KTM 250 EXC TPI 2019 Repair Manual

KTM 250 EXC TPI 2019

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REPAIR MANUAL 2019

250 EXC TPI

250 EXC Six Days TPI

250 XC‑W TPI

300 EXC TPI

300 EXC Six Days TPI

300 XC-W TPI

300 XC-W Six Days TPI

Art. no. 3206345en

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation 19
- Symbols Used9
- Formats Used9
2 Safety Advice10
- Repair Manual10
- Degrees of Risk and Symbols10
- Work Rules10
3 Important Notes 311
- Manufacturer and Implied Warranty11
- Operating and Auxiliary Substances11
- Spare Parts, Accessories11
- Figures11
4 Serial Numbers12
- Chassis Number12
- Type Label12
- Engine Number12
- Fork Part Number12
- Shock Absorber Article Number13
5 Motorcycle14
- Raising the Motorcycle with a Lift Stand14
- Removing the Motorcycle from the Lift Stand14
- Starting the Vehicle14
- Starting the Motorcycle to Check the Function15
6 Fork, Triple Clamp16
- Adjusting the Compression Damping of the Fork16
- Adjusting the Rebound Damping of the Fork17
- Adjusting the Spring Preload of the Fork (All Six Days Models)18
- Bleeding the Fork Legs18
- Cleaning the Dust Boots of the Fork Legs19
- Removing the Fork Legs19
- Installing the Fork Legs20
- Removing the Fork Protector21
- Installing the Fork Protector21
- All Standard EXC/XC-W Models22
- Servicing the Fork22
- Disassembling the Fork Legs22
- Disassembling the Cartridge25
- Disassembling the Tap Compression28
- Checking the Fork Legs29
- Assembling the Tap Compression30
- Assembling the Cartridge31
- Assembling the Fork Legs35
- Lubricating the Steering Head Bearing39
- Removing the Lower Triple Clamp39
- Installing the Lower Triple Clamp40
- Changing the Steering Head Bearing42
- Checking the Play of the Steering Head Bearing44
- Adjusting the Steering Head Bearing Play44
- All Six Days Models45
- Servicing the Fork45
- Disassembling the Fork Legs45
- Disassembling the Cartridge48
- Disassembling the Tap Compression51
- Checking the Fork Legs52
- Assembling the Tap Compression53
- Assembling the Cartridge54
- Assembling the Fork Legs58
- Lubricating the Steering Head Bearing63
- Removing the Lower Triple Clamp63
- Installing the Lower Triple Clamp64
- Changing the Steering Head Bearing66
- Checking the Play of the Steering Head Bearing67
- Adjusting the Steering Head Bearing Play68
7 Handlebar, Controls 769
- Handlebar Position69
- Adjusting the Handlebar Position69
- Adjusting the Basic Position of the Clutch Lever71
- Checking the Rubber Grip72
- Checking Throttle Cable Routing72
- Checking the Play in the Throttle Cable73
- Adjusting the Play in the Throttle Cable73
- Setting the Characteristic Map of the Throttle Response74
8 Frame76
- Checking the Frame76
- Removing the Engine Guard (All Six Days Models)76
- Installing the Engine Guard (All Six Days Models)76
- Changing the Footrests76
9 Shock Absorber, Swingarm80
- Adjusting the High-Speed Compression Damping of the Shock Absorber80
- Adjusting the Low-Speed Compression Damping of the Shock Absorber80
- Adjusting the Rebound Damping of the Shock Absorber81
- Measuring the Rear Wheel Dimension Unloaded82
- Checking the Static Sag of the Shock Absorber82
- Checking the Riding Sag of the Shock Absorber83
- Adjusting the Spring Preload of the Shock Absorber83
- Adjusting the Riding Sag84
- Removing the Shock Absorber85
- Installing the Shock Absorber85
- Servicing the Shock Absorber85
- Removing the Spring86
- Disassembling the Damper87
- Disassembling the Seal Ring Retainer88
- Disassembling the Piston Rod89
- Replacing the Pilot Bushing90
- Checking the Damper91
- Removing the Heim Joint92
- Installing the Heim Joint93
- Assembling Seal Ring Retainer93
- Assembling the Piston Rod94
- Assembling the Damper96
- Bleeding and Filling the Damper98
- Filling Damper with Nitrogen101
- Installing the Spring102
- Checking the Swingarm103
- Checking the Heim Joint for Play103
- Changing the Heim Joint104
- Changing the Heim Joint on the Swingarm105
- Checking the Swingarm Bearing for Play107
- Removing the Swingarm107
- Installing the Swingarm108
- Changing the Swingarm Bearing110
10 Exhaust 10113
- Removing the Manifold113
- Installing the Manifold114
- Removing the Main Silencer115
- Installing the Main Silencer116
- Changing the Glass Fiber Yarn Filling in the Main Silencer116
11 Air Filter118
- Air Filter118
- Removing the Air Filter Box Cover118
- Installing the Air Filter Box Cover118
- Removing the Air Filter119
- Installing the Air Filter119
- Cleaning the Air Filter and Air Filter Box120
- Preparing Air Filter Box Cover for Securing120
- Sealing the Air Filter Box121
12 Fuel Tank, Seat, Trim122
- Opening the Filler Cap122
- Closing the Filler Cap122
- Removing the Seat123
- Mounting the Seat123
- Removing the Fuel Tank124
- Installing the Fuel Tank125
- Changing the Fuel Screen127
- Changing the Fuel Filter128
- Changing the Fuel Pump131
- Checking the Fuel Pressure134
13 Mask, Fender136
- Removing Front Fender136
- Installing Front Fender136
- Removing the Headlight Mask with the Headlight137
- Installing the Headlight Mask with the Headlight137
14 Wheels 14139
- Checking the Tire Air Pressure139
- Checking the Tire Condition139
- Checking the Wheel Bearing for Play140
- Checking the Brake Discs141
- Checking the Rim Run-Out141
- Checking Spoke Tension142
- Front Wheel143
- Removing the Front Wheel143
- Installing the Front Wheel144
- Changing the Front Brake Disc144
- Changing Front Wheel Bearing145
- Rear Wheel146
- Removing the Rear Wheel146
- Installing the Rear Wheel147
- Changing the Rear Brake Disc148
- Changing the Rear Wheel Bearing149
- Checking the Chain for Dirt151
- Cleaning the Chain151
- Checking the Chain Tension152
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide153
- Adjusting the Chain Tension155
- Changing the Drivetrain Kit156
15 Wiring Harness, Battery 15159
- Ignition Curve Plug-In Connector159
- Changing the Main Fuse159
- Changing the Fuses of Individual Power Consumers161
- Disconnecting the Negative Cable of the Battery162
- Connecting the Negative Cable of the Battery163
- Removing the Battery163
- Installing the Battery164
- Recharging the Battery165
- Checking the Charging Voltage166
- Checking the Open-Circuit Current167
- Checking the Starter Relay167
- Diagnostics Connector168
16 Brake System 16169
- Checking the Front Brake Linings169
- Changing the Front Brake Linings169
- Checking the Free Travel of the Hand Brake Lever171
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)172
- Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)172
- Checking the Front Brake Fluid Level172
- Adding Front Brake Fluid173
- Changing the Front Brake Fluid174
- Checking the Brake Linings of the Rear Brake176
- Changing the Rear Brake Linings176
- Checking the Free Travel of Foot Brake Lever178
- Adjusting the Basic Position of the Foot Brake Lever179
- Checking the Rear Brake Fluid Level180
- Adding Rear Brake Fluid180
- Changing the Rear Brake Fluid181
17 Lighting System, Instruments184
- Changing the Headlight Bulb184
- Changing the Turn Signal Bulb (All EXC Models)184
- Checking the Headlight Setting185
- Adjusting the Headlight Range186
- Changing the Combination Instrument186
- Combination Instrument Overview187
- Activation and Test187
- Setting the Kilometers or Miles187
- Adjusting the Combination Instrument Function188
- Setting the Clock189
- Activating Additional Functions189
- Setting the Wheel Circumference190
- Viewing the Lap Time190
18 Engine192
- Cleaning the Pressure Sensor Hose192
- Removing the Engine192
- Installing the Engine198
- Engine Disassembly205
- Clamping the Engine into the Engine Work Stand205
- Removing the Shift Lever205
- Removing the Clutch Push Rod205
- Draining the Gear Oil205
- Removing the Spacer206
- Removing the Alternator Cover206
- Removing the Kick Starter207
- Removing Injection Valves207
- Removing the Cylinder Head207
- Removing the Cylinder208
- Removing the Piston210
- Removing the Water Pump Cover211
- Removing the Clutch Cover211
- Removing the Clutch Discs212
- Removing the Clutch Basket213
- Removing the Balancer Shaft214
- Removing the Kick Starter Shaft215
- Removing the Intermediate Kick Starter Gear215
- Removing the Shift Shaft216
- Removing the Shift Drum Locating Unit216
- Removing the Locking Lever216
- Removing the Rotor216
- Removing the Starter Motor217
- Removing the Reed Valve Housing218
- Removing the Left Engine Case Section219
- Removing the Shift Rails219
- Removing the Shift Drum219
- Removing the Shift Forks220
- Removing the Transmission Shafts220
- Removing the Crankshaft220
- Working on Individual Parts221
- Working on the Right Section of the Engine Case221
- Working on the Left Section of the Engine Case222
- Removing the Crankshaft Bearing Inner Race224
- Installing the Crankshaft Bearing Inner Race224
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin225
- Checking the Crankshaft Run-Out at the Bearing Pin226
- Checking/Measuring the Cylinder226
- Cleaning the Pressure Sensor Cylinder Connection227
- Removing the Exhaust Control227
- Checking the Exhaust Control229
- Installing the Exhaust Control231
- Cylinder - Nikasil Coating234
- Checking/Measuring the Piston234
- Checking the Piston Ring End Gap235
- Measuring the Piston/Cylinder Mounting Clearance235
- Disassemble the Reed Valve Housing236
- Checking the Reed Valve Housing, Reed Valve and Intake Flange237
- Assemble the Reed Valve Housing237
- Working on the Clutch Cover239
- Checking the Clutch242
- Preassembling Shift Shaft243
- Checking the Shift Mechanism244
- Disassembling the Main Shaft245
- Disassembling the Countershaft246
- Checking the Transmission246
- Assembling the Main Shaft248
- Assembling the Countershaft248
- Checking the Kick Starter250
- Preassembling the Kick Starter Shaft250
- Checking the Electric Starter Drive251
- Engine Assembly252
- Installing the Crankshaft252
- Installing the Transmission Shafts253
- Installing the Shift Forks253
- Installing the Shift Drum254
- Installing the Shift Rails254
  - Installing the Left Engine Case Section254
  - Installing the Reed Valve Housing255
  - Installing the Starter Motor256
  - Installing the Rotor257
  - Installing the Locking Lever257
  - Installing the Shift Drum Locating Unit258
  - Installing the Shift Shaft258
  - Installing the Intermediate Kick Starter Gear258
  - Installing the Kick Starter Shaft258
  - Installing the Balancer Shaft259
  - Installing the Clutch Basket260
  - Installing the Clutch Discs261
  - Installing the Clutch Cover263
  - Installing the Water Pump Cover265
  - Installing the Piston266
  - Installing the Cylinder267
  - Checking the X-Distance269
  - Adjusting the X-Distance269
  - Adjusting the Z-Distance271
  - Installing the Cylinder Head273
  - Installing Injection Valves274
  - Installing the Kick Starter274
  - Installing the Alternator Cover274
  - Installing the Spacer275
  - Installing the Gear Oil Drain Plug275
  - Installing the Clutch Push Rod276
  - Installing the Shift Lever276
  - Removing the Engine from the Engine Work Stand276
19 Clutch 19277
- Checking/Correcting the Fluid Level of the Hydraulic Clutch277
- Changing the Hydraulic Clutch Fluid278
- Checking the Clutch279
20 Water Pump, Cooling System288
- Cooling System288
- Checking the Antifreeze and Coolant Level288
- Checking the Coolant Level289
- Draining the Coolant289
- Refilling with Coolant290
21 Exhaust Control 21293
- Checking/Adjusting the Exhaust Control293
22 Lubrication System296
- Changing the Gear Oil296
- Checking the Gear Oil Level297
- Adding Gear Oil297
- Checking 2-Stroke Oil Level298
- Opening 2-Stroke Oil Tank Cap299
- Adding 2-Stroke Oil299
- Closing 2-Stroke Oil Tank Cap299
- Priming the Oil Pump300
- Replacing the Oil Pump301
23 Ignition System304
- Checking the Ignition System304
- Ignition Coil - Checking the Primary Winding305
- Checking the Spark Plug Connector306
- Alternator - Checking the Stator Winding306
- Checking the Crankshaft Position Sensor307
- Changing the Spark Plug308
- Changing the Spark Plug and Spark Plug Connector309
- Removing the Stator309
- Installing the Stator310
24 Electric Starter 24311
- Checking the Starter Motor311
25 Throttle Valve Body312
- Adjusting the Idle Speed312
- Programming Ambient Pressure312
- Cold Start Button313
26 Technical Data314
- Engine314
- All 250 Models314
- All 300 Models314
- Tolerance, Engine Wear Limits315
- Engine Tightening Torques316
- Capacities317
- Gear Oil317
- Engine Oil317
- Coolant317
- Fuel318
- Chassis318
- Electrical System319
- Tires319
- Fork319
- All Standard EXC/XC-W Models319
- All Six Days Models320
- Shock Absorber320
- Chassis Tightening Torques321
27 Cleaning, Care324
- Cleaning, Care324
- Cleaning the Motorcycle324
- Checks and Maintenance Steps for Winter Operation325
28 Storage326
- Preparing for Use after Storage327
29 Service Schedule328
- Additional Information328
- Required Work328
- Recommended Work329
30 Wiring Diagram332
- 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 Substances360
32 Auxiliary Substances362
33 Special Tools364
34 Standards 34379
35 Index of Special Terms380
36 List of Abbreviations 36381
- Index382

Other manuals for KTM 250 EXC TPI 2019

Owner's Manual176 pages

Setup Instructions45 pages

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KTM 250 EXC TPI 2019 Specifications

General

Displacement	249 cc
Bore x Stroke	66.4 x 72 mm
Transmission	6-speed
Seat Height	960 mm
Front Suspension	WP Xplor 48 upside-down fork
Starter	Electric starter
Ground Clearance	370 mm
Engine Type	2-stroke, single cylinder
Fuel System	Electronic Fuel Injection
Fuel Tank Capacity	9 liters
Cooling System	Liquid-cooled
Rear Suspension	WP Xplor PDS
Front Brake	Disc brake
Rear Brake	220 mm disc
Frame	Central double-cradle type in chrome molybdenum steel

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