GENERATOR 7 3 REPLACING THE STATOR 7 3 MEASURING WITH THE PEAK VOLTAGE ADAPTER STATIC I...

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Page 87: ...peak voltage adapter If the ignition is being supplied with voltage but no spark is visible check The ground connection from the CDI unit and ignition coil The cable from the CDI unit to the ignition...

Page 88: ...r Use an ohmmeter to take the following measurements Measurement Cable colors Resistance Pulse generator coil red green 100 20 Generator charging coil red black red white 32 5 NOTE the measurements mu...

Page 89: ...suring tip of the peak voltage adapter 584 29 042 000 to the green cable and the black measuring tip to the red cable disconnect plug 4 to disconnect the CDI unit 5 Multimeter display 4 5 volts 0 5 vo...

Page 90: ...7 5 O L R F Q R L W L Q J L UHG EODFN Q H H U J U R W D U H Q H J S X N F L S Q R W W X E S R W V N F D O E Z R O O H N F D O E Q Z R U E G H U H W L K Z H X O E UHG ZKLWH 4 6 7 5...

Page 91: ...CCELERATOR PUMP 8 7 CHECKING THE JET NEEDLE 8 7 CHECKING THE FLOAT NEEDLE VALVE 8 7 CHECKING THE THROTTLE VALVE 8 7 ASSEMBLING THE CARBURETOR 8 8 ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR 8...

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Page 93: ...8 2 Repair manual KTM 250 SX F Art No 3 206 027 E 550 mm 630 mm 630 mm 550 mm 400 mm CARBURATOR KEIHIN FCR MX 39...

Page 94: ...ot and remove from the left side To mount the carburetor insert in the connection boot and attach with the hose clamps Make sure the carburetor is mounted vertically Attach Adjust both throttle cables...

Page 95: ...the carburetor in perfect order Dismount the carburetor and remove any coarse dirt Loosen both screws 1 and remove all of the vent hoses from the carburetor Remove both screws 2 and remove the slide...

Page 96: ...float together with the float needle valve Remove the main jet 2 Remove the screw 3 and use pliers to carefully extract the seat of the float needle valve from the carburetor Screw out the idling jet...

Page 97: ...and pull the connecting piece out of the carburetor Remove the 2 screws and take the intake trumpet together with the O ring 4 off the carburetor Unscrew the idle air jet 5 and the main air jet 6 Tho...

Page 98: ...celerator pump Check the membranes for cracking or brittleness Check gaskets for damage Check if the bores 2 are unobstructed Checking the jet needle Check the jet needle for bending and wear Checking...

Page 99: ...t knob 6 and actuate several times checking for smooth operation Also make sure the choke and the hot start knob lock into place Thread the spring the washer and the O ring onto the mixture control sc...

Page 100: ...abeling facing upwards and the spring into the pump housing Place the O ring 6 into the groove Secure the sealing ring 7 with some grease in the cover and fasten the cover by means of 3 screws Mount t...

Page 101: ...6 027 E Apply Loctite 243 to the screw 1 and tighten Mount the jet needle and fix with the screw 2 Position the slide cover with the gasket and fasten with the 2 screws 3 Fix the vent hoses on the flo...

Page 102: ...or resistance bl s 5 k Throttle valve sensor resistance ge s 5 k x 0 15 750 50 Connect the multimeter measuring range x100 to the yellow and the black cable of the throttle valve sensor and measure th...

Page 103: ...open the throttle grip slowly the resistance must change evenly Resistance of throttle valve sensor 0 5 k 1 k while opening the throttle grip Dismounting and installing the throttle valve sensor Disc...

Page 104: ...ied in 4 Serious competitive racers will choose a setting approx 1 4 turn clockwise leaner than this ideal value because their engine will heat up more when used in competitions NOTE If you fail to ob...

Page 105: ...oat needle valve but not compress it In this position the edge of the float should be parallel with the float chamber sealing surface see illustration If the float height does not correspond to the de...

Page 106: ......

Page 107: ...TROUBLE SHOOTING Repair manual KTM 250 SX F Art No 3 206 027 E TROUBLE SHOOTING 9 2 INDEX 9 1 9...

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Page 109: ...ose from the carburetor place the end in a vessel and open the fuel tap if fuel leaks out clean the carburetor if no fuel leaks out check the tank ventilation and clean the fuel tap Open the throttle...

Page 110: ...he cooling system Bent radiator hose Bent engine ventilation hose Engine oil level is too high Engine oil is too thin viscosity REMEDY Disassemble the carburetor and check for wear Tighten the jets Ha...

Page 111: ...TECHNICAL SPECIFICATIONS Repair manual KTM 250 SX F Art No 3 206 027 E ENGINE 11 2 CHASSIS 11 3 MOUNTING CLEARANCES WEAR LIMITS 11 4 TIGHTENING TORQUES ENGINE 11 5 CHASSIS 11 6 INDEX 10 1 10...

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Page 113: ...ubrication pressure circulation lubrication with 2 rotor pumps Engine oil full synthetic oil Motorex Power Synt 4T 10W 50 Quantity of engine oil 1 1 liters Primary drive 22 68 Transmission claw shifte...

Page 114: ...SX F WP PDS 5018 DCC 12187A03 Compression adjuster 15 LS low speed 2 HS high speed Rebound adjuster 22 Spring 80 250 Spring preload 5 mm Chassis 250 SXF Frame Central tube chrome moly steel frame Fork...

Page 115: ...size I 0 030 0 052 mm assembly clearance size II 0 032 0 055 mm wear limit 0 070 mm Piston ring end gap compression ring max 0 80 mm oil scraper ring max 1 00 mm Valves seat sealing intake max 1 50 mm...

Page 116: ...w shift roller lock M6 Loctite 243 10 Nm HH collar screw locking lever M5 Loctite 243 6 Nm Lock screw on shift drum bearing M6 Loctite 243 6 Nm Lock screw on main shaft bearing M6 Loctite 243 6 Nm HH...

Page 117: ...AH screw on handlebar mount M10 Loctite 243 40 Nm HH collar screw on upper lower shock absorber M12 70 Nm HH collar nut on rear wheel spindle M20x1 5 80 Nm AH rear sprocket screws M8 Loctite 243 35 Nm...

Page 118: ......

Page 119: ...PERIODIC MAINTENANCE SCHEDULE Repair manual KTM 250 SX F Art No 3 206 027 E 250 SX F 12 2 INDEX 11 1 11...

Page 120: ...f handbrake foot brake lever z z Check the screws and guide bolts on the brake system for a tight fit z z CHASSIS Check shock absorber and fork for leaks and function z z Clean fork dust bellows z Ble...

Page 121: ...perating hours every 10 hours 70 liter every 20 hours 140 liter every 40 hours 270 liter every 60 hours 400 liter every 80 hours 540 liter Check the clutch disks for wear z z z z Check the length of t...

Page 122: ......

Page 123: ...WIRING DIAGRAMS Repair manual KTM 250 SX F Art No 3 206 027 E 12 1 12 WIRING DIAGRAM 13 2 CABLE COLORS 13 3 INDEX...

Page 124: ...i o c n o i t i n g i red black n e e r g r o t a r e n e g 0 0 0 2 3 0 9 3 4 9 5 s s e n r a h I D C 5 0 0 2 2 0 0 2 p u k c i p n o t t u b p o t s k c a l b w o l l e y k c a l b n w o r b d e r e...

Page 125: ...12 3 Repair manual KTM 250 SX F Art No 3 206 027 E Cable colours bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple...

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