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General| Engine Type | Single-cylinder, 4-stroke |
|---|---|
| Displacement | 249.5 cc |
| Starter | Kickstarter |
| Transmission | 5-speed |
| Cooling | Liquid cooled |
| Clutch | Wet multi-disc clutch, hydraulically operated |
| Ignition | Kokusan digital |
| Fuel System | Keihin MX FCR 39 carburetor |
Procedures for bleeding the motorcycle's cooling system.
Steps for replacing the engine oil and oil filter.
Explanation of the oil circulation system and bleeding the hydraulic clutch.
Adjusting throttle cables and listing engine-specific tools.
Step-by-step instructions for removing the engine from the motorcycle chassis.
Procedures for reinstalling the engine into the motorcycle chassis.
Initial steps and cleaning before engine disassembly begins.
Aligning engine to TDC and removing camshafts.
Procedures for detaching the cylinder head, piston, and clutch cover.
Dismantling clutch, shift mechanism, oil pumps, and shafts.
Servicing engine casing halves, bearings, crankshaft, and related components.
Measuring piston and cylinder clearances and checking wear.
Servicing camshafts, bearings, tensioner, and cylinder head components.
Servicing the clutch, kickstarter, shift mechanism, and transmission shafts.
Installing transmission shafts, crankshaft, and assembling engine casing halves.
Mounting oil pumps, shift mechanism, primary pinion, chain drive, and clutch.
Procedures for mounting the piston, cylinder head, and camshafts.
Mounting chain tensioner, checking valve clearance, and final engine assembly.
Checks and troubleshooting for CDI unit, ignition coil, stator, and pulse generator.
Procedures for checking starter, start relay, battery, and charging system.
Procedures for checking charging voltage, current loss, and static values.
Procedures for removing, disassembling, and cleaning the carburetor.
Checking choke, accelerator pump, jet needle, float valve, and throttle valve.
Assembling the carburetor and adjusting idle speed and float height.
Diagnosing and resolving problems related to engine cranking and starting.
Troubleshooting engine not revving up, losing power, or stopping.
Diagnosing overheating and high oil consumption problems.
Troubleshooting battery discharge and related electrical problems.
Technical specifications for various KTM 250 models and years.
Table of critical component clearances and wear limits for assembly.
Specifications for torque values for engine and chassis fasteners.
Maintenance intervals and tasks organized by motorcycle model year (2005-2008).
Detailed maintenance tasks and schedules for 250 SX-F/XC-F and 250 XCF-W/EXC-F models.
Electrical wiring diagrams for various KTM 250 models from 2005 to 2008.
Reference guide for wire color codes used in the wiring diagrams.
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