KTM Freeride 250 R EU 2014 Handbuch

SETUP INSTRUCTIONS 2014

Freeride 250 R EU

Freeride 250 R AUS

Art. no. 3213149en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

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

est 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 AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial 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 assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2

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.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

2 SAFETY ADVICE 3

2.1 Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-

theses. E.g.: bearing puller (15112017000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be

replaced by new parts.

In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After you complete the repair or service work, check the operating safety of the vehicle.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety

instructions are highlighted in the text and are referred to at the relevant passages.

Info

The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If

they are missing, you or others may not recognize dangers and may therefore be injured.

2.3 Degrees of risk and symbols

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures

are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Note

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

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Operating and auxiliary substances

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.

3 SETUP 4

3.1 Unpacking and setting up the vehicle

B01160-01

Packaging 2

–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 the separate enclosure and unpack it. Check that the scope of supply

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Carefully loosen and remove the tension belt of the footrest bracket.

Info

An assistant prevents the motorcycle from falling over.

402050-01

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

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

B01161-01

Package 12

–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 the separate enclosure and unpack it. Check that the scope of supply

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

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

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

402051-01

–Install the shock absorber. ( p. 8)

3 SETUP 5

B01997-01

–Route the clutch line with the clutch master cylinder toward the front between

the upper and lower triple clamps.

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp M8 22 Nm

(16.2 lbf ft)

Screw, bottom triple clamp M8 18 Nm

(13.3 lbf ft)

Info

The upper milled groove in the fork leg must be flush with the upper

edge of the upper triple clamp.

Position the bleeder screws toward the front.

B01036-10

–Remove screws . Remove the handlebar clamps.

–Remove screws . Take off the handlebar supports.

–Move the handlebar supports into the desired position. Mount and tighten

screws .

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

B01164-01

–Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

–Position the handlebar clamps. Mount and tighten the screws evenly.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

The markings on the handlebar should be at the center of the handlebar

clamps.

Keep the gap widths equal when tightening.

–Install the front wheel. ( p. 9)

–Mount the handlebar cushion.

B01998-01

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

Info

The routing of the cables can be seen in the figure.

B01999-01

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

Info

The figure shows how to route the clutch line and wiring harness.

3 SETUP 6

B02005-10

–Mount the holder for the turn signal indicator lamp, connector retainer, and

speedometer on the upper triple clamp.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–Position the turn signal indicator lamp .

–Connect all plug-in connectors with the connector retainer.

B02000-10

–Remove the fuel tank. ( p. 10)

–Disconnect the plug-in connector from the main wiring harness.

–Connect the plug-in connector of the turn signal wiring harness with the plug-in

connector of the main wiring harness.

–Mount the turn signal relay with the retaining bracket and plug in the connec-

tor.

B02006-01

–Position the turn signal wiring harness against the main wiring harness and secure

with cable binders.

Info

The routing of the wiring harness is shown in the figure.

–Install the fuel tank. ( p. 11)

401382-01

–Mount the turn signal switch and connect the plug-in connector with the wiring har-

ness.

B02001-10

–Insert the black and violet cables of bulb included in the separate enclosure into

the socket and position it in the turn signal indicator lamp.

–Position the turn signal on each side and mount and tighten nuts .

–Connect the plug-in connector of the right turn signal with the connector

marked green on the wiring harness.

–Connect the plug-in connector of the left turn signal with the connector marked

red on the wiring harness.

–Install the front fender. ( p. 14)

–Refit the headlight mask with the headlight. ( p. 15)

3 SETUP 7

800042-10

–Mount the footrests with the springs and pins. Secure the pins using the washers

and cotter pins.

Pliers for footrest spring (58429083000)

B02002-01

–Mount the license plate holder with the license plate lamp, turn signals, and reflec-

tor.

–Connect the electrical components.

–Connect the plug-in connector of the right turn signal with the connector marked

green on the wiring harness.

–Connect the plug-in connector of the left turn signal with the connector marked red

on the wiring harness.

B02004-01

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in

well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If battery

acid gets in the eyes, rinse with water for at least 15 minutes and con-

tact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 12)

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

Info

Read the accompanying KTM PowerParts fitting instructions.

–Apply the label included in the delivery (optional).

B01172-01

–Mount the mirror clamps on both sides.

B02003-01

–Mount and tighten the rear mirror on both sides.

–Position all controls in their exact positions on the handlebar. Tighten all screws.

–Refuel. ( p. 17)

–Print out the current PDI form found on KTM DEALER.NET and perform the

pre-delivery inspection.

4 SERVICE WORK ON THE CHASSIS 8

4.1 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.

B01729-01

–Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

The wheels must no longer touch the ground.

–Secure the motorcycle against falling over.

4.2 Removing the motorcycle from 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.

B01666-10

–Remove the motorcycle from the lift stand.

–Remove the lift stand.

–To park the motorcycle, press side stand to the ground with your foot and lean

the motorcycle on it.

Info

When you are riding, the side stand must be folded up and secured with the

rubber band.

4.3 Removing the shock absorber

Preparatory work

–Raise the motorcycle with the lift stand. ( p. 8)

–Fold the seat up. ( p. 10)

B01727-10

Main work

–Remove screw .

–Remove screw and lower the rear wheel with the swing arm as far as possible

without blocking the rear wheel. Fix the rear wheel in this position.

–Remove screw .

–Push splash protector to the side and remove the shock absorber.

4.4 Installing the shock absorber

B01727-11

Main work

–Push splash protector to the side and position the shock absorber. Mount and

tighten screw .

Guideline

Screw, top shock absorber M12 80 Nm

(59 lbf ft)

Loctite®243™

–Mount and tighten screw .

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