Ktm freeride 250 r мануал

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

• Page 4: Table Of Contents

  TABLE OF CONTENTS SHOCK ABSORBER, SWINGARM …….. 36 TABLE OF CONTENTS MEANS OF REPRESENTATION ……..5 Adjusting the high-speed compression Symbols used ……….. 5 damping of the shock absorber……36 Formats used………… 5 Adjusting the low-speed compression damping SAFETY ADVICE…………6 of the shock absorber ……..

• Page 5
  TABLE OF CONTENTS 14 WHEELS …………..69 18 30/ENGINE …………. 101 14.1 Checking the tire air pressure……69 18.1 Removing the engine……..101 14.2 Checking the tire condition ……69 18.2 Installing the engine……..104 14.3 Checking the brake discs ……… 70 18.3 Engine disassembly……..
• Page 6
  19.12 Assembling the carburetor ……152 29 WIRING DIAGRAM ……….. 182 19.13 Checking/adjusting the float level ….153 29.1 Page 1 of 5 (Freeride 250 R EU)….182 20 CLUTCH …………..155 29.2 Page 2 of 5 (Freeride 250 R EU)….184 20.1…

• Page 7: Means Of Representation

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

• Page 8: Safety Advice

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

• Page 9: Important Notes

  Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer’s Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

• Page 10: Serial Numbers

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

• Page 11: Shock Absorber Part Number

  SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. B01654-10…

• Page 12: Motorcycle

  MOTORCYCLE Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) ( p.

• Page 13: Starting The Motorcycle To Make Checks

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

• Page 14: Fork, Triple Clamp

  FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

• Page 15: Cleaning The Dust Boots Of The Fork Legs

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

• Page 16: Removing The Fork Legs

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

• Page 17: Performing A Fork Service

  FORK, TRIPLE CLAMP – Position the brake caliper. Mount and tighten screws with the spacers. Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount cable binder – Position the brake line, wiring harness, and clamp. Mount and tighten screws 602805-11 Finishing work –…

• Page 18
  FORK, TRIPLE CLAMP – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T612S) ( p. 214) 201424-10 – Loosen screw cap Info The screw cap cannot be removed yet. 201425-10 – Unclamp the fork leg and clamp it with the axle clamp. Info Use soft jaws.
• Page 19
  FORK, TRIPLE CLAMP – Pull the spring downward. Remove the special tool. – Remove spring. 201430-10 – Drain the fork oil. Info Pull out the piston rod all the way and push it back in several times in order to pump out the cartridge until it is empty. 201431-10 –…

• Page 20: Disassembling The Cartridge

  FORK, TRIPLE CLAMP – Warm up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) – Jerk the outer tube out of the inner tube. Info The lower sliding bushing must be pulled out of its bearing seat when doing this.

• Page 21
  FORK, TRIPLE CLAMP – Pull piston rod out of cartridge – Clamp in the piston rod. Remove water excluder Clamping stand (T14016S) ( p. 211) 200695-10 – Remove screw sleeve with washer and spring seat from the cartridge. 200696-10 – Degrease the piston rod.

• Page 22: Disassembling The Compression Holder

  FORK, TRIPLE CLAMP – Remove spring – Remove valve of the rebound damping together with the spring. – Take out the piston rod. 200701-10 6.12 Disassembling the compression holder Info The steps are identical for both fork legs. Preparatory work –…

• Page 23
  FORK, TRIPLE CLAMP – Measure the outside diameter of the inner tube at several locations. Outside diameter of the inner tube 42.975… 43.005 mm (1.69193… 1.69311 in) » If the measured value is less than the specified value: – Change the inner tube. 200684-10 –…

• Page 24: Assembling The Compression Holder

  FORK, TRIPLE CLAMP 6.14 Assembling the compression holder Info The steps are identical for both fork legs. – Clamp the compression holder in a bench vise using soft jaws. – Mount O-ring and seal ring – Grease the O-ring. Lubricant (T158) ( p.

• Page 25
  FORK, TRIPLE CLAMP – Grease the O-ring of tap rebound Lubricant (T158) ( p. 204) – Mount and tighten the tap rebound. Guideline Tap rebound M9x1 18 Nm Loctite ® 2701™ (13.3 lbf ft) – Position spring 200718-10 – Mount shim stack with the smaller shims facing downward.

• Page 26: Assembling The Fork Legs

  FORK, TRIPLE CLAMP – Mount and tighten screw sleeve Guideline Screw sleeve M29x1 46 Nm Loctite ® (33.9 lbf ft) 200722-10 6.16 Assembling the fork legs Info The operations are the same on both fork legs. Preparatory work – Check the fork legs. ( p.

• Page 27
  FORK, TRIPLE CLAMP – Push on the lower sliding bushing – Mount the upper sliding bushing Info Without using a tool, pull the stack apart by hand slightly. 201440-10 – Warm up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) –…
• Page 28
  FORK, TRIPLE CLAMP – Mount the special tool on the cartridge. Support tool (T14026) ( p. 212) Info The special tool must be used in order that the adjustment tube is not raised. Otherwise, oil will reach the piston rod. –…
• Page 29
  FORK, TRIPLE CLAMP Info The screw cap must be screwed in all the way before the piston rod begins to turn. In case of tight piston rod threads, it must be held to keep it from turning. If the screw cap is not screwed in all the way, the rebound adjust- ment will not function properly.

• Page 30: Greasing The Steering Head Bearing

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

• Page 31: Installing The Lower Triple Clamp

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

• Page 32: Checking The Steering Head Bearing Play

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

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

  FORK, TRIPLE CLAMP Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. »…

• Page 34: Handlebar, Controls

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

• Page 35: Checking The Throttle Cable Routing

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

• Page 36: Adjusting The Play In The Throttle Cable

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

• Page 37: Frame

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

• Page 38: Shock Absorber, Swingarm

  SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. Preparatory work –…

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

  SHOCK ABSORBER, SWINGARM Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. –…

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

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

• Page 41: Adjusting The Riding Sag

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

• Page 42: Removing The Shock Absorber

  SHOCK ABSORBER, SWINGARM Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Fold the seat up. ( p. 62) Main work – Remove screw – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel.

• Page 43: Removing The Spring

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

• Page 44: Disassembling The Piston Rod

  SHOCK ABSORBER, SWINGARM – Remove protection cap of the reservoir. – Slowly unscrew screw The pressurized nitrogen is bled off. 201741-10 – Remove screw . Drain the oil. 201740-10 – Remove protection cap – Push in seal ring retainer – Remove lock ring Info Do not scratch the inner surface.

• Page 45
  SHOCK ABSORBER, SWINGARM Main work – Clamp the piston rod into a vise. – Remove nut – Remove rebound shim stack Info Guide the rebound shim stack onto a screwdriver and put them aside together. 201743-10 – Remove piston – Remove compression shim stack Info Guide the compression shim stack onto a screwdriver and put them aside…

• Page 46: Disassembling The Seal Ring Retainer

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

• Page 47: Checking The Damper

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

• Page 48: Removing The Heim Joint

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

• Page 49: Installing The Heim Joint

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

• Page 50: Assembling The Seal Ring Retainer

  SHOCK ABSORBER, SWINGARM 9.20 Assembling the seal ring retainer – Mount dust boot with the special tool. Mounting sleeve (T1204) ( p. 210) – Grease the sealing lip of the dust boot. Lubricant (T625) ( p. 204) 200792-10 – Grease the O-ring groove. Lubricant (T158) ( p.

• Page 51
  SHOCK ABSORBER, SWINGARM – Position the special tool on the piston rod. Mounting sleeve (T1554) ( p. 213) – Grease the dust boot and slide seal ring retainer onto the piston rod. Lubricant (T625) ( p. 204) – Remove the special tool. –…

• Page 52: Assembling The Damper

  SHOCK ABSORBER, SWINGARM – Sand both sides of piston on a surface plate using 1200-grit sandpaper. – Clean the piston. – Mount the piston. Guideline View Top view of piston View Bottom view of piston 201757-11 – Mount rebound shim stack with the smaller shims at the top.

• Page 53
  SHOCK ABSORBER, SWINGARM – Pull out the piston rod in order that the seal ring retainer fits closely against the lock ring. – Mount protection cap of the damper cartridge. – Bleed and fill the damper. ( p. 52) – Fill the damper with nitrogen.

• Page 54: Bleeding And Filling The Damper

  SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle’s ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.

• Page 55
  SHOCK ABSORBER, SWINGARM – When the vacuum gauge reaches the required value, turn control lever Oil reser- voir to Equalize pressure. Guideline 4 mbar The pressure gauge increases to the required value. 0 bar 200267-10 – When the pressure gauge reaches the required value, turn control lever Damper to Pressure.

• Page 56: Filling The Damper With Nitrogen

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

• Page 57: Installing The Spring

  SHOCK ABSORBER, SWINGARM – Open filler tap – Fill the damper for at least 15 seconds. Guideline Gas pressure 10 bar (145 psi) Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pressure. – Close the filling port screw using tap handle –…

• Page 58
  SHOCK ABSORBER, SWINGARM – Tighten the spring by turning adjusting ring to the value measured when it was removed. Hook wrench (T106S) ( p. 210) – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft)

• Page 59: Exhaust

  EXHAUST 10.1 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws – Pull off the main silencer from the manifold at rubber sleeve B01720-10 10.2 Installing the main silencer…

• Page 60
  EXHAUST Main work – Remove screws . Pull out connecting cap – Pull glass fiber yarn filling from the connecting cap. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling on the connecting cap. –…

• Page 61: Air Filter

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

• Page 62: Installing The Air Filter

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

• Page 63: Fuel Tank, Seat, Trim

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

• Page 64: Closing The Filler Cap

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

• Page 65: Removing The Seat

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

• Page 66: Mounting The Spoiler

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

• Page 67: Removing The Fuel Tank

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

• Page 68: Fuel Tap

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

• Page 69: Mask, Fender

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

• Page 70: Refitting The Headlight Mask With The Headlight

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

• Page 71: Wheels

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

• Page 72: Checking The Brake Discs

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

• Page 73: Front Wheel

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

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

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

• Page 75: Installing The Rear Wheel

  WHEELS Main work – Remove nut – Remove chain adjuster Info Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

• Page 76: Removing The Brake Disc Of The Rear Brake

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

• Page 77: Checking The Chain Tension

  WHEELS 14.6.5 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

• Page 78: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

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

• Page 79: Checking For Chain Dirt Accumulation

  WHEELS – Check the chain sliding piece for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »…

• Page 80
  WHEELS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage. –…

• Page 81: Wiring Harness, Battery

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

• Page 82: Removing The Battery

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

• Page 83: Installing The Battery

  – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 84: Checking The Charging Voltage

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

• Page 85: Checking The Quiescent Current

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

• Page 86: Brake System

  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

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

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

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

• Page 89: Adding Front Brake Fluid

  BRAKE SYSTEM 16.6 Adding front brake fluid Warning Danger of accidents Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.

• Page 90
  BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Cover the painted parts. – Remove screws – Remove cover with membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.

• Page 91: Checking The Rear Brake Linings

  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

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

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

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

• Page 94: Adding Rear Brake Fluid

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

• Page 95: Changing The Rear Brake Fluid

  BRAKE SYSTEM 16.14 Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. –…

• Page 96
  BRAKE SYSTEM Info This prevents overfilling of the brake fluid reservoir. – Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro- tection cap. – Disconnect the bleeding device. Remove the bleeder cover. – Stand the vehicle upright. –…

• Page 97: Lighting System, Instruments

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

• Page 98: Setting Kilometers Or Miles

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

• Page 99: Setting The Service Display

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

• Page 100: Adjusting The Headlight Range

  LIGHTING SYSTEM, INSTRUMENTS 17.7 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 97) Main work – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (the mark is created in: Checking the headlight setting).

• Page 101: Changing The Speedometer Battery

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

• Page 102
  LIGHTING SYSTEM, INSTRUMENTS – Set the speedometer. ( p. 95)

• Page 103: 30/Engine

  30/ENGINE 18.1 Removing the engine Preparatory work – Drain the coolant. ( p. 158) – Remove the engine guard. ( p. 35) – Raise the motorcycle with the lift stand. ( p. 10) – Remove the battery. ( p. 80) –…

• Page 104
  30/ENGINE – Swing the radiator slightly toward the rear and pull down. – Remove the radiator sideways. 202705-10 – Pull off the spark plug connector 202706-10 – Detach connector – Remove screws – Take off the ground wire. Remove the ignition coil. 202707-10 –…
• Page 105
  30/ENGINE – Remove screws – Take off the throttle slide cover and pull the throttle slide out of the carburetor. – Hang the throttle slide to the side. Info Protect the vehicle and its attachments from damage by covering them. –…

• Page 106: Installing The Engine

  30/ENGINE – Remove nut – Remove the swingarm pivot. – Pull the swingarm back slightly. 202717-10 – Remove screws 202718-10 – Lift out the engine from the side. Info You should have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage.

• Page 107
  30/ENGINE – Position the brace. – Mount screw on both sides but do not tighten yet. Guideline Screw, engine brace on 25 Nm Loctite ® 243™ frame (18.4 lbf ft) – Mount and tighten fitting Guideline Screw, engine brace on cylinder head 33 Nm 202716-11 (24.3 lbf ft)
• Page 108
  30/ENGINE – Mount and tighten screw Guideline Screw, battery box EJOT 3 Nm (2.2 lbf ft) – Position the carburetor. – Mount and tighten hose clip – Position the throttle slide in the carburetor. Mount the throttle slide cover and tighten screws Guideline Screw, carburetor cover…
• Page 109
  30/ENGINE – Mount spark plug connector 202706-11 – Position the radiator. 202705-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202704-11 – Mount the radiator hoses. – Position and tighten hose clips – Mount hose 202703-11 –…

• Page 110: Engine Disassembly

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

• Page 111: Draining The Gear Oil

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

• Page 112: Removing The Starter Motor

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

• Page 113: Removing The Cylinder Head

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

• Page 114: Removing The Cylinder

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

• Page 115: Removing The Water Pump Cover

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

• Page 116: Removing The Clutch Basket

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

• Page 117: Removing The Shift Shaft

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

• Page 118: Removing The Reed Valve Housing

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

• Page 119: Removing The Shift Rails

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

• Page 120: Work On Individual Parts

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

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

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

• Page 122: Installing The Crankshaft Bearing Inner Race

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

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

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

• Page 124: Cylinder — Nikasil ® Coating

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

• Page 125: Checking The Piston Ring End Gap

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

• Page 126: Work On The Clutch Cover

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

• Page 127: Checking The Clutch

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

• Page 128: Preassembling The Shift Shaft

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

• Page 129: Checking The Shift Mechanism

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

• Page 130: Disassembling The Main Shaft

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

• Page 131: Disassembling The Countershaft

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

• Page 132: Assembling The Main Shaft

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

• Page 133: Assembling The Countershaft

  30/ENGINE Preparatory work – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 129) 303334-11 Main work – Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws – Mount needle bearing –…

• Page 134
  30/ENGINE 303335-11 Main work – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar facing downward. – Mount stop disk and lock ring –…

• Page 135: Checking The Electric Starter Drive

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

• Page 136: Engine Assembly

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

• Page 137: Installing The Shift Forks

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

• Page 138: Installing The Reed Valve Housing

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

• Page 139: Installing The Locking Lever

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

• Page 140: Installing The Clutch Discs

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

• Page 141: Installing The Clutch Cover

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

• Page 142: Installing The Piston

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

• Page 143: Checking The X-Distance

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

• Page 144: Installing The Cylinder Head

  30/ENGINE Main work – Remove nuts – Carefully slide the cylinder up and take it off. 308133-11 – Replace cylinder base gasket with a cylinder base gasket of the required X-distance. Info Multiple cylinder base gaskets can be combined. 302967-12 Finishing work –…

• Page 145
  30/ENGINE Main work – Grease and mount Bendix Lubricant (T625) ( p. 204) 202734-11 – Mount dowels – Position the gasket. 202733-11 – Position the alternator cover. – Mount and tighten screw Guideline Screw, alternator cover 8 Nm (5.9 lbf ft) 202732-11 –…

• Page 146: Installing The Spacer

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

• Page 147: Installing The Clutch Push Rod

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

• Page 148: Carburetor

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

• Page 149: Emptying The Carburetor Float Chamber

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

• Page 150: Installing The Carburetor

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

• Page 151: Checking/Setting The Carburetor Components

  CARBURETOR Finishing work – Install the fuel tank. ( p. 65) – Lock the seat. ( p. 62) – Check the play in the throttle cable. ( p. 33) – Carburetor — adjust the idle speed. ( p. 146) 19.6 Checking/setting the carburetor components Condition The carburetor has been removed.

• Page 152
  CARBURETOR – Remove fulcrum pin – Remove float and float needle valve. 306308-10 – Remove main jet 306309-10 – Remove needle jet holder with needle jet. Info The needle jet is usually lodged in the carburetor housing. 306310-10 – Remove idling jet 306311-10 –…

• Page 153: Checking The Choke Slide

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

• Page 154: Checking The Float Needle Valve

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

• Page 155: Checking/Adjusting The Float Level

  CARBURETOR – Mount and tighten main jet Guideline Main jet M5x0.75 2 Nm (1.5 lbf ft) 306309-11 – Position float needle valve and float – Mount fulcrum pin – Check/adjust the float level. ( p. 153) 306308-11 – Position the hoses on the carburetor. –…

• Page 156
  CARBURETOR – Tilt the carburetor sideways while preventing the fulcrum pin from falling out. – Tilt the carburetor until the float is resting against the float needle valve but the float needle valve is not squeezed. » If, when in this position, the edge of the float is not parallel (max. 1° deviation in an upward direction) to the sealing surface of the float housing: –…

• Page 157: Clutch

  CLUTCH 20.1 Checking fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Check the fluid level in viewer »…

• Page 158
  CLUTCH – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) ( p. 206) Brake fluid DOT 4 / DOT 5.1 ( p. 202) – On the clutch slave cylinder, remove bleeder screw and mount bleeding syringe B01707-10 –…

• Page 159: Water Pump, Cooling System

  WATER PUMP, COOLING SYSTEM 21.1 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 160: Draining The Coolant

  WATER PUMP, COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 202) – Mount the radiator cap. 21.3 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 161
  WATER PUMP, COOLING SYSTEM – Return the vehicle to the horizontal position. – Completely fill the radiator with coolant. – Mount radiator cap – Let the engine warm up. B01679-10 Finishing work – Check the coolant level. ( p. 157)

• Page 162: Lubrication System

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

• Page 163: Filling In Gear Oil

  LUBRICATION SYSTEM 22.3 Filling in gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Main work – Remove screw cap and fill in gear oil. Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p.

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

• Page 165: Ignition System

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

• Page 166: Ignition Coil — Checking The Primary Winding

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

• Page 167: Checking The Spark Plug Connector

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

• Page 168: Alternator — Checking The Light Winding

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

• Page 169: Removing The Stator And Crankshaft Position Sensor

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

• Page 170: Cleaning The Alternator

  IGNITION SYSTEM 23.11 Cleaning the alternator – Remove screws – Take off the cover. B01730-10 – Remove screws – Take off the alternator cover B01895-10 – Clean alternator cover and rotor – Take off Bendix and clean. – Grease gear teeth and the points marked with a Lubricant (T625) ( p.

• Page 171: Electric Starter

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

• Page 172: Technical Data

  TECHNICAL DATA 25.1 Engine Design 1-cylinder 2-stroke gasoline engine, water-cooled, with mem- brane inlet Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Bore 66.4 mm (2.614 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing…

• Page 173: Engine Tightening Torques

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

• Page 174: Chassis

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

• Page 175: Tires

  Front tires Rear tires 2.75 — 21 M/C 45M TT 4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX Additional information is available in the Service section under: http://www.ktm.com 25.8 Fork Fork part number 05.18.7N.42 fork WP Suspension 4357 MXMA…

• Page 176: Chassis Tightening Torques

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

• Page 177: Carburetor

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

• Page 178: Carburetor Tuning

  TECHNICAL DATA 25.12 Carburetor tuning 25.12.1 Carburetor tuning Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 401798-01 M/FT ASL Sea level…

• Page 179: Cleaning, Care

  CLEANING, CARE 26.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

• Page 180: Checks And Maintenance Steps For Winter Operation

  CLEANING, CARE 26.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

• Page 181: Storage

  – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 10) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

• Page 182: Service Schedule

  Check idle. ● Check that the radiator fan is functioning properly. ● Final check: Check the vehicle for roadworthiness and take a test ride. ● Make the service entry in KTM DEALER.NET and in the service record. ● Periodic interval…

• Page 183: Service Work (As Additional Order)

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

• Page 184: Wiring Diagram

  WIRING DIAGRAM 29.1 Page 1 of 5 (Freeride 250 R EU) bl-rd bl-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bu-rd wh-rd bu-rd wh-rd wh-rd 202674-01…

• Page 185
  WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Electric starter button Voltage regulator…

• Page 186: Freeride 250 R Eu)

  WIRING DIAGRAM 29.2 Page 2 of 5 (Freeride 250 R EU) ye-bu rd-gr wh-gr wh-gr rd-gr wh-gr wh-rd ye-bu 202675-01…

• Page 187
  WIRING DIAGRAM Components: CDI controller Low beam, high beam Fuse Horn High beam indicator lamp Parking light Light switch, horn button, kill switch…

• Page 188: Freeride 250 R Eu)

  WIRING DIAGRAM 29.3 Page 3 of 5 (Freeride 250 R EU) ye-bu ye-bu wh-rd bl-gn bl-gn wh-gn wh-gn wh-gn wh-gn wh-gn ye-bu ye-bu 202676-01…

• Page 189
  WIRING DIAGRAM Components: Radiator fan temperature switch Wheel speed sensor, front Brake light switch, front Brake light switch, rear License plate lamp Fuse Radiator fan Speedometer Brake/tail light…

• Page 190: Freeride 250 R Eu)

  WIRING DIAGRAM 29.4 Page 4 of 5 (Freeride 250 R EU) ye-or ye-bu ye-or 202677-01…

• Page 191
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 192: Freeride 250 R Eu)

  WIRING DIAGRAM 29.5 Page 5 of 5 (Freeride 250 R EU) wh-pu wh-pu wh-bl wh-bl 202678-01…

• Page 193
  WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow…

• Page 194: Freeride 250 R Aus)

  WIRING DIAGRAM 29.6 Page 1 of 5 (Freeride 250 R AUS) bl-rd bl-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bu-rd wh-rd bu-rd wh-rd wh-rd 202695-01…

• Page 195
  WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button Voltage regulator…

• Page 196: Freeride 250 R Aus)

  WIRING DIAGRAM 29.7 Page 2 of 5 (Freeride 250 R AUS) ye-bu rd-gr wh-gr wh-gr BA/1 BF/1 rd-gr wh-rd ye-bu 202696-01…

• Page 197
  WIRING DIAGRAM Components: CDI controller Low beam, high beam Fuse Horn High beam indicator lamp Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button…

• Page 198: Freeride 250 R Aus)

  WIRING DIAGRAM 29.8 Page 3 of 5 (Freeride 250 R AUS) ye-bu ye-bu wh-rd bl-gn bl-gn wh-gn wh-gn wh-gn wh-gn wh-gn ye-bu ye-bu 202697-01…

• Page 199
  WIRING DIAGRAM Components: Radiator fan temperature switch Wheel speed sensor, front Brake light switch, front Brake light switch, rear License plate lamp Fuse Radiator fan Speedometer Brake/tail light…

• Page 200: Freeride 250 R Aus)

  WIRING DIAGRAM 29.9 Page 4 of 5 (Freeride 250 R AUS) ye-or ye-bu ye-or 202698-01…

• Page 201
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 202: Freeride 250 R Aus)

  WIRING DIAGRAM 29.10 Page 5 of 5 (Freeride 250 R AUS) wh-pu wh-pu wh-bl wh-bl 202699-01…

• Page 203
  WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow…

• Page 204: Substances

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

• Page 205
  SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) Standard/classification – SAE ( p. 215) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –…

• Page 206: Auxiliary Substances

  AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Twin Air Dirt Bio Remover Carburetor cleaner Recommended supplier Motorex ® – Carburetor Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ®…

• Page 207
  AUXILIARY SUBSTANCES Off-road chain spray Recommended supplier Motorex ® – Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ® – Twin Air Liquid Bio Power Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex…

• Page 208: Special Tools

  SPECIAL TOOLS Bleeder cover Art. no.: 00029013012 201608-10 Bleeder cover Art. no.: 00029013018 201965-10 Bleeding device Art. no.: 00029013100 201491-10 Spring hooks Art. no.: 50305017000 400363-01 Bleed syringe Art. no.: 50329050000 400058-01…

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

• Page 217: Standards

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

• Page 218: Index

  INDEX Carburetor — work on individual parts INDEX choke slide, checking ….. . . 151 float level, checking/adjusting ….153 Accessories .

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

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Инструкция KTM Freeride 250 R (2014) доступно в русский?

1. Manuals
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3. KTM Manuals
4. Motorcycle
5. Freeride 250 R EU
6. Owner’s manual

• Page 1
  OWNER’S MANUAL 2015 Freeride 250 R EU Freeride 250 R AU Freeride 250 R US Art. no. 3213185en…
• Page 3
  KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

• Page 4: Table Of Contents

  TABLE OF CONTENTS Speed, time, and DST distance 1 ….. 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ……..4 Speed, time, and DST2 distance 2 ….21 Symbols used ……….. 4 7.10 AVG average speed, ART operating hours, and Formats used………… 4 ODO total distance covered ……

• Page 5
  TABLE OF CONTENTS 12.20 Removing the air filter housing ….. 45 15.6 Removing the headlight mask with the headlight…………75 12.21 Installing the air filter housing …… 46 15.7 Refitting the headlight mask with the 12.22 Removing the air filter ………

• Page 6: Means Of Representation

  All work marked with 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 opti- mally cared for by specially trained experts using the specialist tools required.

• Page 7: Safety Advice

  SAFETY ADVICE Use definition — intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.

• Page 8: Safe Operation

  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.

• Page 9: Important Notes

  Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer’s Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

• Page 10: View Of Vehicle

  VIEW OF VEHICLE View of vehicle, front left (example) B02269-10 Speedometer Clutch lever ( p. 12) Filler cap Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 16) Fuel tap ( p. 15) Shift lever ( p.

• Page 11: View Of Vehicle, Rear Right (Example)

  VIEW OF VEHICLE View of vehicle, rear right (example) B02270-10 Kill switch ( p. 12) Horn button ( p. 12) Light switch ( p. 13) Turn signal switch ( p. 13) Electric starter button ( p. 13) Throttle grip ( p.

• Page 12: Serial Numbers

  SERIAL NUMBERS Chassis number  The chassis number is stamped on the right side of the steering head. 401946-10 Type label (EU/AU) The type label  is mounted on the frame at the front right. 402270-10 Key number  The key number for the steering lock is stamped onto the key connector.

• Page 13: Shock Absorber Part Number

  SERIAL NUMBERS Shock absorber part number  The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 0 0 1 401948-10…

• Page 14: Controls

  CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B02271-10 Hand brake lever The hand brake lever  is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

• Page 15: Light Switch

  CONTROLS Light switch  The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on –…

• Page 16: Overview Of Indicator Lamps (Eu/Au)

  CONTROLS 6.11 Overview of indicator lamps (EU/AU) Possible states High beam indicator light lights up blue – High beam is switched on. FI warning lamp (MIL) – inoperative Low fuel warning lamp – inoperative Turn signal indicator light flashes green – Turn signal is switched on. B02275-01 6.12 Overview of indicator lamps (US)

• Page 17: Closing The Filler Cap

  CONTROLS 6.14 Closing the filler cap Main work –  Replace the filler cap and turn clockwise until the release button locks in place. Info  Run the fuel tank breather hose without kinks. B01662-11 Finishing work – Lock the seat. ( p.

• Page 18: Foot Brake Lever

  CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.18 Foot brake lever Foot brake lever  is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.19 Side stand…

• Page 19: Locking The Steering

  CONTROLS 6.21 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –…

• Page 20: Speedometer

  Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized KTM workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary.

• Page 21: Setting Kilometers Or Miles

  SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –…

• Page 22: Setting The Clock

  SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –…

• Page 23: Speed, Time, And Dst Distance 1

  SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0.

• Page 24: Preparing For Use

  When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

• Page 25: Running In The Engine

  PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 280 kg (617 lb.) Maximum permissible front axle load 135 kg (298 lb.) Maximum permissible rear axle load 175 kg (386 lb.)

• Page 26: Riding Instructions

  RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 86) –…

• Page 27: Starting Off

  Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

• Page 28: Stopping, Parking

  RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.

• Page 29: Refueling

  – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

• Page 30: Service Schedule

  Check idle. ● Check that the radiator fan is functioning properly. ● Final check: Check the vehicle for roadworthiness and take a test ride. ● Make the service entry in KTM DEALER.NET and in the service record. ● Periodic interval…

• Page 31: Service Work (As Additional Order)

  SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 100 operating hours Every 50 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. p.

• Page 32: Tuning The Chassis

  Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

• Page 33: Adjusting The High-Speed Compression Damping Of The Shock Absorber

  Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

• Page 34: Measuring Rear Wheel Sag Unloaded

  TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover.

• Page 35: Checking The Riding Sag Of The Shock Absorber

  Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

• Page 36: Adjusting The Riding Sag

  TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 44) – Lock the seat. ( p. 45) – Remove the motorcycle from the lift stand. ( p. 37) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p.

• Page 37: Adjusting The Compression Damping Of The Fork

  TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. –  Remove protection caps –  Turn adjusting screws clockwise all the way. Info  Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

• Page 38: Adjusting The Handlebar Position

  TUNING THE CHASSIS 11.15 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. –  Remove screws . Remove the handlebar clamps. Take off the handlebar and lay it to one side.

• Page 39: Service Work On The Chassis

  SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) Neither wheel is in contact with the ground.

• Page 40: Cleaning The Dust Boots Of The Fork Legs

  SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) – Remove the fork protector. p. 39) Main work –  Push dust boots of both fork legs downward.

• Page 41: Installing The Fork Legs

  SERVICE WORK ON THE CHASSIS 12.6 Installing the fork legs Main work – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the upper edge of the upper triple clamp.  Position bleeder screws toward the front.

• Page 42: Installing The Fork Protector

  SERVICE WORK ON THE CHASSIS 12.8 Installing the fork protector –  Position the fork protection on the right fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B02281-11 –  Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

• Page 43: Installing The Lower Triple Clamp

  SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 103) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

• Page 44: Checking The Steering Head Bearing Play

  Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-…

• Page 45: Adjusting The Play Of The Steering Head Bearing

  SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing.

• Page 46: Removing The Shock Absorber

  SERVICE WORK ON THE CHASSIS 12.14 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) – Fold the seat up. ( p. 45) Main work –  Remove screw –  Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel.

• Page 47: Installing The Front Fender

  SERVICE WORK ON THE CHASSIS 12.17 Installing the front fender – Ensure that the spacers are mounted in the fender. –  Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the headlight mask.

• Page 48: Installing The Air Filter Housing

  SERVICE WORK ON THE CHASSIS Main work –  Pull air filter housing up and off. B01726-10 12.21 Installing the air filter housing Main work –  Mount air filter housing on the intake flange. Info If the air filter housing is not mounted correctly, dust and dirt may enter the engine and cause damage.

• Page 49: Cleaning The Air Filter And Air Filter Housing

  SERVICE WORK ON THE CHASSIS –  Insert both parts together and close air filter housing by turning clockwise. Info If the air filter is not mounted correctly, dust and dirt may enter the engine and cause damage. B01722-10 Finishing work –…

• Page 50: Installing The Main Silencer

  SERVICE WORK ON THE CHASSIS 12.26 Installing the main silencer –  Mount the main silencer with rubber sleeve –  Mount and tighten screws Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) B01720-10 12.27 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

• Page 51: Installing The Fuel Tank

  SERVICE WORK ON THE CHASSIS 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.

• Page 52: Checking For Chain Dirt Accumulation

  SERVICE WORK ON THE CHASSIS –  Mount and tighten screws on both sides. Guideline Screw, fuel tank 15 Nm Loctite ® 243™ (11.1 lbf ft) –  Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –…

• Page 53: Checking The Chain Tension

  SERVICE WORK ON THE CHASSIS 12.32 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

• Page 54: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

  SERVICE WORK ON THE CHASSIS Info The wide adjustment range of the chain adjusters enables different sec- ondary ratios with the same chain length. Chain adjusters  can be turned by 180°. Finishing work – Remove the motorcycle from the lift stand. ( p.

• Page 55: Checking The Frame

  If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. B01723-10…

• Page 56: Checking The Swingarm

  If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 401463-01 12.37 Checking the throttle cable routing Preparatory work –…

• Page 57: Additionally Securing The Rubber Grip

  SERVICE WORK ON THE CHASSIS 12.39 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 54) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip.

• Page 58: Changing The Hydraulic Clutch Fluid

  SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilt brake fluid immediately with water. 12.43 Changing the hydraulic clutch fluid 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 59: Removing The Engine Guard

  SERVICE WORK ON THE CHASSIS 12.44 Removing the engine guard –   Remove screws – Lower the engine guard at the rear and remove it toward the front. B01706-10 12.45 Installing the engine guard –  Position the engine guard on the frame at the front and mount screws but do not tighten yet.

• Page 60: Brake System

  Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk …

• Page 61: Checking The Brake Fluid Level Of The Front Brake

  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.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

• Page 62: Checking The Front Brake Linings

  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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

• Page 63
  BRAKE SYSTEM 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 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.

• Page 64: Checking The Free Travel Of Foot Brake Lever

  BRAKE SYSTEM – Remove the fixation of the hand brake lever. –  Add brake fluid to level Guideline 5 mm (0.2 in) Level  (brake fluid level below con- tainer rim) Brake fluid DOT 4 / DOT 5.1 ( p.

• Page 65: Checking The Rear Brake Fluid Level

  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.) – Stand the vehicle upright.

• Page 66: Checking The Rear Brake Linings

  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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

• Page 67
  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
• Page 68
  BRAKE SYSTEM –  Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 101) –  Mount the cover with membrane –  Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water. B01692-10…

• Page 69: Wheels, Tires

  WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work –  Loosen screw by several rotations. – Release screws  –  Press on screw to push the wheel spindle on the axle clamp. –…

• Page 70: Removing The Rear Wheel

  WHEELS, TIRES – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. –  Tighten screw Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 14.3 Removing the rear wheel Preparatory work –…

• Page 71: Checking The Tire Condition

  Checking the 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 major impact on the handling characteristics of the motorcycle.

• Page 72: Checking The Tire Air Pressure

  Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.

• Page 73: Electrical System

  ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms. Preparatory work – Raise the motorcycle with the lift stand.

• Page 74: Recharging The Battery

  – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 75: Changing The Main Fuse

  ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly when the 3 months motorcycle is not in use Finishing work – Install the battery. p. 71) – Install the shock absorber. p.

• Page 76: Changing The Fuses Of Individual Power Consumers

  ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Fold the seat up.

• Page 77: Removing The Headlight Mask With The Headlight

  ELECTRICAL SYSTEM 15.6 Removing the headlight mask with the headlight – Switch off all power consumers and switch off the engine. –  Detach the brake line and wiring harness –  Release rubber band . Slide the headlight mask up and swing it forward. B01681-10 –…

• Page 78: Changing The Headlight Bulb

  ELECTRICAL SYSTEM –  Position the headlight mask and fix it with the rubber band Info Make sure that the holding lugs engage in the fender. –  Position the brake line and wiring harness B01041-11 Finishing work – Check the headlight setting. ( p.

• Page 79: Changing The Turn Signal Bulb

  ELECTRICAL SYSTEM 15.9 Changing the turn signal 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. Main work –…

• Page 80: Changing The Speedometer Battery

  ELECTRICAL SYSTEM Info Turn clockwise to increase the headlight range, turn counterclockwise to reduce the headlight range. A change in weight on the vehicle may require a correction of the headlight range. 15.12 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight.

• Page 81: Cooling System

  COOLING SYSTEM 16.1 Cooling system  Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve  in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

• Page 82: Checking The Coolant Level

  COOLING SYSTEM 16.3 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 system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 83: Refilling Coolant

  COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately.

• Page 84: Tuning The Engine

  TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and  forth slightly and determine the play in throttle cable Throttle cable play 2……

• Page 85: Carburetor — Idle

  TUNING THE ENGINE 17.3 Carburetor — idle The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. Info The carburetor and its components are subject to increased wear caused by engine vibration.

• Page 86: Emptying The Carburetor Float Chamber

  TUNING THE ENGINE Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 15) Idle speed 1,400… 1,500 rpm –  Turn idle air adjusting screw slowly clockwise until the idle speed starts to drop.

• Page 87: Checking The Basic Position Of The Shift Lever

  TUNING THE ENGINE 17.6 Checking the basic position of the shift lever –  Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10……

• Page 88: Service Work On The Engine

  SERVICE WORK ON THE ENGINE 18.1 Cleaning the alternator –  Remove screws – Take off the cover. B01730-10 –  Remove screws –  Take off the alternator cover B01895-10 –  Clean alternator cover and rotor –  Take off Bendix and clean.

• Page 89: Changing The Gear Oil

  SERVICE WORK ON THE ENGINE 18.3 Changing the gear oil – Drain the gear oil. p. 87) 400721-01 – Fill in gear oil. p. 88) 400722-01 18.4 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –…

• Page 90: Filling In Gear Oil

  SERVICE WORK ON THE ENGINE 18.5 Filling in gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Main work –  Remove screw cap and fill in gear oil. Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p.

• Page 91: Cleaning, Care

  CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

• Page 92: Checks And Maintenance Steps For Winter Operation

  CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

• Page 93: Storage

  – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 37) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

• Page 94: Troubleshooting

  TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 24) tric starter) – Battery is discharged Check the charging voltage. – Check the open-circuit current. – Check the alternator. –…

• Page 95
  TROUBLESHOOTING Faults Possible cause Action – Engine overheats Too little air stream Switch off the engine when standing. – Radiator fins very dirty Clean the radiator fins. – Foam formation in cooling system Drain the coolant. p. 80) – Refill the coolant. p.

• Page 96: Technical Data

  TECHNICAL DATA 22.1 Engine Design 1-cylinder 2-stroke gasoline engine, water-cooled, with mem- brane inlet Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Bore 66.4 mm (2.614 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing…

• Page 97: Capacities

  TECHNICAL DATA – Nut, cylinder base 35 Nm (25.8 lbf ft) – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –…

• Page 98: Electrical System

  Front tires Rear tires 2.75 — 21 M/C 45M TT 4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 05.18.7N.42 WP Suspension 4357 MXMA fork…

• Page 99: Shock Absorber

  TECHNICAL DATA Fork length 835 mm (32.87 in) Air chamber length mm (4.72 +0.39 −40 −1.57 Fork oil per fork leg 390 ml (13.19 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 101) 22.8 Shock absorber Shock absorber part number 15.18.7N.42 WP Suspension 4618 PDS DCC Shock absorber…

• Page 100
  TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw of rear brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ – Screw, bottom triple clamp 18 Nm (13.3 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) –…

• Page 101: Carburetor

  TECHNICAL DATA 22.10 Carburetor 22.10.1 EU/AU Carburetor type KEIHIN PWK 28 Carburetor identification number Needle position 2nd position from top Jet needle JJH (JJG) Main jet 110 (120/122/125) Idling jet 40 (45/48) Idle air adjusting screw Open 2.0 rotations Throttle slide Slide stop Present 22.10.2 US…

• Page 102
  TECHNICAL DATA 401798-01 M/FT ASL Sea level TEMP Temperature Open idle air adjusting screw Idling jet Needle Needle position from top Main jet Does not apply on sandy terrain.

• Page 103: Substances

  SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®…

• Page 104
  SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 105) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –…

• Page 105: Auxiliary Substances

  Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ® – Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE…

• Page 106
  AUXILIARY SUBSTANCES 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 107: Standards

  STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

• Page 108: Index

  INDEX Clutch INDEX fluid level, checking ……55 Accessories ……..7 fluid level, correcting .

• Page 109
  INDEX Front fender Motorcycle installing ……. . . 45 cleaning ……. . . 89 removing .
• Page 110
  INDEX Spoke tension checking ……. . . 70 Starting ……..24 Steering locking .
• Page 111
  *3213185en* 3213185en 08/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com…