2013r 250-300 Repair manual.pdf

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REPAIR MANUAL
2013
250 SX EU
250 SX USA
250 XC EU/USA
300 XC EU/USA
Art. no. 3206176en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Bleeding and filling the cartridge......................
Filling the cartridge with nitrogen .....................
Greasing the steering head bearing ...................
Removing the lower triple clamp.......................
Installing the lower triple clamp .......................
Checking the play of the steering head
bearing ..........................................................
6.38 Adjusting the play of the steering head
bearing ..........................................................
7
HANDLEBAR, CONTROLS...........................................
7.1
Handlebar position..........................................
7.2
Adjusting the handlebar position ......................
7.3
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the routing of the throttle cable..........
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
8
SHOCK ABSORBER, SWINGARM ................................
8.1
Adjusting the high-speed compression
damping of the shock absorber.........................
8.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
8.3
Adjusting the rebound damping of the shock
absorber.........................................................
8.4
Measuring the sag of the unloaded rear wheel....
8.5
Checking the static sag of the shock absorber ....
8.6
Checking the riding sag of the shock absorber....
8.7
Adjusting the spring preload of the shock
absorber.........................................................
8.8
Adjusting the riding sag ...................................
8.9
Removing the shock absorber ...........................
8.10 Installing the shock absorber............................
8.11 Servicing the shock absorber............................
8.12 Removing the spring........................................
8.13 Disassembling the damper ...............................
8.14 Disassembling the piston rod ...........................
8.15 Disassembling the seal ring retainer..................
8.16 Changing the pilot bushing ..............................
8.17 Checking the damper ......................................
8.18 Removing the heim joint..................................
8.19 Installing the heim joint...................................
8.20 Assembling the seal ring retainer ......................
8.21 Assembling the piston rod................................
8.22 Assembling the damper ...................................
8.23 Bleeding and filling the damper .......................
8.24 Filling the damper with nitrogen .......................
8.25 Installing the spring (250 SX EU) .....................
8.26 Installing the spring (250 SX USA) ...................
8.27 Installing the spring (250/300 XC) ...................
9
EXHAUST ..................................................................
9.1
Removing the main silencer .............................
9.2
Installing the main silencer..............................
9.3
Changing the glass fiber yarn filling of the
main silencer..................................................
10 AIR FILTER ...............................................................
10.1 Removing the air filter box lid ..........................
10.2 Installing the air filter box lid ...........................
10.3 Removing the air filter .....................................
10.4 Installing the air filter......................................
10.5 Cleaning the air filter and air filter box ..............
10.6 Sealing the air filter box ..................................
10.7 Securing the air filter box lid............................
6.32
6.33
6.34
6.35
6.36
6.37
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1
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MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT INFORMATION ......................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number .............................................. 9
4.5
Shock absorber part number .............................. 9
MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2
Removing the motorcycle from the lift stand...... 10
5.3
Starting.......................................................... 10
5.4
Starting the motorcycle for checking ................. 11
FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs...................................... 13
6.4
Cleaning the dust boots of the fork legs............. 13
6.5
Loosening the fork protection ........................... 13
6.6
Positioning the fork protection.......................... 14
6.7
Removing the fork legs .................................... 14
6.8
Installing the fork legs ..................................... 14
6.9
Removing the fork protector ............................. 15
6.10 Installing the fork protector.............................. 15
6.11 Conducting major fork service .......................... 15
6.12 Conducting minor fork service .......................... 16
6.13 Disassembling the fork legs.............................. 16
6.14 Disassembling the cartridge ............................. 19
6.15 Disassembling the piston rod ........................... 21
6.16 Disassembling the screw cap with the
membrane holder............................................ 22
6.17 Disassembling the screw sleeve ........................ 23
6.18 Checking the fork legs (250 SX EU).................. 24
6.19 Checking the fork legs (250 SX USA)................ 25
6.20 Checking the fork legs (250/300 XC) ................ 27
6.21 Checking the fork legs - during a minor fork
service (250 SX EU)........................................ 28
6.22 Checking the fork legs - during a minor fork
service (250 SX USA)...................................... 29
6.23 Checking the fork legs - during a minor fork
service (250/300 XC) ...................................... 31
6.24 Changing the pilot bushing .............................. 32
6.25 Assembling the screw sleeve ............................ 33
6.26 Assembling the screw cap with the membrane
holder ............................................................ 33
6.27 Assembling the piston rod................................ 34
6.28 Assembling the cartridge ................................. 35
6.29 Assembling the fork legs (250 SX EU) .............. 37
6.30 Assembling the fork legs (250 SX USA) ............ 40
6.31 Assembling the fork legs (250/300 XC) ............. 44
TABLE OF CONTENTS
11 FUEL TANK, SEAT, TRIM ........................................... 84
11.1 Opening the filler cap...................................... 84
11.2 Closing the filler cap ....................................... 84
11.3 Removing the seat .......................................... 85
11.4 Mounting the seat ........................................... 85
11.5 Removing the fuel tank.................................... 85
11.6 Installing the fuel tank .................................... 86
11.7 Fuel tap (250 SX) ........................................... 87
11.8 Fuel tap (250/300 XC) .................................... 87
12 MASK, FENDER......................................................... 88
12.1 Removing the front fender ............................... 88
12.2 Installing the front fender ................................ 88
12.3 Removing the start number plate ...................... 88
12.4 Installing the start number plate....................... 89
13 WHEELS ................................................................... 90
13.1 Checking the tire air pressure........................... 90
13.2 Checking the tire condition .............................. 90
13.3 Checking the brake discs ................................. 90
13.4 Checking the spoke tension.............................. 91
13.5 Front wheel .................................................... 91
13.5.1
Removing the front wheel ............................ 91
13.5.2
Installing the front wheel ............................. 92
13.5.3
Removing the brake disc of the front brake.... 93
13.5.4
Installing the brake disc of the front brake .... 93
13.6 Rear wheel ..................................................... 93
13.6.1
Removing the rear wheel ............................. 93
13.6.2
Installing the rear wheel .............................. 94
13.6.3
Removing the brake disc of the rear brake ..... 95
13.6.4
Installing the brake disc of the rear brake...... 95
13.6.5
Checking the chain for dirt .......................... 95
13.6.6
Cleaning the chain ...................................... 96
13.6.7
Checking the chain tension.......................... 96
13.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 96
13.6.9
Adjusting the chain tension ......................... 98
13.6.10 Adjusting the chain guide ............................ 99
14 WIRING HARNESS, BATTERY................................... 100
14.1 Plug-in connection, ignition timing map .......... 100
14.2 Removing the main fuse (250/300 XC) ........... 100
14.3 Installing the main fuse (250/300 XC) ............ 100
14.4 Recharging the battery (250/300 XC) ............. 101
14.5 Disconnecting the negative cable of the
battery (250/300 XC) .................................... 102
14.6 Connecting the negative cable of the battery
(250/300 XC) ............................................... 102
14.7 Removing the battery (250/300 XC) ............... 102
14.8 Installing the battery (250/300 XC) ................ 103
14.9 Checking the charging voltage (250/300 XC) ... 103
14.10 Checking the closed current (250/300 XC) ...... 103
14.11 Checking the starter relay (250/300 XC) ......... 104
15 BRAKE SYSTEM ...................................................... 105
15.1 Checking the front brake linings ..................... 105
15.2 Changing the front brake linings ..................... 105
15.3 Checking the free travel of the hand brake
lever ............................................................ 107
15.4 Adjusting the basic position of the hand
brake lever ................................................... 107
15.5 Checking the front brake fluid level ................ 107
15.6 Adding front brake fluid................................. 108
15.7 Changing the front brake fluid ........................ 108
15.8 Checking the rear brake linings ...................... 109
15.9 Changing the rear brake linings ...................... 110
15.10 Checking the free travel of foot brake lever ......
15.11 Adjusting the basic position of the foot brake
lever ............................................................
15.12 Checking the rear brake fluid level..................
15.13 Adding brake fluid for the rear brake...............
15.14 Changing the rear brake fluid .........................
16 ENGINE ..................................................................
16.1 Removing the engine.....................................
16.2 Installing the engine......................................
16.3 Engine disassembly.......................................
16.3.1
Clamping the engine into the engine work
stand .......................................................
16.3.2
Draining the gear oil..................................
16.3.3
Removing the clutch push rod....................
16.3.4
Removing the shift lever ............................
16.3.5
Removing the engine sprocket....................
16.3.6
Removing the spacer.................................
16.3.7
Removing the alternator cover (250 SX) ......
16.3.8
Removing the starter motor
(250/300 XC)...........................................
16.3.9
Removing the kick starter ..........................
16.3.10 Removing the cylinder head .......................
16.3.11 Removing the cylinder...............................
16.3.12 Removing the piston .................................
16.3.13 Removing the water pump cover.................
16.3.14 Removing the clutch cover.........................
16.3.15 Removing the clutch discs .........................
16.3.16 Removing the clutch basket .......................
16.3.17 Removing the kick starter shaft ..................
16.3.18 Removing the intermediate kick starter
gear.........................................................
16.3.19 Removing the shift shaft............................
16.3.20 Removing the shift drum locating unit ........
16.3.21 Removing the locking lever ........................
16.3.22 Removing the rotor....................................
16.3.23 Removing the reed valve housing................
16.3.24 Removing the left engine case section ........
16.3.25 Removing the shift rails.............................
16.3.26 Removing the shift drum ...........................
16.3.27 Removing the shift forks............................
16.3.28 Removing the transmission shafts...............
16.3.29 Removing the crankshaft ...........................
16.4 Work on individual parts ................................
16.4.1
Work on the right section of the engine
case ........................................................
16.4.2
Work on the left section of the engine
case ........................................................
16.4.3
Removing the crankshaft bearing inner
race.........................................................
16.4.4
Installing the crankshaft bearing inner
race.........................................................
16.4.5
Changing the connecting rod, conrod
bearing, and crank pin ..............................
16.4.6
Checking the crankshaft run-out at the
bearing pin...............................................
16.4.7
Checking/measuring the cylinder ................
16.4.8
Removing the exhaust control ....................
16.4.9
Checking the exhaust control .....................
16.4.10 Installing the exhaust control .....................
16.4.11 Cylinder - Nikasil
®
coating .........................
16.4.12 Checking/measuring the piston...................
16.4.13 Checking the piston ring end gap ...............
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