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KTM 250 SX Manual

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9-38C
TIGHTENING TORQUES
Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb)
Nuts-cylinder base M 10 35 Nm (25 ft.lb)
Flywheel collar nut M 12x1 60 Nm (44 ft.lb)
Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb)
Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb)
Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb)
Crankcase and cover bolts M 6 8 Nm (6 ft.lb)
Swingarm pivot M 14 100 Nm (74 ft.lb)
Other screws M 6 10 Nm (7 ft.lb)
M 8 25 Nm (19 ft.lb)
M 10 45 Nm (33 ft.lb)
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet nozzle
250/300 EXC
throttled
Keihin PWK 38 AG
120202
175 (182,185)
35 (48)
85
R 1475 J
(N3CH/N3CW)
III
6.5
1.5
slide stop 34mm
250 EXC USA
Keihin PWK 38 AG
140202
182 (185)
48
85
N3CH (N3CW)
IV
6.5
1.5
–
–
300 EXC AUS
throttled
Keihin PWK 38 AG
130202
175 (172,178)
35 (45,48)
85
R1475J (NOZ H/NOZ
I)
II
6.5
1.5
slide stop 34mm
Keihin PWK 38 AG
150202
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6.5
1.5
–
–
300 MXC / EXC
USA
Piston fitting clearance 0.06 mm (250 / 300)
Piston ring end gap 0.3– 0.4 mm
Connecting rod bearing - radial clearance
0.021– 0.032 mm
Transmission shafts end float 0.1– 0.2 mm
Clutch springs - length Ø 2.5 minimum length = 42 mm, new = 43 mm
Crankshaft webs – outer dimension 60 mm
± 0,05 mm
Runout Crankshaft journal Crankshaft max 0,06 (neu 0,03)
TOLERANCES AND FITTING CLEARANCES
GASKET THICKNESSES
Crankcase 0.5 mm
Clutch cover 0.5 mm
Cylinder bottom gasket as required
Available cylinder bottom gaskets 0.2/0.4/0.5 /0.75 mm
Cylinder-head gasket O-rings
… 122 …


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