KTM 250 EXC TPI 2019 Repair Manual page 383

D
Diagnostics connector . . . . . . . . . . . . . . . . . . . 166
Drivetrain kit
changing . . . . . . . . . . . . . . . . . . . . . . . . . 154
E
Engine
assembling . . . . . . . . . . . . . . . . . . . . . . . 250
disassembling . . . . . . . . . . . . . . . . . . . . . 203
installing . . . . . . . . . . . . . . . . . . . . . . . . . 196
removing . . . . . . . . . . . . . . . . . . . . . . . . . 190
technical data - engine . . . . . . . . . . . . . . . 312
working on individual parts
Engine – work on the individual parts
connecting rod, conrod bearing, and crank pin,
changing . . . . . . . . . . . . . . . . . . . . . . . . . 223
crankshaft bearing inner race, installing . . . . 222
crankshaft bearing inner race, removing . . . . 222
crankshaft run-out at the bearing pin, checking 224
cylinder, checking/measuring . . . . . . . . . . . 224
engine case section, right . . . . . . . . . . . . . 219
exhaust control, checking . . . . . . . . . . . . . 227
exhaust control, removing . . . . . . . . . . . . . 225
kick starter, checking . . . . . . . . . . . . . . . . 248
main shaft, disassembling . . . . . . . . . . . . . 243
piston ring end gap, checking . . . . . . . . . . . 233
piston, checking . . . . . . . . . . . . . . . . . . . . 232
piston, measuring . . . . . . . . . . . . . . . . . . . 232
piston/cylinder, measuring the mounting
clearance . . . . . . . . . . . . . . . . . . . . . . . . 233
reed valve housing, assembling . . . . . . . . . . 235
reed valve housing, disassembling . . . . . . . . 234
shift mechanism, checking
shift shaft, preassembling . . . . . . . . . . . . . 241
stator, installing . . . . . . . . . . . . . . . . . . . . 308
transmission, checking . . . . . . . . . . . . . . . 244
Engine – working on the individual parts
clutch cover . . . . . . . . . . . . . . . . . . . . . . . 237
clutch, checking . . . . . . . . . . . . . . . . . . . . 240
countershaft, assembling . . . . . . . . . . . . . . 246
countershaft, disassembling . . . . . . . . . . . . 244
cylinder - Nikasil ® coating . . . . . . . . . . . . . 232
electric starter drive, checking . . . . . . . . . . 249
engine case section, left . . . . . . . . . . . . . . 220
exhaust control, installing . . . . . . . . . . . . . 229
intake flange, checking . . . . . . . . . . . . . . . 235
main shaft, assembling . . . . . . . . . . . . . . . 246
reed valve housing, checking . . . . . . . . . . . 235
reed valve, checking . . . . . . . . . . . . . . . . . 235
stator, removing . . . . . . . . . . . . . . . . . . . . 307
Engine assembly
alternator cover, installing . . . . . . . . . . . . . 272
balancer shaft, installing . . . . . . . . . . . . . . 257
. . . . . . . . . . . . 219
Engine disassembly
. . . . . . . . . . . . 242
clutch basket, installing . . . . . . . . . . . . . . 258
clutch cover, installing . . . . . . . . . . . . . . . 261
clutch discs, installing . . . . . . . . . . . . . . . 259
clutch push rod, installing . . . . . . . . . . . . . 274
crankshaft, installing . . . . . . . . . . . . . . . . . 250
cylinder head, installing . . . . . . . . . . . . . . 271
cylinder, installing . . . . . . . . . . . . . . . . . . 265
engine, removing from the engine work stand 274
gear oil drain plug, installing . . . . . . . . . . . 273
intermediate kick starter gear, installing
kick starter shaft, installing . . . . . . . . . . . . 256
kick starter shaft, preassembling . . . . . . . . . 248
kick starter, installing . . . . . . . . . . . . . . . . 272
left engine case section, installing
locking lever, installing . . . . . . . . . . . . . . . 255
piston, installing . . . . . . . . . . . . . . . . . . . 264
reed valve housing, installing . . . . . . . . . . . 253
rotor, installing . . . . . . . . . . . . . . . . . . . . . 255
shift drum locating unit, installing . . . . . . . 256
shift drum, installing . . . . . . . . . . . . . . . . . 252
shift forks, installing . . . . . . . . . . . . . . . . . 251
shift lever, installing . . . . . . . . . . . . . . . . . 274
shift rails, installing . . . . . . . . . . . . . . . . . 252
shift shaft, installing . . . . . . . . . . . . . . . . . 256
spacer, installing . . . . . . . . . . . . . . . . . . . 273
starter motor, installing . . . . . . . . . . . . . . . 254
transmission shafts, installing . . . . . . . . . . 251
water pump cover, installing
X-distance, adjusting . . . . . . . . . . . . . . . . . 267
X-distance, checking . . . . . . . . . . . . . . . . . 267
Z-distance, setting . . . . . . . . . . . . . . . . . . 269
alternator cover, removing . . . . . . . . . . . . . 204
balancer shaft, removing . . . . . . . . . . . . . . 212
clutch basket, removing . . . . . . . . . . . . . . . 211
clutch cover, removing . . . . . . . . . . . . . . . 209
clutch discs, removing . . . . . . . . . . . . . . . 210
clutch push rod, removing . . . . . . . . . . . . . 203
crankshaft, removing . . . . . . . . . . . . . . . . . 218
cylinder head, removing . . . . . . . . . . . . . . . 205
cylinder, removing . . . . . . . . . . . . . . . . . . 206
engine, clamping into the engine work stand
gear oil, draining . . . . . . . . . . . . . . . . . . . 203
injection valves, installing . . . . . . . . . . . . . 272
Injection valves, removing . . . . . . . . . . . . . 205
intermediate kick starter gear, removing . . . . 213
kick starter shaft, removing . . . . . . . . . . . . 213
kick starter, removing . . . . . . . . . . . . . . . . 205
left engine case section, removing . . . . . . . . 217
locking lever, removing . . . . . . . . . . . . . . . 214
piston, removing . . . . . . . . . . . . . . . . . . . . 208
reed valve housing, removing . . . . . . . . . . . 216
rotor, removing . . . . . . . . . . . . . . . . . . . . . 214
. . . 256
. . . . . . . 252
. . . . . . . . . . . 263
203
381
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