Instant download of the factory repair manual for 2012 KTM 450 and 500 EXC and DOWNLOAD Instant download of the factory repair manual for 2012 KTM 450 and 500 EXC and DOWNLOAD Browse Catalog Publish & Sell. KTM EXC REPAIR MANUAL Pdf Download. SX,MXC,EXC REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5. Mattighofen Austria www. SX,MXC,EXC REPAIR MANUAL ENGINE.. SERVICE- INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 TROUBLE SHOOTING 9 TECHNICAL SPECIFICATIONS 1. PERIODIC MAINTENANCE SCHEDULE 1. WIRING DIAGRAMS.. Shop for KTM Dirt Bike Parts in our Dirt Bike section at Rocky Mountain ATV/MC. In addition to KTM Dirt Bike Parts, we have the best prices on dirt bike. View and Download KTM EXC repair manual online. KTM Automobile Parts User Manual. EXC Automobile Parts pdf manual download. Sign In Upload Page of 153 Go Download Table of Contents Contents Print This Page Print Share Share Url of this page. 2016 KTM 350 SX-F XC-F Service Repair Manual 2016 KTM 450 & 500 EXC & XC-W &6DAYS Service Repair Manual 2016 KTM 125 & 150 SX Service Repair Manual. 78703013000 REINFORCING B. 500 XC-W 2012 2 SPARE PARTS MANUAL: CHASSIS - ktm-parts.com http:// shapes, materials, services, service work. 1* 14187L6901 GABEL WP 450/500 EXC/XC-W. KTM REPAIR MANUAL IN LOOSE- LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. KTM Austria’s certificate of achievement for its quality system ISO 9. REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –.. C GENERAL INFORMATION INDEX OPERATING RANGES OF THE CARBURETOR .. CARBURETOR ADJUSTMENT ... CHECKING OF THE SETTING OF THE TVC SYSTEM . OPERATING RANGES OF THE CARBURETOR mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve. This range is influenced by the position of the air control screw . C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. Mixing ratio 2- stroke motor oil : super fuel 1: 4. Make sure that the oil does not overflow. CAUTION – H AVING COMPLETED THE BLEEDING PROCEDURE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT – KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL EVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS – A.. C SPECIAL TOOLS – ENGINE Fig. Description Universal engine work stand Clutch holder.. Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand- name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. EVER CLEAN YOUR MOTORCYCLE WITH A HIGH ELECTRICAL COMPONENTS CONNECTORS.. C REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE .... Filling in of transmission oil: – Remove the plug and top up with engine oil 1. W- 5. 0 (i. MOTOREX TOP SPEED 4. T). Draining gear oil NOTE: The transmission oil should already be drained when the engine is dismounted. Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch. C – Undo the screws and remove the right control cover. AREFULLY RELEASE THE KICKSTARTER SPRING – Take the complete kickstarter shaft out of the housing. Dismounting of the shift lock –.. Dismounting of the ignition (Kokusan) – Hold the flywheel with the holding spanner – Put the protection cover on the crankshaft thread, twist in the flywheel extractor and remove the flywheel. Parting of engine housing halves – Top ignition- gear upwards and remove all 1. NOTE: During disassembly, watch out for the shift rollers driving pins of the shift forks. They may remain in the shift roller. Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. SERVICING ON INDIVIDUAL COMPONENTS WORKING ON THE RIGHT- HAND HOUSING HALF .. WORKING ON THE LEFT- HAND HOUSING HALF .. CRANKSHAFT . Working on the right- hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. Grooved ball bearing of crankshaft Press old grooved ball- bearing inwards. Press in new ball bearing to the stop. C Working on the left- hand housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. Crankshaft roller bearing Press old roller bearing inwards, press in new ball bearing to the stop with the open side of ball cage downwards (outside). Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be renewed. Press the special tool together tightly so as to obtain a good heat transfer and pull the inner ring off the crankshaft. C 1. 0mm Checking cylinder for wear Measure diameter of cylinder approx. Check diameter in several corresponding places to see if cylinder in worn oval. Control rollers – Check clearance of bearings. Remove oil- derived deposits. Check toothing of control rollers for signs of wear. Gear segments –.. C – Mount and grease silicon O- rings (1. Slightly grease the bearing sleeves – Mount toothed segments (the toothed segment with the cylindrical pin has to be mounted on the right side). Damaged or worn reed paddles must be replaced. If the reed sealing surfaces of the reed valve housing are also damaged, replace the complete reed valve housing. CAUTION 2. 43. 5- 1. C 1. 3,5 mm LOCTITE 2. Clutch Thrust bearing check for wear Push rod Check for wear. Minimum length: 1. Clutch springs New spring length 4. Replace all 6 springs if applicable. Lining discs Minimum thickness 2. C Replace outer clutch hub – Drill open the clutch rivets remove parts. HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN THAT THE OUTER CLUTCH HUB ON THE PRIMARY GEAR CROWN TENSION WITH THE CLUTCH RIVETTING TOOL in area of retaining bracket for signs of mechanical damage.. LOCTITE 2. 43 LOCTITE 2. LOCTITE 2. 43 Shift mechanism Shift forks Check shift fork blades and shift roller driving pin Shift roller Check shift grooves for wear. Check position of shift roller in grooved ball bearings Slide plate Check slide plate at meshing points Check return surface for wear (renew, if strongly notched). C Kokusan 2. K- 1/2. K- 4 Kokusan 2. K- 2 Kokusan 2. K- 3 Ignition (Kokusan) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. C Transmission Secure mainshaft or countershaft in the vice (using soft jaw- covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels – Tooth faces of all gears –.. Transmission Secure mainshaft or countershaft in the vice (using soft jaw- covers). Remove gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels – Tooth faces of all gears –.. C LOCTITE 2. 43 LOCTITE 2. Kickstarter Starter gear Check clearance of starter gear. Starter intermediate gear Check clearance of starter intermediate gear. Locking pawl Check for signs of wear and damage. Kickstarter shaft Check for signs of wear and damage. For changing the locking pawl, press bearing needle kickstarter shaft. C ASSEMBLING THE ENGINE INDEX CRANKSHAFT ..... TRANSMISSION .– Secure the right- hand housing half in the engine work stand. Crankshaft – Insert crankshaft from above through grooved ball bearing and push carefully as far as stop. HEN PUSHING IN CRANKSHAFT Transmission – Grease the driving pins of the shift forks and mount the shift rollers –.. C M6 x .. Insert gearshift rails into the casing bores as far as they will go. NOTE: It must now be possible to gently turn gear shafts. Mounting shift mechanism – Place locating spring with bent leg upwards into engine housing. Mounting clutch discs and pressure cap – Oil the thrust bearing , and slide it over the drive shaft. Model 1. 99. 9 : 4. Model 2. 00. 0 : 5. Model 2. 00. 1 : 4. C Mounting steering covers – Mount the right- hand control cover – Place gasket in position and fix left- hand steering cover Mounting cylinder head – Clean cylinder and cylinder head sealing surface, place O- rings in grooves. STATIC IGNITION VALUES 2. SX, EXC .. 7- 5 STATIC GENERATOR VALUES 2. EXC . Checking the voltage regulator- rectifier (Shindengen) – Start the engine and switch on the low beam. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp –.. Checking the voltage regulator – Start the engine and switch on the low beam. In the case of a significant deviation from the nominal value: –.. C STATIC IGNITION VALUES 2. SX, EXC (KOKUSAN 2. K- 1, 2. K- 3, 2. K- 4) Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non- corroding condition, connectors tightly connected – spark plug screwed out and spark plug connector attached to ground –.. C 2. 50- 3. 80 EXC 2. S P O R T M O T O R C Y C L E S.. NOTE: – the black measuring lead applied to the ground. Features no rectifi- cation, only an over- voltage regulation. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. TROUBLE Engine fails to start Operating error.. C TROUBLE Engine has not enough Reed paddles tensionless or dama- power ged, surface of reed valve housing damaged Wear Electronical ignition timing faulty Engine revs not high and Carburetor overflows if level adjust running with four stroke too high, float needle seating is cycle dirty or enlarged Loose carburetor jets.. C TECHNICAL SPECIFICATIONS INDEX MODEL 1. ENGINE 2. 50 - 3. USA .... 9- 2 ENGINE 2. With the aid of cookies we analyze the typical use pattern of visitors to the website. Your continued use of our website shall be conclusively deemed acceptance of the use of cookies. For further information please read our Privacy Policy.
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