KTM 250 DUKE Owner'S Manual Download Page 148

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SERVICE WORK ON THE ENGINE

146

101918-10

–

Remove screws



. Remove oil filter cover



with the O-ring.

–

Pull oil filter



out of the oil filter housing.

Circlip pliers reverse (51012011000)

–

Completely drain the engine oil.

–

Thoroughly clean the parts and sealing surface.

L02271-10

–

Insert oil filter



–

Lubricate the O-ring of the oil filter cover. Mount oil filter cover



–

Mount and tighten the screws.
Guideline

Screw, oil filter cover

8 Nm (5.9 lbf ft)

Screw, oil filter cover

12 Nm (8.9 lbf ft)

Info

Too little engine oil or poor-quality engine oil results in premature wear of the
engine.

Summary of Contents for 250 DUKE

Page 1: ...OWNER S MANUAL 2016 250 Duke Art no 3213414en ...

Page 2: ......

Page 3: ... differences due to develop ments in design cannot be ruled out completely All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a parti...

Page 4: ...12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen Austria This document is valid for the following models 250 Duke EU F4203P1 250 Duke MY F4289P1 250 Duke TH F4283P1 ...

Page 5: ... 20 5 2 Type label 20 5 3 Engine number 21 5 4 Key number 21 6 CONTROLS 22 6 1 Clutch lever 22 6 2 Hand brake lever 22 6 3 Throttle grip 23 6 4 Horn button 23 6 5 Light switch 24 6 6 High beam flasher button 24 6 7 Turn signal switch 25 6 8 Emergency OFF switch 25 6 9 Electric starter button 26 6 10 Ignition steering lock 26 6 11 Locking the steering 27 6 12 Unlocking the steering 27 6 13 Combinat...

Page 6: ...cks and maintenance when preparing for use 60 8 2 Starting 61 8 3 Starting off 63 8 4 Shifting riding 63 8 5 Applying the brakes 66 8 6 Stopping parking 68 8 7 Transport 69 8 8 Refueling 70 9 SERVICE SCHEDULE 72 9 1 Additional information 72 9 2 Required work 72 9 3 Recommended work 74 10 TUNING THE CHASSIS 75 10 1 Adjusting the spring preload of the shock absorber 75 10 2 Adjusting the shift leve...

Page 7: ...the battery 114 14 2 Installing the battery 115 14 3 Recharging the battery 116 14 4 Changing the ABS fuses 119 14 5 Changing the fuses of individual power consumers 120 14 6 Changing the headlight bulb 122 14 7 Changing the parking light bulb 125 14 8 Checking the headlight setting 129 14 9 Adjusting the headlight range 130 15 COOLING SYSTEM 133 15 1 Cooling system 133 15 2 Checking the antifreez...

Page 8: ... 4 Chassis 162 21 5 Electrical system 164 21 6 Tires 165 21 7 Fork 165 21 8 Shock absorber 165 21 9 Chassis tightening torques 166 22 SUBSTANCES 171 23 AUXILIARY SUBSTANCES 173 24 STANDARDS 175 25 INDEX OF SPECIAL TERMS 176 26 LIST OF ABBREVIATIONS 177 27 LIST OF SYMBOLS 178 27 1 Red symbols 178 27 2 Yellow and orange symbols 178 27 3 Green and blue symbols 178 INDEX 179 ...

Page 9: ...ith 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 optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or...

Page 10: ...s document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary ...

Page 11: ... version only 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or ...

Page 12: ...n Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design i...

Page 13: ... may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and t...

Page 14: ...ts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you can ensure that p...

Page 15: ...then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury 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 The Owner s Manual is an important component of the vehicle ...

Page 16: ...vironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and hav...

Page 17: ...o inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components may be shown disassembled or may not be s...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example M00960 10 ...

Page 19: ...4 VIEW OF VEHICLE 17 1 Combination instrument 2 Rear mirror 3 Clutch lever p 22 4 Seat 5 Passenger seat 6 Seat lock p 51 7 Grab handles p 52 8 Shift lever p 53 9 Side stand p 55 10 Engine number p 21 ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example M00961 10 ...

Page 21: ...urn signal switch p 25 2 Horn button p 23 3 Ignition steering lock p 26 4 Emergency OFF switch p 25 5 Throttle grip p 23 6 Hand brake lever p 22 7 Electric starter button p 26 8 Chassis number p 20 8 Type label p 20 9 Engine oil level viewer 10 Foot brake lever p 54 11 Passenger footrests p 53 ...

Page 22: ...ERS 20 5 1 Chassis number 0 0 1 1 402408 10 The chassis number is stamped on the right side of the steering head 5 2 Type label 0 0 1 1 402174 10 The type label is on the right of the frame behind the steering head ...

Page 23: ...10 The engine number is stamped on the left side of the engine under the engine sprocket 5 4 Key number 402245 10 The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place ...

Page 24: ...lever M00705 10 The clutch lever is fitted on the left side of the handlebar 6 2 Hand brake lever M00708 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 25: ...hrottle grip is fitted on the right side of the handlebar 6 4 Horn button M00706 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position ...

Page 26: ...ail light are switched on High beam on The light switch is turned upwards In this position the high beam and the tail light are switched on 6 6 High beam flasher button M00705 12 The high beam flasher button is fitted on the left side of the handlebar Possible states High beam flasher button in neutral position High beam flasher button pressed In this position the headlight flasher high beam is ac...

Page 27: ...o the right The turn signal switch returns automatically to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 6 8 Emergency OFF switch M00707 11 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is interrupted a running engine stops and ...

Page 28: ...steering lock M00709 01 The ignition steering lock is in front of the upper triple clamp Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignitio...

Page 29: ...e 400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock press in and turn to the left Remove the key Steering is no longer possible 6 12 Unlocking the steering 400731 01 Insert the key into the ignition handlebar lock press in and turn to the right Remove the key You can now steer the bike again ...

Page 30: ...6 CONTROLS 28 6 13 Combination instrument 6 13 1 Overview 401685 10 1 Display p 35 2 Function buttons p 33 3 Info display p 39 4 Indicator lamps p 34 ...

Page 31: ...witched on Test The segments of the tachometer and the gear display light up and switch off in sequence The speed display counts from 0 to 199 and back The remaining display segments outside the info display light up briefly The READY TO RACE logo appears on the info display The display then changes to the last selected mode ...

Page 32: ...OLS 30 6 13 3 Warning notes 401309 01 Low Oil Pressure appears on the info display if the oil pressure is too low 401310 01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark ...

Page 33: ... temperature rises above the specified value Coolant temperature 125 C 257 F 401312 01 Side Stand Down appears on the info display if the side stand is folded down 401313 01 Low Battery appears on the info display if the battery voltage falls below the specified value Battery voltage 10 80 V ...

Page 34: ...Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment ...

Page 35: ...lay modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the SET button changes the info display to the next display mode The ABS can be switched off with the button ...

Page 36: ...The set shift speed has been reached The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The immobilizer indicator lamp lights up or flashes red Status or error message for immobilizer alarm system optional The general warning lamp lights up yellow An operating safety warning message was detect...

Page 37: ...ute The gear display shows the engaged gear The coolant temperature appears in segment The time appears in segment The filling level in the fuel tank is displaced in segment The info display shows additional information Info The time must be reset after the battery was disconnected or the fuse was removed The intensity of the LED display depends on the ambient brightness ...

Page 38: ...6 CONTROLS 36 6 13 7 Filling level display in fuel tank 401292 01 The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank ...

Page 39: ...reserve mark the display mode automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info At the same time as the display mode TRIP F the general warning lamp lights up and the warning note Low Fuel Level appears on the info display ...

Page 40: ... 13 bars The more bars that light up the hotter the coolant When all bars light up the following warning note appears on the info display High Coolant Temperature Possible states Engine cold Up to three bars light up Engine warm Four to ten bars light up Engine hot Eleven to thirteen bars light up ...

Page 41: ...6 CONTROLS 39 6 13 10 Info display 401291 10 Various warning notes appear on info display If the general warning lamp lights up the corresponding warning note is shown on the info display ...

Page 42: ...u Info If the ignition was switched off for over 60 minutes the display is reset to 0 Press the SET button briefly Next display mode on the info display 6 13 12 Average speed average fuel consumption 1 menu 401465 01 Condition Alternative 1 The ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press the SET button briefly and repeatedly until the...

Page 43: ...ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears In this menu the average fuel consumption 1 in L 100 km or L 100 miles and the aver age fuel consumption 2 in km L or miles L are displayed Info The average fuel consumptions 1 and 2 are displayed after several 100 ...

Page 44: ...ntil the desired info display appears The average fuel consumption 2 in km L or miles L and the distance to the next service are displayed in this menu Info The average fuel consumption 2 is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average fuel consumption 2 is reset to 0 Press the SET but...

Page 45: ...info display appears This menu shows the distance to the next service and the range Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to 0 Press the SET button b...

Page 46: ...ired info display appears The range and the riding time are displayed in this menu Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to 0 Press the SET button br...

Page 47: ...lternative 2 The ignition is on The motorcycle is moving Press the MODE button briefly and repeatedly until ODO appears on the display ODO shows the total distance covered Info This value is retained even if the battery is disconnected from the vehicle and or the fuse blows Press the MODE but ton Next display mode on the display ...

Page 48: ...TRIP 1 is always running and counts up to 999 9 Press the SET button for 5 10 seconds Display of TRIP 1 is reset Press the MODE but ton Next display mode on the display 6 13 19 Distance menu 2 TRIP 2 401305 01 Condition Alternative 1 The ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 2 ap...

Page 49: ...iles Info Make the country specific setting Condition The ignition is on The motorcycle is stationary 401303 01 Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE button for 5 10 seconds The display changes from km h to mph or from mph to km h 6 13 21 Setting the time Condition The ignition is on The motorcycle is stationary ...

Page 50: ...justing the shift speed RPM 1 Condition The ignition is on The motorcycle is stationary 401307 01 Press the MODE button briefly and repeatedly until TRIP 2 appears on the display Press the MODE button for 5 10 seconds The display RPM 1 appears Info The engine speed can be set at intervals of 50 RPM 1 is the engine speed above which the shift warning light starts flashing Set the speed with the MOD...

Page 51: ...button for 5 10 seconds The display RPM 2 appears Info The engine speed can be set at intervals of 50 RPM 2 is the engine speed above which the shift warning light lights up con stantly The speed RPM 2 must always be higher than the speed RPM 1 Set the speed with the MODE and SET buttons Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for...

Page 52: ... occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the envir...

Page 53: ...r closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water Close the filler cap Push down the filler cap until the lock engages 6 16 Seat lock M00967 10 The seat lock is located to the left of the seat It can be locked with the ignition key ...

Page 54: ...00758 10 The tool set is located under the passenger seat 6 18 Grab handles 101882 10 The grab handles are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip ...

Page 55: ...er footrests can be folded in and out Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 20 Shift lever 401950 10 Shift lever is mounted on the left side of the engine ...

Page 56: ... can be seen in the photograph The neutral or idle position is between the first and second gears 6 21 Foot brake lever 402177 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake ...

Page 57: ...e side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand The safety start system is active Side stand folded in This position is mandatory for all trips The safety start system is inactive ...

Page 58: ...g due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteristic Only use tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents...

Page 59: ...before making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p 57 7 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine speed During the first 1 000 km 620 mi 7 500 rpm Tip During the...

Page 60: ...Warning Danger of accidents Risk of breakage of suitcase system If you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage If the tail light is covered you are less visible to traffic behind you especially when it is dark Check that your baggage is fixe...

Page 61: ...of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 125 kg 276 lb Maximum permissible rear axle load 210 kg 463 lb ...

Page 62: ...e fluid level p 100 Check the front brake linings p 97 Check the rear brake linings p 103 Check the brake system function Check the coolant level p 136 Check for chain dirt accumulation p 83 Check the chain tension p 84 Check the tire condition p 111 Check the tire air pressure p 112 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the elect...

Page 63: ...icle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increase...

Page 64: ... up and goes back out after starting off Press the electric starter button Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 secon...

Page 65: ...neously open the throttle carefully Tip If the engine dies while starting off only pull the clutch lever and press the electric starter button You do not need to shift into neutral 8 4 Shifting riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions Wa...

Page 66: ...g the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal ...

Page 67: ...ue with the coolant temperature warning lamp alight you may have engine failure Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop 401950 11 When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the c...

Page 68: ...g the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of...

Page 69: ... ABS is enabled you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the wheels Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface Warning Danger of accidents Road grip is reduced when braking w...

Page 70: ...n them Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Some vehic...

Page 71: ...es only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering p 27 8 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the veh...

Page 72: ...erfilled Follow the instructions on refueling 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 If fuel is swallowed contact a physic...

Page 73: ...a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system M00964 10 Switch off the engine Open the filler cap p 50 Fill the fuel tank with fuel up to the lower edge of the fuel filler Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 172 Close the filler cap p 51 ...

Page 74: ...l Check that the electrical system is functioning properly Change the engine oil and oil filter and clean the oil screens p 144 Check the brake discs p 94 Check the front brake linings p 97 Check the rear brake linings p 103 Check the tire condition p 111 Check the tire air pressure p 112 Check the brake lines for damage and leakage Check the brake fluid level of the front brake p 95 Check the rea...

Page 75: ...Check the cables for damage and routing without sharp bends Check the valve clearance Check the valve clearance change the spark plugs Change the front brake fluid Change the rear brake fluid Check the play of the steering head bearing Check the headlight setting p 129 Final check Check the vehicle for roadworthiness and take a test ride Read out the fault memory using the KTM diagnostics tool aft...

Page 76: ...nge the coolant Grease all moving parts e g side stand hand lever chain and check for smooth operation Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and correct routing Check the swingarm bearing Check the wheel bearing for play Check the screws and nuts for tightness One time interval Periodic interval ...

Page 77: ...defines the initial situation of the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability M00974 10 Adjust the spring preload by turning adjusting ring Guideline Spring preload Comfort 1 click Standard 3 clicks Sport ...

Page 78: ...e same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle Guideline Adjusting angle shift rod linkage shift lever 90 Tighten nuts Info After the nuts have been tightened the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells Check the shift lever to en...

Page 79: ...e wheel stand Insert the adapter in the rear wheel stand Bushing kit for lifting gear 90229955044 Universal V adapter 61029955244 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle 11 2 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always ...

Page 80: ...lean the vehicle on the side stand 11 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 77 M00971 10 Condition Remove protection cap ...

Page 81: ...29055500 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 11 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface M00973 01 Main work Secure the motorcycle against falling over Remove the front wheel stand ...

Page 82: ...work Take the motorcycle off of the rear wheel stand p 77 11 5 Removing the passenger seat M00967 10 Insert the ignition key in seat lock and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards Remove the ignition key from the seat lock ...

Page 83: ... place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up Finally check that the passenger seat is correctly mounted 11 7 Removing the seat Preparatory work Remove the passenger seat p 80 M00969 10 Main work Remove screws Raise the rear of the seat pull it ...

Page 84: ...THE CHASSIS 82 11 8 Mounting the seat M00970 10 Main work Attach seat recesses at screws and lower at the rear Mount and tighten screws Guideline Screw seat M6 9 Nm 6 6 lbf ft Finishing work Mount the passenger seat p 81 ...

Page 85: ...s reduces their grip Remove oil and grease with a suitable cleaning material 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 Oil grease filters fuel cleaners brake fluid etc sh...

Page 86: ...rear wheel stand p 77 11 11 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 bearings 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 t...

Page 87: ... 11 12 Adjusting 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 bearings 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...

Page 88: ...t the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts Make sure that chain adjusters are fitted correctly on adjusting screws Tighten nut Guideline Nut rear ...

Page 89: ...chain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and motor sprocket for wear If the rear sprocket and motor sprocket are worn Change the power set Info The motor sprocket rear sprocket and chain should always be replaced together ...

Page 90: ... 20 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 301 6 mm 11 874 in If distance is greater than the specified measurement Change the power set Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out f...

Page 91: ...heck the chain sliding guard for wear If the chain sliding guard has lost material due to wear to the extent that in area drilled hole is visible from above Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screws on the chain sliding guard ...

Page 92: ...on the chain guard and tighten screw Guideline Screw chain guard EJOT PT K60x20 4 Nm 3 lbf ft Mount and tighten screw Guideline Screw chain guard EJOT PT K60x20 4 Nm 3 lbf ft Mount and tighten the nut Guideline Remaining nuts chassis M5 5 Nm 3 7 lbf ft ...

Page 93: ...11 SERVICE WORK ON THE CHASSIS 91 11 14 Removing the front spoiler 101895 10 Remove screws M00717 10 Remove screws Take off the front spoiler ...

Page 94: ...Fitting front spoiler 101895 10 Position the front spoiler Mount screws but do not tighten yet M00717 10 Mount and tighten screws Guideline Screw front spoiler M6 7 Nm 5 2 lbf ft Tighten screw Guideline Screw front spoiler M6 7 Nm 5 2 lbf ft ...

Page 95: ...ied tire air pressure Service work and repairs must be performed professionally Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Warning Danger of accidents Vehicle rollover It is not always possible to prevent vehicle rollover in extreme riding situations e g luggage...

Page 96: ...s for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when the vehicle is switched on again The ABS warning lamp goes out when you start off Button can be used to switch ABS off manually see Starting 12 2 Checking the brake discs Warning Danger of accidents R...

Page 97: ...below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help 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 he...

Page 98: ...gles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately 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 Environmental hazard Hazardous substances cause envir...

Page 99: ... spilt brake fluid immediately with water 12 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake linin...

Page 100: ... linings for damage and cracking If there is wear or tearing Change the front brake linings 12 6 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 over heating Adjust the free travel on foot brake lever according to specification...

Page 101: ... 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 99 Reconnect spring 12 7 Adjusting the free travel of the 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 over heating Adjust the free travel on foot br...

Page 102: ...e of adjustment is limited Hold screw and tighten nut Attach spring 12 8 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help ...

Page 103: ...ng rear brake fluid Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and ey...

Page 104: ...e filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 103 101899 10 Main work Stand the vehicle upright Remove screw cap with membrane Add brake fluid to level Brake flui...

Page 105: ...maged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly M00721 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the ...

Page 106: ...peed sensor out of the hole Loosen screw by several rotations Release screws Press on screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork ...

Page 107: ...e discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary M00724 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 173 Insert the spacers ...

Page 108: ...peed sensor in the drill hole Mount and tighten screw Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Mount and tighten screws Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Take the motorcycle off of the front wheel stand p 79 Take the motorcycle off of the rear wheel stand p 77 Operate the front brake ...

Page 109: ...the rear wheel withdraw wheel spindle with the washer and chain adjuster Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Pull the rear wheel back and take it out of the swingarm Info Do not operate the...

Page 110: ...rear hub rubber dampers p 109 M00726 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 173 Clean the thread of the wheel spindle and axle nut Clean and grease wheel spindle Long life grease p 173 Clean the mating surfaces of the brake caliper sup...

Page 111: ...must be in the same position relative to the reference marks Nut rear wheel spindle M14x1 5 90 Nm 66 4 lbf ft Position wheel speed sensor in the drill hole Mount and tighten screw Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 77 Check the chain tension p 84 13 5 Checking the rear hub rubber dampers Info The engine powe...

Page 112: ... dampers in the rear hub M00728 10 Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If play is larger than the specified value Change all rubber dampers ...

Page 113: ...he vehicle Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteristic Only use tires wheels approved by KTM with the corresponding speed index Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces 40060...

Page 114: ...ecommends that the tires are changed regardless of the actual wear at the latest after 5 years If a tire is more than 5 years old Change the tires 13 7 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check tire air pressur...

Page 115: ...13 WHEELS TIRES 113 If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap ...

Page 116: ...ttery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Remove the passenger seat p 80 Remove the seat p 81 101903 10 Main work Pull back the negative terminal co...

Page 117: ...ged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 14 2 Installing the battery 101904 11 Main work Position the battery in the battery holder Guideline The terminals of the battery must face upwards Battery ETZ 9 BS p 164 Reconnect rubber band Position the positive cable and mount and tighten the scr...

Page 118: ... of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse ...

Page 119: ...h a high charging current shortens the battery s service life If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become o...

Page 120: ...y Info Never remove lid Charge the battery with a maximum of 10 of the capacity specified on battery housing Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Position the negative cable and mount and tighten the screw ...

Page 121: ...hird fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the passenger seat p 80 K00032 10 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse Info A defective fuse is indicated by a burned out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong ...

Page 122: ...the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 90111088025 p 164 Tip Replace spare fuse in the fuse box so that it is available if needed Mount the protection cap Finishing work Mount the passenger seat p 81 14 5 Changing the fuses of individual power consumers Info The fuse box with the main fuse ...

Page 123: ...ol unit fuel pump Fuse 4 15 A ignition coil Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 10 A ABS control unit Fuse 8 10 A combination instrument control unit Fuse 9 10 A auxiliary equipment Info A defective fuse is indicated by a burned out fuse wire Warning Fire hazard The electrical system can be overload...

Page 124: ... Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the passenger seat p 81 14 6 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and swit...

Page 125: ...14 ELECTRICAL SYSTEM 123 101907 10 Main work Remove expanding rivets 101908 10 Remove screws Lift the headlight mask slightly and swing forward B00760 10 Remove protection cap Unplug connector ...

Page 126: ...adlight housing Guideline Insert the headlight bulb so that the catches latch into the recesses Headlight H4 socket P43t p 164 Attach retaining clamp B00760 10 Plug in connector Mount protection cap 101908 10 Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask M6 9 Nm 6 6 lbf ft Loctite 243 ...

Page 127: ...ging the parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine 101907 10 Main work Remove expanding rivets ...

Page 128: ...14 ELECTRICAL SYSTEM 126 308243 10 Remove screws Lift the headlight mask slightly and swing forward B00762 10 Remove screws Remove cover ...

Page 129: ...Pull the socket with bulb out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 164 Position the socket with bulb in the housing B00762 10 Position cover Mount and tighten screws ...

Page 130: ...128 308243 10 Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask M6 9 Nm 6 6 lbf ft Loctite 243 101907 10 Mount expanding rivets on both sides Check that the lighting is functioning properly ...

Page 131: ... in Position the vehicle perpendicular to the wall at a distance from the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger...

Page 132: ...14 ELECTRICAL SYSTEM 130 14 9 Adjusting the headlight range 101907 10 Main work Remove expanding rivets 101908 10 Remove screws Lift the headlight mask slightly and swing forward ...

Page 133: ...ble the light dark boundary must be exactly on the lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range 101908 10 Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask M6 9 Nm 6 6 lbf ft Loctite 243 101907 10 Mount expanding rivets on both sides ...

Page 134: ...14 ELECTRICAL SYSTEM 132 Finishing work Check the headlight setting p 129 ...

Page 135: ...the cooling system is regulated by a valve in radiator cap Heat expansion causes excess coolant to flow into compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 125 C 257 F ...

Page 136: ...ins also reduce the cooling effect 15 2 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 In case of scalding rinse immediately with lukewarm water ...

Page 137: ...t is contaminated with coolant Keep coolant out of reach of children Condition The motor is cold K00033 10 Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank Check the antifreeze in the coolant 25 45 C 13 49 F If the antifreeze in the coolant does not match the specified value Correct the antifreeze in the coolant Check the coolant level in the compensatin...

Page 138: ...e Check the coolant level and the reason for the loss Coolant p 171 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 139 Mount the radiator cap 15 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 sys...

Page 139: ...ach of children Condition The motor is cold K00033 10 Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank The coolant level must be between MIN and MAX If the coolant level does not match the specified value Correct the coolant level Coolant p 171 K00034 10 Remove radiator cap and check the coolant level in the radiator The radiator must be filled ...

Page 140: ...nto contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Preparatory work Remove the fro...

Page 141: ...in with soap and water If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children K00034 11 Main work Remove radiator cap K00035 10 Release bleeder screw by three turns Tilt the vehicle slightly to the right Pour in coolant until it emerges without bubbles at the bleeder screw and then mount and tighten the bleeder ...

Page 142: ... the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run warm K00033 11 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of the compensating tank and top up the coolant level up to the MAXmarking Mount the cap of the compensating tank Finishing...

Page 143: ...specifications Adjust the play in the throttle cable p 142 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 ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handleb...

Page 144: ...he clutch lever for smooth operation Move the handlebar to the straight ahead position Pull the clutch lever until resistance is perceptible and determine the play in the clutch lever Clutch lever play 1 3 mm 0 04 0 12 in If the clutch lever play does not meet specifications Adjust the clutch cable play p 143 Note Clutch damage If there is no play on the clutch lever the clutch will begin to slip ...

Page 145: ...lutch cable 16 4 Adjusting the clutch cable play M00732 10 Move the handlebar to the straight ahead position Push back sleeve Loosen lock nut Adjust the play in the clutch level by turning adjusting screw Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut Position bellows ...

Page 146: ...el is below the marking Add the engine oil p 147 When the engine oil level is above the marking Correct the engine oil level 17 2 Changing the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Wa...

Page 147: ...er the engine Remove oil drain plug with the O ring Remove oil screen with the O ring Remove screw plug with oil screen Completely drain the engine oil Thoroughly clean the oil drain plugs and oil screens Position oil screen and mount and tighten oil drain plug with the O ring Guideline Oil drain plug M24x1 5 15 Nm 11 1 lbf ft Mount and tighten screw plug with oil screen and the O ring Guideline O...

Page 148: ...tely drain the engine oil Thoroughly clean the parts and sealing surface L02271 10 Insert oil filter Lubricate the O ring of the oil filter cover Mount oil filter cover Mount and tighten the screws Guideline Screw oil filter cover M5 8 Nm 5 9 lbf ft Screw oil filter cover M6 12 Nm 8 9 lbf ft Info Too little engine oil or poor quality engine oil results in premature wear of the engine ...

Page 149: ...xic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Fit the front spoiler p 92 Check the engine oil level p 144 17 3 Adding engine oil Info Too litt...

Page 150: ...recommended changing the engine oil when necessary Install and tighten the oil filler plug with the O ring 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 ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start...

Page 151: ... malfunctions or destroy these parts 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 If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Sea...

Page 152: ...due to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate After ...

Page 153: ...s 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 corrosion If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 149 Clean the brakes Info After EVERY trip on salted roads thoroughly wash...

Page 154: ...all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 83 ...

Page 155: ... for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 173 Refuel p 70 Clean the motorcycle p 149 Change the engine oil and oil filter and clean the oil screens p 144 Check the antifreeze and coolant level p 134 Check the tire air pressure p 112 Remove the battery p 114 Recharge the battery p 116 Guideline Storage temperature of battery without direct sunl...

Page 156: ...ing the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401059 01 Take the motorcycle off of the front wheel stand p 79 Take the motorcycle off of the rear wheel stand p 77 Install the battery p 115 Set the clock p 47 Perform checks and mainte...

Page 157: ...does not start Operating error Go through the steps of starting the engine p 61 Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine has too little power Air filter is very dirty Change the air filter Fuel filter is very dirty Check the fuel pressure Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine overheats ...

Page 158: ...ain Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 144 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screens p 144 Headlight and parking light are not functioning Fus...

Page 159: ... Check the open circuit current Combination instrument shows nothing on the display Fuse 8 blown Change the fuses of individual power consumers p 120 Set the clock p 47 Speedometer in combination instru ment not functioning Speedometer wiring harness is dam aged or plug in connector is oxidized Check the wiring harness and plug in connector ...

Page 160: ...nce intake cold 0 08 0 12 mm 0 0031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Crankshaft bearing 2 slide bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two rotary pumps Primary transmission 30 80 Clutch Clutch in o...

Page 161: ... 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 21 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite 243 Screw gear sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw ignition pulse generator M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil filter cover M5 8 Nm 5 9 lbf ft Screw retaining bracket M5 6 Nm 4 4 lbf f...

Page 162: ...e case M6x35 12 Nm 8 9 lbf ft Loctite 243 Screw engine case M6x75 12 Nm 8 9 lbf ft Screw engine sprocket M6 11 Nm 8 1 lbf ft Screw engine vent plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel gear retaining bracket M6 12 Nm 8 9 lbf ft Loctite 243 Screw lock washer engine sprocket M6 12 Nm 8 9 lbf ft Loctite 243 Screw locking lever M6 12 Nm 8 9 lbf ft Loctite 243 Screw oil filter cover M6 12 N...

Page 163: ...alancer shaft gear M8 25 Nm 18 4 lbf ft Loctite 243 Screw return spring quick shifter M8 20 Nm 14 8 lbf ft Loctite 243 Stud exhaust flange M8 22 Nm 16 2 lbf ft Screw conrod bearing M8x1 34 Nm 25 1 lbf ft Oil pressure sensor M10 14 Nm 10 3 lbf ft Rotor screw M10 110 Nm 81 1 lbf ft Loctite 243 Screw camshaft drive sprocket M10 32 Nm 23 6 lbf ft Loctite 243 Screw cylinder head M10 1st stage 30 Nm 22 ...

Page 164: ...over M24x1 5 10 Nm 7 4 lbf ft Nut balancer shaft gear M28x1 5 60 Nm 44 3 lbf ft Loctite 243 21 3 Capacities 21 3 1 Engine oil Engine oil 1 7 l 1 8 qt Engine oil SAE 15W 50 p 171 21 3 2 Coolant Coolant 1 2 l 1 3 qt Coolant p 171 21 3 3 Fuel Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 172 Fuel reserve approx 1 5 l 1 6 qt 21 4 Chassis Frame Lattice frame of s...

Page 165: ...ar 230 mm 9 06 in Brake discs wear limit Front 3 6 mm 0 142 in Rear 3 6 mm 0 142 in Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary ratio 14 46 Chain 5 8 x 1 4 520 X ring Steering head angle 65 Wheelbase 1 367 15 mm 53 82 0 59 in Seat height unloaded 800 mm 31 5 in Ground clearance unlo...

Page 166: ...21 5 Electrical system Battery ETZ 9 BS Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED ...

Page 167: ... section under http www ktm com 21 7 Fork Fork part number 90201000044 Fork WP Suspension Fork length 736 mm 28 98 in Fork oil 440 ml 14 88 fl oz Fork oil SAE 4 48601166S1 p 172 21 8 Shock absorber Shock absorber article number 90104010100 Shock absorber WP Suspension Spring preload Comfort 1 click Standard 3 clicks Sport 6 clicks Full payload 10 clicks Static sag 15 mm 0 59 in Riding sag 50 55 mm...

Page 168: ...ttom M4 5 Nm 3 7 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw ABS hose clamp M5 5 Nm 3 7 lbf ft Screw brake line holder rear M5 5 Nm 3 7 lbf ft Loctite 243 Screw chain guard M5 4 Nm 3 lbf ft Loctite 243 Screw fuel pump M5 5 Nm 3 7 lbf ft Screw fuel tank closure flange M5 5 Nm 3 7 lbf ft Screw fuel tank cover M5 4 Nm 3 lbf ft Screw fuel tank tri...

Page 169: ...box M6 6 Nm 4 4 lbf ft Screw air filter box lid M6 3 Nm 2 2 lbf ft Screw brake fluid reservoir of rear brake M6 8 Nm 5 9 lbf ft Loctite 243 Screw cable holder side stand switch M6 9 Nm 6 6 lbf ft Loctite 243 Screw chain sliding guard M6 8 Nm 5 9 lbf ft Screw compensating tank M6 9 Nm 6 6 lbf ft Screw damping rubber retaining bracket M6 7 Nm 5 2 lbf ft Screw foot brake cylinder M6 9 Nm 6 6 lbf ft L...

Page 170: ... 6 6 lbf ft Screw retaining bracket clutch cable pull M6 8 Nm 5 9 lbf ft Loctite 243 Screw rollover sensor holder M6 9 Nm 6 6 lbf ft Screw seat M6 9 Nm 6 6 lbf ft Screw shift lever linkage M6 9 Nm 6 6 lbf ft Loctite 243 Screw voltage regulator M6 9 Nm 6 6 lbf ft Screw voltage regulator holder M6 9 Nm 6 6 lbf ft Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Fitting engine mounting bracket M8 2...

Page 171: ...riple clamp M8 11 Nm 8 1 lbf ft Screw front brake caliper M8x1 25 Nm 18 4 lbf ft Loctite 204 Banjo bolt brake line M10 24 Nm 17 7 lbf ft Fitting side stand M10 35 Nm 25 8 lbf ft Loctite 243 Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw engine bearer on engine M10 45 Nm 33 2 lbf ft Fitting bottom shock absorber M10x1 25 45 Nm 33 2 lbf ft Fitting h...

Page 172: ...ndle M14x1 5 90 Nm 66 4 lbf ft Nut swingarm pivot M14x1 5 100 Nm 73 8 lbf ft Screw top steering head M16x1 5 53 Nm 39 1 lbf ft Loctite 243 Lambda sensor M18x1 5 19 Nm 14 lbf ft Swingarm bearing adjusting ring M22x1 Tighten and ensure that there is no play Nut steering head M30x1 Step 1 55 Nm 40 6 lbf ft 2nd stage loosen counter clockwise 2 turns Step 3 5 Nm 3 7 lbf ft ...

Page 173: ...RAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 25 45 C 13 49 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil SAE 15...

Page 174: ... 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to...

Page 175: ... Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean ...

Page 176: ...rex Moto Polish Shine 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 Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 177: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 178: ...25 INDEX OF SPECIAL TERMS 176 ABS ABS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces ...

Page 179: ...26 LIST OF ABBREVIATIONS 177 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 180: ...prompt intervention Active driving aids are also represented by yellow or orange symbols The general warning lamp lights up yellow An operating safety warning message was detected This is also shown in the info display ABS warning lamp lights up flashes yellow Status or error messages relating to ABS antilock brake system 27 3 Green and blue symbols Green and blue symbols reflect information The t...

Page 181: ...ing 97 rear brake checking 103 Brakes 66 Brakes applying 66 C Capacity coolant 162 engine oil 162 fuel 71 162 Chain chain dirt accumulation checking 83 checking 87 cleaning 83 Chain tension adjusting 85 checking 84 Chassis number 20 Clutch cable play adjusting 143 Clutch lever 22 Clutch lever play checking 142 Combination instrument activation and test 29 average fuel consumption 1 average fuel co...

Page 182: ...ng 134 136 Cooling system 133 filling bleeding 139 Customer service 15 E Electric starter button 26 Emergency OFF switch 25 Engine running in 57 Engine number 21 Engine oil adding 147 changing 144 Engine oil level checking 144 Environment 12 F Figures 15 Filler cap closing 51 opening 50 Filling up fuel 70 Foot brake lever 54 free travel adjusting 99 free travel checking 98 Front spoiler installing...

Page 183: ...torcycle cleaning 149 raising with the front wheel stand 78 raising with the rear wheel stand 77 taking off of the front wheel stand 79 taking off of the rear wheel stand 77 O Oil filter changing 144 Oil screens cleaning 144 Operating substances 14 Owner s Manual 13 P Parking 68 Parking light bulb changing 125 Passenger footrests 53 Passenger seat mounting 81 removing 80 Play in throttle cable adj...

Page 184: ... lever 53 adjusting 76 Shift speed RPM 1 adjusting 48 Shift speed RPM 2 adjusting 49 Shifting 63 Shock absorber spring preload adjusting 75 Side stand 55 Spare parts 14 Starting 61 Steering locking 27 unlocking 27 Steering lock 26 Stopping 68 Storage 153 T Technical data capacities 162 chassis 162 chassis tightening torques 166 electrical system 164 engine 158 engine tightening torques 159 fork 16...

Page 185: ...ondition checking 111 Tool set 52 Transport 69 Troubleshooting 155 157 Turn signal switch 25 Type label 20 U Use definition 9 V View of vehicle front left 16 rear right 18 W Warranty 14 Winter operation checks and maintenance steps 151 Work rules 12 ...

Page 186: ... 3213414en 3213414en 11 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 250 DUKE, Owner'S Manual

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Summary of Contents for 250 DUKE

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