Page 1 OWNER'S MANUAL 2019 Freeride 250 F Art. no. 3213861en...
Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy riding this motorcycle! Enter the serial numbers of your vehicle below.
Page 4: Table Of Contents
TABLE OF CONTENTS 6.17 Side stand........20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 6.18 Ignition lock ........20 Symbols used ........5 6.19 Steering lock ........21 Formats used........5 6.20 Locking the steering ......21 SAFETY ADVICE..........6 6.21 Unlocking the steering......
Page 5 TABLE OF CONTENTS Stopping, parking......39 12.12 Adjusting steering head bearing play ..........62 Transporting ........40 12.13 Greasing the steering head Refueling ........41 bearing ........63 10 SERVICE SCHEDULE ........43 12.14 Removing front fender ...... 63 12.15 Installing front fender....... 64 10.1 Additional information ......
Page 6 TABLE OF CONTENTS 13.7 Changing the front brake linings ..89 17.6 Checking the basic position of the shift lever........123 13.8 Checking the free travel of foot brake lever ..........92 17.7 Adjusting the basic position of the shift lever ........
Page 7: Means Of Representation 1
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.
Page 8: Safety Advice
2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of offroad use. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version. The derestricted version of this vehicle must only be operated in closed off areas away from public high- way traffic.
Page 9: Tampering Warning
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.
Page 10: Protective Clothing
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.
Page 11: Important Notes 3
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in the KTM Dealer.net, otherwise any warranty coverage will become void.
Page 12 3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...
Page 13: View Of Vehicle 4
VIEW OF VEHICLE 4 View of vehicle, front left (example) F01690-10 Hand brake lever ( p. 15) Clutch lever ( p. 15) Fuel tank filler cap Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 20) 12-V battery Shift lever ( p.
Page 14: View Of Vehicle, Rear Right (Example)
4 VIEW OF VEHICLE View of vehicle, rear right (example) F01691-10 Fork compression adjuster Kill switch ( p. 15) Horn button ( p. 16) Light switch ( p. 16) Turn signal switch ( p. 16) Emergency OFF switch ( p. 16) Electric starter button ( p.
Page 15: Serial Numbers 5
SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Key number The key number can be found on the KEYCODECARD.
Page 16: Fork Part Number
5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the axle clamp. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the motor side. H02222-10...
Page 17: Controls 6
CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. F01169-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.
Page 18: Horn Button
6 CONTROLS Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this posi- • Horn button tion. F01183-11 Light switch The light switch is fitted on the left side of the handlebar.
Page 19: Electric Starter Button
– The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
Page 20: Closing The Fuel Tank Filler Cap
6 CONTROLS Preparatory work – Fold the seat up. ( p. 66) Main work – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. E00979-10 6.12 Closing the fuel tank filler cap Main work –...
Page 21: Idle Speed Adjusting Screw
CONTROLS 6 6.14 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi- cle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.
Page 22: Foot Brake Lever
6 CONTROLS 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.17 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.
Page 23: Steering Lock
CONTROLS 6 6.19 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and there- fore riding, is no longer possible. F01185-10 6.20 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over.
Page 24: Combination Instrument
7 COMBINATION INSTRUMENT Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.
Page 25: Setting The Combination Instrument
COMBINATION INSTRUMENT 7 – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.
Page 26: Setting The Clock
7 COMBINATION INSTRUMENT Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust the hour display with the button and/or button –...
Page 27: Display Mode Speed (Speed)
COMBINATION INSTRUMENT 7 Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.
Page 28: Adjusting The Unit Of Measurement
7 COMBINATION INSTRUMENT Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...
Page 29: Display Mode Speed/Clk (Time)
COMBINATION INSTRUMENT 7 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.
Page 30: Viewing The Lap Time
7 COMBINATION INSTRUMENT Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.
Page 31: Display Mode Speed/Tr1 (Trip Master 1)
COMBINATION INSTRUMENT 7 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.
Page 32: Display Mode Speed/A1 (Average Speed 1)
7 COMBINATION INSTRUMENT Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.
Page 33: Display Mode Speed/S1 (Stop Watch 1)
COMBINATION INSTRUMENT 7 Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.
Page 34: Table Of Functions
7 COMBINATION INSTRUMENT 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...
Page 35: Table Of Conditions And Menu Activation
COMBINATION INSTRUMENT 7 Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Adjusting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.
Page 36: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service & Manufacturer Warranty Booklet at vehicle handover.
Page 37: Running In The Engine
PREPARING FOR USE 8 – Adjust the basic position of the foot brake lever. p. 92) – Set the basic position of the shift lever. p. 124) – Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip. Info When off road, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.
Page 38 8 PREPARING FOR USE If the charged lithium-ion battery does not turn, or only weakly turns over the electric starter when temperatures are below 15 °C (60 °F), then the battery is not faulty, but needs to be warmed up internally to increase its starting power (current output).
Page 39: Riding Instructions 9
RIDING INSTRUCTIONS 9 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...
Page 40: Starting Off
Do not change into a low gear at high engine speed. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an autho- rized KTM workshop. First gear is used for starting off and for steep inclines. –...
Page 41: Applying The Brakes
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.
Page 42: Transporting
9 RIDING INSTRUCTIONS – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...
Page 43: Refueling
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.
Page 44 9 RIDING INSTRUCTIONS Main work – Fill the fuel tank with fuel up to level Guideline 30 mm (1.18 in) Dimension Total fuel tank Super unleaded capacity, approx. (1.3 US gal) (ROZ 95/RON 95/PON 91) p. 148) Info Observe the labels on the fuel pump. F01694-10 Finishing work –...
Page 45: Service Schedule 10
Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
Page 46: Recommended Work
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● Make the service entry in KTM Dealer.net and in the Service & Manufacturer Warranty Book- let. ○ One-time interval ● Periodic interval 10.3...
Page 47: Tuning The Chassis 11
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting takes effect during slow to normal compression of the shock absorber.
Page 48: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting takes effect during fast compression of the shock absorber.
Page 49: Adjusting The Rebound Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.
Page 50: Checking The Static Sag Of The Shock Absorber
11 TUNING THE CHASSIS Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the rear fairing. – Note down the value as dimension 400988-10 Finishing work –...
Page 51: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.
Page 52: Adjusting The Riding Sag
11 TUNING THE CHASSIS Main work – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (90129051000) – Measure the overall spring length while the spring is not under tension. – Tighten the spring by turning adjusting ring to specified measurement Guideline...
Page 53: Checking The Basic Setting Of The Fork
TUNING THE CHASSIS 11 Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. Finishing work – Install the shock absorber. p. 65) – Lock the seat. ( p.
Page 54: Adjusting The Rebound Damping Of The Fork
11 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the...
Page 55: Handlebar Position
TUNING THE CHASSIS 11 11.14 Handlebar position On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center.
Page 56 11 TUNING THE CHASSIS Info Make sure the cables and wiring are positioned cor- rectly. – Position handlebar clamps. Mount screws and tighten evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the gap widths are even.
Page 57: Service Work On The Chassis 12
SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) Neither wheel is in contact with the ground.
Page 58: Cleaning The Dust Boots Of The Fork Legs
12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Remove the fork protector. ( p. 56) Main work – Push dust boots of both fork legs downward.
Page 59: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 12 – Remove screws on the right fork leg. Take off the fork pro- tector. F01202-10 12.6 Installing the fork protector – Position the fork protection on the right fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)
Page 60: Installing The Fork Legs
12 SERVICE WORK ON THE CHASSIS – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. F01201-10 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front.
Page 61: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 12 12.9 Removing the lower triple clamp Preparatory work – Remove the headlight mask with the headlight. ( p. 109) – Raise the motorcycle with a lift stand. ( p. 55) – Remove the front wheel. p.
Page 62: Installing The Lower Triple Clamp
12 SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 149) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
Page 63 SERVICE WORK ON THE CHASSIS 12 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head F01208-10 – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) Loctite 243™ ® steering stem F01208-11 –...
Page 64: Checking Steering Head Bearing Play
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
Page 65: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 12 Main work – Pull out hose from the front steering head screw. – Loosen screws . Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head –...
Page 66: Installing Front Fender
12 SERVICE WORK ON THE CHASSIS Main work – Remove screws – Remove screws – Take off the front fender. E00985-10 12.15 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
Page 67: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS 12 12.16 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Fold the seat up. ( p. 66) Main work – Detach brake line – Remove screw –...
Page 68: Folding The Seat Up
12 SERVICE WORK ON THE CHASSIS 12.18 Folding the seat up – Press release lever – Lift the seat and fold it up. E00976-10 12.19 Locking the seat – Fold down the seat and push it down. The seat engages with an audible click. –...
Page 69: Mounting The Spoiler
SERVICE WORK ON THE CHASSIS 12 – Remove screw – Remove screw – Take off the spoiler. – Repeat the operation on the opposite side. F01212-10 12.21 Mounting the spoiler Main work – Position the spoiler and hook it in at area F01213-10 –...
Page 70: Removing The Air Filter Housing
12 SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter housing Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter.
Page 71: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 12 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Preparatory work – Fold the seat up. ( p.
Page 72: Cleaning The Air Filter And Air Filter Housing
12 SERVICE WORK ON THE CHASSIS 12.26 Cleaning the air filter and air filter housing Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Page 73: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS 12 12.28 Installing the main silencer – Position the main silencer. – Mount screw but do not tighten yet. Guideline Screw, main silencer M8x25 25 Nm (18.4 lbf ft) – Mount screw but do not tighten yet. Guideline Screw, main silencer M8x20...
Page 74: Removing The Fuel Tank
12 SERVICE WORK ON THE CHASSIS Main work – Remove screws – Take off connecting cap – Remove the silencer cap together with the perforated pipe and glass fiber yarn fillings – Clean the parts that need to be reinstalled and check for dam- age.
Page 75 SERVICE WORK ON THE CHASSIS 12 Main work – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –...
Page 76: Installing The Fuel Tank
12 SERVICE WORK ON THE CHASSIS – Release hose clamp – Detach the intake flange from the throttle valve body. F01189-10 – Pull up the fuel tank slightly and disconnect the connector for the fuel pump. – Remove the fuel tank from above. F01167-10 12.31 Installing the fuel tank...
Page 77 SERVICE WORK ON THE CHASSIS 12 – Position the fuel tank. – Position the intake flange on the throttle valve body. – Tighten hose clamp F01189-11 – Plug in connector – Position engine breather hose F01166-11 – Mount and tighten screws on both sides.
Page 78: Checking For Chain Dirt Accumulation
12 SERVICE WORK ON THE CHASSIS Finishing work – Lock the seat. ( p. 66) 12.32 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p.
Page 79: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12 12.34 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
Page 80: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 36 … 40 mm (1.42 … 1.57 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
Page 81 SERVICE WORK ON THE CHASSIS 12 – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.
Page 82 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.
Page 83: Checking The Frame
» If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. F01162-01 12.39 Checking throttle cable routing Preparatory work –...
Page 84: Checking The Rubber Grip
12 SERVICE WORK ON THE CHASSIS – Lock the seat. ( p. 66) 12.40 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right.
Page 85: Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 12 – Move the clutch fluid reservoir mounted on the handlebar into a horizontal position. – Check the fluid level in viewer » If the fluid has dropped below marking in the level viewer: – Correct the fluid level of the hydraulic clutch.
Page 86: Changing The Hydraulic Clutch Fluid
12 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
Page 87: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS 12 – Inject the liquid into the system until it escapes from open- of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. – Remove the bleeding syringe. Tighten the bleeder screw. Mount the protection cap.
Page 88: 13 Brake System
Do not make any adjustments while riding. 13.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
Page 89: Checking The Front Brake Fluid Level
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake reservoir mounted on the handlebar to a hori- zontal position.
Page 90: Adding Front Brake Fluid
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
Page 91: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
Page 92 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
Page 93 BRAKE SYSTEM 13 – Remove cotter pin – Remove pin – Take off retainer spring and remove the brake linings. – Clean the brake caliper. – Position new brake linings. Info Always change the brake linings in pairs. E01011-10 – Position retaining spring –...
Page 94: Checking The Free Travel Of Foot Brake Lever
13 BRAKE SYSTEM 13.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
Page 95: Checking The Rear Brake Fluid Level
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Page 96: Checking The Brake Linings Of The Rear Brake
E01015-10 13.12 Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
Page 97: Changing The Rear Brake Linings
Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
Page 98 13 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
Page 99 BRAKE SYSTEM 13 – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 147) – Position the cover with the washer and membrane – Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.
Page 100: 14 Wheels, Tires
14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) Main work – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp.
Page 101: Removing The Rear Wheel
WHEELS, TIRES 14 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.
Page 102: Installing The Rear Wheel
14 WHEELS, TIRES Main work – Remove nut – Remove chain adjuster – Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.
Page 103: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.
Page 104: Checking Tire Pressure
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-01 years at the latest, regardless of the actual state of wear.
Page 105: Checking The Spoke Tension
Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
Page 106: 15 Electrical System
15 ELECTRICAL SYSTEM 15.1 Removing the 12 V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.
Page 107: Installing The 12 V Battery
ELECTRICAL SYSTEM 15 15.2 Installing the 12 V battery – Position the positive cable and mount and tighten the screw. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) 12-V battery (HJTZ5S-FP-C) ( p. 143) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal.
Page 108 15 ELECTRICAL SYSTEM Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage. –...
Page 109: Changing The Main Fuse
ELECTRICAL SYSTEM 15 The charging time may be longer at low temperatures. This battery charger is not suitable for the trickle charging of lithium-ion batteries. Info Never remove cover – Switch off the battery charger after charging and disconnect from the 12 V battery. Finishing work –...
Page 110: Changing The Fuses Of Individual Power Consumers
15 ELECTRICAL SYSTEM Insert a spare fuse so that it is available if needed. – Mount the protection caps. Finishing work – Install the shock absorber. p. 65) – Lock the seat. ( p. 66) – Remove the motorcycle from the lift stand. ( p.
Page 111: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15 Fuse (75011088010) ( p. 143) Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. – Mount EFI control unit on the holder.
Page 112: Installing The Headlight Mask With The Headlight
15 ELECTRICAL SYSTEM – Disconnect plug-in connector of the turn signal relay, plug- in connectors of the turn signals, plug-in connector the headlight and plug-in connector of the ignition lock. E00968-11 15.7 Installing the headlight mask with the headlight Main work –...
Page 113: Changing The Headlight Bulb
ELECTRICAL SYSTEM 15 15.8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...
Page 114: Checking The Headlight Setting
15 ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze together the orange cap in the area of the holding lugs and take it off. –...
Page 115: Adjusting The Headlight Range
ELECTRICAL SYSTEM 15 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 112) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).
Page 116: Diagnostics Connector
15 ELECTRICAL SYSTEM Finishing work – Install the headlight mask with the headlight. ( p. 110) – Check the headlight setting. ( p. 112) – Set kilometers or miles. ( p. 22) – Set the combination instrument. ( p. 23) –...
Page 117: Cooling System 16
COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
Page 118: Checking The Coolant Level
16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...
Page 119: Draining The Coolant
COOLING SYSTEM 16 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
Page 120: Refilling Coolant
16 COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...
Page 121: Tuning The Engine 17
TUNING THE ENGINE 17 17.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...
Page 122: Adjusting The Characteristic Map Of The Throttle Response
17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
Page 123: Adjusting The Idle Speed
17.4 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)
Page 124 17 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 18) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...
Page 125: Teaching The Throttle Valve Position
TUNING THE ENGINE 17 » If the idle speed does not meet the specifications: – Adjust the idle speed. 17.5 Teaching the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be retaught, then the mal- function indicator lamp flashes 2x per second.
Page 126: Adjusting The Basic Position Of The Shift Lever
17 TUNING THE ENGINE 17.7 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing.
Page 127: Service Work On The Engine 18
SERVICE WORK ON THE ENGINE 18 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
Page 128: Checking The Engine Oil Level
18 SERVICE WORK ON THE ENGINE Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
Page 129 SERVICE WORK ON THE ENGINE 18 Main work – Place an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws E00990-10 – Remove screw plug with oil screen and the O-rings.
Page 130 18 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surfaces. E00993-10 – Lay the motorcycle on its right side and fill the oil filter hous- ing approx.
Page 131: Adding Engine Oil
SERVICE WORK ON THE ENGINE 18 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...
Page 132: 19 Cleaning, Care
19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
Page 133: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 149) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Page 134: 20 Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 55) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Page 135: Preparing For Use After Storage
STORAGE 20 Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 20.2 Preparing for use after storage –...
Page 136: 21 Troubleshooting
Check the electrical system. tive – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool.
Page 137 Action – Engine has too little power Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Exhaust system leaky, Check exhaust system for damage. deformed or too little glass – Change the glass fiber yarn filling of fiber yarn filling in main the main silencer.
Page 138 21 TROUBLESHOOTING Faults Possible cause Action – Combination instrument values The combination instrument Change the combination instrument deleted (time, stop watch, lap battery is empty battery. ( p. 113) times) – The high beam, low beam, Fuse 2 blown Change the fuses of individual power position light, tail light, and consumers.
Page 139: Blink Code 22
BLINK CODE 22 Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short...
Page 140 22 BLINK CODE Blink code for malfunction indicator lamp 22 Malfunction indicator lamp flashes 2x long, 2x short Gear position sensor – circuit fault Error level condition Gear position sensor – input signal too high Gear position sensor – malfunction Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short...
Page 141: Technical Data 23
TECHNICAL DATA 23 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 12.8:1 Idle speed 1,750 … 1,850 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)
Page 142: Engine Tightening Torques
23 TECHNICAL DATA 23.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) Loctite ®...
Page 143 TECHNICAL DATA 23 Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft)
Page 144: Capacities
23 TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) p. 147) 23.3.2 Coolant Coolant 0.7 l (0.7 qt.) Coolant ( p. 147) 23.3.3 Fuel Please observe the labels on EU fuel pumps. A00420-10 Total fuel tank capacity, approx.
Page 145: Electrical System
Front tire Rear tire 2.75 - 21 M/C 45M TT 4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...
Page 146: Fork
23 TECHNICAL DATA 23.7 Fork Fork article number 05.18.8S.40 WP SuspensionXplor 43 Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with spring guide and preload spacer(s) 427 mm (16.81 in) Spring rate Weight of rider: 65 …...
Page 147: Chassis Tightening Torques
TECHNICAL DATA 23 Fitted length 367 mm (14.45 in) Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 148) 23.9 Chassis tightening torques Screw for spoiler, top EJOT PT ® K60x20AL 3 Nm (2.2 lbf ft) Screw, front spoiler EJOT PT ®...
Page 148 23 TECHNICAL DATA Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fuel tank 15 Nm (11.1 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, main silencer M8x20 25 Nm (18.4 lbf ft) Screw, main silencer M8x25 25 Nm (18.4 lbf ft)
Page 149: Substances 24
SUBSTANCES 24 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
Page 150 24 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 151) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...
Page 151: Auxiliary Substances 25
AUXILIARY SUBSTANCES 25 Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
Page 152 25 AUXILIARY SUBSTANCES Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...
Page 153: Standards 26
STANDARDS 26 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
Page 154: 27 Index Of Special Terms
27 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...
Page 155: List Of Abbreviations 28
LIST OF ABBREVIATIONS 28 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
Page 156: 29 List Of Symbols
Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
Page 157: Index
INDEX Chain tension INDEX checking ......77 setting ......77 12-V battery charging .
Page 158 INDEX High-speed compression damping shock absorber, adjusting ....46 Figures ....... 9 Horn button .
Page 159 INDEX checks and maintenance measures when Steering head bearing preparing for use ....37 greasing ......63 Protective clothing .
Page 160 *3213861en* 3213861en 07/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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