KTM Freeride 250 R EU Repair Manual
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KTM Freeride 250 R EU Repair Manual

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REPAIR MANUAL
2014
Freeride 250 R EU
Freeride 250 R AUS
Art. no. 3206188en

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Summary of Contents for KTM Freeride 250 R EU

  • Page 1 REPAIR MANUAL 2014 Freeride 250 R EU Freeride 250 R AUS Art. no. 3206188en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SHOCK ABSORBER, SWINGARM ........ 36 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Adjusting the high-speed compression Symbols used ........... 5 damping of the shock absorber......36 Formats used............ 5 Adjusting the low-speed compression damping SAFETY ADVICE............6 of the shock absorber ........
  • Page 5 TABLE OF CONTENTS 14 WHEELS ..............69 18 30/ENGINE ............. 101 14.1 Checking the tire air pressure......69 18.1 Removing the engine........101 14.2 Checking the tire condition ......69 18.2 Installing the engine........104 14.3 Checking the brake discs ......... 70 18.3 Engine disassembly........
  • Page 6 19.12 Assembling the carburetor ......152 29 WIRING DIAGRAM ........... 182 19.13 Checking/adjusting the float level ....153 29.1 Page 1 of 5 (Freeride 250 R EU)....182 20 CLUTCH ..............155 29.2 Page 2 of 5 (Freeride 250 R EU)....184 20.1...

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

  • Page 8: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

  • 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: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. B01005-10 Type label The type label is fixed to the frame at the front right. B01124-10 Key number The key number for the steering lock is stamped onto the key connector. 500125-10 Engine number The engine number...

  • Page 11: 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. B01654-10...

  • Page 12: Motorcycle

    MOTORCYCLE 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) ( p.

  • Page 13: Starting The Motorcycle To Make Checks

    MOTORCYCLE – Raise the motorcycle off of the stand and secure the stand with the rubber band – Shift gear to neutral. (Freeride 250 R AUS) – Press the emergency OFF switch into the position The engine is cold – Pull the choke lever out as far as possible.

  • Page 14: Fork, Triple Clamp

    FORK, TRIPLE CLAMP 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 15: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Finishing work – Remove the motorcycle from the lift stand. ( p. 10) Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Push dust boots of both fork legs downward.

  • Page 16: Removing The Fork Legs

    FORK, TRIPLE CLAMP – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line, wiring harness, and clamp. Mount and tighten screws B01734-11 Removing the fork legs Preparatory work –...

  • Page 17: Performing A Fork Service

    FORK, TRIPLE CLAMP – Position the brake caliper. Mount and tighten screws with the spacers. Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount cable binder – Position the brake line, wiring harness, and clamp. Mount and tighten screws 602805-11 Finishing work –...
  • Page 18 FORK, TRIPLE CLAMP – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T612S) ( p. 214) 201424-10 – Loosen screw cap Info The screw cap cannot be removed yet. 201425-10 – Unclamp the fork leg and clamp it with the axle clamp. Info Use soft jaws.
  • Page 19 FORK, TRIPLE CLAMP – Pull the spring downward. Remove the special tool. – Remove spring. 201430-10 – Drain the fork oil. Info Pull out the piston rod all the way and push it back in several times in order to pump out the cartridge until it is empty. 201431-10 –...

  • Page 20: Disassembling The Cartridge

    FORK, TRIPLE CLAMP – Warm up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) – Jerk the outer tube out of the inner tube. Info The lower sliding bushing must be pulled out of its bearing seat when doing this.
  • Page 21 FORK, TRIPLE CLAMP – Pull piston rod out of cartridge – Clamp in the piston rod. Remove water excluder Clamping stand (T14016S) ( p. 211) 200695-10 – Remove screw sleeve with washer and spring seat from the cartridge. 200696-10 – Degrease the piston rod.

  • Page 22: Disassembling The Compression Holder

    FORK, TRIPLE CLAMP – Remove spring – Remove valve of the rebound damping together with the spring. – Take out the piston rod. 200701-10 6.12 Disassembling the compression holder Info The steps are identical for both fork legs. Preparatory work –...
  • Page 23 FORK, TRIPLE CLAMP – Measure the outside diameter of the inner tube at several locations. Outside diameter of the inner tube 42.975… 43.005 mm (1.69193… 1.69311 in) » If the measured value is less than the specified value: – Change the inner tube. 200684-10 –...

  • Page 24: Assembling The Compression Holder

    FORK, TRIPLE CLAMP 6.14 Assembling the compression holder Info The steps are identical for both fork legs. – Clamp the compression holder in a bench vise using soft jaws. – Mount O-ring and seal ring – Grease the O-ring. Lubricant (T158) ( p.
  • Page 25 FORK, TRIPLE CLAMP – Grease the O-ring of tap rebound Lubricant (T158) ( p. 204) – Mount and tighten the tap rebound. Guideline Tap rebound M9x1 18 Nm Loctite ® 2701™ (13.3 lbf ft) – Position spring 200718-10 – Mount shim stack with the smaller shims facing downward.

  • Page 26: Assembling The Fork Legs

    FORK, TRIPLE CLAMP – Mount and tighten screw sleeve Guideline Screw sleeve M29x1 46 Nm Loctite ® (33.9 lbf ft) 200722-10 6.16 Assembling the fork legs Info The operations are the same on both fork legs. Preparatory work – Check the fork legs. ( p.
  • Page 27 FORK, TRIPLE CLAMP – Push on the lower sliding bushing – Mount the upper sliding bushing Info Without using a tool, pull the stack apart by hand slightly. 201440-10 – Warm up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) –...
  • Page 28 FORK, TRIPLE CLAMP – Mount the special tool on the cartridge. Support tool (T14026) ( p. 212) Info The special tool must be used in order that the adjustment tube is not raised. Otherwise, oil will reach the piston rod. –...
  • Page 29 FORK, TRIPLE CLAMP Info The screw cap must be screwed in all the way before the piston rod begins to turn. In case of tight piston rod threads, it must be held to keep it from turning. If the screw cap is not screwed in all the way, the rebound adjust- ment will not function properly.

  • Page 30: Greasing The Steering Head Bearing

    FORK, TRIPLE CLAMP 6.17 Greasing the steering head bearing – Remove the lower triple clamp. ( p. 28) – Install the lower triple clamp. ( p. 29) 800010-10 6.18 Removing the lower triple clamp Preparatory work – Remove the headlight mask with the headlight. ( p.

  • Page 31: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.19 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 204) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 32: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) B01745-10 – Tighten screws Guideline Screw, top triple clamp 22 Nm (16.2 lbf ft) B01054-13 – Secure the cable holder. B01756-01 –...

  • Page 33: Adjusting The Play Of The Steering Head Bearing

    FORK, TRIPLE CLAMP Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) 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 34: Handlebar, Controls

    HANDLEBAR, CONTROLS Handlebar position On the upper triple clamp, there are two holes at a distance of to each other. Hole distance 15 mm (0.59 in) The holes on the handlebar supports are placed at a distance of from the center. Hole distance 3.5 mm (0.138 in) The handlebar supports can be mounted in four different positions.

  • Page 35: Checking The Throttle Cable Routing

    HANDLEBAR, CONTROLS Checking the throttle cable routing Preparatory work – Fold the seat up. ( p. 62) – Remove the fuel tank. ( p. 65) Main work – Check the throttle cable routing. The throttle cable must be routed to the carburetor along the back of the handle- bar, below the seat fixing.

  • Page 36: Adjusting The Play In The Throttle Cable

    HANDLEBAR, CONTROLS Adjusting the play in the throttle cable Preparatory work – Fold the seat up. ( p. 62) – Remove the fuel tank. ( p. 65) – Check the throttle cable routing. ( p. 33) Main work – Move the handlebar to the straight-ahead position. –...

  • Page 37: Frame

    FRAME Removing the engine guard – Remove screws – Lower the engine guard at the rear and remove it toward the front. B01706-10 Installing the engine guard – Position the engine guard on the frame at the front and mount screws but do not tighten yet.

  • Page 38: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM 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. Info The high-speed setting can be seen during the fast compression of the shock absorber. Preparatory work –...

  • Page 39: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting the rebound 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. –...

  • Page 40: Checking The Static Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 37) – Hold the motorcycle upright with the aid of an assistant. – Measure the distance between the rear axle and the fixed point again. –...

  • Page 41: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) ( p. 210) – Measure the overall spring length while the spring is not under tension. –...

  • Page 42: Removing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Fold the seat up. ( p. 62) 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 43: Removing The Spring

    SHOCK ABSORBER, SWINGARM – Remove the spring. ( p. 41) – Disassemble the damper. ( p. 41) – Disassemble the piston rod. ( p. 42) – Disassemble the seal ring retainer. ( p. 44) – Check the damper. ( p. 45) –...

  • Page 44: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM – Remove protection cap of the reservoir. – Slowly unscrew screw The pressurized nitrogen is bled off. 201741-10 – Remove screw . Drain the oil. 201740-10 – Remove protection cap – Push in seal ring retainer – Remove lock ring Info Do not scratch the inner surface.
  • Page 45 SHOCK ABSORBER, SWINGARM Main work – Clamp the piston rod into a vise. – Remove nut – Remove rebound shim stack Info Guide the rebound shim stack onto a screwdriver and put them aside together. 201743-10 – Remove piston – Remove compression shim stack Info Guide the compression shim stack onto a screwdriver and put them aside...

  • Page 46: Disassembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM – Remove protection cap and rubber buffer 201749-10 9.15 Disassembling the seal ring retainer Preparatory work – Remove the spring. ( p. 41) – Disassemble the damper. ( p. 41) – Disassemble the piston rod. ( p. 42) Main work –...

  • Page 47: Checking The Damper

    SHOCK ABSORBER, SWINGARM Main work – Press pilot bushing out of seal ring retainer using the special tool. Press drift (T1504) ( p. 212) 200796-10 – Slide the new pilot bushing onto the special tool. Press drift (T1504) ( p. 212) –...

  • Page 48: Removing The Heim Joint

    SHOCK ABSORBER, SWINGARM » If the measured value is greater than the specified value: – Replace the piston rod. – Check the piston rod for damage and wear. » If there is damage or wear: – Replace the piston rod. –...

  • Page 49: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM – Place special tool underneath and press out heim joint using special tool Pressing tool (T1207S) ( p. 211) 201776-10 9.19 Installing the heim joint Info The steps are identical on the upper and lower heim joints. –...

  • Page 50: Assembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM 9.20 Assembling the seal ring retainer – Mount dust boot with the special tool. Mounting sleeve (T1204) ( p. 210) – Grease the sealing lip of the dust boot. Lubricant (T625) ( p. 204) 200792-10 – Grease the O-ring groove. Lubricant (T158) ( p.
  • Page 51 SHOCK ABSORBER, SWINGARM – Position the special tool on the piston rod. Mounting sleeve (T1554) ( p. 213) – Grease the dust boot and slide seal ring retainer onto the piston rod. Lubricant (T625) ( p. 204) – Remove the special tool. –...

  • Page 52: Assembling The Damper

    SHOCK ABSORBER, SWINGARM – Sand both sides of piston on a surface plate using 1200-grit sandpaper. – Clean the piston. – Mount the piston. Guideline View Top view of piston View Bottom view of piston 201757-11 – Mount rebound shim stack with the smaller shims at the top.
  • Page 53 SHOCK ABSORBER, SWINGARM – Pull out the piston rod in order that the seal ring retainer fits closely against the lock ring. – Mount protection cap of the damper cartridge. – Bleed and fill the damper. ( p. 52) – Fill the damper with nitrogen.

  • Page 54: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
  • Page 55 SHOCK ABSORBER, SWINGARM – When the vacuum gauge reaches the required value, turn control lever Oil reser- voir to Equalize pressure. Guideline 4 mbar The pressure gauge increases to the required value. 0 bar 200267-10 – When the pressure gauge reaches the required value, turn control lever Damper to Pressure.

  • Page 56: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar The pressure gauge drops to the required value. 0 bar – When the pressure gauge reaches the required value, activate the On/Off switch. Guideline 200269-10 0 bar...

  • Page 57: Installing The Spring

    SHOCK ABSORBER, SWINGARM – Open filler tap – Fill the damper for at least 15 seconds. Guideline Gas pressure 10 bar (145 psi) Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pressure. – Close the filling port screw using tap handle –...
  • Page 58 SHOCK ABSORBER, SWINGARM – Tighten the spring by turning adjusting ring to the value measured when it was removed. Hook wrench (T106S) ( p. 210) – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft)

  • Page 59: Exhaust

    EXHAUST 10.1 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws – Pull off the main silencer from the manifold at rubber sleeve B01720-10 10.2 Installing the main silencer...
  • Page 60 EXHAUST Main work – Remove screws . Pull out connecting cap – Pull glass fiber yarn filling from the connecting cap. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling on the connecting cap. –...

  • Page 61: Air Filter

    AIR FILTER 11.1 Removing the air filter housing Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Preparatory work –...

  • Page 62: Installing The Air Filter

    AIR FILTER 11.4 Installing the air filter Main work – Mount the clean air filter onto the air filter support. – Apply grease to the air filter around area Long-life grease ( p. 204) B01757-10 – Insert both parts together and close air filter housing by turning clockwise.

  • Page 63: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 64: Closing The Filler Cap

    FUEL TANK, SEAT, TRIM Main work – Fill the fuel tank with fuel up to measurement Guideline Measurement of 30 mm (1.18 in) Total fuel tank 7.0 l Super unleaded (95 octane) mixed capacity, approx. (1.85 US gal) with 2-stroke engine oil (1:80) p.

  • Page 65: Removing The Seat

    FUEL TANK, SEAT, TRIM 12.6 Removing the seat Preparatory work – Fold the seat up. ( p. 62) – Take off the spoiler. ( p. 63) Main work – Remove screws 305981-10 – Remove sliding bushings with the O-ring. – Remove the seat.

  • Page 66: Mounting The Spoiler

    FUEL TANK, SEAT, TRIM Main work – Remove screws 305979-10 – Remove screw – Remove screw – Take off the spoiler. – Repeat the operation on the opposite side. 305978-10 12.9 Mounting the spoiler Main work – Position the spoiler and hook it in at area 305980-10 –...

  • Page 67: Removing The Fuel Tank

    FUEL TANK, SEAT, TRIM 12.10 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 68: Fuel Tap

    FUEL TANK, SEAT, TRIM Main work – Check the throttle cable routing. ( p. 33) – Make sure that no cables are trapped or damaged. – Position the fuel tank. – Position the intake flange on the carburetor. – Tighten hose clamp –...

  • Page 69: Mask, Fender

    MASK, FENDER 13.1 Removing the front fender – Remove screws . Remove the front fender. – Ensure that the spacers remain in place. B01030-10 13.2 Installing the front fender – Ensure that the spacers are mounted in the fender. – Position the front fender.

  • Page 70: Refitting The Headlight Mask With The Headlight

    MASK, FENDER 13.4 Refitting the headlight mask with the headlight Main work – Connect connector of the headlight and turn signals. 602812-11 – Position the headlight mask and fix it with the rubber band Info Make sure that the holding lugs engage in the fender. –...

  • Page 71: Wheels

    The first two digits refer to the week of manufac- ture and last two digits refer to the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

  • Page 72: Checking The Brake Discs

    WHEELS 14.3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the...

  • Page 73: Front Wheel

    WHEELS 14.5 Front wheel 14.5.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Loosen screw by several rotations. – Release screws – Press on screw to push the wheel spindle on the axle clamp. –...

  • Page 74: Removing The Brake Disc Of The Front Brake

    WHEELS – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. – Remove the motorcycle from the lift stand. ( p. 10) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

  • Page 75: Installing The Rear Wheel

    WHEELS Main work – Remove nut – Remove chain adjuster Info Withdraw wheel spindle only 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 76: Removing The Brake Disc Of The Rear Brake

    WHEELS – Position chain adjuster . Mount nut , but do not tighten it yet. – Make sure that chain adjusters are fitted correctly on adjusting screws – Check the chain tension. ( p. 75) – Tighten nut Guideline Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Info...

  • Page 77: Checking The Chain Tension

    WHEELS 14.6.5 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 78: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    WHEELS Finishing work – Remove the motorcycle from the lift stand. ( p. 10) 14.6.7 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work –...

  • Page 79: Checking For Chain Dirt Accumulation

    WHEELS – Check the chain sliding piece for wear. » If the bottom edge of the chain bolt 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 80 WHEELS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 81: Wiring Harness, Battery

    WIRING HARNESS, BATTERY 15.1 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat. Preparatory work –...

  • Page 82: Removing The Battery

    WIRING HARNESS, BATTERY – Remove the defective fuse. Guideline Fuse 1 - 10 A - horn, brake light, turn signal Fuse 2 - 10 A - radiator fan Fuses res - 10 A - spare fuses Info A defective fuse is indicated by a burned-out fuse wire B01683-01 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are...

  • Page 83: Installing 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 84: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 85: Checking The Quiescent Current

    WIRING HARNESS, BATTERY – Change the voltage regulator. Finishing work – Install the shock absorber. ( p. 40) – Lock the seat. ( p. 62) – Remove the motorcycle from the lift stand. ( p. 10) 15.7 Checking the quiescent current Preparatory work –...

  • Page 86: Brake System

    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 87 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane B01696-10 – Remove screws and spacers. – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.

  • Page 88: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM 16.3 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.

  • Page 89: Adding Front Brake Fluid

    BRAKE SYSTEM 16.6 Adding front brake fluid Warning Danger of accidents Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.
  • Page 90 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Cover the painted parts. – Remove screws – Remove cover with membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.

  • Page 91: Checking The Rear Brake Linings

    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 92 BRAKE SYSTEM – Stand the vehicle upright. – Remove screws – Remove cover with membrane – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. B01689-10 – Take off cotter pin and remove bolt –...

  • Page 93: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 16.10 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.

  • Page 94: Adding Rear Brake Fluid

    BRAKE SYSTEM – Stand the vehicle upright. – Check the brake fluid level in the viewer » If the brake fluid level drops below marking – Add rear brake fluid. ( p. 92) B01693-10 16.13 Adding rear brake fluid Warning Danger of accidents Brake system failure.

  • Page 95: Changing The Rear Brake Fluid

    BRAKE SYSTEM 16.14 Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. –...
  • Page 96 BRAKE SYSTEM Info This prevents overfilling of the brake fluid reservoir. – Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro- tection cap. – Disconnect the bleeding device. Remove the bleeder cover. – Stand the vehicle upright. –...

  • Page 97: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 17.1 Setting the speedometer Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H.

  • Page 98: Setting Kilometers Or Miles

    LIGHTING SYSTEM, INSTRUMENTS 17.2 Setting kilometers or miles Info If you change the unit of measure, the ODO value is retained and converted accordingly. Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. –...

  • Page 99: Setting The Service Display

    LIGHTING SYSTEM, INSTRUMENTS – Wait for the menu TIRE to flash. Reducing the wheel circumference – Press the left button. The value decreases. Enlarging the wheel circumference – Press the right button. The value increases. 401910-01 Finishing work – Connect the speedometer connector CZ. 17.5 Setting the service display Condition...

  • Page 100: Adjusting The Headlight Range

    LIGHTING SYSTEM, INSTRUMENTS 17.7 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 97) 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).

  • Page 101: Changing The Speedometer Battery

    LIGHTING SYSTEM, INSTRUMENTS Main work – Turn rubber cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull bulb socket of the parking light out of the reflector. 602813-10 – Press headlight bulb lightly into the bulb socket, turn it counterclockwise, and pull it out.
  • Page 102 LIGHTING SYSTEM, INSTRUMENTS – Set the speedometer. ( p. 95)

  • Page 103: 30/Engine

    30/ENGINE 18.1 Removing the engine Preparatory work – Drain the coolant. ( p. 158) – Remove the engine guard. ( p. 35) – Raise the motorcycle with the lift stand. ( p. 10) – Remove the battery. ( p. 80) –...
  • Page 104 30/ENGINE – Swing the radiator slightly toward the rear and pull down. – Remove the radiator sideways. 202705-10 – Pull off the spark plug connector 202706-10 – Detach connector – Remove screws – Take off the ground wire. Remove the ignition coil. 202707-10 –...
  • Page 105 30/ENGINE – Remove screws – Take off the throttle slide cover and pull the throttle slide out of the carburetor. – Hang the throttle slide to the side. Info Protect the vehicle and its attachments from damage by covering them. –...

  • Page 106: Installing The Engine

    30/ENGINE – Remove nut – Remove the swingarm pivot. – Pull the swingarm back slightly. 202717-10 – Remove screws 202718-10 – Lift out the engine from the side. Info You should have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage.
  • Page 107 30/ENGINE – Position the brace. – Mount screw on both sides but do not tighten yet. Guideline Screw, engine brace on 25 Nm Loctite ® 243™ frame (18.4 lbf ft) – Mount and tighten fitting Guideline Screw, engine brace on cylinder head 33 Nm 202716-11 (24.3 lbf ft)
  • Page 108 30/ENGINE – Mount and tighten screw Guideline Screw, battery box EJOT 3 Nm (2.2 lbf ft) – Position the carburetor. – Mount and tighten hose clip – Position the throttle slide in the carburetor. Mount the throttle slide cover and tighten screws Guideline Screw, carburetor cover...
  • Page 109 30/ENGINE – Mount spark plug connector 202706-11 – Position the radiator. 202705-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202704-11 – Mount the radiator hoses. – Position and tighten hose clips – Mount hose 202703-11 –...

  • Page 110: Engine Disassembly

    30/ENGINE – Position the exhaust manifold. – Mount springs Spring hooks (50305017000) ( p. 206) – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Install the battery. ( p. 81) 202700-11 – Install the shock absorber. ( p.

  • Page 111: Draining The Gear Oil

    30/ENGINE 18.3.2 Draining the gear oil – Remove gear oil drain plug with the magnet and seal ring. – Completely drain the gear oil. 202722-10 18.3.3 Removing the clutch push rod – Remove clutch push rod 202723-10 18.3.4 Removing the shift lever –...

  • Page 112: Removing The Starter Motor

    30/ENGINE 18.3.6 Removing the starter motor – Remove screws – Take off cover 202727-10 – Remove screws – Remove starter motor. 202728-10 – Remove screws – Remove the cover. 202729-10 – Remove gasket and dowels 202730-10 – Remove starter idler gear 202731-10 –...

  • Page 113: Removing The Cylinder Head

    30/ENGINE – Remove gasket and dowels 202733-10 – Take off Bendix 202734-10 18.3.7 Removing the cylinder head – Alternately loosen screws and remove them. – Remove the cylinder head. 202737-10 – Remove O-rings 202738-10...

  • Page 114: Removing The Cylinder

    30/ENGINE 18.3.8 Removing the cylinder – Remove nuts – Carefully slide the cylinder up and take it off. 202739-10 – Take off gasket 202740-10 18.3.9 Removing the piston – Uncover the crankcase. – Remove the piston ring lock – Remove piston pin. –...

  • Page 115: Removing The Water Pump Cover

    30/ENGINE 18.3.10 Removing the water pump cover – Remove screws – Take off the water pump cover. 202743-10 – Remove dowels – Remove the form ring. 202744-10 18.3.11 Removing the clutch cover – Remove screws . Take off the clutch cover. 202745-10 –...

  • Page 116: Removing The Clutch Basket

    30/ENGINE – Remove clutch push rod 202748-10 – Remove clutch disc pack entirely. – Remove inner clutch hub sleeves 202749-10 18.3.13 Removing the clutch basket – Bend up the lock washer. – Hold the inner clutch hub with the special tool. Loosen nut Clutch holder (51129003000) ( p.

  • Page 117: Removing The Shift Shaft

    30/ENGINE – Take off primary gear – Remove the distance sleeve. 202754-10 18.3.14 Removing the shift shaft – Push sliding plate away from the shift drum locating unit . Remove shift shaft with the washer. 202755-10 18.3.15 Removing the shift drum locating unit –...

  • Page 118: Removing The Reed Valve Housing

    30/ENGINE – Mount special tool , apply counterpressure, and pull off the rotor by screwing in the screw. Extractor (58012009000) ( p. 208) 202759-10 18.3.18 Removing the reed valve housing – Remove screws – Take off the intake flange. 202760-10 –...

  • Page 119: Removing The Shift Rails

    30/ENGINE 18.3.20 Removing the shift rails – Remove shift rails with the springs. 202764-10 18.3.21 Removing the shift drum – Tilt shift forks to the side. Info Do not misplace the shift rollers. – Remove shift drum 202765-10 18.3.22 Removing the shift forks –...

  • Page 120: Work On Individual Parts

    30/ENGINE – Remove O-ring 202769-10 18.4 Work on individual parts 18.4.1 Work on the right section of the engine case – Remove all dowels. – Remove shaft seal ring of the crankshaft. – Remove screws . Remove the bearing retainers. –...

  • Page 121: Work On The Left Section Of The Engine Case

    30/ENGINE 18.4.2 Work on the left section of the engine case – Remove all dowels. – Remove shaft seal ring of the crankshaft, shift shaft and countershaft. – Clean the engine case section thoroughly. – Warm the engine case section in an oven. Guideline 150 °C (302 °F) –...

  • Page 122: Installing The Crankshaft Bearing Inner Race

    30/ENGINE – Push the warmed up special tool onto the crankshaft bearing inner race, press firmly together and pull jointly from the crankshaft. 18.4.4 Installing the crankshaft bearing inner race – Fixate the crankshaft in the vice with special tool Separator plate (54829009000) ( p.

  • Page 123: Checking The Crankshaft Run-Out At The Bearing Pin

    30/ENGINE – Position special tool on the press. Pressing device for crankshaft, complete (75029047000) ( p. 209) Insert for crankshaft pressing tool (54829108000) ( p. 207) – Insert the crankweb with the connecting rod and bearing. Position the second crankweb. 303487-10 –...

  • Page 124: Cylinder - Nikasil ® Coating

    30/ENGINE – Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. Feeler gauge (59029041100) ( p. 209) Info The cylinder size is labeled on the back of the cylinder. ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - distortion of sealing area 202784-10...

  • Page 125: Checking The Piston Ring End Gap

    30/ENGINE Info Piston dimensions are marked on the piston head. 18.4.10 Checking the piston ring end gap – Remove the piston ring from the piston. – Place the piston ring in the cylinder and align with the piston. Guideline Below the upper edge of the cylinder 20 mm (0.79 in) –...

  • Page 126: Work On The Clutch Cover

    30/ENGINE 18.4.13 Work on the clutch cover Info Remove the outer clutch cover to avoid damage. – Remove screw – Take off water pump impeller 202788-10 – Remove water pump shaft 202789-10 – Remove shaft seal ring 202790-10 – Press out bearing toward the inside.

  • Page 127: Checking The Clutch

    30/ENGINE – Carefully mount the water pump shaft Info Watch out for the shaft seal ring. 202789-10 – Mount water pump impeller – Mount and tighten screw Guideline Screw, water pump wheel 6 Nm Loctite ® 243™ (4.4 lbf ft) 202788-10 18.4.14 Checking the clutch 309385-10...

  • Page 128: Preassembling The Shift Shaft

    30/ENGINE » If the thrust surface exhibits excessive wear: – Change the clutch facing discs and the clutch basket. – Check needle bearing and collar bushing for damage and wear. » If there is damage or wear: – Change the needle bearing and collar bushing. –...

  • Page 129: Checking The Shift Mechanism

    30/ENGINE 18.4.16 Checking the shift mechanism 303007-10 – Check shift forks on disc for damage and wear (visual check). » If there is damage or wear: – Change the shift fork and gear wheel pair. – Check shift grooves of shift drum for wear.

  • Page 130: Disassembling The Main Shaft

    30/ENGINE – Preassemble the shift shaft. ( p. 126) – Check clearance between the sliding plate and the shift quadrant. Shift shaft - sliding plate/shift quad- 0.40… 0.80 mm (0.0157… rant clearance 0.0315 in) » If the measured value does not meet specifications: –...

  • Page 131: Disassembling The Countershaft

    30/ENGINE 18.4.18 Disassembling the countershaft 303335-10 – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk – Remove sixth-gear sliding gear –...

  • Page 132: Assembling The Main Shaft

    30/ENGINE 303336-10 – Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearing. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...

  • Page 133: Assembling The Countershaft

    30/ENGINE Preparatory work – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 129) 303334-11 Main work – Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws – Mount needle bearing –...
  • Page 134 30/ENGINE 303335-11 Main work – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar facing downward. – Mount stop disk and lock ring –...

  • Page 135: Checking The Electric Starter Drive

    30/ENGINE 18.4.22 Checking the electric starter drive 303006-10 – Check the gear mesh and bearing of starter idler gear for damage and wear. » If there is damage or wear: – Change the starter idler gear. – Check the gear mesh and bearing of Bendix for smooth operation, damage and wear.

  • Page 136: Engine Assembly

    30/ENGINE – Move starter idler gear back and forth in the direction of rotation. – Check for play. Guideline Play may not exceed half the tooth width. » If the play is greater: – Remove the cover. – Add enough compensating disks to eliminate the play.

  • Page 137: Installing The Shift Forks

    30/ENGINE 18.5.3 Installing the shift forks – Arrange the shift forks as shown. 202770-10 – Position shift forks in the shift grooves. 202766-10 18.5.4 Installing the shift drum – Push shift drum into the bearing seat. – Put shift forks in the shift drum.

  • Page 138: Installing The Reed Valve Housing

    30/ENGINE – Mount the left section of the engine case. Info Do not use the screws to pull the two sections of the engine case together. – Mount screws and, once all screws of the left section of the engine case have been mounted, tighten them.

  • Page 139: Installing The Locking Lever

    30/ENGINE 18.5.9 Installing the locking lever – Position locking lever with the sleeve and spring – Mount and tighten screw Guideline Screw, shift drum locating 10 Nm Loctite ® 243™ (7.4 lbf ft) 202771-10 18.5.10 Installing the shift drum locating unit –...

  • Page 140: Installing The Clutch Discs

    30/ENGINE – Mount collar bushing – Oil and mount needle bearing Engine oil (15W/50) ( p. 202) – Slide clutch basket onto the gearbox main shaft. 202753-11 – Hold the primary gear using special tool. Gear segment (56012004000) ( p. 208) –...

  • Page 141: Installing The Clutch Cover

    30/ENGINE – Position pressure cap . Mount screws with the washers and springs. – Tighten the screws in a crisscross pattern. Guideline Screw, clutch pressure cap 10 Nm (7.4 lbf ft) 202747-11 18.5.14 Installing the clutch cover – Apply a thin layer of sealing compound in area on both sides.

  • Page 142: Installing The Piston

    30/ENGINE – Position the water pump cover. – Mount and tighten screws Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 202743-11 18.5.16 Installing the piston – Oil the upper conrod bearing and position it in the connecting rod. –...

  • Page 143: Checking The X-Distance

    30/ENGINE – Position the piston ring. The anti-rotation lock engages in piston ring end 202775-10 – Slide the cylinder over the piston. – Push the cylinder down carefully. – Mount nuts on both sides and tighten in a crisscross pattern. Guideline Nut, cylinder base 35 Nm...

  • Page 144: Installing The Cylinder Head

    30/ENGINE Main work – Remove nuts – Carefully slide the cylinder up and take it off. 308133-11 – Replace cylinder base gasket with a cylinder base gasket of the required X-distance. Info Multiple cylinder base gaskets can be combined. 302967-12 Finishing work –...
  • Page 145 30/ENGINE Main work – Grease and mount Bendix Lubricant (T625) ( p. 204) 202734-11 – Mount dowels – Position the gasket. 202733-11 – Position the alternator cover. – Mount and tighten screw Guideline Screw, alternator cover 8 Nm (5.9 lbf ft) 202732-11 –...

  • Page 146: Installing The Spacer

    30/ENGINE – Grease the O-ring. Position the starter motor. Long-life grease ( p. 204) – Mount and tighten screws Guideline Screw, starter motor 8 Nm (5.9 lbf ft) 202728-11 – Position cover – Mount and tighten screws Guideline Screw, alternator cover 8 Nm (5.9 lbf ft) 202727-11 18.5.22 Installing the spacer...

  • Page 147: Installing The Clutch Push Rod

    30/ENGINE 18.5.24 Installing the clutch push rod – Mount clutch push rod 202723-10 18.5.25 Installing the gear oil drain plug – Mount and tighten the gear oil drain plug with the magnet and the new seal ring. Guideline Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)

  • Page 148: Carburetor

    CARBURETOR 19.1 Choke Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.

  • Page 149: Emptying The Carburetor Float Chamber

    CARBURETOR 19.3 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 150: Installing The Carburetor

    CARBURETOR Main work – Remove screws – Take off the throttle slide cover and pull the throttle slide out of the carburetor. 202690-10 – Pull back the throttle slide spring and plastic retainer – Detach throttle cable – Take off the throttle slide. 202691-10 –...

  • Page 151: Checking/Setting The Carburetor Components

    CARBURETOR Finishing work – Install the fuel tank. ( p. 65) – Lock the seat. ( p. 62) – Check the play in the throttle cable. ( p. 33) – Carburetor - adjust the idle speed. ( p. 146) 19.6 Checking/setting the carburetor components Condition The carburetor has been removed.
  • Page 152 CARBURETOR – Remove fulcrum pin – Remove float and float needle valve. 306308-10 – Remove main jet 306309-10 – Remove needle jet holder with needle jet. Info The needle jet is usually lodged in the carburetor housing. 306310-10 – Remove idling jet 306311-10 –...

  • Page 153: Checking The Choke Slide

    CARBURETOR – Pull jet needle out pf the throttle slide. 306314-10 19.8 Checking the choke slide Condition The choke slide has been removed. – Check the choke slide for smooth operation. » If the choke slide is stiff and soiled: –...

  • Page 154: Checking The Float Needle Valve

    CARBURETOR 19.11 Checking the float needle valve Condition The float needle valve has been removed. – Check the float needle valve and valve seat for deposits. » If there are deposits: – Clean the valve seat. Clean the float needle valve or change it. Carburetor cleaner ( p.

  • Page 155: Checking/Adjusting The Float Level

    CARBURETOR – Mount and tighten main jet Guideline Main jet M5x0.75 2 Nm (1.5 lbf ft) 306309-11 – Position float needle valve and float – Mount fulcrum pin – Check/adjust the float level. ( p. 153) 306308-11 – Position the hoses on the carburetor. –...
  • Page 156 CARBURETOR – Tilt the carburetor sideways while preventing the fulcrum pin from falling out. – Tilt the carburetor until the float is resting against the float needle valve but the float needle valve is not squeezed. » If, when in this position, the edge of the float is not parallel (max. 1° deviation in an upward direction) to the sealing surface of the float housing: –...

  • Page 157: Clutch

    CLUTCH 20.1 Checking fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Check the fluid level in viewer »...
  • Page 158 CLUTCH – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) ( p. 206) Brake fluid DOT 4 / DOT 5.1 ( p. 202) – On the clutch slave cylinder, remove bleeder screw and mount bleeding syringe B01707-10 –...

  • Page 159: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM 21.1 Checking the antifreeze and 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 160: Draining The Coolant

    WATER PUMP, COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 202) – Mount the radiator cap. 21.3 Draining the coolant 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 161 WATER PUMP, COOLING SYSTEM – Return the vehicle to the horizontal position. – Completely fill the radiator with coolant. – Mount radiator cap – Let the engine warm up. B01679-10 Finishing work – Check the coolant level. ( p. 157)

  • Page 162: Lubrication System

    LUBRICATION SYSTEM 22.1 Changing the gear oil – Drain the gear oil. ( p. 160) 400721-01 – Fill in gear oil. ( p. 161) 400722-01 22.2 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –...

  • Page 163: Filling In Gear Oil

    LUBRICATION SYSTEM 22.3 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 164 LUBRICATION SYSTEM – Remove screw cap – Fill in gear oil until it emerges from the drilled hole of the gear oil monitoring screw. Engine oil (15W/50) ( p. 202) – Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level check 10 Nm (7.4 lbf ft) –...

  • Page 165: Ignition System

    IGNITION SYSTEM 23.1 Checking the ignition system Warning Risk of injury The ignition system is under high voltage. – To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme- diately after measuring.

  • Page 166: Ignition Coil - Checking The Primary Winding

    IGNITION SYSTEM 23.2 Ignition coil - checking the primary winding Warning Risk of injury The ignition system is under high voltage. – To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme- diately after measuring.

  • Page 167: Checking The Spark Plug Connector

    IGNITION SYSTEM 23.4 Checking the spark plug connector Condition Spark plug connector cylinder 1 has been removed. – Measure the resistance between the specified points. Measuring point 1 – Measuring point 2 Spark plug connector Resistance at: 20 °C (68 °F) 3.75…...

  • Page 168: Alternator - Checking The Light Winding

    IGNITION SYSTEM 0.55… 0.74 Ω Battery winding resistance at: 20 °C (68 °F) » If the specification is not reached: – Change the stator. 23.7 Alternator - checking the light winding Condition The alternator has been disconnected. – Measure the resistance between the specified points. Alternator, connector CR pin 1 (White) –...

  • Page 169: Removing The Stator And Crankshaft Position Sensor

    IGNITION SYSTEM Check the ignition pulse generator voltage – Measure the voltage between the specified points. Alternator, charging coil/ignition pulse generator, connector AN pin 3 – Alternator, charging coil/ignition pulse generator, connector AN pin 4 Crankshaft position sensor Voltage 2… 4 V »...

  • Page 170: Cleaning The Alternator

    IGNITION SYSTEM 23.11 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. – Grease gear teeth and the points marked with a Lubricant (T625) ( p.

  • Page 171: Electric Starter

    ELECTRIC STARTER 24.1 Checking the starter motor Condition The starter motor has been removed. – Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly with connector the starter motor.

  • Page 172: Technical Data

    TECHNICAL DATA 25.1 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 173: Engine Tightening Torques

    TECHNICAL DATA 25.3 Engine tightening torques Loctite 243™ Screw ,stator 6 Nm (4.4 lbf ft) ® – Screw, alternator cover 5 Nm (3.7 lbf ft) Screw, angle lever, exhaust control 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, clutch spring retainer 6 Nm (4.4 lbf ft) Screw, crankshaft position sensor 6 Nm (4.4 lbf ft)

  • Page 174: Chassis

    TECHNICAL DATA Fuel reserve, approx. 1.65 l (1.74 qt.) 25.5 Chassis Frame Perimeter, steel-aluminum composite frame fork WP Suspension 4357 MXMA Suspension travel Front 250 mm (9.84 in) Rear 260 mm (10.24 in) Fork offset 20 mm (0.79 in) WP Suspension 4618 BAVP DCC Shock absorber Brake system Front...

  • Page 175: Tires

    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 25.8 Fork Fork part number 05.18.7N.42 fork WP Suspension 4357 MXMA...

  • Page 176: Chassis Tightening Torques

    TECHNICAL DATA Standard 8 mm (0.31 in) Sport 8 mm (0.31 in) Spring designation Weight of rider: 65… 75 kg (143… 165 lb.) (61/59) 55-215 Weight of rider: 75… 85 kg (165… 187 lb.) (61/59) 55/63/71-215 Weight of rider: 85… 95 kg (187… 209 lb.) (61/59) 58/62/74-215 Spring length 215 mm (8.46 in)

  • Page 177: Carburetor

    TECHNICAL DATA Loctite 243™ Screw, upper subframe 45 Nm (33.2 lbf ft) ® Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ® 243™ Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 243™ – Nut, swingarm pivot M14x1.5 75 Nm (55.3 lbf ft) –...

  • Page 178: Carburetor Tuning

    TECHNICAL DATA 25.12 Carburetor tuning 25.12.1 Carburetor tuning Danger Loss of approval for road use and insurance coverage 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. 401798-01 M/FT ASL Sea level...

  • Page 179: Cleaning, Care

    CLEANING, CARE 26.1 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 180: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 26.2 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 181: 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. 10) – 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 182: 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 183: Service Work (As Additional Order)

    SERVICE SCHEDULE 28.2 Service work (as additional order) Annually Every 100 operating hours Every 50 operating hours Once after 10 operating hours ● Change the front brake fluid. ( p. 87) ● Change the rear brake fluid. ( p. 93) ●...

  • Page 184: Wiring Diagram

    WIRING DIAGRAM 29.1 Page 1 of 5 (Freeride 250 R EU) bl-rd bl-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bu-rd wh-rd bu-rd wh-rd wh-rd 202674-01...
  • Page 185 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Electric starter button Voltage regulator...

  • Page 186: Freeride 250 R Eu)

    WIRING DIAGRAM 29.2 Page 2 of 5 (Freeride 250 R EU) ye-bu rd-gr wh-gr wh-gr rd-gr wh-gr wh-rd ye-bu 202675-01...
  • Page 187 WIRING DIAGRAM Components: CDI controller Low beam, high beam Fuse Horn High beam indicator lamp Parking light Light switch, horn button, kill switch...

  • Page 188: Freeride 250 R Eu)

    WIRING DIAGRAM 29.3 Page 3 of 5 (Freeride 250 R EU) ye-bu ye-bu wh-rd bl-gn bl-gn wh-gn wh-gn wh-gn wh-gn wh-gn ye-bu ye-bu 202676-01...
  • Page 189 WIRING DIAGRAM Components: Radiator fan temperature switch Wheel speed sensor, front Brake light switch, front Brake light switch, rear License plate lamp Fuse Radiator fan Speedometer Brake/tail light...

  • Page 190: Freeride 250 R Eu)

    WIRING DIAGRAM 29.4 Page 4 of 5 (Freeride 250 R EU) ye-or ye-bu ye-or 202677-01...
  • Page 191 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

  • Page 192: Freeride 250 R Eu)

    WIRING DIAGRAM 29.5 Page 5 of 5 (Freeride 250 R EU) wh-pu wh-pu wh-bl wh-bl 202678-01...
  • Page 193 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • Page 194: Freeride 250 R Aus)

    WIRING DIAGRAM 29.6 Page 1 of 5 (Freeride 250 R AUS) bl-rd bl-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bu-rd wh-rd bu-rd wh-rd wh-rd 202695-01...
  • Page 195 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button Voltage regulator...

  • Page 196: Freeride 250 R Aus)

    WIRING DIAGRAM 29.7 Page 2 of 5 (Freeride 250 R AUS) ye-bu rd-gr wh-gr wh-gr BA/1 BF/1 rd-gr wh-rd ye-bu 202696-01...
  • Page 197 WIRING DIAGRAM Components: CDI controller Low beam, high beam Fuse Horn High beam indicator lamp Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button...

  • Page 198: Freeride 250 R Aus)

    WIRING DIAGRAM 29.8 Page 3 of 5 (Freeride 250 R AUS) ye-bu ye-bu wh-rd bl-gn bl-gn wh-gn wh-gn wh-gn wh-gn wh-gn ye-bu ye-bu 202697-01...
  • Page 199 WIRING DIAGRAM Components: Radiator fan temperature switch Wheel speed sensor, front Brake light switch, front Brake light switch, rear License plate lamp Fuse Radiator fan Speedometer Brake/tail light...

  • Page 200: Freeride 250 R Aus)

    WIRING DIAGRAM 29.9 Page 4 of 5 (Freeride 250 R AUS) ye-or ye-bu ye-or 202698-01...
  • Page 201 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

  • Page 202: Freeride 250 R Aus)

    WIRING DIAGRAM 29.10 Page 5 of 5 (Freeride 250 R AUS) wh-pu wh-pu wh-bl wh-bl 202699-01...
  • Page 203 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • Page 204: Substances

    SUBSTANCES 2-stroke engine oil Standard/classification – JASO FC ( p. 215) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 Standard/classification –...
  • Page 205 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) Standard/classification – SAE ( p. 215) (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 –...

  • Page 206: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Twin Air Dirt Bio Remover Carburetor cleaner Recommended supplier Motorex ® – Carburetor Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ®...
  • Page 207 AUXILIARY SUBSTANCES Off-road chain spray Recommended supplier Motorex ® – Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ® – Twin Air Liquid Bio Power Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex...

  • Page 208: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013012 201608-10 Bleeder cover Art. no.: 00029013018 201965-10 Bleeding device Art. no.: 00029013100 201491-10 Spring hooks Art. no.: 50305017000 400363-01 Bleed syringe Art. no.: 50329050000 400058-01...
  • Page 209 SPECIAL TOOLS Clutch holder Art. no.: 51129003000 400289-01 Adjustment gauge Art. no.: 54829001100 303079-10 Separator plate Art. no.: 54829009000 303483-10 Lift stand Art. no.: 54829055000 500071-01 Insert for crankshaft pressing tool Art. no.: 54829108000 303484-10...
  • Page 210 SPECIAL TOOLS Holding spanner, rotor Art. no.: 55129001000 302997-10 Gear segment Art. no.: 56012004000 302982-10 Engine fixing arm Art. no.: 56029002030 302945-10 Extractor Art. no.: 58012009000 400073-01 Tool for inner bearing race Art. no.: 58429037040 400082-01...
  • Page 211 SPECIAL TOOLS Peak voltage adapter Art. no.: 58429042000 400083-01 Torque wrench with various accessories in set Art. no.: 58429094000 200910-10 Feeler gauge Art. no.: 59029041100 400110-01 Engine assembly stand Art. no.: 61229001000 200306-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01...
  • Page 212 SPECIAL TOOLS Gear quadrant Art. no.: 80029004000 500164-01 Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10 Mounting sleeve Art. no.: T1204 200788-10...
  • Page 213 SPECIAL TOOLS Calibration pin Art. no.: T1205 200790-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Vacuum pump Art. no.: T1240S 200273-10 Clamping stand Art. no.: T14016S 200688-10...
  • Page 214 SPECIAL TOOLS Support tool Art. no.: T14026 200639-10 Open-end wrench Art. no.: T14032 200640-10 Spring compressor Art. no.: T14050S 201648-10 Press drift Art. no.: T1504 200789-10...
  • Page 215 SPECIAL TOOLS Assembly tool Art. no.: T150S 200791-10 Mounting sleeve Art. no.: T1554 300578-10 Nitrogen filling tool Art. no.: T170S1 300574-10 Protecting sleeve Art. no.: T512 200635-10 Mounting tool Art. no.: T528S 200634-10...
  • Page 216 SPECIAL TOOLS Art. no.: T605 200687-10 Clamping stand Art. no.: T612S 200638-10...

  • Page 217: Standards

    STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –...

  • Page 218: Index

    INDEX Carburetor - work on individual parts INDEX choke slide, checking ..... . . 151 float level, checking/adjusting ....153 Accessories .
  • Page 219 INDEX connecting rod, conrod bearing, and crank pin, changing 120 cylinder, removing ......112 countershaft, assembling ..... 131 engine, clamping into the engine work stand .
  • Page 220 INDEX Fuel tank installing ....... . . 65 Open-circuit current removing .
  • Page 221 INDEX kilometers or miles, setting ....96 service display, setting ..... . . 97 setting .
  • Page 222 *3206188en* 3206188en 10/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

Freeride 250 r eu 2014Freeride 250 r aus 2014

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