KTM 250 EXC TPI 2019 Repair Manual page 5

9 SHOCK ABSORBER, SWINGARM ................. 78
9.1 Adjusting the high-speed
compression damping of the shock
absorber.......................................... 78
9.2 Adjusting the low-speed
compression damping of the shock
absorber.......................................... 78
9.3 Adjusting the rebound damping of
the shock absorber ........................... 79
9.4 Measuring the rear wheel dimension
unloaded......................................... 80
9.5 Checking the static sag of the shock
absorber.......................................... 80
9.6 Checking the riding sag of the shock
absorber.......................................... 81
9.7 Adjusting the spring preload of the
shock absorber ................................ 81
9.8 Adjusting the riding sag .................... 82
9.9 Removing the shock absorber ............ 83
9.10 Installing the shock absorber............. 83
9.11 Servicing the shock absorber............. 83
9.12 Removing the spring......................... 84
9.13 Disassembling the damper ................ 85
9.14 Disassembling the seal ring
retainer ........................................... 86
9.15 Disassembling the piston rod ............ 87
9.16 Replacing the pilot bushing .............. 88
9.17 Checking the damper ....................... 89
9.18 Removing the heim joint................... 90
9.19 Installing the heim joint.................... 91
9.20 Assembling seal ring retainer ............ 91
9.21 Assembling the piston rod................. 92
9.22 Assembling the damper .................... 94
9.23 Bleeding and filling the damper ........ 96
9.24 Filling damper with nitrogen ............. 99
9.25 Installing the spring ....................... 100
9.26 Checking the swingarm................... 101
9.27 Checking the heim joint for play ...... 101
9.28 Changing the heim joint.................. 102
9.29 Changing the heim joint on the
swingarm ...................................... 103
9.30 Checking the swingarm bearing for
play .............................................. 105
9.31 Removing the swingarm.................. 105
9.32 Installing the swingarm................... 106
9.33 Changing the swingarm bearing ....... 108
10 EXHAUST ................................................. 111
10.1 Removing the manifold................... 111
10.2 Installing the manifold ................... 112
10.3 Removing the main silencer ............ 113
10.4 Installing the main silencer............. 114
10.5 Changing the glass fiber yarn filling
in the main silencer ....................... 114
11 AIR FILTER .............................................. 116
11.1 Removing the air filter box cover ..... 116
11.2 Installing the air filter box cover ...... 116
11.3 Removing the air filter .................... 117
11.4 Installing the air filter..................... 117
11.5 Cleaning the air filter and air filter
box ............................................... 118
11.6 Preparing air filter box cover for
securing........................................ 118
11.7 Sealing the air filter box ................. 119
12 FUEL TANK, SEAT, TRIM .......................... 120
12.1 Opening the filler cap..................... 120
12.2 Closing the filler cap ...................... 120
12.3 Removing the seat ......................... 121
12.4 Mounting the seat .......................... 121
12.5 Removing the fuel tank................... 122
12.6 Installing the fuel tank ................... 123
12.7 Changing the fuel screen ................ 125
12.8 Changing the fuel filter................... 126
12.9 Changing the fuel pump ................. 129
12.10 Checking the fuel pressure.............. 132
13 MASK, FENDER........................................ 134
13.1 Removing front fender .................... 134
13.2 Installing front fender..................... 134
13.3 Removing the headlight mask with
the headlight ................................. 135
13.4 Installing the headlight mask with
the headlight ................................. 135
14 WHEELS .................................................. 137
14.1 Checking the tire air pressure.......... 137
14.2 Checking the tire condition ............. 137
14.3 Checking the wheel bearing for
play .............................................. 138
14.4 Checking the brake discs ................ 139
14.5 Checking the rim run-out ................ 139
14.6 Checking spoke tension .................. 140
14.7 Front wheel ................................... 141
14.7.1 Removing the front wheel ........... 141
14.7.2 Installing the front wheel ............ 142
14.7.3 Changing the front brake disc ..... 142
14.7.4 Changing front wheel bearing ...... 143
14.8 Rear wheel .................................... 144
14.8.1 Removing the rear wheel ............ 144
14.8.2 Installing the rear wheel ............. 145
14.8.3 Changing the rear brake disc....... 146
14.8.4 Changing the rear wheel
bearing ..................................... 147
14.8.5 Checking the chain for dirt ......... 149
14.8.6 Cleaning the chain ..................... 149
14.8.7 Checking the chain tension......... 150
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