KTM Freeride 250 R EU Repair Manual page 6

TABLE OF CONTENTS
18.5.3 Installing the shift forks............................. 135
18.5.4 Installing the shift drum ............................ 135
18.5.5 Installing the shift rails ............................. 135
18.5.6 Installing the left engine case section ......... 135
18.5.7 Installing the reed valve housing ................ 136
18.5.8 Installing the rotor .................................... 136
18.5.9 Installing the locking lever ......................... 137
18.5.10 Installing the shift drum locating unit ......... 137
18.5.11 Installing the shift shaft ............................ 137
18.5.12 Installing the clutch basket........................ 137
18.5.13 Installing the clutch discs.......................... 138
18.5.14 Installing the clutch cover ......................... 139
18.5.15 Installing the water pump cover.................. 139
18.5.16 Installing the piston .................................. 140
18.5.17 Installing the cylinder................................ 140
18.5.18 Checking the X-distance ............................ 141
18.5.19 Adjusting the X-distance............................ 141
18.5.20 Installing the cylinder head........................ 142
18.5.21 Installing the starter motor......................... 142
18.5.22 Installing the spacer.................................. 144
18.5.23 Installing the shift lever............................. 144
18.5.24 Installing the clutch push rod .................... 145
18.5.25 Installing the gear oil drain plug ................. 145
18.5.26 Removing the engine from the work stand ... 145
19 CARBURETOR ......................................................... 146
19.1 Choke .......................................................... 146
19.2 Carburetor - adjusting idle ............................. 146
19.3 Emptying the carburetor float chamber ........... 147
19.4 Removing the carburetor................................ 147
19.5 Installing the carburetor ................................ 148
19.6 Checking/setting the carburetor components.... 149
19.7 Disassembling the carburetor ......................... 149
19.8 Checking the choke slide ............................... 151
19.9 Checking the jet needle ................................. 151
19.10 Checking the throttle slide ............................. 151
19.11 Checking the float needle valve ...................... 152
19.12 Assembling the carburetor ............................. 152
19.13 Checking/adjusting the float level ................... 153
20 CLUTCH .................................................................. 155
20.1 Checking fluid level of the hydraulic clutch ..... 155
20.2 Correcting the fluid level of the hydraulic
clutch .......................................................... 155
20.3 Changing the hydraulic clutch fluid ................ 155
21 WATER PUMP, COOLING SYSTEM ............................ 157
21.1 Checking the antifreeze and coolant level ........ 157
21.2 Checking the coolant level ............................. 157
21.3 Draining the coolant ...................................... 158
21.4 Refilling coolant ........................................... 158
22 LUBRICATION SYSTEM............................................ 160
22.1 Changing the gear oil..................................... 160
22.2 Draining the gear oil...................................... 160
22.3 Filling in gear oil........................................... 161
22.4 Checking the gear oil level ............................. 161
22.5 Adding gear oil ............................................. 161
23 IGNITION SYSTEM................................................... 163
23.1 Checking the ignition system.......................... 163
23.2 Ignition coil - checking the primary winding..... 164
23.3 Ignition coil - checking the secondary
winding........................................................ 164
23.4 Checking the spark plug connector ................. 165
23.5 Alternator - checking the charging coil of the
ignition ........................................................ 165
23.6 Alternator - checking the battery winding ........ 165
23.7 Alternator - checking the light winding ............ 166
23.8 Checking the ignition pulse generator ............. 166
23.9 Removing the stator and crankshaft position
sensor.......................................................... 167
23.10 Installing the stator and crankshaft position
sensor.......................................................... 167
23.11 Cleaning the alternator .................................. 168
24 ELECTRIC STARTER ................................................ 169
24.1 Checking the starter motor ............................. 169
25 TECHNICAL DATA.................................................... 170
25.1 Engine ......................................................... 170
25.2 Engine tolerance, wear limits ......................... 170
25.3 Engine tightening torques .............................. 171
25.4 Capacities .................................................... 171
25.4.1 Gear oil.................................................... 171
25.4.2 Coolant .................................................... 171
25.4.3 Fuel ........................................................ 171
25.5 Chassis ........................................................ 172
25.6 Electrical system........................................... 172
25.7 Tires ............................................................ 173
25.8 Fork............................................................. 173
25.9 Shock absorber ............................................. 173
25.10 Chassis tightening torques ............................. 174
25.11 Carburetor .................................................... 175
25.12 Carburetor tuning.......................................... 176
25.12.1 Carburetor tuning...................................... 176
26 CLEANING, CARE .................................................... 177
26.1 Cleaning the motorcycle ................................ 177
26.2 Checks and maintenance steps for winter
operation...................................................... 178
27 STORAGE ................................................................ 179
27.1 Storage ........................................................ 179
27.2 Preparing for use after storage........................ 179
28 SERVICE SCHEDULE ............................................... 180
28.1 Service schedule........................................... 180
28.2 Service work (as additional order) ................... 181
29 WIRING DIAGRAM ................................................... 182
29.1 Page 1 of 5 (Freeride 250 R EU).................... 182
29.2 Page 2 of 5 (Freeride 250 R EU).................... 184
29.3 Page 3 of 5 (Freeride 250 R EU).................... 186
29.4 Page 4 of 5 (Freeride 250 R EU).................... 188
29.5 Page 5 of 5 (Freeride 250 R EU).................... 190
29.6 Page 1 of 5 (Freeride 250 R AUS).................. 192
29.7 Page 2 of 5 (Freeride 250 R AUS).................. 194
29.8 Page 3 of 5 (Freeride 250 R AUS).................. 196
29.9 Page 4 of 5 (Freeride 250 R AUS).................. 198
29.10 Page 5 of 5 (Freeride 250 R AUS).................. 200
30 SUBSTANCES ......................................................... 202
31 AUXILIARY SUBSTANCES ........................................ 204
32 SPECIAL TOOLS ...................................................... 206
33 STANDARDS ........................................................... 215
INDEX ............................................................................ 216
4