KTM Freeride 250 R EU Owner's Manual
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KTM Freeride 250 R EU Owner's Manual

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OWNER'S MANUAL
2016
Freeride 250 R EU
Freeride 250 R AU
Freeride 250 R US
Art. no. 3213341en

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Summary of Contents for KTM Freeride 250 R EU

  • Page 1 OWNER'S MANUAL 2016 Freeride 250 R EU Freeride 250 R AU Freeride 250 R US Art. no. 3213341en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Speed, time, and DST distance 1 ..... 22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Speed, time, and DST2 distance 2 ....22 Symbols used ........... 5 7.10 AVG average speed, ART operating hours, and Formats used............ 5 ODO total distance covered ......
  • Page 5 TABLE OF CONTENTS 12.20 Removing the air filter housing ..... 46 15.6 Removing the headlight mask with the headlight............75 12.21 Installing the air filter housing ...... 47 15.7 Refitting the headlight mask with the 12.22 Removing the air filter .........
  • Page 6 TABLE OF CONTENTS 27.2 Green and blue symbols......... 109 INDEX ................110...

  • Page 7: 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 8: 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 9: 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 10: 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 11: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) B02269-10 Speedometer Clutch lever ( p. 13) Filler cap Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 17) Fuel tap ( p. 16) Shift lever ( p.

  • Page 12: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) B02270-10 Kill switch ( p. 13) Horn button ( p. 13) Light switch ( p. 14) Turn signal switch ( p. 14) Electric starter button ( p. 14) Throttle grip ( p.

  • Page 13: 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 14: Shock Absorber Article Number

    SERIAL NUMBERS Shock absorber article number  The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...

  • Page 15: 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 16: 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 17: 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 Fuel level warning lamp – inoperative Turn signal indicator light flashes green – Turn signal is switched on. B02275-01 6.12 Overview of indicator lamps (US)

  • Page 18: 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. C00896-11 Finishing work – Lock the seat. ( p.

  • Page 19: 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 20: 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 21: 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 22: 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 23: 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 24: 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 25: 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 and Warranty Booklet at vehicle handover.

  • Page 26: Running In The Engine

    PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed maximum permissible weight and maximum permissible 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 27: 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. 88) –...

  • Page 28: 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 29: 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 30: 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 31: Service Schedule

    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 the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 32: Service Work (As Additional Order)

    SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. p.

  • Page 33: 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 34: 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 35: 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. 38) 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.

  • Page 36: 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 37: Adjusting The Riding Sag

    TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 45) – Lock the seat. ( p. 46) – Remove the motorcycle from the lift stand. ( p. 38) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p.

  • Page 38: 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 39: Handlebar Position

    TUNING THE CHASSIS 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 of from the center.

  • Page 40: 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 (78929955100) Neither wheel is in contact with the ground.

  • Page 41: 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. 38) – Remove the fork protector. ( p. 40) Main work –  Push dust boots of both fork legs downward.

  • Page 42: 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 43: 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 44: 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. 105) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 45: 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 46: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 38) 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 47: 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. 38) – Fold the seat up. ( p. 46) 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 48: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 12.17 Installing the front 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. B01030-10 12.18 Folding the seat up...

  • Page 49: 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 50: 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 51: 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) M01031-10 12.27 Changing glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

  • Page 52: 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 53: 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 54: 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 55: 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 56: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. B01723-10...

  • Page 57: Checking The Swingarm

    » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. 401463-01 12.37 Checking the throttle cable routing Preparatory work –...

  • Page 58: Additionally Securing The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12.39 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 55) 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 59: 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 60: 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 61: 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 62: 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 63: 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 64 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.

  • Page 65: 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 66: 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 67: 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 68 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 69 BRAKE SYSTEM –  Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 103) –  Position the cover with the membrane –  Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water. B01692-10...

  • Page 70: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 38) Main work –  Loosen screw by several rotations. – Release screws  –  Press on screw to push the wheel spindle on the axle clamp. –...

  • Page 71: Removing The Rear Wheel

    WHEELS, TIRES – Pull the front brake and compress the fork forcefully a few times. The fork legs straighten. – Tighten screw  Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 14.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the lift stand.

  • Page 72: 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 73: 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 74: 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. – Maintain the minimum clearance to inflammable materials while charging. Minimum clearance 1 m (3 ft) –...

  • Page 75: Recharging The Battery

    – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 76: Changing The Main Fuse

    ELECTRICAL SYSTEM You can also use the battery charger to test the rest potential and starting ability of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Only charge the battery with the specified battery charge. Read the notes in the battery package.

  • Page 77: 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 78: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Main work –  Detach the brake line and wiring harness –  Release rubber straps . Slide the headlight mask up and swing it forward. M01035-10 –   Disconnect the plug-in connectors for the turn signals and for the head- light.

  • Page 79: Changing The Headlight Bulb

    ELECTRICAL SYSTEM –  Position the headlight mask and secure it with rubber straps The holding lugs on the fender engage in the headlight mask. –  Attach the brake line and wiring harness M01037-10 Finishing work – Check the headlight setting. ( p.

  • Page 80: Changing The Turn Signal Bulb (Eu/Au)

    ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb (EU/AU) 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.

  • Page 81: Changing The Speedometer Battery

    ELECTRICAL SYSTEM Main work –  Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (the mark is created in: Checking the headlight setting). Info Turn clockwise to increase the headlight range, turn counterclockwise to reduce the headlight range.

  • Page 82: 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 83: 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 84: 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 fuel is swal- lowed, contact a physician immediately.

  • Page 85: 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 86: 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 87: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 16) Idle speed 1,400… 1,500 rpm –  Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall.

  • Page 88: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17.6 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the driver's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 89: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Cleaning the alternator –    Remove screws – Take off the cover. M01048-10 –    Remove screws –  Take off the alternator cover M01049-10 –  Clean alternator cover and rotor –...

  • Page 90: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 18.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –  Remove the gear oil monitoring screw –...

  • Page 91: Filling In Gear Oil

    SERVICE WORK ON THE ENGINE Main work –  Remove the gear oil drain plug with magnet – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug with magnet. – Clean the sealing surface on the engine. –...
  • Page 92 SERVICE WORK ON THE ENGINE –  Mount and tighten filler plug Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 93: 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 94: 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 95: 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. 38) – 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 96: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 25) tric starter) – Battery is discharged Check the charging voltage. – Check the open-circuit current. – Check the alternator. –...
  • Page 97 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Too little coolant in cooling system Check the cooling system for leaks. – Check the coolant level. ( p. 81) – Too little air stream Switch off the engine when standing. – Radiator fins very dirty Clean the radiator fins.

  • Page 98: 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 99: Capacities

    TECHNICAL DATA Loctite ® 243™ Screw, stator 8 Nm (5.9 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) Transmission venting connection 4 Nm (3 lbf ft) Loctite ® 243™ – Screw, cylinder head 27 Nm (19.9 lbf ft) –...

  • Page 100: Electrical System

    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 Fork WP Performance Systems 4357 MXMA...

  • Page 101: Shock Absorber

    TECHNICAL DATA Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm (27.4 lb/in) Fork length 835 mm (32.87 in) Air chamber length...
  • Page 102 TECHNICAL DATA Loctite ® 243™ Screw, rear brake disc 14 Nm (10.3 lbf ft) – Screws, throttle grip 3 Nm (2.2 lbf ft) – Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ®...

  • Page 103: 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 104 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.

  • Page 105: 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 exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 106 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 107) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 107: Auxiliary Substances

    Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ®...
  • Page 108 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 109: 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 110: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 111: Lisy Of Symbols

    LISY OF SYMBOLS 27.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. FI warning lamp (MIL) – inoperative Fuel level warning lamp – inoperative 27.2 Green and blue symbols Green and blue symbols reflect information.
  • Page 112 INDEX Clutch INDEX fluid level, checking ......56 Accessories ........8 fluid level, correcting .
  • Page 113 INDEX Front fender Motorcycle installing ....... . . 46 cleaning ....... . . 91 removing .
  • Page 114 INDEX Spoke tension checking ....... . . 71 Starting ........25 Steering locking .
  • Page 115 *3213341en* 3213341en 04/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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