KTM Freeride 250 F Handbuch

SETUP INSTRUCTIONS 2018

Freeride 250 F

Art. no. 3213743en

INTRODUCTION

*3213743en*

3213743en

08/2017

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make

changes in the interest of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop

are not specified here. It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete

technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice

and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular

model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descrip-

tions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to

the regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assur-

ance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

Freeride 250 F EU (F8103R4)

1 MEANS OF REPRESENTATION

1.1 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.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

SETUP 2

2.1 Unpacking and setting up the vehicle

Condition

Packaging V2

–Unpack and set up the V2 vehicle. ( p. 4)

–Remove V2 headlight mask. ( p. 4)

Condition

Packaging V12

–Unpack and set up the V12 vehicle. ( p. 5)

–Install V12 fork legs. ( p. 5)

–Install V12 shock absorber. ( p. 6)

–Install C12 combination instrument. ( p. 6)

–Stick on the reflector. ( p. 7)

–Install handlebars. ( p. 7)

–Install the handlebar cushion. ( p. 8)

–Install left side controls. ( p. 8)

–Install right side controls. ( p. 10)

–Install left and right rear mirrors. ( p. 11)

–Install left and right hand guards. ( p. 11)

–Install front fender. ( p. 12)

–Install the front wheel. ( p. 12)

–Install the front and rear turn signals. ( p. 13)

–Install the license plate lamp. ( p. 14)

–Install the reflector. ( p. 14)

–Route the front turn signal cable. ( p. 14)

–Route the rear turn signal cable. ( p. 15)

–Install the license plate holder extension. ( p. 18)

–Remove the motorcycle from the lift stand. ( p. 19)

–Install the engine guard. ( p. 19)

–Install the footrests. ( p. 19)

–Recharge the battery. ( p. 20)

–Install the headlight mask with the headlight. ( p. 22)

–Check the headlight setting. ( p. 23)

–Adjust the combination instrument. ( p. 23)

–Adjust kilometers or miles. ( p. 24)

–Adjust the clock. ( p. 25)

–Refuel. ( p. 25)

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts fitting instructions.

–Remove remaining protective film.

–Attach the sticker included in the delivery (optional).

–Prepare the vehicle according to the specifications in the KTM Dealer.net for handover to the customer.

Info

Transport mode must be deactivated to be able to start the motorcycle.

3 SERVICE WORK ON THE CHASSIS

3.1 Unpacking and setting up the V2 vehicle

E00851-10

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup,

leave the protective film on the vehicle until you have

finished.

–Remove and unpack the separate enclosure and attachments.

Check that the scope of supply is complete using the enclosed

packing list.

–Have a lift stand available.

Lift stand (78929955100)

–Carefully loosen and remove the tension belt of the footrest

mount.

Info

An assistant prevents the motorcycle from falling over.

402050-01

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

3.2 Removing V2 headlight mask

F01233-10

–Remove the spare key and KEYCODECARD and keep in a safe

place for the handover.

–Loosen rubber band 1and tilt headlight mask forwards.

E00971-10

–Disconnect the plug-in connector 2of the headlight and the

plug-in connector 3of the ignition lock.

–Lay down the headlight mask carefully to the side and protect

from damage.

SERVICE WORK ON THE CHASSIS 3

3.3 Unpacking and setting up the V12 vehicle

E00850-10

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup,

leave the protective film on the vehicle until you have

finished.

–Remove and unpack the separate enclosure and attachments.

Check that the scope of supply is complete using the enclosed

packing list.

–Remove the spare key and KEYCODECARD and keep in a safe

place for the handover.

–Have a lift stand available.

Lift stand (78929955100)

–Remove the two cable ties on the triple clamp.

402051-01

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle and attachments for transport damage.

3.4 Installing V12 fork legs

402556-10

–Position the fork legs.

Bleeder screws 1are positioned toward the front.

Info

Grooves are milled into the side of the upper end of the

fork legs. The second milled groove (from the top) must

be flush with the upper edge of the upper triple clamp.

E00974-10

–Tighten screws 2.

Guideline

Screw, top triple

clamp

M8 22 Nm (16.2 lbf ft)

–Tighten screws 3.

Guideline

Screw, bottom triple

clamp

M8 18 Nm (13.3 lbf ft)

3 SERVICE WORK ON THE CHASSIS

F01200-10

–Position the brake caliper. Mount and tighten screws 4with

the spacers.

Guideline

Screw, front

brake caliper

M8 25 Nm (18.4 lbf ft)

Loctite®243™

–Connect plug-in connector 5and mount the cable tie(s).

–Position the brake line, wiring harness, and clamp. Mount and

tighten screws 6.

3.5 Installing V12 shock absorber

F01209-11

–Push splash protector 1to the side and position the shock

absorber. Mount and tighten screw 2.

Guideline

Screw, top

shock absorber

M12 80 Nm (59 lbf ft)

Loctite®2701™

–Mount and tighten screw 3.

Guideline

Screw, bottom

shock absorber

M12 80 Nm (59 lbf ft)

Loctite®2701™

Info

The heim joint for the shock absorber at the swingarm

is Teflon-coated. It must not be greased with grease,

nor with any other lubricants. Lubricants dissolve the

Teflon coating, thereby drastically reducing the service

life.

–Mount and tighten screw 4.

Guideline

Screw, upper

subframe

M10 45 Nm (33.2 lbf ft)

Loctite®243™

–Attach brake line 5.

3.6 Installing V12 combination instrument

H02569-10

–Position the connector retainer and speedometer on the upper

triple clamp.

–Mount and tighten screws 1.

Guideline

Remaining screws,

chassis

M6 10 Nm (7.4 lbf ft)

–Route the clutch line with the clutch master cylinder toward

the front between the upper and lower triple clamps.

SERVICE WORK ON THE CHASSIS 3

3.7 Sticking on the reflector

F01234-01

–Make sure that the reflectors are glued on to the left and right

fork leg.

» If there are no reflectors stuck on:

–Stick on the reflector.

Info

The reflectors must not be covered by trim

parts.

3.8 Installing handlebars

F01235-10

–Remove screws 1. Take off the handlebar supports.

–Place the handlebar supports in the required position. Mount

and tighten screws 1.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

E00957-10

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the handlebar is bent or straightened, the mate-

rial becomes fatigued. The handlebar may break as a

result.

–Change the handlebar if the handlebar is damaged

or bent.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount and tighten the screws

evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

3 SERVICE WORK ON THE CHASSIS

Info

The handlebar clamps and screws are in the accessory

pack.

The markings on the handlebar should be at the center

of the handlebar clamps.

Keep the gap widths equal when tightening.

3.9 Installing the handlebar cushion

E00958-10

–Secure the handlebar cushion with two cable ties.

3.10 Installing left side controls

402148-01

–Mount turn signal switch and route cable to the front.

E00959-01

–Position the controls on the left half of the handlebar.

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