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KTM 250 SX manual

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Table of contents for the manual

  • Page 1

    ERSA TZTEIL KA T ALOG 20 0 4 ERSA TZTEILKA T ALOG: MOTOR SP ARE P ARTS MANUAL: ENGINE 250 SX 300 MXC 250/300 EXC[...]

  • Page 2

    INHAL TSVERZEICHNIS INDEX # ETRIEBELAGER RANSMISSION BEARINGS 625 062054 0625 160040 x 546.32.095.000 1 LOCTITE 243 2 4 bs bs bt bt ck cr cr cs cs dt et et fo gk gk gk gk gk gk 3 #1 #2 #1 #2 5 7 8 6 bp bq bs ck cl cm cn cr dk dq dr dr er er fk fk co ds 1 2 3 8 9 bm bn br bs cn cq cs ct dk fk fm fn fo fp fs gl go gq gr hk hk hl LOCTITE 243 4 5 LOCTI[...]

  • Page 3

    INHAL TSVERZEICHNIS INDEX X X X 7 bl bm bn bp bq bq bq cl cm cn cp cq cs ct dk dk dl dm dn dp el en 7 8 9 cr do dp dt ek el em 100 mm 100 mm 100 mm 40 mm bk bn bn bp bq br bs bs bt bt bt ck ck ck ck ck ck ck ck ck ck ck ck cn co co cp cp cp cp cp cq cs cs 6 4 8 1 4 5 7 8 9 bk bn bo bp bq dr bl X X X 7 bl bm bn bp bq bq bq cl cm cn cp cq cs ct dk dk[...]

  • Page 4

    MOTORGEHÄUSE ENGINE CASE 250/300 #, # + GETRIEBELAGER TRANSMISSION BEARINGS 0625 062054, 0625 160040, 0625 062035, 0625 613742, 0625 068050, 0625 623204, 565.30.123.200, 546.37.098.100 + 2 x 546.32.095.000 1 LOCTITE 243 LOCTITE 243 2 4 bs bs bt bt ck ck cq cr cr cs cs dt et et fo fo fo fo gk gk gk gk gk gk gk gk gk gn gn gn jt 3 04-548.30.0 3 FIG [...]

  • Page 5

    MEMBRANGEHÄUSE REED V AL VE CASE 250/300 LOCTITE 243 LOCTITE 243 eo fl fm gm gm em MXC, EXC SX dk dl dm do en #1, #2 #2 #1 04-548.30.1 4 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 30* 548.30.050.000 ANSAUGSTUTZEN V -FORCE 04 INT AKE FLANGE V -FORCE 04 1 31* 548.30.051.144 MEMBRANKAS. V -FORCE KPL. SX 04 REED V AL VE ASSY V -FORCE CPL.04 1 32* [...]

  • Page 6

    KUPPLUNGSDECKEL CLUTCH COVER 250/300 7 8 9 9 9 9 9 cl cm cp cq do dp dr ds dt ep ep ep ep ep ep ep eq eq fk fk fl fl fl fl #, # 1 x 580.30.010.000, 0625 160020, 0760 082472, 0760 193070, 1 + 2 x 546.37.096.000, bp bq ek eo 03-548.30.4 5 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 548.30.001.044 KUPPL.ZWISCHENDECK.KPL. 03 INTERM. CLUTCH COVER C[...]

  • Page 7

    KURBEL WELLE, KOLBEN CRANKSHAFT , PISTON 250/300 KUPPLUNG CLUTCH LOCTITE 243 1 3 3 4 7 9 bk 6 bl bo bp bq br bs bt ck dk dl bm 3 3 4 SX MXC, EXC 2 bn dm dm 04-548.30.2 6 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 548.30.007.000/ I KOLBEN I KPL. 250 VER TEX 2003 PISTON I CPL. 250 VERTEX 2003 1 1 548.30.007.000/ II KOLBEN II KPL. 250 VERTEX 200[...]

  • Page 8

    ZYLINDER, ZYLINDERKOPF CYLINDER, CYLINDER HEAD 250/300 #1 #2 #1 #2 5 7 8 6 bp bq br bs ck cl cm cn cq cr dk dq dr dr er er fk fk fk fk fk fk cp co ds 03-548.30.3 7 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 5* 548.30.005.144 ZYLINDER KPL. M.FLANSCH 250 04 CYLINDER CPL. W . FLANGE 250 04 1 5* 548.30.305.044 ZYLINDER KPL. M.FLANSCH 300 04 CYLINDE[...]

  • Page 9

    AUSLASSSTEUERUNG EXHAUST CONTROL 250/300 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 STEUERW ALZE LINKS CONTROL SHAFT L / S ZAHNSEGMENT LINKS GEAR SEGMENT L / S STEUERW ALZE RECHTS CONTROL SHAFT R / S ZAHNSEGMENT RECHTS GEAR SEGMENT R / S 1 1 2 3 4 4 5 8 bk 6 bl bm bn bo bp bq br bs bs bt bt ck cl cm cn cp cp[...]

  • Page 10

    AUSLASSSTEUERUNG EXHAUST CONTROL 250/300 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 STEUERW ALZE LINKS CONTROL SHAFT L / S ZAHNSEGMENT LINKS GEAR SEGMENT L / S STEUERW ALZE RECHTS CONTROL SHAFT R / S ZAHNSEGMENT RECHTS GEAR SEGMENT R / S 1 1 2 3 4 4 5 8 bk 6 bl bm bn bo bp bq br bs bs bt bt ck cl cm cn cp cp[...]

  • Page 11

    VERGASER KEIHIN PWK 36-S AG, 38-S AG CARBURETOR KEIHIN PWK 36-S AG, 38-S AG 250/300 1 7 9 bk bl bm bm bo bo bo bp br bs bt ck cl cn cp cr cs ct dk dl dm do dp ep eq eq eq eq er er er et fk ACHTUNG !!! V or dem Einbau des V ergasers, Bedüsung kontrollier en. CAUTION !!! Before mounting the carburetor , check the jetting. 8 es cq fm fn 04-548.31.0 1[...]

  • Page 12

    VERGASER KEIHIN PWK 36-S AG, 38-S AG CARBURETOR KEIHIN PWK 36-S AG, 38-S AG 250/300 1 7 9 bk bl bm bm bo bo bo bp br bs bt ck cl cn cp cr cs ct dk dl dm do dp ep eq eq eq eq er er er et fk ACHTUNG !!! V or dem Einbau des V ergasers, Bedüsung kontrollier en. CAUTION !!! Before mounting the carburetor , check the jetting. 8 es cq fm fn 04-548.31.0 1[...]

  • Page 13

    ZÜNDANLAGE KOKUSAN IGNITION SYSTEM KOKUSAN 250/300 1 4 7 bm bq br ck ck bk cl cl bo bp cm cm 2 5 7 2K-2 2K-1 2K-3 3 6 7 bn bt 04-548.39.0 12 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 547.39.005.000 ROTOR KOKUSAN 2K-1/2K-4 ‘97 FL YWHEEL KOKUSAN 2K-1/2K-4 ‘97 1 250 SX 250 SX 2 547.39.005.144 ROTOR KOKUSAN 2K-2 KPL. ‘97 FL YWHEEL KOKUSAN[...]

  • Page 14

    KUPPLUNG CLUTCH 250/300 1 2 3 8 9 bl bm bn br bs cn cq cs ct dk fk fm fn fo fp fs gl go gq gr hk hk hk hl LOCTITE 243 4 5 03-548.32.0 13 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 548.32.001.072 KUPPLUNGSKORB 72-Z KPL. 03 OUTER CLUTCH HUB 72-T CPL. 03 1 2 548.32.002.000 MITNEHMER 546/548 2003 INNER CLUTCH HUB 546/548 2003 1 3 546.32.003.000 D[...]

  • Page 15

    KICKST ARTER KICKST ARTER 250/300 LOCTITE 243 LOCTITE 243 LOCTITE 243 1 2 3 4 7 8 bn br bt co cp cs dl dm dn do fk fl fm gk gl cq 03-548.33.0 14 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 548.33.070.044 KICKST ARTER KPL. ‘03 KICKST ARTER CPL. ‘03 1 2 546.10.052.000 KETTENRADSCHR. M8X20 ISK SW=6 SPROCKET SCREW -AH M8X20 WS=6 1 3 546.33.037[...]

  • Page 16

    GETRIEBE I - ANTRIEBSWELLE TRANSMISSION I - MAIN SHAFT 250 SX, 300 MXC ACHTUNG ! Bei Bestellung von Getrieberädern, Markierung beachten. CAUTION ! When you order transmission gears, check marking. X 1 2 3 4 5 bk bl bm bp bq bq ck dk en 03-548.33.1 15 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 548.33.001.000 ANTRIEBSWELLE 14-Z „1S14“ 03 M[...]

  • Page 17

    GETRIEBE I - ANTRIEBSWELLE TRANSMISSION I - MAIN SHAFT 250/300 EXC ACHTUNG ! Bei Bestellung von Getrieberädern, Markierung beachten. CAUTION ! When you order transmission gears, check marking. X 1 2 3 4 5 bk bl bm bp bq bq ck dk en 03-548.33.1 16 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 548.33.101.000 ANTRIEBSWELLE 14-Z „1E14“ 04 MAIN[...]

  • Page 18

    GETRIEBE II - ABTRIEBSWELLE TRANSMISSION II - COUNTERSHAFT 250 SX, 300 MXC X X ACHTUNG ! Bei Bestellung von Getrieberädern, Markierung beachten. CAUTION ! When you order transmission gears, check marking. X 7 bl bm bn bo bp bq bq bq cl cm cn cp cq cs ct dk dk dl dm dn dp el en 03-548.33.2 17 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 548.33.[...]

  • Page 19

    GETRIEBE II - ABTRIEBSWELLE TRANSMISSION II - COUNTERSHAFT 250/300 EXC X X ACHTUNG ! Bei Bestellung von Getrieberädern, Markierung beachten. CAUTION ! When you order transmission gears, check marking. X 7 bl bm bn bo bp bq bq bq cl cm cn cp cq cs ct dk dk dl dm dn dp el en 03-548.33.2 18 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7* 548.33.007[...]

  • Page 20

    SCHAL TUNG SHIFTING MECHANISM 250/300 7 7 7 LOCTITE 243 cn co LOCTITE 243 LOCTITE 243 LOCTITE 243 1 2 3 4 4 4 5 8 8 9 9 bk bl bm bn bo bp bq br bs bt ck cp cq cr dl dm dn do dp dq dq dr ds dt ek #, # 04-548.34.0 19 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 548.34.001.000 SCHAL TGABEL 4./5. GANG 03 SHIFTING FORK 4TH/5TH GEAR 03 1 2 548.34.002[...]

  • Page 21

    KÜHLSYSTEM SX, MXC, EXC (USA) COOLING SYSTEM SX, MXC, EXC (USA) 250/300 7 8 9 ck ck ck ck ck ck ck cn co cp cq cr dn do dp dt ek el em 04-548.35.0 20 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 503.35.007.000 KÜHLER LINKS NA TUR (45286) ‘98 RADIA TOR L/S NA TURE (45286)’98 1 8 503.35.008.000 KÜHLER RECHTS NA TUR (45285)’98 RADIA TOR R[...]

  • Page 22

    KÜHLSYSTEM EXC (EU+AUS) COOLING SYSTEM EXC (EU+AUS) 250/300 7 8 9 cr do dp dt ek el em 100 mm 100 mm 100 mm 40 mm bk bn bn bp bq br bs bs bt bt bt ck ck ck ck ck ck ck ck ck ck ck ck cn co co cp cp cp cp cp cq cs cs 04-548.35.1 21 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 503.35.007.000 KÜHLER LINKS NA TUR (45286) ‘98 RADIA TOR L/S NA TU[...]

  • Page 23

    SPEZIAL WERKZEUGE SPECIAL TOOLS 250/300 HOLZGABEL SELBSTGEFERTIGT WOODEN FORK PLATE HOME MADE 6 4 8 1 3 4 5 7 8 9 bk bn bo bp bq bt dr bl 04-548.29.0 22 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 560.12.001.000 UNIVERSALMONT AGEBOCK ‘96 UNIVERSAL MOUNTING RACK ‘96 1 3 546.29.003.000 KUPPLUNGSHAL TER 250’90 CLUTCH HOLDER 250 ‘90 1 4 56[...]

  • Page 24

    KTM Sportmotorcycle AG A–5230 Mattighofen www .ktm.at KTM Group Partner Art.NR.: 3.208.121 3/2003 Foto: Frauscher , KTM 3208121[...]