KTM Freeride 250 R AUS 2014, Руководство по ремонту

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TABLE OF CONTENTS
2
TABLE OF CONTENTS 1 MEANS OF REPRESENTATION ..................................... 5
1.1
Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1
Repair Manual .................................................. 6
2.2 Safety advice.................................................... 6
2.3 Degrees of risk and symbols ............................... 6
2.4 Work rules........................................................ 6
3 IMPORTANT NOTES..................................................... 7
3.1
Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Figures ............................................................ 7
4 SERIAL NUMBERS ...................................................... 8
4.1
Chassis number ................................................ 8
4.2 Type label ........................................................ 8
4.3 Key number...................................................... 8
4.4 Engine number ................................................. 8
4.5 Fork part number .............................................. 8
4.6 Shock absorber part number .............................. 9
5 MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2 Removing the motorcycle from the lift stand...... 10
5.3 Starting.......................................................... 10
5.4 Starting the motorcycle to make checks ............ 11
6 FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2 Adjusting the rebound damping of the fork ........ 12
6.3 Bleeding the fork legs...................................... 12
6.4 Cleaning the dust boots of the fork legs............. 13
6.5 Removing the fork protector ............................. 13
6.6 Installing the fork protector.............................. 13
6.7 Removing the fork legs .................................... 14
6.8 Installing the fork legs..................................... 14
6.9 Performing a fork service ................................. 15
6.10 Disassembling the fork legs.............................. 15
6.11 Disassembling the cartridge ............................. 18
6.12 Disassembling the compression holder .............. 20
6.13 Checking the fork legs ..................................... 20
6.14 Assembling the compression holder .................. 22
6.15 Assembling the cartridge ................................. 22
6.16 Assembling the fork legs.................................. 24
6.17 Greasing the steering head bearing ................... 28
6.18 Removing the lower triple clamp....................... 28
6.19 Installing the lower triple clamp ....................... 29
6.20 Checking the steering head bearing play............ 30
6.21 Adjusting the play of the steering head
bearing .......................................................... 31
7 HANDLEBAR, CONTROLS........................................... 32
7.1
Handlebar position.......................................... 32
7.2 Adjusting the handlebar position ...................... 32
7.3 Adjusting the basic position of the clutch
lever .............................................................. 32
7.4 Checking the throttle cable routing ................... 33
7.5 Checking the play in the throttle cable .............. 33
7.6 Adjusting the play in the throttle cable.............. 34
8 FRAME ..................................................................... 35
8.1
Removing the engine guard.............................. 35
8.2 Installing the engine guard .............................. 35
9 SHOCK ABSORBER, SWINGARM ................................ 36
9.1
Adjusting the high-speed compression
damping of the shock absorber......................... 36
9.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 36
9.3 Adjusting the rebound damping of the shock
absorber......................................................... 37
9.4 Measuring rear wheel sag unloaded................... 37
9.5 Checking the static sag of the shock absorber .... 38
9.6 Checking the riding sag of the shock absorber.... 38
9.7 Adjusting the spring preload of the shock
absorber......................................................... 38
9.8 Adjusting the riding sag................................... 39
9.9 Removing the shock absorber........................... 40
9.10 Installing the shock absorber............................ 40
9.11 Servicing the shock absorber............................ 40
9.12 Removing the spring........................................ 41
9.13 Disassembling the damper ............................... 41
9.14 Disassembling the piston rod ........................... 42
9.15 Disassembling the seal ring retainer.................. 44
9.16 Replacing the pilot bushing ............................. 44
9.17 Checking the damper ...................................... 45
9.18 Removing the heim joint.................................. 46
9.19 Installing the heim joint................................... 47
9.20 Assembling the seal ring retainer...................... 48
9.21 Assembling the piston rod................................ 48
9.22 Assembling the damper ................................... 50
9.23 Bleeding and filling the damper ....................... 52
9.24 Filling the damper with nitrogen ....................... 54
9.25 Installing the spring ........................................ 55
10 EXHAUST.................................................................. 57
10.1 Removing the main silencer ............................. 57
10.2 Installing the main silencer.............................. 57
10.3 Changing the glass fiber yarn filling of the
main silencer.................................................. 57
11 AIR FILTER ............................................................... 59
11.1 Removing the air filter housing......................... 59
11.2 Installing the air filter housing ......................... 59
11.3 Removing the air filter..................................... 59
11.4 Installing the air filter...................................... 60
11.5 Cleaning the air filter and air filter housing........ 60
12 FUEL TANK, SEAT, TRIM ........................................... 61
12.1 Opening the filler cap...................................... 61
12.2 Refueling ....................................................... 61
12.3 Closing the filler cap ....................................... 62
12.4 Folding the seat up ......................................... 62
12.5 Locking the seat ............................................. 62
12.6 Removing the seat .......................................... 63
12.7 Mounting the seat ........................................... 63
12.8 Taking off the spoiler....................................... 63
12.9 Mounting the spoiler ....................................... 64
12.10 Removing the fuel tank.................................... 65
12.11 Installing the fuel tank .................................... 65
12.12 Fuel tap ......................................................... 66
13 MASK, FENDER......................................................... 67
13.1 Removing the front fender ............................... 67
13.2 Installing the front fender ................................ 67
13.3 Removing the headlight mask with the
headlight........................................................ 67
13.4 Refitting the headlight mask with the
headlight........................................................ 68