2012r 250-300 Repair manual.pdf

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REPAIR MANUAL
2012
250 EXC EU
250 EXC SIX DAYS EU
250 EXC AUS
250 XC‑W USA
300 EXC EU
300 EXC SIX DAYS EU
300 EXC AUS
300 XC‑W USA
Art. no. 3206134en
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
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the throttle cable routing ...................
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 Replacing the pilot bushing .............................
8.17 Checking the damper ......................................
8.18 Disassembling the rebound adjuster..................
8.19 Removing the heim joint..................................
8.20 Installing the heim joint...................................
8.21 Assembling the rebound adjuster......................
8.22 Assembling the seal ring retainer ......................
8.23 Assembling the piston rod................................
8.24 Assembling the damper ...................................
8.25 Bleeding and filling the damper .......................
8.26 Filling the damper with nitrogen .......................
8.27 Installing the spring ........................................
8.28 Changing the heim joint...................................
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 ..................................
11 FUEL TANK, SEAT, TRIM ...........................................
11.1 Opening the filler cap......................................
11.2 Closing the filler cap .......................................
11.3 Removing the seat ..........................................
11.4 Mounting the seat ...........................................
11.5 Removing the fuel tank....................................
11.6 Installing the fuel tank ....................................
11.7 Fuel tap .........................................................
12 MASK, FENDER.........................................................
12.1 Removing the front fender ...............................
12.2 Installing the front fender ................................
7.3
1
2
3
4
5
6
7
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 ............................................ 10
4.5
Shock absorber part number ............................ 10
MOTORCYCLE ........................................................... 11
5.1
Raising the motorcycle with the lift stand.......... 11
5.2
Removing the motorcycle from the lift stand...... 11
5.3
Starting.......................................................... 11
5.4
Starting the motorcycle for checking ................. 12
FORK, TRIPLE CLAMP ............................................... 13
6.1
Adjusting the compression damping of the
fork ............................................................... 13
6.2
Adjusting the rebound damping of the fork ........ 13
6.3
Adjusting the spring preload of the fork............. 13
6.4
Bleeding the fork legs...................................... 14
6.5
Cleaning the dust boots of the fork legs............. 14
6.6
Loosening the fork protection ........................... 15
6.7
Positioning the fork protection.......................... 15
6.8
Removing the fork legs .................................... 15
6.9
Installing the fork legs ..................................... 16
6.10 Removing the fork protector ............................. 17
6.11 Installing the fork protector.............................. 17
6.12 Performing a fork service ................................. 18
6.13 Disassembling the fork legs.............................. 18
6.14 Cartridge disassembly...................................... 21
6.15 Disassembling the compression damping
fitting ............................................................ 23
6.16 Checking the fork legs ..................................... 23
6.17 Assembling the compression damping fitting ..... 24
6.18 Assembling the cartridge ................................. 25
6.19 Assembling the fork legs.................................. 27
6.20 Greasing the steering head bearing ................... 31
6.21 Removing the lower triple clamp
(EXC EU/AUS, XC‑W)....................................... 31
6.22 Removing the lower triple clamp
(EXC SIX DAYS) .............................................. 31
6.23 Installing the lower triple clamp (EXC EU/AUS,
XC‑W) ............................................................ 32
6.24 Installing the lower triple clamp
(EXC SIX DAYS) .............................................. 34
6.25 Checking the play of the steering head
bearing .......................................................... 35
6.26 Adjusting the play of the steering head
bearing .......................................................... 36
HANDLEBAR, CONTROLS........................................... 37
7.1
Handlebar position.......................................... 37
7.2
Adjusting the handlebar position ...................... 37
37
38
38
38
40
40
40
41
41
41
42
42
43
43
43
44
44
45
46
47
48
49
49
50
51
52
52
53
54
57
59
60
61
63
63
63
63
65
65
65
65
65
66
66
67
67
67
67
68
68
69
70
71
71
71
TABLE OF CONTENTS
Removing the headlight mask with the
headlight (All EXC models)...............................
12.4 Refitting the headlight mask with the headlight
(All EXC models).............................................
12.5 Removing the start number plate (XC‑W) ...........
12.6 Installing the start number plate (XC‑W)............
WHEELS ...................................................................
13.1 Checking the tire air pressure...........................
13.2 Checking the tire condition ..............................
13.3 Checking the brake discs .................................
13.4 Checking the spoke tension..............................
13.5 Front wheel ....................................................
13.5.1
Removing the front wheel ............................
13.5.2
Installing the front wheel .............................
13.5.3
Removing the brake disc of the front brake....
13.5.4
Installing the brake disc of the front brake ....
13.6 Rear wheel .....................................................
13.6.1
Removing the rear wheel .............................
13.6.2
Installing the rear wheel ..............................
13.6.3
Removing the brake disc of the rear brake .....
13.6.4
Installing the brake disc of the rear brake......
13.6.5
Checking the chain for dirt ..........................
13.6.6
Cleaning the chain ......................................
13.6.7
Checking the chain tension..........................
13.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide.............................
13.6.9
Adjusting the chain tension .........................
13.6.10 Adjusting the chain guide ............................
WIRING HARNESS, BATTERY.....................................
14.1 Plug-in connection, ignition timing map ............
14.2 Removing the main fuse ..................................
14.3 Installing the main fuse ...................................
14.4 Recharging the battery ....................................
14.5 Disconnecting the negative cable of the
battery ...........................................................
14.6 Connecting the negative cable of the battery......
14.7 Removing the battery ......................................
14.8 Installing the battery .......................................
14.9 Checking the charging voltage ..........................
14.10 Checking the closed current .............................
14.11 Checking the starter relay ................................
BRAKE SYSTEM ........................................................
15.1 Checking the front brake linings .......................
15.2 Changing the front brake linings .......................
15.3 Checking free travel of hand brake lever ............
15.4 Adjusting free travel of hand brake lever (All
EXC models)...................................................
15.5 Adjusting the basic position of the hand brake
lever (XC‑W) ...................................................
15.6 Checking the front brake fluid level ..................
15.7 Adding front brake fluid...................................
15.8 Changing the front brake fluid ..........................
15.9 Checking the rear brake linings ........................
15.10 Changing the rear brake linings ........................
15.11 Checking the free travel of foot brake lever ........
15.12 Adjusting the basic position of the foot brake
lever ..............................................................
15.13 Checking the rear brake fluid level....................
15.14 Adding brake fluid for the rear brake.................
15.15 Changing the rear brake fluid ...........................
LIGHTING SYSTEM, INSTRUMENTS ...........................
16.1 Adjusting the speedometer functions ................
12.3
71
71
72
72
73
73
73
74
74
75
75
75
76
76
76
76
77
78
78
78
79
79
80
81
82
83
83
83
83
83
84
85
85
86
86
86
87
88
88
88
90
90
90
91
91
92
93
94
95
95
96
96
97
99
99
16.2
16.3
16.4
16.5
16.6
16.7
3
Setting kilometers or miles............................... 99
Activating the additional functions.................. 100
Setting the wheel circumference .................... 100
Setting the clock........................................... 101
Changing the speedometer battery .................. 101
Checking the headlight setting (All EXC
models)........................................................ 102
16.8 Adjusting the headlight range (All EXC
models)........................................................ 103
17 ENGINE .................................................................. 104
17.1 Removing the engine..................................... 104
17.2 Installing the engine...................................... 108
17.3 Engine disassembly....................................... 113
17.3.1
Clamping the engine into the engine work
stand ....................................................... 113
17.3.2
Draining the gear oil.................................. 113
17.3.3
Removing the clutch push rod.................... 113
17.3.4
Removing the shift lever ............................ 113
17.3.5
Removing the engine sprocket.................... 113
17.3.6
Removing the spacer................................. 114
17.3.7
Removing the starter motor........................ 114
17.3.8
Removing the kick starter .......................... 115
17.3.9
Removing the spark plug ........................... 116
17.3.10 Removing the cylinder head ....................... 116
17.3.11 Removing the cylinder............................... 116
17.3.12 Removing the piston ................................. 117
17.3.13 Removing the water pump cover................. 118
17.3.14 Removing the clutch cover......................... 118
17.3.15 Removing the clutch discs ......................... 119
17.3.16 Removing the outer clutch hub .................. 119
17.3.17 Removing the kick starter shaft .................. 120
17.3.18 Removing the intermediate kick starter
gear......................................................... 120
17.3.19 Removing the shift shaft............................ 120
17.3.20 Removing the shift drum locating unit ........ 121
17.3.21 Removing the locking lever ........................ 121
17.3.22 Removing the rotor.................................... 121
17.3.23 Removing the reed valve housing................ 121
17.3.24 Removing the left engine case section ........ 122
17.3.25 Removing the shift rails............................. 122
17.3.26 Removing the shift drum ........................... 122
17.3.27 Removing the shift forks............................ 123
17.3.28 Removing the transmission shafts............... 123
17.3.29 Removing the crankshaft ........................... 123
17.4 Work on individual parts ................................ 124
17.4.1
Work on the right section of the engine
case ........................................................ 124
17.4.2
Work on the left section of the engine
case ........................................................ 125
17.4.3
Removing the crankshaft bearing inner
race......................................................... 125
17.4.4
Installing the crankshaft bearing inner
race......................................................... 126
17.4.5
Changing the connecting rod, conrod
bearing, and crank pin .............................. 126
17.4.6
Checking the crankshaft run-out at the
bearing pin............................................... 127
17.4.7
Checking/measuring the cylinder ................ 127
17.4.8
Removing the exhaust control .................... 128
17.4.9
Checking the exhaust control ..................... 130
17.4.10 Installing the exhaust control ..................... 130
17.4.11 Cylinder - Nikasil
®
coating ......................... 132
17.4.12 Checking/measuring the piston................... 133
13
14
15
16

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