KTM 250 EXC RACING Owner's Manual page 102

4-1E
4
DISMANTLING THE ENGINE
INDEX
DRAINING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
DISMOUNTING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
DISMOUNTING THE CHAIN WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
DISASSEMBLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
DISMOUNTING THE IGNITION SYSTEM (400/520 MODELS UNTIL 2002) . . . . . . .4-3
DISMOUNTING THE IGNITION SYSTEM AND LOOSENING THE PRIMARY
GEAR (250 EXC MODELS FROM 2002, 450/525 MODELS FROM 2003) . . . . . . . .4-4
REMOVING THE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE CLUTCH DRIVE AND THE OUTER CLUCH HUB . . . . . . . . . . . . . . .4-5
DISMOUNTING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
DISMOUNTING THE UPPER CYLINDER HEAD PORTION . . . . . . . . . . . . . . . . . . . .4-7
DISMOUNTING CYLINDER HEAD, CYLINDER AND PISTON . . . . . . . . . . . . . . . . . .4-7
DISMOUNTING THE TIMING CHAIN AND THE TIMING GEAR . . . . . . . . . . . . . . . . .4-9
DISMOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER . . . . . . . . . . . .4-10
DISMOUNTING THE PRIMARY GEAR AND FREEWHEEL . . . . . . . . . . . . . . . . . . .4-11
DISMOUNTING THE SHIFT MECHANISM AND TRANSMISSION . . . . . . . . . . . . . .4-12
DISMOUNTING THE BALANCER SHAFT AND CRANKSHAFT . . . . . . . . . . . . . . . .4-13