2004 ktm 125sx engine repair manual

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KTM 250-525 SX, MXC, EXC RACING ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 07-02-2012

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TM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. T he respective headings can be entered in the list of contents. Remove page (s) Replace by page (s) Insert page (s) after page 2-1 / 2-7 2-1C 2-7C to 2-9C 3-1 3-1C 4-1 to 4-14 4-1C to 4-13C 5-1 / 5-3 5-1C / 5-3C 5-6 to 5-8 5-6C to 5-8C 5-12 to 5-26 5-12C to 5-27C 6-1 / 6-4 6-1C / 6-4C 6-7 to 6-16 6-7C to 6-17C 7-1 to 7-2 7-1C to 7-2C 7-7 to 7-11 7-7C to 7-11C 8-1 to 8-13 8-1C to 8-21C 9-1 9-1C 9-10 to 9-13 9-10C to 9-16C 10-1 10-1C 10-8C to 10-11C 11-1 11-1C 11-11C to 11-13C
Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E EXPLANATION – UPDATING Edition 01/2003 3.205.85-ERepair Manual 400/520 SX, MXC, EXC RACING Basic version Model year 2000 (Engine number with first digit “0″) 2/2000 3.210.01-EUpdating of Rep.Manual 3.205.85-E Model year 2001 (Engine number with first digit “1″) 1/2001 3.210.44-EUpdating of Rep.Manual 3.205.85-E Model year 2002 (Engine number with first digit “2″)

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KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 12-11-2010

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. Opening up B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB:

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KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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Filed Under (KTM) by admin on 12-11-2010

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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KTM 250 – 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 04-02-2012

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KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.

MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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2004-2005 KTM 85 SX / 105 SX REPAIR MANUAL

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Filed Under (KTM) by admin on 24-02-2012

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TORING THE REPAIR MANUAL IN THE BINDER -Put the index (3.205.44) into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5, 3 = chapter 3, 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. T he respective headings can be entered in the list of contents

2003 KTM RA 250 SX REPAIR MANUAL ENGINE

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Filed Under (KTM) by admin on 08-02-2012

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STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. T he respective headings can be entered in the list of contents

2004 KTM 950 ADVENTURE REPAIR MANUAL

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Filed Under (KTM) by admin on 23-11-2010

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Intake system Fresh air is drawn into the filter box through the intake snorkel 1 , past the carburetors 2 and through the air filter 3 . The cleaned air is conducted to the combustion chamber through the carburetors and intake ports. 1 2 2 3 2-4 Repair manual KTM LC8 Art.-Nr . 3.206.016-E Secondary air system The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box 1 to the control valve 2 which opens as soon as the throttle valves 3 are opened. The line continues to the reed valves 4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas temperature cause the emissions to oxidize. If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture). 1 2 3 3 4 4 4 2-5 Closed thermostat The thermostat is closed if the temperature of the cooling liquid drops below 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 and the thermostat 2 . Open thermostat The thermostat 3 opens at 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 , the aluminum cooler 4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator cap 5 . The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold. The fan 7 switches on at 102°C.

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2004 Honda CRF450R OWNER'S MANUAL

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Filed Under (Honda) by admin on 21-11-2010

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motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Check the engine oil, transmission oil and coolant levels before starting the engine (page 21, 23, 24). Cold Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. If the temperature is 35°C (95°F) or below, pull the choke knob fully out. 4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 5. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kick- starting difficult.) 6. About a minute after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. (1) FUEL FILL CAP (2) BREATHER TUBE WARNING (1) FUEL VALVE (2) CHOKE KNOB Warm Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever 1. Shift the transmission into neutral. 2. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 3. As soon as the engine starts, release the hot start lever. Starting the engine excessively charged with fuel by throttle blipping or other reasons: 1. Shift the transmission into neutral. 2. With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine. 3. Pull the hot start lever and kick-start the engine (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever. Stopping The Engine 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle 2 – 3 times, and then close it. 4. Depress and hold the engine stop button until the engine stops completely. NOTE: • Failure to close the fuel valve may cause the carburetor to overflow. (1) THROTTLE GRIP (2) ENGINE STOP BUTTON Break-In Procedure Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: • Piston is replaced • Rings are replaced • Cylinder is replaced • Crankshaft or crank bearing are replaced

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POLINI MINICROSS AND MlNlMOTARD OWNER'S AND MAINTENANCE MANUAL

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Filed Under (Polini) by admin on 22-11-2010

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Fit the stand using the M8x18 screw to fasten it and the spring provided (photo 1 6). A DANGER! We suggest you to remove the stand during competitions as it could be dangerous and bruising. 18- Fit the gear lever l~hoto 171. 19- Fill the fuel tank (See section 4.13). 20- Check the engine oil level (See section 4.3). INTRODUCTION Always ensure that the motorcycle has been efficiently serviced and check it over before riding it. Take your motorcycle to an authorised POIJNI MOTOR1 dealer for all maior servicing and repair. Because of the manufacturer’s policy OF continuous development, and because of constant innovations in technology, your motorcycle may differ in some details from that described in the illustrations and text in this manual. Original POLlNl MOTOR1 spare parts are always made from the same materials and in the same way as the parts originally fitted to your minicross motorcycle. Always insist on original POIJNI MOTOR1 spore parts. Their use ensures a longer life and improved efficiency for your motorcycle. 2. STARTING THE ENGINE FOR THE FIRST TIME Always check over your motorcycle thoroughly before starting the engine. To start the engine for the first time, as instructed below. 1 – Turn the fuel tap located under the fuel tank to #ON” position (photo 18) Run your new motorcycle in as instructed How to ensure that the engine and transmission bed in correctly and to ensure continuous reliability in Future. A CAUTION! The first time yw ride your new motorcycle, ride for about two hours at low engine speeds to ensure that it runs in correctly. Also respect the following precautions. 2- Once the engine starts, leave it idle until it warms up to normal temperature. If you switch the engine off for a short time, wait for it to cool down completely before you re-start it. – 3- During the running in period, always ride at constant 2- Before starting the engine put the gear in neutral position speeds. AVOID RAPID ACCELERATION. (photo 19, gear N). 4- Even when riding at low engine speeds, avoid extended A WARNING! IF the gear position is not neutral the bike could move when started. 3- If the engine is cold, lift the choke lever on the carburettor (photo 20). A WARNING! Lower the starter lever again as won as the engine starts to warm up. 4- Leove the throttle closed. Pivot the kick-start lever out wards and push energetically downwards with your foot to start the engine. 5- Return the kick-start lever to its rest position. Leave the engine idle for a few minutes to warm it up. A WARNING! Check that the engine stop button stops the engine effectively before yw begin riding the motorcycle. difficult sections of road or Lck that could cause the engine to become very hot. 5- Once you have run in your motorcycle following all these instructions, take it to a Polini Motori dealer for its post- running-in service. Apart from a change of spark plug and engine oil, this service also includes the disassembly

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