KTM 250 EXC TPI 2019 Repair Manual page 7

18.5 Working on individual parts............. 219
18.5.1 Working on the right section of
the engine case ......................... 219
18.5.2 Working on the left section of
the engine case ......................... 220
18.5.3 Removing the crankshaft
bearing inner race...................... 222
18.5.4 Installing the crankshaft bearing
inner race ................................. 222
18.5.5 Changing the connecting rod,
conrod bearing, and crank pin..... 223
18.5.6 Checking the crankshaft run-out
at the bearing pin ...................... 224
18.5.7 Checking/measuring the
cylinder .................................... 224
18.5.8 Cleaning the pressure sensor
cylinder connection.................... 225
18.5.9 Removing the exhaust control ..... 225
18.5.10 Checking the exhaust control ...... 227
18.5.11 Installing the exhaust control ...... 229
18.5.12 Cylinder - Nikasil
®
18.5.13 Checking/measuring the piston.... 232
18.5.14 Checking the piston ring end
gap........................................... 233
18.5.15 Measuring the piston/cylinder
mounting clearance.................... 233
18.5.16 Disassemble the reed valve
housing..................................... 234
18.5.17 Checking the reed valve
housing, reed valve and intake
flange ....................................... 235
18.5.18 Assemble the reed valve
housing..................................... 235
18.5.19 Working on the clutch cover........ 237
18.5.20 Checking the clutch ................... 240
18.5.21 Preassembling shift shaft ........... 241
18.5.22 Checking the shift mechanism .... 242
18.5.23 Disassembling the main shaft ..... 243
18.5.24 Disassembling the
countershaft .............................. 244
18.5.25 Checking the transmission .......... 244
18.5.26 Assembling the main shaft.......... 246
18.5.27 Assembling the countershaft ....... 246
18.5.28 Checking the kick starter ............ 248
18.5.29 Preassembling the kick starter
shaft......................................... 248
18.5.30 Checking the electric starter
drive......................................... 249
18.6 Engine assembly ............................ 250
18.6.1 Installing the crankshaft ............. 250
18.6.2 Installing the transmission
shafts ....................................... 251
18.6.3 Installing the shift forks.............. 251
18.6.4 Installing the shift drum ............. 252
18.6.5 Installing the shift rails .............. 252
coating .......... 232
19 CLUTCH ................................................... 275
20 WATER PUMP, COOLING SYSTEM ............. 286
21 EXHAUST CONTROL ................................. 291
18.6.6 Installing the left engine case
section ..................................... 252
18.6.7 Installing the reed valve
housing..................................... 253
18.6.8 Installing the starter motor.......... 254
18.6.9 Installing the rotor ..................... 255
18.6.10 Installing the locking lever .......... 255
18.6.11 Installing the shift drum
locating unit.............................. 256
18.6.12 Installing the shift shaft ............. 256
18.6.13 Installing the intermediate kick
starter gear................................ 256
18.6.14 Installing the kick starter shaft.... 256
18.6.15 Installing the balancer shaft........ 257
18.6.16 Installing the clutch basket......... 258
18.6.17 Installing the clutch discs........... 259
18.6.18 Installing the clutch cover .......... 261
18.6.19 Installing the water pump
cover ........................................ 263
18.6.20 Installing the piston ................... 264
18.6.21 Installing the cylinder................. 265
18.6.22 Checking the X-distance ............. 267
18.6.23 Adjusting the X-distance............. 267
18.6.24 Adjusting the Z-distance............. 269
18.6.25 Installing the cylinder head......... 271
18.6.26 Installing injection valves ........... 272
18.6.27 Installing the kick starter ............ 272
18.6.28 Installing the alternator cover...... 272
18.6.29 Installing the spacer................... 273
18.6.30 Installing the gear oil drain
plug ......................................... 273
18.6.31 Installing the clutch push rod ..... 274
18.6.32 Installing the shift lever.............. 274
18.6.33 Removing the engine from the
engine work stand...................... 274
19.1 Checking/correcting the fluid level
of the hydraulic clutch.................... 275
19.2 Changing the hydraulic clutch
fluid ............................................. 276
19.3 Checking the clutch ....................... 277
20.1 Cooling system .............................. 286
20.2 Checking the antifreeze and
coolant level .................................. 286
20.3 Checking the coolant level .............. 287
20.4 Draining the coolant ....................... 287
20.5 Refilling with coolant ..................... 288
21.1 Checking/adjusting the exhaust
control .......................................... 291
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