KTM 250 EXC TPI 2019 Manuals

Manuals and User Guides for KTM 250 EXC TPI 2019. We have 3 KTM 250 EXC TPI 2019 manuals available for free PDF download: Repair Manual, Owner's Manual, Setup Instructions

KTM 250 EXC TPI 2019 Repair Manual (387 pages)

Brand: KTM | Category: Motorcycle | Size: 19.58 MB

Table of Contents
4
1 Means of Representation 1

9
- Symbols Used
  9
- Formats Used
  9
2 Safety Advice

10
- Repair Manual
  10
- Degrees of Risk and Symbols
  10
- Work Rules
  10
3 Important Notes 3

11
- Manufacturer and Implied Warranty
  11
- Operating and Auxiliary Substances
  11
- Spare Parts, Accessories
  11
- Figures
  11
4 Serial Numbers

12
- Chassis Number
  12
- Type Label
  12
- Engine Number
  12
- Fork Part Number
  12
- Shock Absorber Article Number
  13
5 Motorcycle

14
6 Fork, Triple Clamp

16
7 Handlebar, Controls 7

69
8 Frame

76
9 Shock Absorber, Swingarm

80
10 Exhaust 10

113
- Removing the Manifold
  113
- Installing the Manifold
  114
- Removing the Main Silencer
  115
- Installing the Main Silencer
  116
- Changing the Glass Fiber Yarn Filling in the Main Silencer
  116
11 Air Filter

118
- Air Filter
  118
- Removing the Air Filter Box Cover
  118
- Installing the Air Filter Box Cover
  118
- Removing the Air Filter
  119
- Installing the Air Filter
  119
- Cleaning the Air Filter and Air Filter Box
  120
- Preparing Air Filter Box Cover for Securing
  120
- Sealing the Air Filter Box
  121
12 Fuel Tank, Seat, Trim

122
- Opening the Filler Cap
  122
- Closing the Filler Cap
  122
- Removing the Seat
  123
- Mounting the Seat
  123
- Removing the Fuel Tank
  124
- Installing the Fuel Tank
  125
- Changing the Fuel Screen
  127
- Changing the Fuel Filter
  128
- Changing the Fuel Pump
  131
- Checking the Fuel Pressure
  134
13 Mask, Fender

136
14 Wheels 14

139
- Checking the Tire Air Pressure
  139
- Checking the Tire Condition
  139
- Checking the Wheel Bearing for Play
  140
- Checking the Brake Discs
  141
- Checking the Rim Run-Out
  141
- Checking Spoke Tension
  142
- Front Wheel
  143
- Removing the Front Wheel
  143
- Installing the Front Wheel
  144
- Changing the Front Brake Disc
  144
- Changing Front Wheel Bearing
  145
- Rear Wheel
  146
- Removing the Rear Wheel
  146
- Installing the Rear Wheel
  147
- Changing the Rear Brake Disc
  148
- Changing the Rear Wheel Bearing
  149
- Checking the Chain for Dirt
  151
- Cleaning the Chain
  151
- Checking the Chain Tension
  152
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
  153
- Adjusting the Chain Tension
  155
- Changing the Drivetrain Kit
  156
15 Wiring Harness, Battery 15

159
- Ignition Curve Plug-In Connector
  159
- Changing the Main Fuse
  159
- Changing the Fuses of Individual Power Consumers
  161
- Disconnecting the Negative Cable of the Battery
  162
- Connecting the Negative Cable of the Battery
  163
- Removing the Battery
  163
- Installing the Battery
  164
- Recharging the Battery
  165
- Checking the Charging Voltage
  166
- Checking the Open-Circuit Current
  167
- Checking the Starter Relay
  167
- Diagnostics Connector
  168
16 Brake System 16

169
17 Lighting System, Instruments

184
- Changing the Headlight Bulb
  184
- Changing the Turn Signal Bulb (All EXC Models)
  184
- Checking the Headlight Setting
  185
- Adjusting the Headlight Range
  186
- Changing the Combination Instrument
  186
- Combination Instrument Overview
  187
- Activation and Test
  187
- Setting the Kilometers or Miles
  187
- Adjusting the Combination Instrument Function
  188
- Setting the Clock
  189
- Activating Additional Functions
  189
- Setting the Wheel Circumference
  190
- Viewing the Lap Time
  190
18 Engine

192
- Cleaning the Pressure Sensor Hose
  192
- Removing the Engine
  192
- Installing the Engine
  198
- Engine Disassembly
  205
- Clamping the Engine into the Engine Work Stand
  205
- Removing the Shift Lever
  205
- Removing the Clutch Push Rod
  205
- Draining the Gear Oil
  205
- Removing the Spacer
  206
- Removing the Alternator Cover
  206
- Removing the Kick Starter
  207
- Removing Injection Valves
  207
- Removing the Cylinder Head
  207
- Removing the Cylinder
  208
- Removing the Piston
  210
- Removing the Water Pump Cover
  211
- Removing the Clutch Cover
  211
- Removing the Clutch Discs
  212
- Removing the Clutch Basket
  213
- Removing the Balancer Shaft
  214
- Removing the Kick Starter Shaft
  215
- Removing the Intermediate Kick Starter Gear
  215
- Removing the Shift Shaft
  216
- Removing the Shift Drum Locating Unit
  216
- Removing the Locking Lever
  216
- Removing the Rotor
  216
- Removing the Starter Motor
  217
- Removing the Reed Valve Housing
  218
- Removing the Left Engine Case Section
  219
- Removing the Shift Rails
  219
- Removing the Shift Drum
  219
- Removing the Shift Forks
  220
- Removing the Transmission Shafts
  220
- Removing the Crankshaft
  220
- Working on Individual Parts
  221
- Working on the Right Section of the Engine Case
  221
- Working on the Left Section of the Engine Case
  222
- Removing the Crankshaft Bearing Inner Race
  224
- Installing the Crankshaft Bearing Inner Race
  224
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin
  225
- Checking the Crankshaft Run-Out at the Bearing Pin
  226
- Checking/Measuring the Cylinder
  226
- Cleaning the Pressure Sensor Cylinder Connection
  227
- Removing the Exhaust Control
  227
- Checking the Exhaust Control
  229
- Installing the Exhaust Control
  231
- Cylinder - Nikasil Coating
  234
- Checking/Measuring the Piston
  234
- Checking the Piston Ring End Gap
  235
- Measuring the Piston/Cylinder Mounting Clearance
  235
- Disassemble the Reed Valve Housing
  236
- Checking the Reed Valve Housing, Reed Valve and Intake Flange
  237
- Assemble the Reed Valve Housing
  237
- Working on the Clutch Cover
  239
- Checking the Clutch
  242
- Preassembling Shift Shaft
  243
- Checking the Shift Mechanism
  244
- Disassembling the Main Shaft
  245
- Disassembling the Countershaft
  246
- Checking the Transmission
  246
- Assembling the Main Shaft
  248
- Assembling the Countershaft
  248
- Checking the Kick Starter
  250
- Preassembling the Kick Starter Shaft
  250
- Checking the Electric Starter Drive
  251
- Engine Assembly
  252
- Installing the Crankshaft
  252
- Installing the Transmission Shafts
  253
- Installing the Shift Forks
  253
- Installing the Shift Drum
  254
- Installing the Shift Rails
  254
  - Installing the Left Engine Case Section
    254
  - Installing the Reed Valve Housing
    255
  - Installing the Starter Motor
    256
  - Installing the Rotor
    257
  - Installing the Locking Lever
    257
  - Installing the Shift Drum Locating Unit
    258
  - Installing the Shift Shaft
    258
  - Installing the Intermediate Kick Starter Gear
    258
  - Installing the Kick Starter Shaft
    258
  - Installing the Balancer Shaft
    259
  - Installing the Clutch Basket
    260
  - Installing the Clutch Discs
    261
  - Installing the Clutch Cover
    263
  - Installing the Water Pump Cover
    265
  - Installing the Piston
    266
  - Installing the Cylinder
    267
  - Checking the X-Distance
    269
  - Adjusting the X-Distance
    269
  - Adjusting the Z-Distance
    271
  - Installing the Cylinder Head
    273
  - Installing Injection Valves
    274
  - Installing the Kick Starter
    274
  - Installing the Alternator Cover
    274
  - Installing the Spacer
    275
  - Installing the Gear Oil Drain Plug
    275
  - Installing the Clutch Push Rod
    276
  - Installing the Shift Lever
    276
  - Removing the Engine from the Engine Work Stand
    276
19 Clutch 19

277
20 Water Pump, Cooling System

288
- Cooling System
  288
- Checking the Antifreeze and Coolant Level
  288
- Checking the Coolant Level
  289
- Draining the Coolant
  289
- Refilling with Coolant
  290
21 Exhaust Control 21

293
- Checking/Adjusting the Exhaust Control
  293
22 Lubrication System

296
- Changing the Gear Oil
  296
- Checking the Gear Oil Level
  297
- Adding Gear Oil
  297
- Checking 2-Stroke Oil Level
  298
- Opening 2-Stroke Oil Tank Cap
  299
- Adding 2-Stroke Oil
  299
- Closing 2-Stroke Oil Tank Cap
  299
- Priming the Oil Pump
  300
- Replacing the Oil Pump
  301
23 Ignition System

304
24 Electric Starter 24

311
- Checking the Starter Motor
  311
25 Throttle Valve Body

312
- Adjusting the Idle Speed
  312
- Programming Ambient Pressure
  312
- Cold Start Button
  313
26 Technical Data

314
- Engine
  314
- All 250 Models
  314
- All 300 Models
  314
- Tolerance, Engine Wear Limits
  315
- Engine Tightening Torques
  316
- Capacities
  317
- Gear Oil
  317
- Engine Oil
  317
- Coolant
  317
- Fuel
  318
- Chassis
  318
- Electrical System
  319
- Tires
  319
- Fork
  319
- All Standard EXC/XC-W Models
  319
- All Six Days Models
  320
- Shock Absorber
  320
- Chassis Tightening Torques
  321
27 Cleaning, Care

324
- Cleaning, Care
  324
- Cleaning the Motorcycle
  324
- Checks and Maintenance Steps for Winter Operation
  325
28 Storage

326
- Preparing for Use after Storage
  327
29 Service Schedule

328
- Additional Information
  328
- Required Work
  328
- Recommended Work
  329
30 Wiring Diagram

332
- All EXC Models)
  332
- All EXC Models)
  334
- All EXC Models)
  336
- All EXC Models)
  338
- All EXC Models)
  340
- All EXC Models)
  342
- All EXC Models)
  344
- All EXC Models)
  346
- All XC-W Models)
  348
- All XC-W Models)
  350
- All XC-W Models)
  352
- All XC-W Models)
  354
- All XC-W Models)
  356
- All XC-W Models)
  358
31 Substances

360
32 Auxiliary Substances

362
33 Special Tools

364
34 Standards 34

379
35 Index of Special Terms

380
36 List of Abbreviations 36

381
- Index
  382

KTM 250 EXC TPI 2019 Owner's Manual (176 pages)

Brand: KTM | Category: Motorcycle | Size: 6.37 MB

Table of Contents
4
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice 2
9
Use Definition - Intended Use
9
Misuse
9
Degrees of Risk and Symbols
10
Tampering Warning
10
Safe Operation
10
Protective Clothing
11
Work Rules
11
Environment
11
Owner's Manual
12
Important Notes 3
13
Manufacturer and Implied Warranty
13
Operating and Auxiliary Substances
13
Spare Parts, Accessories
13
Service
13
Figures
13
Customer Service
13
View of Vehicle 4
15
View of Vehicle, Front Left (Example)
15
View of Vehicle, Rear Right (Example)
16
Serial Numbers 5
17
Chassis Number
17
Type Label
17
Key Number (All EXC Models)
17
Engine Number
17
Fork Part Number
18
Shock Absorber Article Number
18
Controls 6
19
Clutch Lever
19
Hand Brake Lever
19
Throttle Grip
19
Kill Switch (All EXC Models)
19
Kill Switch (All XC-W Models)
20
Horn Button (All EXC Models)
20
Light Switch (All EXC Models)
20
Light Switch (All XC-W Models)
20
Turn Signal Switch (All EXC Models)
21
Emergency off Switch (All EXC Models)
21
Electric Starter Button
21
Map Switch (All Six Days Models)
21
Indicator Lamps Overview (All EXC Models)
22
Indicator Lamps Overview (All XC-W Models)
22
Opening the Filler Cap
22
Closing the Filler Cap
23
Opening 2-Stroke Oil Tank Cap
23
Closing 2-Stroke Oil Tank Cap
24
Cold Start Button
24
Idle Speed Adjusting Screw
25
Shift Lever
25
Kick Starter
26
Foot Brake Lever
26
Side Stand
26
Steering Lock (All EXC Models)
27
Locking the Steering (All EXC Models)
27
Unlocking the Steering (All EXC Models)
27
Combination Instrument
28
Combination Instrument Overview
28
Activation and Test
28
Setting the Kilometers or Miles
28
Adjusting the Combination Instrument Function
29
Setting the Clock
30
Viewing the Lap Time
30
Display Mode SPEED (Speed)
31
Display Mode SPEED/H (Operating Hours)
31
Setup Menu
31
Setting the Unit of Measurement
32
Display Mode SPEED/CLK (Time)
33
Setting the Clock
33
Display Mode SPEED/LAP (Lap Time)
33
Viewing the Lap Time
34
Display Mode SPEED/ODO (Odometer)
34
Display Mode SPEED/TR1 (Trip Master 1)
35
Display Mode SPEED/TR2 (Trip Master 2)
35
Setting TR2 (Trip Master 2)
35
Display Mode SPEED/A1 (Average Speed 1)
36
Display Mode SPEED/A2 (Average Speed 2)
36
Display Mode SPEED/S1 (Stop Watch 1)
37
Display Mode SPEED/S2 (Stop Watch 2)
37
Table of Functions
38
Table of Conditions and Menu Activation
39
Preparing for Use
40
Advice on First Use
40
Running in the Engine
41
Starting Power of Lithium-Ion Batteries at Low Temperatures
42
Preparing the Vehicle for Difficult Riding Conditions
42
Preparing Vehicle for Rides on Dry Sand
43
Preparing Vehicle for Rides on Wet Sand
44
Preparing Vehicle for Rides on Wet and Muddy Circuits
45
Preparing Vehicle for High Temperatures or Slow Riding
45
Preparing Vehicle for Low Temperatures or Snow
46
Riding Instructions 9
47
Checks and Maintenance Measures When Preparing for Use
47
Starting the Vehicle
47
Starting off
48
Shifting, Riding
48
Braking
49
Stopping, Parking
50
Transporting
50
Refueling
51
Adding 2-Stroke Oil
52
Service Schedule 10
53
Additional Information
53
Required Work
53
Recommended Work
54
11 Tuning the Chassis
56
Checking the Basic Chassis Setting with the Rider's Weight
56
Compression Damping of the Shock Absorber
56
Adjusting the Low-Speed Compression Damping of the Shock Absorber
56
Adjusting the High-Speed Compression Damping of the Shock Absorber
57
Adjusting the Rebound Damping of the Shock Absorber
58
Measuring the Rear Wheel Dimension Unloaded
58
Checking the Static Sag of the Shock Absorber
59
Checking the Riding Sag of the Shock Absorber
59
Adjusting the Spring Preload of the Shock Absorber
60
Adjusting the Riding Sag
61
Checking the Basic Setting of the Fork
61
Adjusting the Compression Damping of the Fork
62
Adjusting the Rebound Damping of the Fork
63
Adjusting the Spring Preload of the Fork (All Six Days Models)
64
Handlebar Position
65
Adjusting the Handlebar Position
65
12 Service Work on the Chassis
68
Raising the Motorcycle with a Lift Stand
68
Removing the Motorcycle from the Lift Stand
68
Bleeding the Fork Legs
68
Cleaning the Dust Boots of the Fork Legs
69
Removing the Fork Protector
69
Installing the Fork Protector
70
Removing the Fork Legs
70
Installing the Fork Legs
71
Removing the Lower Triple Clamp (All Standard EXC/XC-W Models)
72
Removing the Lower Triple Clamp (All Six Days Models)
72
Installing the Lower Triple Clamp (All Standard EXC/XC-W Models)
73
Installing the Lower Triple Clamp (All Six Days Models)
76
Checking the Play of the Steering Head Bearing
78
Adjusting the Steering Head Bearing Play
78
Lubricating the Steering Head Bearing
80
Removing Front Fender
80
Installing Front Fender
80
Removing the Shock Absorber
81
Installing the Shock Absorber
81
Removing the Seat
82
Mounting the Seat
82
Removing the Air Filter Box Cover
83
Installing the Air Filter Box Cover
83
Removing the Air Filter
84
Installing the Air Filter
84
Cleaning the Air Filter and Air Filter Box
85
Preparing Air Filter Box Cover for Securing
85
Sealing the Air Filter Box
86
Removing the Main Silencer
86
Installing the Main Silencer
86
Changing the Glass Fiber Yarn Filling in the Main Silencer
87
Removing the Fuel Tank
87
Installing the Fuel Tank
89
Checking the Chain for Dirt
91
Cleaning the Chain
91
Checking the Chain Tension
92
Adjusting the Chain Tension
92
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
93
Checking the Frame
96
Checking the Swingarm
96
Checking Throttle Cable Routing
96
Checking the Rubber Grip
97
Adjusting the Basic Position of the Clutch Lever
97
Checking/Correcting the Fluid Level of the Hydraulic Clutch
98
Changing the Hydraulic Clutch Fluid
99
Removing the Engine Guard (All Six Days Models)
100
Installing the Engine Guard (All Six Days Models)
100
Brake System 13
101
Checking the Free Travel of the Hand Brake Lever
101
Adjusting Free Travel of Hand Brake Lever (All EXC Models)
101
Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)
102
Checking the Brake Discs
102
Checking the Front Brake Fluid Level
103
Adding Front Brake Fluid
103
Checking the Front Brake Linings
104
Changing the Front Brake Linings
105
Checking the Free Travel of Foot Brake Lever
107
Adjusting the Basic Position of the Foot Brake Lever
107
Checking the Rear Brake Fluid Level
108
Adding Rear Brake Fluid
109
Checking the Brake Linings of the Rear Brake
110
Changing the Rear Brake Linings
110
Wheels, Tires 14
113
Removing the Front Wheel
113
Installing the Front Wheel
114
Removing the Rear Wheel
114
Installing the Rear Wheel
115
Checking the Tire Condition
117
Checking the Tire Air Pressure
117
Checking Spoke Tension
118
Electrical System 15
119
Removing the Battery
119
Installing the Battery
120
Recharging the Battery
120
Changing the Main Fuse
122
Changing the Fuses of Individual Power Consumers
124
Removing the Headlight Mask with the Headlight
125
Installing the Headlight Mask with the Headlight
126
Changing the Headlight Bulb
127
Changing the Turn Signal Bulb (All EXC Models)
127
Checking the Headlight Setting
128
Adjusting the Headlight Range
129
Changing the Combination Instrument
129
Diagnostics Connector
130
Cooling System 16
131
Checking the Antifreeze and Coolant Level
131
Checking the Coolant Level
132
Draining the Coolant
132
Refilling with Coolant
133
17 Tuning the Engine
136
Checking the Play in the Throttle Cable
136
Adjusting the Play in the Throttle Cable
136
Setting the Characteristic Map of the Throttle Response
137
Adjusting the Idle Speed
138
Programming Ambient Pressure
139
Ignition Curve Plug-In Connector
140
Changing the Ignition Timing Map
140
Checking the Basic Position of the Shift Lever
141
Adjusting the Basic Position of the Shift Lever
141
18 Service Work on the Engine
142
Changing the Fuel Screen
142
Checking 2-Stroke Oil Level
143
Priming the Oil Pump
143
Checking the Gear Oil Level
145
Changing the Gear Oil
145
Adding Gear Oil
146
19 Cleaning, Care
148
Cleaning the Motorcycle
148
Checks and Maintenance Steps for Winter Operation
149
20 Storage
150
Preparing for Use after Storage
151
21 Troubleshooting
152
Technical Data 22
155
Engine
155
All 250 Models
155
All 300 Models
155
Engine Tightening Torques
156
Capacities
158
Gear Oil
158
Coolant
158
Fuel
158
Chassis
158
Electrical System
159
Tires
160
Fork
160
All Standard EXC/XC-W Models
160
All Six Days Models
160
Shock Absorber
161
Chassis Tightening Torques
162
23 Substances
164
24 Auxiliary Substances
166
25 Standards
168
Index of Special Terms 26
169
27 List of Abbreviations
170
List of Symbols 28
171
Red Symbols
171
Yellow and Orange Symbols
171
Green and Blue Symbols
171
Index
172

KTM 250 EXC TPI 2019 Setup Instructions (45 pages)

Brand: KTM | Category: Motorcycle | Size: 2.76 MB

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KTM 250 EXC TPI 2019 Manuals

KTM 250 EXC TPI 2019 Repair Manual (387 pages)

Table of Contents

1 Means of Representation 1

2 Safety Advice

3 Important Notes 3

4 Serial Numbers

5 Motorcycle

6 Fork, Triple Clamp

7 Handlebar, Controls 7

8 Frame

9 Shock Absorber, Swingarm

10 Exhaust 10

11 Air Filter

12 Fuel Tank, Seat, Trim

13 Mask, Fender

14 Wheels 14

15 Wiring Harness, Battery 15

16 Brake System 16

17 Lighting System, Instruments

18 Engine

19 Clutch 19

20 Water Pump, Cooling System

21 Exhaust Control 21

22 Lubrication System

23 Ignition System

24 Electric Starter 24

25 Throttle Valve Body

26 Technical Data

27 Cleaning, Care

28 Storage

29 Service Schedule

30 Wiring Diagram

31 Substances

32 Auxiliary Substances

33 Special Tools

34 Standards 34

35 Index of Special Terms

36 List of Abbreviations 36

KTM 250 EXC TPI 2019 Owner's Manual (176 pages)

Table of Contents

KTM 250 EXC TPI 2019 Setup Instructions (45 pages)

Table of Contents

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