KTM RC 250 R Owner'S Manual Download

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OWNER'S MANUAL

2014

RC 250 R

Art. no. 3213113en

Summary of Contents for RC 250 R

Page 1: ...OWNER S MANUAL 2014 RC 250 R Art no 3213113en...

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: ...g preload of the fork 27 10 4 Fork offset 28 10 5 Adjusting the fork offset x 28 10 6 Compression damping of the shock absorber 29 10 7 Adjusting the low speed compression damping of the shock absorbe...

Page 5: ...sting the idle speed x 64 17 4 Quick shifter 64 17 5 Checking the position of the quick shifter 64 17 6 Positioning the quick shifter 65 18 SERVICE WORK ON THE ENGINE 66 18 1 Checking the engine oil l...

Page 6: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be opti mally cared for by specially trained experts using the specialist...

Page 7: ...that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are...

Page 8: ...otorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcy cle sport make sure that you use your motorcycle legally display environmental consci...

Page 9: ...ual Incorrect adjustment and tuning of the engine and suspension can lead to damage and breakage of components Use of the vehicle under difficult conditions such in rain or high heat can lead to consi...

Page 10: ...ch p 12 1 Launch Control button p 12 1 Pit Limiter button p 12 1 Tail light switch p 11 2 Clutch lever p 11 3 Filler cap 4 Shock absorber compression adjustment High Speed 5 Shock absorber compression...

Page 11: ...on switch p 11 2 Fork rebound adjustment 2 Fork spring preload adjustment 3 Indicator lamps p 12 4 Throttle grip p 11 5 Hand brake lever p 11 6 Foot brake lever p 18 7 Shock absorber rebound adjustmen...

Page 12: ...r 1 is stamped on the right side of the engine 5 3 Fork part number L00557 10 The fork part number 1 is stamped on the upper side of the fork 5 4 Shock absorber part number L00558 10 The shock absorbe...

Page 13: ...is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start Ignition...

Page 14: ...imiter button L00465 12 The Pit Limiter button 1 is fitted on the left side of the handlebar The Pit Limiter is activated by pressing the Pit Limiter button The Pit Limiter is active until the Pit Lim...

Page 15: ...ning lamp lights up The coolant temperature has reached a critical value The shift warning light flashes yellow The set shift speed will soon be reached The shift warning light flashes red The set shi...

Page 16: ...on setting instruction Battery type 9V 1604 6LR61 Thermometer Pre Shift light Design and specification are subject to change without notice 4 1 Press Adjust button one time to switch the o o temperatu...

Page 17: ...15...

Page 18: ...back the main screen o EX Now the setting is changed from 100 C o to 105 C Main screen Press the Select button to enter the over heat warning light setting screen EX Now the pre shift light setting is...

Page 19: ...h soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Envi...

Page 20: ...urning the screw counterclockwise increases the idle speed 6 16 Shift lever L00467 10 The shift lever 1 is mounted on the left of the engine L00467 11 The gear positions can be seen in the figure The...

Page 21: ...d persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your vehicle remember that others may feel disturbed by excessive n...

Page 22: ...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 sufficient ventilation and do...

Page 23: ...er Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicl...

Page 24: ...10 Switch off the engine Open the filler cap p 17 Fill the fuel tank with fuel up to the lower edge 1 of the fuel filler neck Total fuel tank capacity approx 10 5 l 2 77 US gal Super unleaded ROZ 100...

Page 25: ...lean and grease the bearings and gaskets of the swingarm and the linkage x Grease all moving parts e g hand lever shift lever and check for smooth operation x Check all hoses e g fuel cooling bleeder...

Page 26: ...x Change the cylinder head gasket and cylinder base gasket x Change the crankshaft bearing x Change the double wheel bearings x Change the balancer bearing x Change the shaft seal rings of the balance...

Page 27: ...correctly x Check the chain link x Change the engine oil and oil filter clean the oil screen x p 66 Check the valve clearance x Periodic interval 9 4 Maintenance work as an additional order 14 000 rp...

Page 28: ...cam lever x Change the tensioning rail and timing chain x Change the cylinder head gasket and cylinder base gasket x Change the crankshaft bearing x Change the double wheel bearings x Change the bala...

Page 29: ...hydraulic rebound damping determines the fork suspension behavior An optimally adjusted rebound damping attenuates the spring energy and enables the fork to return to the zero position quickly and wi...

Page 30: ...teering head bearing The fork offset can be adjusted as necessary L00593 10 Distance 1 shows the fork offset setting The standard setting provides for highly agile handling in curves Fork offset Condi...

Page 31: ...of the shock absorber The compression damping of the shock absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspen...

Page 32: ...h speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the...

Page 33: ...ved of weight Turn adjusting screw 1 counterclockwise all the way until the spring is fully relaxed Turn the adjusting screw clockwise and tension it to the specified value Guideline Spring preload St...

Page 34: ...heck the steering for smooth oper ation making sure that the handlebar can be moved from extreme left to extreme right without a tendency to lock 10 13 Vehicle level L00544 01 Warning Danger of accide...

Page 35: ...of fork legs standard 5 mm 0 2 in Upper triple clamp flush with 3rd ring of fork legs 7 5 mm 0 295 in Upper triple clamp flush with 4th ring of fork legs 10 mm 0 39 in Info The standard setting offers...

Page 36: ...ht off the rear wheel and swingarm Loosen nut 1 Distance A must not exceed the specified value Guideline Distance A 12 mm 0 47 in L00533 11 Turn damper 2 in the desired position Guideline Standard sho...

Page 37: ...e the rear lifting gear 11 3 Raising the front of the motorcycle with lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surfa...

Page 38: ...air filter x Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations...

Page 39: ...box Check the distribution of the filter oil If unoiled areas are visible Oil the air filter again Wipe off excess filter oil Info Do not apply too much oil to the air filter Finishing work Install t...

Page 40: ...lock quick releases 1 Take off engine cowl 2 11 9 Installing the engine cowl L00547 11 Position engine cowl 1 Lock quick releases 2 11 10 Removing the front fairing Preparatory work Remove the engine...

Page 41: ...y emerge if overfilled 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 brea...

Page 42: ...structions 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 oc...

Page 43: ...ntact 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 immediatel...

Page 44: ...fairing p 39 Install the engine cowl p 38 11 18 Checking for chain dirt 400678 01 Check the chain for loose dirt If the chain is very dirty Clean the chain p 42 11 19 Cleaning the chain Warning Dange...

Page 45: ...he transmission to neutral Guideline Push the chain up at the front end of the rear wheel cover 1 The chain should touch the rear wheel cover Info The lower chain section must be taut Chain wear is no...

Page 46: ...cal on the left and right The rear wheel is then correctly aligned Tighten nut 1 Guideline Nut rear wheel spindle M18x1 5 60 Nm 44 3 lbf ft Finishing work Remove the rear of the motorcycle from the li...

Page 47: ...less than the specified value Change the brake discs x Check the front and rear brake discs for damage cracking and deformation If damage cracks or deformation are visible on the brake disc Change the...

Page 48: ...stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between b...

Page 49: ...ean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often no...

Page 50: ...with water 12 7 Checking 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...

Page 51: ...rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel clea...

Page 52: ...ss A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 50 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear...

Page 53: ...Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive and will damage painted surfaces Use only clean brake flui...

Page 54: ...on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean wheel spindle 1 Lift the front wheel into the fork position it and insert...

Page 55: ...eel x 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...

Page 56: ...wear If the rubber dampers of the rear hub are damaged or worn Change the rubber dampers x Position the rear sprocket carrier Info Each pin and rubber damper pair should have as little free play as po...

Page 57: ...digits refer to the year of manufac ture KTM recommends that the tires are changed regardless of the actual wear at the latest after five years If a tire is more than five years old Change the tires 1...

Page 58: ...ttery Preparatory work Switch off all power consumers and switch off the engine Remove the engine cowl p 38 Remove the front fairing p 38 L00595 10 Main work Detach rubber band 1 Disconnect the batter...

Page 59: ...engine Remove the engine cowl p 38 Remove the front fairing p 38 Remove the battery x p 56 L00530 10 Main work Connect the battery charger to the battery Switch on the battery charger Battery charger...

Page 60: ...he engine Remove the engine cowl p 38 Remove the front fairing p 38 L00554 10 Main work Take off protection cap 1 Remove the faulty main fuse 2 Install a new main fuse Fuse 58011109110 p 80 Mount prot...

Page 61: ...Battery voltage 12 V 6 Not assigned 15 3 Expansion sensors L00587 10 Connectors exist to connect the following expansion sensors to the engine control unit SUS_F suspension travel sensor front SUS_R...

Page 62: ...0 1 0 8 8 0 1 U steps Stepper target position bypass setpoint 21A SPEED_F 100 0 0 0 16 0 value 100 U km h front wheel speed 21A SPEED_R 100 2 0 16 16 0 value 100 U km h rear wheel speed 21B TC_STATUS...

Page 63: ...with lukewarm water Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Take off the radiator cap Check the coolant level in the radiator Coolant level A above...

Page 64: ...ove the radiator fins Guideline Distance A above the radiator fins 10 mm 0 39 in Coolant 0 7 l 0 7 qt Distilled water Fit the radiator cap Take a short test ride Check the coolant level p 61 Info In m...

Page 65: ...ine in an enclosed space without an effective exhaust 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...

Page 66: ...y to activate the clutch when upshifting the gears between 1st to 6th gear The ignition is briefly interrupted by the control unit during a shift procedure For the quick shifter to function properly t...

Page 67: ...on both sides Info The screw must be screwed in by at least 6 full turns The two heim joints must be parallel to each other Check the ball joints of the heim joints for smooth operation L00652 10 Pos...

Page 68: ...l does not reach the middle of viewer A Add engine oil p 68 Finishing work Install the front fairing p 39 Install the engine cowl p 38 18 2 Changing the engine oil and oil filter cleaning the oil scre...

Page 69: ...the O ring L00521 11 Pull oil filter 5 out of the oil filter housing Completely drain the engine oil Clean the parts and the sealing surface thoroughly L00521 12 Insert the oil filter into the oil fil...

Page 70: ...the clutch cover Fill up with engine oil Engine oil SAE 0W 40 p 94 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install...

Page 71: ...n remain on the vehicle Remove the thrust bearing of the clutch cable and detach the clutch cable from the eyelet of the clutch release lever L00662 11 Main work Support the engine with the scissors s...

Page 72: ...ne spacers 1 to create sufficient space for the engine L00660 10 Raise the engine with the scissors stand Position the lower left engine spacer 2 and chain link 3 Position the upper left engine spacer...

Page 73: ...Nm 25 8 lbf ft Thread greased Mount and tighten nut bk with the washer Guideline Screw rear engine bearer M10 35 Nm 25 8 lbf ft Thread greased L00662 10 Tighten the front engine bracket screw 7 Guide...

Page 74: ...e radiator radiator hoses and cooling air guide Refill with coolant x p 62 Mount the battery holder Connect the battery Mount the air filter box lid Install the fuel tank x p 40 Install the front fair...

Page 75: ...characteristic map 19 2 Adjusting the throttle position sensor Info The position of the throttle position sensor is preset at the factory This screw may only be opened to replace a faulty sensor The s...

Page 76: ...sition sensor must be positioned over the slot ted hole of the fixing screw such that a sensor value of 60 bits 1 bit results when the throttle valve is fully closed After that make the settings as de...

Page 77: ...is displayed in bit in the REAL_TIME_GEAR field L00568 10 Release screws 1 and change the position of the gear position sensor 2 until the specified value is reached Guideline REAL_TIME_GEAR 51 bit Ti...

Page 78: ...normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it...

Page 79: ...not subject to large fluctuations in tem perature Guideline Storage temperature of vehicle 0 35 C 32 95 F Info KTM recommends raising the motorcycle Raise the rear of the motorcycle with lifting gear...

Page 80: ...e Transmission ratio 1st gear 14 30 16 36 15 31 2nd gear 20 36 16 30 19 33 3rd gear 18 28 18 29 18 27 4th gear 21 29 21 30 18 24 5th gear 21 26 22 28 19 24 19 23 20 24 6th gear 22 25 23 27 19 22 26 29...

Page 81: ...mshaft bearing bridge M7 15 Nm 11 1 lbf ft Screw conrod bearing M8 Step 1 20 Nm 14 8 lbf ft Step 2 90 Lubricant p 95 Nut of engine sprocket M10 40 Nm 29 5 lbf ft Plug timing chain tensioner M10 10 Nm...

Page 82: ...y mounted four pot brake caliper floating brake disc Rear Single disc brake with radially connected dual piston brake caliper non floating brake disc Brake discs diameter Front 290 mm 11 42 in Rear 19...

Page 83: ...umber 15 18 7M 50 Shock absorber WP Suspension 4618 with linkage system Compression damping high speed Standard 10 clicks Compression damping low speed Standard 10 clicks Rebound damping Standard 10 c...

Page 84: ...M10 35 Nm 25 8 lbf ft Screw front engine bearer M10 35 Nm 25 8 lbf ft Thread greased Screw linkage lever on angle lever M10 35 Nm 25 8 lbf ft Screw linkage lever on frame M10 35 Nm 25 8 lbf ft Screw...

Page 85: ...83...

Page 86: ...B5 O3 C3 D3 X46 1 CAN 2 3 4 AP 6 5 X65 3 1 VF CU 4 2 F1 E3 YI X78 1 T_DASH 2 X82 13 dash 16 20 21 AO 26 22 F4 X69 1 P_FB 2 CY 3 3 L3 O4 XW X1 Q3 ECU X71 1 SUS_F 2 CY 3 3 J2 B1 ML X97 ML X98 ML X99 2...

Page 87: ...r dashboard ALARM Red indicator lamp MIL Yellow indicator lamp PIT LC LIGHT Green indicator lamp P_FB Pressure front brake VF Wheel speed front dash Dashboard connector SUS_F Suspension sensor front C...

Page 88: ...9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 2 5 Switches B3311075000 Main Loom Switches Hauptkabelstrang Schalter 3 B6 5 B3 3 B3 5 B4 1 B3 1 B6 1 B6 E2 CR 1 X93 1 Q...

Page 89: ...NG DIAGRAM 87 Components QS_SW Quick shifter switch MAP LIGHT_SW Map select and rear light switch left handlebar MAIN_SW Main switch right handlebar PIT_LC_SW Pit limiter launch control switch left ha...

Page 90: ...1 2 3 4 5 6 7 8 9 10 11 3 5 Left B3311075000 Main Loom Left Hauptkabelstrang links 2 B5 5 B3 2 B4 1 B5 5 B5 5 B3 5 B1 splice splice 1 B3 1 B6 4 B3 X39 1 TENG AX 2 2 X55 1 GEARCUT EL 2 2 X62 1 GEAR 2 4...

Page 91: ...23 WIRING DIAGRAM 89 Components TENG Engine temperature sensor GEARCUT Quick shifter sensor GEAR Gear position sensor Rectifier Regulator Voltage regulator XE Ground FUSEBOX Fusebox BATT Battery...

Page 92: ...7 8 9 10 11 4 5 Throttle Body B3311075000 Main Loom Throttle body Hauptkabelstrang Drosselklappenk rper 5 B3 5 B3 5 B3 3 B3 X18 1 INJ_L DQ 2 2 X19 1 INJ_H DQ 2 2 O1 O2 A4 CR 1 X23 1 COIL CMD CR 1 X24...

Page 93: ...Air temperature sensor POIL Oil pressure sensor TPS Throttle position sensor INJ_L Injector low INJ_H Injector high COIL_CMD Ignition coil command COIL_ Ignition coil voltage supply Stepper Motor Step...

Page 94: ...3 B5 splice 2 B4 splice 4 B5 4 B5 4 B6 splice splice 3 B4 1 B6 3 B2 X70 1 P_RB 2 CY 3 3 X72 1 2 SUS_R CY 3 3 N4 J3 DF 2 X43 1 2 PickUp M3 M2 X66 3 VR 1 CU 4 2 G3 D1 E1 X6 1 main relais 2 3 EB 4 4 P2...

Page 95: ...93 Components P_RB Pressure rear brake sensor SUS_R Suspension rear sensor main_relais Power relay light Rear light Laptrigger 12V power supply for laptimer VR Wheel speed rear Fuelpump Fuel pump Pick...

Page 96: ...and that possess the corre sponding properties Fully synthetic engine oil Recommended supplier Motorex Racing Pro 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 96 SAE 4 Guideline Use onl...

Page 97: ...x Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Lubricant Recommended supplier Pankl PLB07 Motorcycle cleaner Recommended supplier Motorex Moto Clean Perfect Finish and hig...

Page 98: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wi...

Page 99: ...g 62 Coolant level checking 61 Coolant overflow reservoir checking 42 Cooling system 61 Customer service 7 D Data recording 59 CAN matrix 60 expansion sensors 59 E Engine installing 70 removing 68 run...

Page 100: ...Safe operation 5 Service 7 Service schedule 23 26 Shift lever 18 Shock absorber compression damping general 29 compression damping high speed adjusting 30 compression damping low speed adjusting 30 re...

Page 101: ...3213113en 3213113en 11 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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KTM RC 250 R, Owner'S Manual

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