KTM Freeride 250 R EU - Repair Manual

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REPAIR MANUAL 2014

Freeride 250 R EU

Freeride 250 R AUS

Art. no. 3206188en

Main Page

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Repair Manual8
- Degrees of Risk and Symbols8
- Work Rules8
3 Important Notes9
- Guarantee, Warranty9
- Operating and Auxiliary Substances9
- Spare Parts, Accessories9
- Figures9
4 Serial Numbers10
- Chassis Number10
- Type Label10
- Key Number10
- Engine Number10
- Fork Part Number10
- Shock Absorber Part Number11
5 Motorcycle12
- Raising the Motorcycle with the Lift Stand12
- Removing the Motorcycle from the Lift Stand12
- Starting12
- Starting the Motorcycle to Make Checks13
6 Fork, Triple Clamp14
- Adjusting the Compression Damping of the Fork14
- Adjusting the Rebound Damping of the Fork14
- Bleeding the Fork Legs14
- Cleaning the Dust Boots of the Fork Legs15
- Removing the Fork Protector15
- Installing the Fork Protector15
- Removing the Fork Legs16
- Installing the Fork Legs16
- Performing a Fork Service17
- Disassembling the Fork Legs17
- Disassembling the Cartridge20
- Disassembling the Compression Holder22
- Checking the Fork Legs22
- Assembling the Compression Holder24
- Assembling the Cartridge24
- Assembling the Fork Legs26
- Greasing the Steering Head Bearing30
- Removing the Lower Triple Clamp30
- Installing the Lower Triple Clamp31
- Checking the Steering Head Bearing Play32
- Adjusting the Play of the Steering Head Bearing33
7 Handlebar, Controls34
- Handlebar Position34
- Adjusting the Handlebar Position34
- Adjusting the Basic Position of the Clutch Lever34
- Checking the Throttle Cable Routing35
- Checking the Play in the Throttle Cable35
- Adjusting the Play in the Throttle Cable36
8 Frame37
- Removing the Engine Guard37
- Installing the Engine Guard37
9 Shock Absorber, Swingarm38
- Adjusting the High-Speed Compression Damping of the Shock Absorber38
- Adjusting the Low-Speed Compression Damping of the Shock Absorber38
- Adjusting the Rebound Damping of the Shock Absorber39
- Measuring Rear Wheel Sag Unloaded39
- Checking the Static Sag of the Shock Absorber40
- Checking the Riding Sag of the Shock Absorber40
- Adjusting the Spring Preload of the Shock Absorber40
- Adjusting the Riding Sag41
- Removing the Shock Absorber42
- Installing the Shock Absorber42
- Servicing the Shock Absorber42
- Removing the Spring43
- Disassembling the Damper43
- Disassembling the Piston Rod44
- Disassembling the Seal Ring Retainer46
- Replacing the Pilot Bushing46
- Checking the Damper47
- Removing the Heim Joint48
- Installing the Heim Joint49
- Assembling the Seal Ring Retainer50
- Assembling the Piston Rod50
- Assembling the Damper52
- Bleeding and Filling the Damper54
- Filling the Damper with Nitrogen56
- Installing the Spring57
10 Exhaust59
- Removing the Main Silencer59
- Installing the Main Silencer59
- Changing the Glass Fiber Yarn Filling of the Main Silencer59
11 Air Filter61
- Removing the Air Filter Housing61
- Installing the Air Filter Housing61
- Removing the Air Filter61
- Installing the Air Filter62
- Cleaning the Air Filter and Air Filter Housing62
12 Fuel Tank, Seat, Trim63
- Opening the Filler Cap63
- Refueling63
- Closing the Filler Cap64
- Folding the Seat up64
- Locking the Seat64
- Removing the Seat65
- Mounting the Seat65
- Taking off the Spoiler65
- Mounting the Spoiler66
- Removing the Fuel Tank67
- Installing the Fuel Tank67
- Fuel Tap68
13 Mask, Fender69
- Removing the Front Fender69
- Installing the Front Fender69
- Removing the Headlight Mask with the Headlight69
- Refitting the Headlight Mask with the Headlight70
14 Wheels71
- Checking the Tire Air Pressure71
- Checking the Tire Condition71
- Checking the Brake Discs72
- Checking the Spoke Tension72
- Front Wheel73
- Removing the Front Wheel73
- Installing the Front Wheel73
- Removing the Brake Disc of the Front Brake74
- Installing the Brake Disc of the Front Brake74
- Rear Wheel74
- Removing the Rear Wheel74
- Installing the Rear Wheel75
- Removing the Brake Disc of the Rear Brake76
- Installing the Brake Disc of the Rear Brake76
- Checking the Chain Tension77
- Adjusting the Chain Tension77
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide78
- Checking for Chain Dirt Accumulation79
- Cleaning the Chain79
15 Wiring Harness, Battery81
- Changing the Main Fuse81
- Changing the Fuses of Individual Power Consumers81
- Removing the Battery82
- Installing the Battery83
- Recharging the Battery83
- Checking the Charging Voltage84
- Checking the Quiescent Current85
- Checking the Starter Relay85
16 Brake System86
- Checking the Front Brake Linings86
- Changing the Front Brake Linings86
- Checking the Free Travel of the Hand Brake Lever88
- Adjusting the Free Travel of the Handbrake Lever88
- Checking the Brake Fluid Level of the Front Brake88
- Adding Front Brake Fluid89
- Changing the Front Brake Fluid89
- Checking the Rear Brake Linings91
- Changing the Rear Brake Linings91
- Checking the Free Travel of Foot Brake Lever93
- Adjusting the Basic Position of the Foot Brake Lever93
- Checking the Rear Brake Fluid Level93
- Adding Rear Brake Fluid94
- Changing the Rear Brake Fluid95
17 Lighting System, Instruments97
- Setting the Speedometer97
- Setting Kilometers or Miles98
- Setting the Clock98
- Setting the Wheel Circumference98
- Setting the Service Display99
- Checking the Headlight Setting99
- Adjusting the Headlight Range100
- Changing the Turn Signal Bulb100
- Changing the Headlight Bulb100
- Changing the Speedometer Battery101
18 30/Engine103
- 30/Engine103
- Removing the Engine103
- Installing the Engine106
- Engine Disassembly110
- Clamping the Engine into the Engine Work Stand110
- Draining the Gear Oil111
- Removing the Clutch Push Rod111
- Removing the Shift Lever111
- Removing the Spacer111
- Removing the Starter Motor112
- Removing the Cylinder Head113
- Removing the Cylinder114
- Removing the Piston114
- Removing the Water Pump Cover115
- Removing the Clutch Cover115
- Removing the Clutch Discs115
- Removing the Clutch Basket116
- Removing the Shift Shaft117
- Removing the Shift Drum Locating Unit117
- Removing the Locking Lever117
- Removing the Rotor117
- Removing the Reed Valve Housing118
- Removing the Left Engine Case Section118
- Removing the Shift Rails119
- Removing the Shift Drum119
- Removing the Shift Forks119
- Removing the Transmission Shafts119
- Removing the Crankshaft119
- Work on Individual Parts120
- Work on the Right Section of the Engine Case120
- Work on the Left Section of the Engine Case121
- Removing the Crankshaft Bearing Inner Race121
- Installing the Crankshaft Bearing Inner Race122
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin122
- Checking the Crankshaft Run-Out at the Bearing Pin123
- Checking/Measuring the Cylinder123
- Cylinder - Nikasil ® Coating124
- Checking/Measuring the Piston124
- Checking the Piston Ring End Gap125
- Piston/Cylinder - Measuring the Mounting Clearance125
- Checking the Reed Valve Housing, Reed Valve, and Intake Flange125
- Work on the Clutch Cover126
- Checking the Clutch127
- Preassembling the Shift Shaft128
- Checking the Shift Mechanism129
- Disassembling the Main Shaft130
- Disassembling the Countershaft131
- Checking the Transmission131
- Assembling the Main Shaft132
- Assembling the Countershaft133
- Checking the Electric Starter Drive135
- Engine Assembly136
- Installing the Crankshaft136
- Installing the Transmission Shafts136
  - Installing the Shift Forks137
  - Installing the Shift Drum137
  - Installing the Shift Rails137
  - Installing the Left Engine Case Section137
  - Installing the Reed Valve Housing138
  - Installing the Rotor138
  - Installing the Locking Lever139
  - Installing the Shift Drum Locating Unit139
  - Installing the Shift Shaft139
  - Installing the Clutch Basket139
  - Installing the Clutch Discs140
  - Installing the Clutch Cover141
  - Installing the Water Pump Cover141
  - Installing the Piston142
  - Installing the Cylinder142
  - Checking the X-Distance143
  - Adjusting the X-Distance143
  - Installing the Cylinder Head144
  - Installing the Starter Motor144
  - Installing the Spacer146
  - Installing the Shift Lever146
  - Installing the Clutch Push Rod147
  - Installing the Gear Oil Drain Plug147
  - Removing the Engine from the Work Stand147
19 Carburetor148
- Choke148
- Carburetor - Adjusting Idle148
- Emptying the Carburetor Float Chamber149
- Removing the Carburetor149
- Installing the Carburetor150
- Checking/Setting the Carburetor Components151
- Disassembling the Carburetor151
- Checking the Choke Slide153
- Checking the Jet Needle153
- Checking the Throttle Slide153
- Checking the Float Needle Valve154
- Assembling the Carburetor154
- Checking/Adjusting the Float Level155
20 Clutch157
- Checking Fluid Level of the Hydraulic Clutch157
- Correcting the Fluid Level of the Hydraulic Clutch157
- Changing the Hydraulic Clutch Fluid157
21 Water Pump, Cooling System159
- Checking the Antifreeze and Coolant Level159
- Checking the Coolant Level159
- Draining the Coolant160
- Refilling Coolant160
22 Lubrication System162
- Changing the Gear Oil162
- Draining the Gear Oil162
- Filling in Gear Oil163
- Checking the Gear Oil Level163
- Adding Gear Oil163
23 Ignition System165
- Checking the Ignition System165
- Ignition Coil - Checking the Primary Winding166
- Ignition Coil - Checking the Secondary Winding166
- Checking the Spark Plug Connector167
- Alternator - Checking the Charging Coil of the Ignition167
- Alternator - Checking the Battery Winding167
- Alternator - Checking the Light Winding168
- Checking the Ignition Pulse Generator168
- Removing the Stator and Crankshaft Position Sensor169
- Installing the Stator and Crankshaft Position Sensor169
- Cleaning the Alternator170
24 Electric Starter171
- Checking the Starter Motor171
25 Technical Data172
- Engine172
- Engine Tolerance, Wear Limits172
- Engine Tightening Torques173
- Capacities173
- Gear Oil173
- Coolant173
- Fuel173
- Chassis174
- Electrical System174
- Tires175
- Fork175
- Shock Absorber175
- Chassis Tightening Torques176
- Carburetor177
- Carburetor Tuning178
26 Cleaning, Care179
- Cleaning the Motorcycle179
- Checks and Maintenance Steps for Winter Operation180
27 Storage181
- Preparing for Use after Storage181
28 Service Schedule182
- Service Work (as Additional Order)183
29 Wiring Diagram184
- Freeride 250 R EU)184
- Freeride 250 R EU)186
- Freeride 250 R EU)188
- Freeride 250 R EU)190
- Freeride 250 R EU)192
- Freeride 250 R AUS)194
- Freeride 250 R AUS)196
- Freeride 250 R AUS)198
- Freeride 250 R AUS)200
- Freeride 250 R AUS)202
30 Substances204
31 Auxiliary Substances206
32 Special Tools208
33 Standards217
- Index218

KTM Freeride 250 R EU - Repair Manual

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