KTM Freeride 250 R Owner's Manual
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- Owner's manual (110 pages) ,
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- Repair manual (222 pages)
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Summary of Contents for KTM Freeride 250 R
- Page 1 OWNER'S MANUAL 2015 Freeride 250 R EU Freeride 250 R AU Freeride 250 R US Art. no. 3213185en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Speed, time, and DST distance 1 ..... 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 Speed, time, and DST2 distance 2 ....21 Symbols used ........... 4 7.10 AVG average speed, ART operating hours, and Formats used............ 4 ODO total distance covered ...... - Page 5 TABLE OF CONTENTS 12.20 Removing the air filter housing ..... 45 15.6 Removing the headlight mask with the headlight............75 12.21 Installing the air filter housing ...... 46 15.7 Refitting the headlight mask with the 12.22 Removing the air filter .........
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Page 6: Means Of Representation
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. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 7: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. -
Page 8: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 9: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 10: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) B02269-10 Speedometer Clutch lever ( p. 12) Filler cap Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 16) Fuel tap ( p. 15) Shift lever ( p. -
Page 11: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) B02270-10 Kill switch ( p. 12) Horn button ( p. 12) Light switch ( p. 13) Turn signal switch ( p. 13) Electric starter button ( p. 13) Throttle grip ( p. -
Page 12: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401946-10 Type label (EU/AU) The type label is mounted on the frame at the front right. 402270-10 Key number The key number for the steering lock is stamped onto the key connector. -
Page 13: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 0 0 1 401948-10... -
Page 14: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B02271-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. -
Page 15: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on –... -
Page 16: Overview Of Indicator Lamps (Eu/Au)
CONTROLS 6.11 Overview of indicator lamps (EU/AU) Possible states High beam indicator light lights up blue – High beam is switched on. FI warning lamp (MIL) – inoperative Low fuel warning lamp – inoperative Turn signal indicator light flashes green – Turn signal is switched on. B02275-01 6.12 Overview of indicator lamps (US) -
Page 17: Closing The Filler Cap
CONTROLS 6.14 Closing the filler cap Main work – Replace the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose without kinks. B01662-11 Finishing work – Lock the seat. ( p. -
Page 18: Foot Brake Lever
CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.18 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 6.19 Side stand... -
Page 19: Locking The Steering
CONTROLS 6.21 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –... -
Page 20: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized KTM workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 21: Setting Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 22: Setting The Clock
SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –... -
Page 23: Speed, Time, And Dst Distance 1
SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0. -
Page 24: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 25: Running In The Engine
PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 280 kg (617 lb.) Maximum permissible front axle load 135 kg (298 lb.) Maximum permissible rear axle load 175 kg (386 lb.) -
Page 26: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 86) –... -
Page 27: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 28: Stopping, Parking
RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. -
Page 29: 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. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 30: Service Schedule
Check idle. ● Check that the radiator fan is functioning properly. ● Final check: Check the vehicle for roadworthiness and take a test ride. ● Make the service entry in KTM DEALER.NET and in the service record. ● Periodic interval... -
Page 31: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 100 operating hours Every 50 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. p. -
Page 32: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 33: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 34: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover. -
Page 35: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to 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 length of the spring. -
Page 36: Adjusting The Riding Sag
TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 44) – Lock the seat. ( p. 45) – Remove the motorcycle from the lift stand. ( p. 37) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 37: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. -
Page 38: Adjusting The Handlebar Position
TUNING THE CHASSIS 11.15 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove screws . Remove the handlebar clamps. Take off the handlebar and lay it to one side. -
Page 39: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) Neither wheel is in contact with the ground. -
Page 40: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) – Remove the fork protector. p. 39) Main work – Push dust boots of both fork legs downward. -
Page 41: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.6 Installing the fork legs Main work – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the upper edge of the upper triple clamp. Position bleeder screws toward the front. -
Page 42: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 12.8 Installing the fork protector – Position the fork protection on the right fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B02281-11 – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 43: Installing The Lower Triple Clamp
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. 103) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 44: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-... -
Page 45: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. -
Page 46: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS 12.14 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) – Fold the seat up. ( p. 45) Main work – Remove screw – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. -
Page 47: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 12.17 Installing the front fender – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the headlight mask. -
Page 48: Installing The Air Filter Housing
SERVICE WORK ON THE CHASSIS Main work – Pull air filter housing up and off. B01726-10 12.21 Installing the air filter housing Main work – Mount air filter housing on the intake flange. Info If the air filter housing is not mounted correctly, dust and dirt may enter the engine and cause damage. -
Page 49: Cleaning The Air Filter And Air Filter Housing
SERVICE WORK ON THE CHASSIS – Insert both parts together and close air filter housing by turning clockwise. Info If the air filter is not mounted correctly, dust and dirt may enter the engine and cause damage. B01722-10 Finishing work –... -
Page 50: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS 12.26 Installing the main silencer – Mount the main silencer with rubber sleeve – Mount and tighten screws Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) B01720-10 12.27 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. -
Page 51: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. -
Page 52: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS – Mount and tighten screws on both sides. Guideline Screw, fuel tank 15 Nm Loctite ® 243™ (11.1 lbf ft) – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –... -
Page 53: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12.32 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. -
Page 54: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Info The wide adjustment range of the chain adjusters enables different sec- ondary ratios with the same chain length. Chain adjusters can be turned by 180°. Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 55: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. B01723-10... -
Page 56: Checking The Swingarm
If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 401463-01 12.37 Checking the throttle cable routing Preparatory work –... -
Page 57: Additionally Securing The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.39 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 54) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip. -
Page 58: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilt brake fluid immediately with water. 12.43 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. –... -
Page 59: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS 12.44 Removing the engine guard – Remove screws – Lower the engine guard at the rear and remove it toward the front. B01706-10 12.45 Installing the engine guard – Position the engine guard on the frame at the front and mount screws but do not tighten yet. -
Page 60: Brake System
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk ... -
Page 61: Checking The Brake Fluid Level Of The Front Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 62: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 63 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. 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.
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Page 64: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Remove the fixation of the hand brake lever. – Add brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below con- tainer rim) Brake fluid DOT 4 / DOT 5.1 ( p. -
Page 65: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 66: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 67 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
- Page 68 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 101) – Mount the cover with membrane – Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water. B01692-10...
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Page 69: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Loosen screw by several rotations. – Release screws – Press on screw to push the wheel spindle on the axle clamp. –... -
Page 70: Removing The Rear Wheel
WHEELS, TIRES – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Tighten screw Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 14.3 Removing the rear wheel Preparatory work –... -
Page 71: 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 air pressure of the tires all have a major impact on the handling characteristics of the motorcycle. -
Page 72: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. -
Page 73: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms. Preparatory work – Raise the motorcycle with the lift stand. -
Page 74: Recharging The Battery
– Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 75: Changing The Main Fuse
ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly when the 3 months motorcycle is not in use Finishing work – Install the battery. p. 71) – Install the shock absorber. p. -
Page 76: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Fold the seat up. -
Page 77: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15.6 Removing the headlight mask with the headlight – Switch off all power consumers and switch off the engine. – Detach the brake line and wiring harness – Release rubber band . Slide the headlight mask up and swing it forward. B01681-10 –... -
Page 78: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and fix it with the rubber band Info Make sure that the holding lugs engage in the fender. – Position the brake line and wiring harness B01041-11 Finishing work – Check the headlight setting. ( p. -
Page 79: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Main work –... -
Page 80: Changing The Speedometer Battery
ELECTRICAL SYSTEM Info Turn clockwise to increase the headlight range, turn counterclockwise to reduce the headlight range. A change in weight on the vehicle may require a correction of the headlight range. 15.12 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. -
Page 81: Cooling System
COOLING SYSTEM 16.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 82: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 83: Refilling Coolant
COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately. -
Page 84: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – 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 2…... -
Page 85: Carburetor - Idle
TUNING THE ENGINE 17.3 Carburetor - idle The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. Info The carburetor and its components are subject to increased wear caused by engine vibration. -
Page 86: Emptying The Carburetor Float Chamber
TUNING THE ENGINE Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 15) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw slowly clockwise until the idle speed starts to drop. -
Page 87: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE 17.6 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…... -
Page 88: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Cleaning the alternator – Remove screws – Take off the cover. B01730-10 – Remove screws – Take off the alternator cover B01895-10 – Clean alternator cover and rotor – Take off Bendix and clean. -
Page 89: Changing The Gear Oil
SERVICE WORK ON THE ENGINE 18.3 Changing the gear oil – Drain the gear oil. p. 87) 400721-01 – Fill in gear oil. p. 88) 400722-01 18.4 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –... -
Page 90: Filling In Gear Oil
SERVICE WORK ON THE ENGINE 18.5 Filling in gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Main work – Remove screw cap and fill in gear oil. Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. -
Page 91: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 92: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 93: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 37) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion. -
Page 94: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 24) tric starter) – Battery is discharged Check the charging voltage. – Check the open-circuit current. – Check the alternator. –... - Page 95 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Too little air stream Switch off the engine when standing. – Radiator fins very dirty Clean the radiator fins. – Foam formation in cooling system Drain the coolant. p. 80) – Refill the coolant. p.
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Page 96: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 2-stroke gasoline engine, water-cooled, with mem- brane inlet Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Bore 66.4 mm (2.614 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing... -
Page 97: Capacities
TECHNICAL DATA – Nut, cylinder base 35 Nm (25.8 lbf ft) – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –... -
Page 98: Electrical System
Front tires Rear tires 2.75 - 21 M/C 45M TT 4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 05.18.7N.42 WP Suspension 4357 MXMA fork... -
Page 99: Shock Absorber
TECHNICAL DATA Fork length 835 mm (32.87 in) Air chamber length mm (4.72 +0.39 −40 −1.57 Fork oil per fork leg 390 ml (13.19 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 101) 22.8 Shock absorber Shock absorber part number 15.18.7N.42 WP Suspension 4618 PDS DCC Shock absorber... - Page 100 TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw of rear brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ – Screw, bottom triple clamp 18 Nm (13.3 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) –...
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Page 101: Carburetor
TECHNICAL DATA 22.10 Carburetor 22.10.1 EU/AU Carburetor type KEIHIN PWK 28 Carburetor identification number Needle position 2nd position from top Jet needle JJH (JJG) Main jet 110 (120/122/125) Idling jet 40 (45/48) Idle air adjusting screw Open 2.0 rotations Throttle slide Slide stop Present 22.10.2 US... - Page 102 TECHNICAL DATA 401798-01 M/FT ASL Sea level TEMP Temperature Open idle air adjusting screw Idling jet Needle Needle position from top Main jet Does not apply on sandy terrain.
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Page 103: Substances
SUBSTANCES 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 possesses the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 104 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 105) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
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Page 105: Auxiliary Substances
Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ® – Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE... - Page 106 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...
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Page 107: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 108: Index
INDEX Clutch INDEX fluid level, checking ......55 Accessories ........7 fluid level, correcting . - Page 109 INDEX Front fender Motorcycle installing ....... . . 45 cleaning ....... . . 89 removing .
- Page 110 INDEX Spoke tension checking ....... . . 70 Starting ........24 Steering locking .
- Page 111 *3213185en* 3213185en 08/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
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