KTM 250 EXC TPI 2019 Repair Manual page 6

TABLE OF CONTENTS
14.8.8
14.8.9
14.8.10
15 WIRING HARNESS, BATTERY.................... 157
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10 Checking the open-circuit current .... 165
15.11 Checking the starter relay ............... 165
15.12 Diagnostics connector .................... 166
16 BRAKE SYSTEM ....................................... 167
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
16.10 Changing the rear brake linings ....... 174
16.11 Checking the free travel of foot
16.12 Adjusting the basic position of the
16.13 Checking the rear brake fluid
16.14 Adding rear brake fluid ................... 178
16.15 Changing the rear brake fluid .......... 179
17 LIGHTING SYSTEM, INSTRUMENTS .......... 182
17.1
17.2
17.3
17.4
4
Checking the chain, rear
sprocket, engine sprocket, and
chain guide ............................... 151
Adjusting the chain tension ........ 153
Changing the drivetrain kit.......... 154
Ignition curve plug-in connector ...... 157
Changing the main fuse .................. 157
Changing the fuses of individual
power consumers ........................... 159
Disconnecting the negative cable
of the battery................................. 160
Connecting the negative cable of
the battery .................................... 161
Removing the battery ..................... 161
Installing the battery ...................... 162
Recharging the battery ................... 163
Checking the charging voltage ......... 164
Checking the front brake linings ...... 167
Changing the front brake linings ...... 167
Checking the free travel of the
hand brake lever ............................ 169
Adjusting free travel of hand brake
lever (All EXC models) .................... 170
Adjusting the basic position of the
hand brake lever (All XC-W
models)......................................... 170
Checking the front brake fluid
level ............................................. 170
Adding front brake fluid.................. 171
Changing the front brake fluid ......... 172
Checking the brake linings of the
rear brake...................................... 174
brake lever .................................... 176
foot brake lever.............................. 177
level ............................................. 178
Changing the headlight bulb ........... 182
Changing the turn signal bulb (All
EXC models).................................. 182
Checking the headlight setting ........ 183
Adjusting the headlight range.......... 184
17.5 Changing the combination
instrument .................................... 184
17.6 Combination instrument overview .... 185
17.7 Activation and test ......................... 185
17.8 Setting the kilometers or miles ........ 185
17.9 Adjusting the combination
instrument function........................ 186
17.10 Setting the clock............................ 187
17.11 Activating additional functions ........ 187
17.12 Setting the wheel circumference ..... 188
17.13 Viewing the lap time....................... 188
18 ENGINE ................................................... 190
18.1 Cleaning the pressure sensor hose ... 190
18.2 Removing the engine...................... 190
18.3 Installing the engine....................... 196
18.4 Engine disassembly........................ 203
18.4.1 Clamping the engine into the
engine work stand...................... 203
18.4.2 Removing the shift lever ............. 203
18.4.3 Removing the clutch push rod..... 203
18.4.4 Draining the gear oil................... 203
18.4.5 Removing the spacer.................. 204
18.4.6 Removing the alternator cover ..... 204
18.4.7 Removing the kick starter ........... 205
18.4.8 Removing injection valves........... 205
18.4.9 Removing the cylinder head ........ 205
18.4.10 Removing the cylinder................ 206
18.4.11 Removing the piston .................. 208
18.4.12 Removing the water pump
cover ........................................ 209
18.4.13 Removing the clutch cover.......... 209
18.4.14 Removing the clutch discs .......... 210
18.4.15 Removing the clutch basket ........ 211
18.4.16 Removing the balancer shaft....... 212
18.4.17 Removing the kick starter shaft ... 213
18.4.18 Removing the intermediate kick
starter gear................................ 213
18.4.19 Removing the shift shaft............. 214
18.4.20 Removing the shift drum
locating unit.............................. 214
18.4.21 Removing the locking lever ......... 214
18.4.22 Removing the rotor..................... 214
18.4.23 Removing the starter motor......... 215
18.4.24 Removing the reed valve
housing..................................... 216
18.4.25 Removing the left engine case
section ..................................... 217
18.4.26 Removing the shift rails.............. 217
18.4.27 Removing the shift drum ............ 217
18.4.28 Removing the shift forks............. 218
18.4.29 Removing the transmission
shafts ....................................... 218
18.4.30 Removing the crankshaft ............ 218