2005-2008 KTM 250 Four Stroke Motorcycle Engine Repair Manual

Description

This 140 page, 2005-2008 KTM 250SX-F 250SXS-F 250XC-F 250XCF-W 250EXC-F 250 EXC-F Six days Engine Repair 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 2005-2008 KTM 250SX-F 250SXS-F 250XC-F 250XCF-W 250EXC-F 250 EXC-F Six days – covers the engine only. If you need more information for the chassis of your bike you will need to also purchase the owners manual.

2005 2006 2007 2008

Table of Contents
Service-Information

General Information
Bleeding the Cooling System
Changing the Oil Filter
Oil Circuit
Bleeding of The Hydraulic Clutch
Adjusting the Throttle Cables
Special Tools Engine

Removing and Refitting Engine
Dismounting the Engine
Mounting the Engine

Disassembling Engine
Preparatory Work
Moving the Engine Into the Tdc Position
Removing the Camshafts
Removing the Cylinder Head and Piston
Removing the Clutch Cover
Dismantling the Clutch
Removing the Chain Drive and Primary Gear
Dismantling the Shift Mechanism
Removing the Oil Pumps
Separating the Casing Halves, Removing the Crank5 Haft and Transmission Shafts

Servicing Individual Components
Left Casing Half
Right Casing Half
Bypass Valve
Clutch Cover
Crankshaft
Measuring the Outside Dimension of The Crankshaft Webs
Crankshaft Bearings
Axial Clearance of The Crankshaft
Cylinder
Measuring the Piston and Cylinder, Mounting Clearance
Piston
Piston Ring End Gap
Checking the Oil Pumps for Wear
Lubricating System
Camshaft Bearing
Camshafts
Automatic Decompression
Camshaft Bearing Bridges
Timing Chain Tensioner
Timing Train
Cylinder Head
Clutch
Kickstarter
Pre-Mounting the Kickstarter Shaft
Shift Mechanism
Pre-Mounting the Shift Shaft
General Information on Servicing the Transmission
Assembling the Main Shaft
Assembling the Countershaft

Assembling Engine
Installing the Transmission Shafts and Crankshaft assembling the Casing Halves
Mounting the Oil Pumps
Mounting the Shift Mechanism
Mounting the Primary Pinion and The Chain Drive
Mounting the Clutch
Mounting the Clutch Cover
Mounting the Piston and Cylinder Head
Mounting the Camshafts
Mounting the Chain Tensioner
Checking the Valve Clearance
Assembling the Engine

Electrical
CDI Unit
Checking the Ignition Coil
Ignition System Troubleshooting
Ignition System
Checking the Stator and Pulse Generator
Replacing the Stator
Main Fuse
Checking the Starter
Checking the Start Relay
Dismounting and Mounting the Battery
Charging the Battery
Checking the Charging Voltage
Checking for Loss of Current
Engine Characteristic (250 Exc-F Eu)
Measuring with The Peak Voltage Adapter
Static Ignition Values
Static Generator Values
Throttle Valve Sensor
Adjusting
Checking

Fuel System
Dismounting and Installing the Carburetor
Disassembling the Carburetor
Choke Knob and Hot Start Slide
Checking the Accelerator Pump
Checking the Jet Needle
Checking the Float Needle Valve
Checking the Throttle Valve
Assembling the Carburetor
Adjusting the Position of The Throttle Valve Sensor
Checking the Throttle Valve Sensor
Dismounting and Installing the Throttle Valve Sensor
Carburetor Adjusting Idling
Checking/adjusting the Float Height

Trouble Shooting

Technical Specifications
Engine 250 SX-F Model 2005-07
Engine 250 SXS-F Model 2006-07
Chassis 250 SX-F Model 2005-06
Chassis 250 SXS-F Model 2006
Chassis 250 SX-F/SXS-F Model 2007
Engine 250 XC-F, XCF-W, EXC-F Model 2007
Chassis 250 XC-F, XCF-W, EXC-F Model 2007
Engine 250 SX-F, XC-F, XCF-W, EXC-F Model 2008
Chassis 250 SX-F, XC-F, XCF-W, EXC-F Model 2008
Mounting Clearances, Wear Limits
Tightening Torques
Engine
Chassis

Periodic Maintenance Schedule
Model 2005
Model 2006
Model 2007
Model 2008
250 SX-F, XC-F
250 XCF-W EXC-F

Wiring Diagrams
Model 2005
250 SX-F
250 EXC-F USA
Model 2006
250 SX-F
250 EXC-F USA
250 EXC-F EU
Model 2007
250 SX-F
250 EXC-F EU
250 XC-F, XCF-W
Model 2008
250 SX-F
250 XC-F, XCF-W
250 EXC-F
Cable Colors