1999 2003 KTM 250-380 SX MXC EXC 2-stroke Motorcycle Engine Manual

Description

Do you need to service a 1999-2003 KTM 250-380 SX MXC EXC with a 2-stroke Engine? This 143 page, printed and bound 1999 – 2003 KTM 250-380 SX MXC EXC Engine Manual is an authorized reproduction of the original, out of print manual. It provides detailed service information, step-by-step repair instruction and maintenance specifications for 1999-2003 250-380 SX, MXC and EXC (two-stroke) motorcycles. Covers the engine only.

This 1999 – 2003 KTM 250-380 SX MXC EXC Engine Manual offers extensive repair-instructions and is an up-to-date version that describes the latest models of the series. 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 professionally trained mechanic. Read through the 1999 – 2003 KTM 250-380 SX MXC EXC Engine Manual before beginning with the repair work.

1999 – 2003 KTM 250-380 SX MXC EXC Engine Manual Table of Contents

Service Information
General Information
Operating Ranges Of The Carburetor
Carburetor Adjustment
Checking Of The Setting Of The Tvc System
Bleeding Of The Hydraulic Clutch
Special Tools – Engine
Cleaning
Storage

Removing And Refitting Engine

Disassembling The Engine
Draining Gear Oil
Dismounting Of Sprocket And Shift Lever
Dismounting Of Cylinder Head, Cylinder And Piston
Dismounting Of Clutch Cover
Dismounting Of Pressure Cap And Clutch Discs
Dismounting Of The Primary Drive
Dismounting Of Kickstarter
Dismounting Of The Shift Lock
Dismounting Of Ignition Cover
Dismounting Of The Ignition (kokusan)
Dismounting Of The Ignition (sem)
Dismounting Of Intake Flange And Reed Valve Housing
Parting Of Engine Housing Halves
Dismounting Of Gearshift Mechanism And Transmission
Dismounting Of The Crankshaft

Servicing On Individual Components
Working On The Right-hand Housing Half
Working On The Left-hand Housing Half
Crankshaft
Crankshaft Webs – Measure Outer Dimension
Piston
Piston Ring End Gap
Checking Cylinder For Wear
Recoated Cylinder
Nikasil Coating Of Cylinder
Cylinder Exhaust Control System
Cylinder Preassembly
Exhaust Control, Clutch Cover
Preassembly Of Clutch Cover
Reed Valve Housing, Intake Flange
Clutch
Replace Outer Clutch Hub
Shift Mechanism
Preassembly Of Shift Shaft
Ignition (kokusan)
Spark Plug
Check Stator And Pulse Generator (kokusan)
Ignition (sem)
Check Stator (sem)
Transmission
Assembly Mainshaft
Assembly Countershaft
Kickstarter
Assemble Of Kickstarter Shaft

Assembling The Engine
Crankshaft
Transmission
Assembling The Engine Housing
Mounting Shift Mechanism
Mounting Kickstarter
Mount Primary Drive And Clutch
Mounting Clutch Discs And Pressure Cap
Mounting Clutch Cover
Mounting Piston And Cylinder
Adjusting Dimension €žx
Adjusting Control Flap (dimension €žz)
Mounting Steering Covers
Mounting Cylinder Head
Mounting Reed Valve Housing And Intake Flange
Mounting Engine Sprocket
Mounting The Ignition (kokusan)
Mounting The Ignition (sem)
Adjusting Ignition Point (sem)
Mounting Ignition Cover
Mounting Starting Lever And Shift Lever

Electrical
Checking The Voltage Regulator-rectifier (shindengen)
Checking The Voltage Regulator (kokusan)
Checking The Voltage Regulator (tympanium)
Checking The Capacitor
Ignition Coil (sem)
Ignition Coil (kokusan)
Cdi Unit
Checking The Voltage Regulator (mod 2000)
Checking The Capacitor (mod 2000)
Static Ignition Values 250 – 380 Sx Exc
Static Generator Values 250 – 380 Exc
Static Ignition And Generator Values 250 Mxc, Exc (usa)

Trouble Shooting

Technical Specifications
Model 1999
Engine 250 – 380 Usa
Engine 250 – 380
Chassis 250 – 380
Carburetor Settings
Model 2000
Engine 250 – 380 Usa
Engine 250 – 380
Chassis 250 – 380
Carburetor Settings
Model 2001
Engine 250 – 380 Usa
Engine 250 – 380
Chassis 250 – 380
Carburetor Settings
Model 2002
Engine 250 – 380 Usa
Engine 250 – 380
Chassis 250 – 380
Carburetor Settings
Model 2003
Engine 250 – 300
Chassis 250 – 300
Carburetor Settings

Periodic Maintenance Schedule
Lubrication Schedule

Wiring Diagrams
Model 1999
Wiring Diagram 250 – 380 Exc
Wiring Diagram 250 – 380 Egs
Wiring Diagram 250 – 380 Exc (usa)
Model 2000
Wiring Diagram 250 – 300 Exc Usa
Wiring Diagram 250 – 380 Exc
Wiring Diagram 380 Exc Usa
Model 2001/2002
Wiring Diagram 250 Exc (usa)
Wiring Diagram 250 – 380 Exc
Wiring Diagram 300 – 380 Exc (usa)
Model 2003
Wiring Diagram 250 – 300 Exc (eu/aus)
Wiring Diagram 250 – 300 Exc (usa)

The following KTM motorcycles are covered in this 1999 – 2003 KTM 250-380 SX MXC EXC Engine Manual

1999 KTM 380SX
1999 KTM 380MXC
1999 KTM 380EXC, EGS
1999 KTM 300MXC
1999 KTM 300EXC, EGS
1999 KTM 250SX
1999 KTM 250MXC
1999 KTM 250EXC, EGS
2000 KTM 380SX
2000 KTM 380EXC, EGS
2000 KTM 300EXC, EGS
2000 KTM 250SX
2000 KTM 250MXC
2000 KTM 250EXC, EGS
2001 KTM 380SX
2001 KTM 380MXC
2001 KTM 380EXC
2001 KTM 300MXC
2001 KTM 300EXC
2001 KTM 250SX (Two Stroke)
2001 KTM 250MXC
2001 KTM 250EXC
2002 KTM 380MXC
2002 KTM 380EXC
2002 KTM 300MXC
2002 KTM 300EXC
2002 KTM 250SX
2002 KTM 250MXC
2002 KTM 250EXC (Two-Stroke)
2003 KTM 300MXC
2003 KTM 300EXC
2003 KTM 250SX
2003 KTM 250MXC
2003 KTM 250EXC (2 Stroke)