KTM Freeride 250 R EU Owner'S Manual Download

Page: 89 / 115

SERVICE WORK ON THE ENGINE

18.1

Cleaning the alternator

M01048-10

–

Remove screws





and



–

Take off the cover.

M01049-10

–

Remove screws





and



–

Take off the alternator cover



M01050-10

–

Clean alternator cover and rotor



–

Take off Bendix



and clean.

–

Grease gear wheel



and pin



Lubricant (T625) (

p. 105)

–

Mount Bendix



–

Position the gasket.

–

Check that dowels



are seated correctly.

–

Position alternator cover



–

Mount and tighten screw



Guideline

Screw, alternator cover

M6x35

8 Nm (5.9 lbf ft)

–

Mount and tighten screws



Guideline

Screw, alternator cover

M6x16

8 Nm (5.9 lbf ft)

–

Mount and tighten screw



Guideline

Screw, alternator cover

M6x70

8 Nm (5.9 lbf ft)

–

Position the cover.

–

Mount and tighten screw



Guideline

Screw, alternator cover

M6x35

8 Nm (5.9 lbf ft)

–

Mount and tighten screw



Guideline

Screw, alternator cover

M6x30

8 Nm (5.9 lbf ft)

–

Mount and tighten screw



Guideline

Screw, alternator cover

M6x25

8 Nm (5.9 lbf ft)

Summary of Contents for Freeride 250 R EU

Page 1: ...OWNER S MANUAL 2016 Freeride 250 R EU Freeride 250 R AU Freeride 250 R US Art no 3213341en...

Page 2: ......

Page 3: ...ical specifica tions 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 o...

Page 4: ...irst use 23 8 2 Running in the engine 24 9 RIDING INSTRUCTIONS 25 9 1 Checks and maintenance work when preparing for use 25 9 2 Starting 25 9 3 Starting off 26 9 4 Shifting riding 26 9 5 Applying the...

Page 5: ...e rear wheel 69 14 5 Checking the tire condition 70 14 6 Checking the tire air pressure 71 14 7 Checking the spoke tension 71 15 ELECTRICAL SYSTEM 72 15 1 Removing the battery 72 15 2 Installing the b...

Page 6: ...TABLE OF CONTENTS 4 27 2 Green and blue symbols 109 INDEX 110...

Page 7: ...your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates i...

Page 8: ...us injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to consi...

Page 9: ...ut can be ordered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers mus...

Page 10: ...PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the se...

Page 11: ...left example B02269 10 1 Speedometer 2 Clutch lever p 13 3 Filler cap 4 Seat 5 Seat release 6 Shock absorber compression adjustment 7 Shock absorber rebound adjustment 8 Side stand p 17 9 Fuel tap p...

Page 12: ...ill switch p 13 1 Horn button p 13 1 Light switch p 14 1 Turn signal switch p 14 2 Electric starter button p 14 3 Throttle grip p 13 4 Hand brake lever p 13 5 Fork rebound adjustment 6 Fork compressio...

Page 13: ...label is mounted on the frame at the front right 5 3 Key number 402247 10 The key number for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number is stampe...

Page 14: ...5 SERIAL NUMBERS 12 5 6 Shock absorber article number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side...

Page 15: ...the right side of the handlebar 6 4 Kill switch C00895 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit i...

Page 16: ...to the right 6 8 Emergency OFF switch AU B01663 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrup...

Page 17: ...ean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health h...

Page 18: ...tank to the carburetor The fuel tank empties down to the reserve level Fuel reserve supply open RES Fuel can flow from the fuel tank to the carburetor The fuel tank empties completely 6 16 Choke C0089...

Page 19: ...lever is used to activate the rear brake 6 19 Side stand 401943 10 The side stand is on the left side of the vehicle 401944 10 The side stand is used to park the motorcycle Info When you are riding si...

Page 20: ...k regularly Universal oil spray p 106 Insert the key in the steering lock p 17 turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave t...

Page 21: ...he speedometer Battery voltage of the speedometer is too low Change the battery Service A service is due Contact an authorized KTM workshop 7 4 Setting the speedometer Condition The motorcycle is stat...

Page 22: ...ortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display P...

Page 23: ...alue decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Set...

Page 24: ...nce the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left but ton briefly Next display mode Press the left but t...

Page 25: ...ng Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehic...

Page 26: ...d 135 kg 298 lb Maximum permissible rear axle load 175 kg 386 lb Check the spoke tension p 71 Info The spoke tension must be checked after half an hour of operation Run the engine in p 24 8 2 Running...

Page 27: ...ess Check the fuel supply 9 2 Starting 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...

Page 28: ...ng the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lower Always open the throttle only as much as the engine can hand...

Page 29: ...is still warm from being run Always let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the m...

Page 30: ...ed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality an...

Page 31: ...ase all moving parts e g side stand hand lever chain and check for smooth operation Check the fluid level of the hydraulic clutch p 56 Check the brake fluid level of the front brake p 60 Check the fre...

Page 32: ...ng head bearing p 44 Change glass fiber yarn filling in the main silencer p 49 Check adjust the carburetor components Service the fork Service the shock absorber Checking cleaning and lubricating the...

Page 33: ...the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed set...

Page 34: ...loosen fitting Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 turn Info Turn...

Page 35: ...value as dimension Finishing work Remove the motorcycle from the lift stand p 38 11 7 Checking the static sag of the shock absorber 400989 10 Measure distance of rear wheel unloaded p 33 Hold the moto...

Page 36: ...can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info Before changing the spring preload...

Page 37: ...215 Info The spring rate is shown on the outside of the spring Smaller weight differences can be compensated by changing the spring preload Finishing work Install the shock absorber p 45 Lock the seat...

Page 38: ...icks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection caps 11 13 Adjusting the rebound damping of the fork Info The...

Page 39: ...bar can break Always replace handle bar M01029 11 Remove screws Remove the handlebar clamps Take off the handlebar and lay it to one side Info Cover the components to protect them against damage Do no...

Page 40: ...ge The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle pr...

Page 41: ...necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 106 Press the dust boots back into their normal position Remove excess oil Finishing work Install th...

Page 42: ...10 Position the brake caliper Mount and tighten screws with the spacers Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Connect the plug in connector and mount the cable tie s Po...

Page 43: ...atory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 75 Raise the motorcycle with the lift stand p 38 Remove the front wheel p 68 Remove t...

Page 44: ...y positioned Slide on protective ring and O ring B01739 10 Position the upper triple clamp with the handlebar Mount screw but do not tighten yet Position the clutch line and wiring harness M01051 10 P...

Page 45: ...nishing work Install the front fender p 46 Install the front wheel p 68 Refit the headlight mask with the headlight p 76 Check that the wiring harness throttle cables and brake and clutch lines can mo...

Page 46: ...eck the steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 38 12 12 Adjusting the play of the steering head bearing Preparatory work Raise the mot...

Page 47: ...e and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Mount and tighten screw Guideline Screw bottom shock absorber M12 80 Nm 59...

Page 48: ...in the direction of the arrow Lift the seat and fold it up 12 19 Locking the seat M01055 01 Fold down the seat and push it down The seat engages with an audible click Finally check that the seat is co...

Page 49: ...ilter as dust and dirt will enter the engine and lead to increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc sh...

Page 50: ...atory work Fold the seat up p 46 Remove the air filter housing p 46 Remove the air filter p 47 B01725 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properl...

Page 51: ...48 B01719 10 Main work Remove screws Pull out connecting cap Remove old glass fiber yarn filling Clean the parts that need to be reinstalled and check for damage Fit the new glass fiber yarn filling o...

Page 52: ...Installing 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...

Page 53: ...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 the...

Page 54: ...shing work Remove the motorcycle from the lift stand p 38 12 33 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components...

Page 55: ...the specified weight Guideline Weight chain wear measurement 10 15 kg 22 33 lb Measure the distance of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat...

Page 56: ...nt of the chain guide If the light part of the chain guide is worn Change the chain guide B01713 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the c...

Page 57: ...Remove the fuel tank p 49 M01056 01 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 If the throttl...

Page 58: ...is limited Turn the adjusting screw by hand only and do not apply force Do not make any adjustments while riding 12 41 Checking fluid level of the hydraulic clutch Info The fluid level rises with incr...

Page 59: ...er with membrane M01057 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 103 On the clutch slave cylinder remove bleeder screw and mo...

Page 60: ...the front 12 45 Installing the engine guard B01706 10 Position the engine guard on the frame at the front and mount screws but do not tighten yet Position the engine guard on the frame at the rear and...

Page 61: ...moves away from the handlebar When the adjusting screw is turned counterclockwise the free travel increases The pressure point moves towards the handlebar The range of adjustment is limited Turn the a...

Page 62: ...e 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 Your authorized KTM workshop will be glad...

Page 63: ...to help 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 If...

Page 64: ...efully pull the brake caliper backwards from the brake disc Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir B01698 10 Remov...

Page 65: ...5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 63 Reconnect spring 13 9 Adjusting the basic position of the foot brake lever Warni...

Page 66: ...aking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cau...

Page 67: ...le Change the rear brake linings p 65 13 13 Changing the rear brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authori...

Page 68: ...ever use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid att...

Page 69: ...SYSTEM 67 B01692 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 103 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately wi...

Page 70: ...er 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 B01046 11 Check t...

Page 71: ...age Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way...

Page 72: ...tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have a...

Page 73: ...22 psi If the tire pressure does not meet specifications Correct the tire pressure Mount protection cap 14 7 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect s...

Page 74: ...he motorcycle with the lift stand p 38 Fold the seat up p 46 Remove the shock absorber p 45 B02295 10 Main work Remove screw Take off fastening plate B02296 10 Remove the battery out of the battery co...

Page 75: ...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 Oil grease filters fuel cl...

Page 76: ...ycle from the lift stand p 38 15 4 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 bypa...

Page 77: ...Fuses res 10 A spare fuses Info A defective fuse is indicated by a burned out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the...

Page 78: ...mask up and swing it forward 602812 10 Disconnect the plug in connectors for the turn signals and for the head light 15 7 Refitting the headlight mask with the headlight 602812 11 Main work EU AU Conn...

Page 79: ...d switch off the engine Remove the headlight mask with the headlight p 75 602813 10 Main work Turn rubber cap together with the underlying bulb socket counterclockwise all the way and remove it Pull b...

Page 80: ...range cap Position the diffuser Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly Finishing work Check that the turn signal system is functi...

Page 81: ...e engine Remove the headlight mask with the headlight p 75 M01039 10 Main work Remove screws Pull the speedometer upward out of the holder M01040 10 Using a coin turn protection cap all the way counte...

Page 82: ...t Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come...

Page 83: ...mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Coolant p 103 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle oper...

Page 84: ...Make sure that screw is tightened Stand the motorcycle upright Completely fill the radiator with coolant Coolant 0 9 l 1 qt Coolant p 103 400677 10 Move the vehicle into the position shown and prevent...

Page 85: ...haust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in th...

Page 86: ...ottle slide partially open This range is influenced by the jet needle form and position The idle setting influences the engine tuning in the lower range and the main jet influences the engine tuning i...

Page 87: ...s switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfi...

Page 88: ...edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 86 17 7 Adjusting the basic position of the shift lever 401950 12 Remove...

Page 89: ...seated correctly Position alternator cover Mount and tighten screw Guideline Screw alternator cover M6x35 8 Nm 5 9 lbf ft Mount and tighten screws Guideline Screw alternator cover M6x16 8 Nm 5 9 lbf...

Page 90: ...0 Nm 7 4 lbf ft 18 3 Changing the gear oil 400721 01 Drain the gear oil p 88 400722 01 Fill in gear oil p 89 18 4 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot...

Page 91: ...and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without...

Page 92: ...ses are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed s...

Page 93: ...then clean with a paintbrush Motorcycle cleaner p 105 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with wa...

Page 94: ...rake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while t...

Page 95: ...or the last time before taking the motorcycle out of service add fuel additive Fuel additive p 105 Refuel p 28 Clean the motorcycle p 91 Change the gear oil p 88 Check the antifreeze and coolant level...

Page 96: ...jet blocked Check adjust the carburetor components Adjusting screws on the carburetor are in turned to the wrong position Carburetor adjust the idle speed p 84 Faulty spark plug Change the spark plug...

Page 97: ...head gasket Check the cylinder head and cylinder head gas ket Bent radiator hose Change the radiator hose Incorrect ignition point due to loose stator Set the ignition Defect in radiator fan system C...

Page 98: ...tightening torques Screw inner reed petals EJOT DELTA PT 35x25 1 Nm 0 7 lbf ft Screw membrane core plate EJOT DELTA PT 30x12 1 Nm 0 7 lbf ft Screw outer reed petals EJOT DELTA PT 30x6 1 Nm 0 7 lbf ft...

Page 99: ...3 Fuel Total fuel tank capacity approx 7 0 l 1 85 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 80 p 104 Fuel reserve approx 1 65 l 1 74 qt 22 4 Chassis Frame Perimeter steel alumin...

Page 100: ...ht S2 socket BA20d 12 V 35 35 W Parking light W5W socket W2 1x9 5d 12 V 5 W Indicator lamps W2 3W socket W2 1x4 6d 12 V 2 3 W Turn signal R10W socket BA15s 12 V 10 W Brake tail light LED License plate...

Page 101: ...der 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 Gas pressure 10 bar 145...

Page 102: ...side stand attachment M8 25 Nm 18 4 lbf ft Loctite 2701 Screw subframe M8 30 Nm 22 1 lbf ft Loctite 243 Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 22 Nm 16 2 l...

Page 103: ...r type KEIHIN PWK 28 Carburetor identification number CC5 Needle position 4th position from top Jet needle JJG Main jet 122 120 125 Idling jet 45 48 Idle air adjusting screw Open 2 0 rotations Throttl...

Page 104: ...22 TECHNICAL DATA 102 401798 01 M FT ASL Sea level TEMP Temperature ASO Open idle air adjusting screw IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Does not apply on sandy terrain...

Page 105: ...9 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil 15W 50 Standard classification JASO T903 MA p 107 SAE p 107 15W 50 Guideline Use only engine oils tha...

Page 106: ...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 use Info Do not use fuel con...

Page 107: ...GRIP GLUE High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Lubricant T625 Recommended supplier Molykote 33 Medium Motorcycle cleaner...

Page 108: ...ARY SUBSTANCES 106 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...

Page 109: ...s In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the...

Page 110: ...26 LIST OF ABBREVIATIONS 108 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 111: ...Active driving aids are also represented by yellow or orange symbols FI warning lamp MIL inoperative Fuel level warning lamp inoperative 27 2 Green and blue symbols Green and blue symbols reflect info...

Page 112: ...king 53 Chain tension adjusting 52 checking 52 Chassis number 11 Choke 16 Clutch fluid level checking 56 fluid level correcting 56 fluid changing 57 Clutch lever 13 basic position adjusting 56 Combina...

Page 113: ...emoving 48 Motorcycle cleaning 91 raising with lift stand 38 removing from lift stand 38 O Operating substances 8 Overview of indicator lamps 15 Owner s Manual 7 P Play in the throttle cable adjusting...

Page 114: ...tightening torques 99 electrical system 98 engine 96 engine tightening torques 96 fork 98 shock absorber 99 tires 98 Throttle cable routing checking 55 Throttle grip 13 Tire air pressure checking 71 T...

Page 115: ...3213341en 3213341en 04 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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KTM Freeride 250 R EU, Owner'S Manual

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