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KTM 250 EXC - 2017 Manual

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TABLE OF CONTENTS 3
11.4 Adjusting the high-speed compression
damping of the shock absorber......................... 42
11.5 Adjusting the rebound damping of the shock
absorber......................................................... 42
11.6 Measuring the rear wheel dimension
unloaded........................................................ 43
11.7 Checking the static sag of the shock absorber.... 44
11.8 Checking the riding sag of the shock absorber.... 44
11.9 Adjusting the spring preload of the shock
absorber ..................................................... 44
11.10 Adjusting the riding sag ............................... 45
11.11 Checking the basic setting of the fork ............... 46
11.12 Adjusting the compression damping of the
fork ............................................................... 46
11.13 Adjusting the rebound damping of the fork ........ 47
11.14 Adjusting the spring preload of the fork (All
Six Days models) ............................................ 48
11.15 Handlebar position.......................................... 48
11.16 Adjusting the handlebar position ................... 49
12 SERVICE WORK ON THE CHASSIS.............................. 51
12.1 Raising the motorcycle with a lift stand............. 51
12.2 Removing the motorcycle from the lift stand...... 51
12.3 Bleeding the fork legs...................................... 51
12.4 Cleaning the dust boots of the fork legs............. 51
12.5 Removing the fork protector ............................. 52
12.6 Installing the fork protector.............................. 52
12.7 Removing the fork legs ................................. 52
12.8 Installing the fork legs ................................. 53
12.9 Removing the lower triple clamp (All
standard EXC/XC-W models)............................. 54
12.10 Removing the lower triple clamp (All
Six Days models) ............................................ 54
12.11 Installing the lower triple clamp (All
standard EXC/XC-W models)............................. 55
12.12 Installing the lower triple clamp (All
Six Days models) ............................................ 57
12.13 Checking the play of the steering head
bearing .......................................................... 58
12.14 Adjusting the steering head bearing play ........ 59
12.15 Lubricating the steering head bearing ............ 59
12.16 Removing the front fender ............................... 60
12.17 Installing the front fender ................................ 60
12.18 Removing the shock absorber ....................... 60
12.19 Installing the shock absorber ........................ 61
12.20 Removing the seat .......................................... 61
12.21 Mounting the seat........................................... 61
12.22 Removing the air filter box cover ...................... 62
12.23 Installing the air filter box cover ....................... 62
12.24 Removing the air filter ................................. 63
12.25 Installing the air filter .................................. 63
12.26 Cleaning the air filter and air filter box .......... 63
12.27 Securing the air filter box cover .................... 64
12.28 Sealing the air filter box ............................... 64
12.29 Removing the main silencer ............................. 65
12.30 Installing the main silencer.............................. 65
12.31 Changing the glass fiber yarn filling in the
main silencer .............................................. 65
12.32 Removing the fuel tank ................................ 66
12.33 Installing the fuel tank ................................. 67
12.34 Checking the chain for dirt............................... 68
12.35 Cleaning the chain .......................................... 68
12.36 Checking the chain tension .............................. 69
12.37 Adjusting the chain tension.............................. 69
12.38 Checking the chain, rear sprocket, motor
sprocket, and chain guide................................ 70
12.39 Checking the frame ..................................... 72
12.40 Checking the swingarm ................................ 72
12.41 Checking throttle cable routing......................... 72
12.42 Checking the rubber grip ................................. 73
12.43 Adjusting the basic position of the clutch
lever .............................................................. 73
12.44 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 73
12.45 Changing the hydraulic clutch fluid ............... 74
12.46 Removing the engine guard (All Six Days
models, EXC AU) ............................................ 75
12.47 Installing the engine guard (All Six Days
models, EXC AU) ............................................ 75
13 BRAKE SYSTEM ........................................................ 76
13.1 Checking the free travel of the hand brake
lever .............................................................. 76
13.2 Adjusting free travel of hand brake lever (All
EXC/EXC Six Days models, 125 XC‑W EU)......... 76
13.3 Adjusting the basic position of the hand brake
lever (XC‑W US, XC‑W Six Days US).................. 76
13.4 Checking the brake discs ................................. 77
13.5 Checking the front brake fluid level .................. 77
13.6 Adding front brake fluid ............................... 78
13.7 Checking the front brake linings ....................... 79
13.8 Changing the front brake linings ................... 79
13.9 Checking the free travel of foot brake lever ........ 81
13.10 Adjusting the basic position of the foot brake
lever ........................................................... 81
13.11 Checking the rear brake fluid level.................... 82
13.12 Adding rear brake fluid ................................ 82
13.13 Checking the rear brake linings ........................ 83
13.14 Changing the rear brake linings ..................... 83
14 WHEELS, TIRES ........................................................ 85
14.1 Removing the front wheel ............................. 85
14.2 Installing the front wheel ............................. 85
14.3 Removing the rear wheel .............................. 86
14.4 Installing the rear wheel ............................... 87
14.5 Checking the tire condition .............................. 88
14.6 Checking the tire air pressure........................... 88
14.7 Checking spoke tension ................................... 89
15 ELECTRICAL SYSTEM ................................................ 90
15.1 Removing the battery (All 250/300 models,
XC‑W US, XC‑W Six Days US)........................... 90
15.2 Installing the battery (All 250/300 models,
XC‑W US, XC‑W Six Days US)........................... 91
15.3 Recharging the battery (All 250/300
models, XC‑W US, XC‑W Six Days US) .............. 91
15.4 Changing the main fuse (All 250/300 models,
XC‑W US, XC‑W Six Days US)........................... 93
15.5 Removing the headlight mask with the
headlight........................................................ 94
15.6 Installing the headlight mask with the
headlight........................................................ 95
15.7 Changing the headlight bulb ............................ 95
15.8 Changing the turn signal bulb (All
EXC/EXC Six Days models)............................... 96
15.9 Checking the headlight setting ......................... 97
15.10 Adjusting the headlight range........................... 97
15.11 Changing the speedometer battery .................... 97
16 COOLING SYSTEM ..................................................... 99
16.1 Cooling system ............................................... 99
… 5 …


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