SETUP INSTRUCTIONS 2014 Freeride 250 R EU

SETUP INSTRUCTIONS 2014 Freeride 250 R EU
SETUP INSTRUCTIONS 2014
Freeride 250 R EU
Freeride 250 R AUS
Art. no. 3213149en
INTRODUCTION
1
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
INTRODUCTION
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 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 AG 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 descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2014 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
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
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
2
SAFETY ADVICE
2.1
Work rules
3
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. 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
3.1
Unpacking and setting up the vehicle
4
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.
B01160-01
–
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.
–
Together with an assistant, take the vehicle off the palette.
–
Position the vehicle on a lift stand.
–
Check the vehicle for transport damage.
402050-01
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.
B01161-01
–
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)
402051-01
–
Together with an assistant, take the vehicle off the palette.
–
Position the vehicle on a lift stand.
–
Check the vehicle for transport damage.
–
Install the shock absorber. (
p. 8)
3
SETUP
5
–
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)
B01997-01
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.
–
0
–
–
. Remove the handlebar clamps.
Remove screws . Take off the handlebar supports.
Remove screws
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
B01036-10
Position the left and right handlebar supports evenly.
–
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)
B01164-01
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. (
–
Mount the handlebar cushion.
–
Position the controls on the right half of the handlebar.
p. 9)
Info
The routing of the cables can be seen in the figure.
B01998-01
–
Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
B01999-01
3
SETUP
6
–
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.
–
Remove the fuel tank. (
–
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
tor.
–
Position the turn signal wiring harness against the main wiring harness and secure
with cable binders.
.
B02005-10
p. 10)
 with the retaining bracket and plug in the connec-
B02000-10
Info
The routing of the wiring harness is shown in the figure.
–
Install the fuel tank. (
–
Mount the turn signal switch and connect the plug-in connector with the wiring harness.
–
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
red on the wiring harness.
–
Install the front fender. (
–
Refit the headlight mask with the headlight. (
p. 11)
B02006-01
401382-01
B02001-10
.

 of the left turn signal with the connector marked
p. 14)
p. 15)
3
SETUP
7
–
Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers for footrest spring (58429083000)
800042-10
–
Mount the license plate holder with the license plate lamp, turn signals, and reflector.
–
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.
B02002-01
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
B02004-01
–
–
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 contact a physician.
Fill the battery.
Info
Read the notes in the battery package.
–
Recharge the battery. (
–
Unpack and mount the KTM PowerParts included in the delivery (optional).
p. 12)
Info
Read the accompanying KTM PowerParts fitting instructions.
–
Apply the label included in the delivery (optional).
–
Mount the mirror clamps on both sides.
–
Mount and tighten the rear mirror on both sides.
–
Position all controls in their exact positions on the handlebar. Tighten all screws.
–
Refuel. (
–
Print out the current PDI form found on KTM DEALER.NET and perform the
pre-delivery inspection.
B01172-01
B02003-01
p. 17)
4
SERVICE WORK ON THE CHASSIS
4.1
Raising the motorcycle with the lift stand
8
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)
The wheels must no longer touch the ground.
–
Secure the motorcycle against falling over.
B01729-01
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.
–
Remove the motorcycle from the lift stand.
–
Remove the lift stand.
–
To park the motorcycle, press side stand
the motorcycle on it.
 to the ground with your foot and lean
Info
When you are riding, the side stand must be folded up and secured with the
rubber band.
B01666-10
4.3
Removing the shock absorber
Preparatory work
– Raise the motorcycle with the lift stand. (
–
Fold the seat up. (
p. 8)
p. 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.
B01727-10
4.4
Installing the shock absorber
Main work
– Push splash protector
tighten screw
.
 to the side and position the shock absorber. Mount and

Guideline
Screw, top shock absorber
–
B01727-11
Mount and tighten screw
.
M12
80 Nm
(59 lbf ft)
Loctite® 243™
4
SERVICE WORK ON THE CHASSIS
9
Guideline
Screw, bottom shock
absorber
M12
80 Nm
(59 lbf ft)
Loctite® 243™
Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.
–
Mount and tighten screw
.
Guideline
Screw, upper subframe
Finishing work
– Lock the seat. (
–
4.5
M10
45 Nm
(33.2 lbf ft)
Loctite® 243™
p. 10)
Remove the motorcycle from the lift stand. (
p. 8)
Installing the front wheel
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.
–
Check the wheel bearing for damage and wear.
»
If the wheel bearing is damaged or worn:
–
–
Change the wheel bearing.
Clean and grease the shaft seal rings
Long-life grease (
 and contact surface  of the spacers.
p. 20)
–
Insert the spacers.
–
Position the front wheel and insert the wheel spindle.
B01046-11
The brake linings are correctly positioned.
–
Mount and tighten screw
.
Guideline
Screw, front wheel spindle
B01044-11
M20x1.5
35 Nm
(25.8 lbf ft)
–
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. (
–
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–
Tighten screw
p. 8)
.
Guideline
Screw, fork stub
M8
15 Nm
(11.1 lbf ft)
4
SERVICE WORK ON THE CHASSIS
4.6
Folding the seat up
–
Press release lever
–
Lift the seat and fold it up.
–
Fold down the seat and push it down.
10
.
B01021-10
4.7
Locking the seat
The seat engages with an audible click.
–
Finally, check that the seat is correctly locked.
B01022-10
4.8
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.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
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. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Preparatory work
– Fold the seat up. (
Main work
– Turn handle
–
p. 10)
 of the fuel tap to the OFF position.
Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
4
SERVICE WORK ON THE CHASSIS
11
–
Remove the tube from the fuel tank breather.
–
Remove screws
–
 on both sides.
Remove screw .
–
Release hose clamp
–
Detach the intake flange from the carburetor.
–
Remove the fuel tank from above.
B01717-10
.
B01718-10
4.9
Installing 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.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
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. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Main work
– Check the throttle cable routing. (
p. 12)
–
Make sure that no cables are trapped or damaged.
–
Position the fuel tank.
–
Position the intake flange on the carburetor.
–
Tighten hose clamp
–
Connect the fuel hose.
.
Info
B01718-11
Route the cable and fuel line at a safe distance from the exhaust system.
–
Mount and tighten screws
 on both sides.
Guideline
Screw, fuel tank
–
M8
Mount and tighten screw
15 Nm
(11.1 lbf ft)
Loctite® 243™
.
Guideline
Remaining screws, chassis
B01717-11
–
Mount the fuel tank breather.
Finishing work
– Lock the seat. (
p. 10)
M6
10 Nm (7.4 lbf ft)
4
SERVICE WORK ON THE CHASSIS
4.10
Checking the throttle cable routing
Preparatory work
– Fold the seat up. (
–
12
p. 10)
Remove the fuel tank. (
p. 10)
Main work
– Check the throttle cable routing.
The throttle cable must be routed to the carburetor along the back of the handlebar, below the seat fixing.
»
If the throttle cable is not routed as specified:
–
Correct the throttle cable routing.
B01712-10
Finishing work
– Install the fuel tank. (
–
4.11
Lock the seat. (
p. 11)
p. 10)
Recharging the battery
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 contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–
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.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
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. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
4
SERVICE WORK ON THE CHASSIS
13
Preparatory work
– Raise the motorcycle with the lift stand. (
–
p. 8)
p. 10)
Fold the seat up. (
–
Remove the shock absorber. (
–
Remove the battery. (
p. 8)
p. 13)
Main work
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the rest potential and starting ability of
the battery, and to test the alternator. With this device, you cannot overcharge the
battery.
Info


Never remove lid
.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing
.
400240-10
–
Switch off the charger after charging. Disconnect the battery.
Guideline
The charging current, charging voltage, and charging time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
Finishing work
– Install the battery. (
4.12
3 months
p. 14)
–
Install the shock absorber. (
–
Lock the seat. (
–
Remove the motorcycle from the lift stand. (
p. 8)
p. 10)
p. 8)
Removing the battery
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 contact a physician.
Preparatory work
– Raise the motorcycle with the lift stand. (
–
Fold the seat up. (
–
Remove the shock absorber. (
Main work
– Remove screw
–
B01686-10
p. 10)
.
Take off fastening plate
.
p. 8)
p. 8)
4
SERVICE WORK ON THE CHASSIS
14
–
Remove the battery out of the battery compartment.
–
Disconnect negative cable
–
 from the battery.
Disconnect positive cable  from the battery.
B01687-10
4.13
Installing the battery
Main work
– Position positive cable
, and mount and tighten the screw.
Guideline
Screw, battery terminal
–
Position negative cable
M5
2.5 Nm
(1.84 lbf ft)
, and mount and tighten the screw.
Guideline
Screw, battery terminal
M5
2.5 Nm
(1.84 lbf ft)
Battery (YTX4L-BS)
Info

Contact disk
must be mounted between screw
with the claws facing down.
 and cable lug 
B01688-10
–
Position the battery in the battery compartment.
Info
Ensure that the battery cable is correctly routed.
–
–
.
Mount and tighten screw .
Attach fastening plate
B01686-11
Finishing work
– Install the shock absorber. (
4.14
p. 8)
–
Lock the seat. (
–
Remove the motorcycle from the lift stand. (
–
Ensure that the spacers are mounted in the fender.
–
Position the front fender. Mount and tighten screws
p. 10)
p. 8)
Installing the front fender
.
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the headlight mask.
B01030-10
4
SERVICE WORK ON THE CHASSIS
4.15
Refitting the headlight mask with the headlight
Main work
– Connect connector
15
 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.
–
Position the brake line and wiring harness
.
B01041-11
Finishing work
– Check the headlight setting. (
4.16
p. 15)
Checking the headlight setting
A
0
–
Position the vehicle upright on a horizontal surface in front of a light wall and make
a mark at the height of the center of the low beam headlight.
–
Make another mark at a distance
 under the first mark.
Guideline
0
B
Distance
–
5 cm (2 in)

Position the vehicle vertically a distance
 away from the wall.
Guideline
Distance
400726-10
5 m (16 ft)

–
The rider now sits down on the motorcycle.
–
Switch on the low beam.
–
Check the headlight setting.
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with driver.
»
If the boundary between light and dark does not meet specifications:
–
Adjust the headlight range. (
p. 16)
4
SERVICE WORK ON THE CHASSIS
4.17
Adjusting the headlight range
Preparatory work
– Check the headlight setting. (
16
p. 15)
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).
Info
B01043-10
4.18
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.
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.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
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. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
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.
Preparatory work
– Fold the seat up. (
p. 10)
Main work
– Press release button
, turn the filler cap counterclockwise, and lift it free.
B01662-10
4.19
Closing the filler cap
Main work
– Replace the filler cap and turn clockwise until the release button
place.
Info
Run the fuel tank breather hose
B01662-11
Finishing work
– Lock the seat. (
p. 10)
 without kinks.
 locks in
4
SERVICE WORK ON THE CHASSIS
4.20
Refueling
17
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.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
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. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Note
Material damage Premature clogging of the fuel filter.
–
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.
–
Only refuel with clean fuel that meets the specified standards.
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.
Preparatory work
– Switch off the engine.
–
Fold the seat up. (
–
Open the filler cap. (
p. 10)
p. 16)
Main work
– Fill the fuel tank with fuel up to measurement
.
Guideline
Measurement of
30 mm (1.18 in)

Total fuel tank
capacity, approx.
7.0 l
(1.85 US gal)
401474-10
Finishing work
– Close the filler cap. (
–
Lock the seat. (
p. 16)
p. 10)
Super unleaded (95 octane) mixed
with 2-stroke engine oil (1:80)
( p. 19)
5
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS
Spoke nipple
M4.5
5… 6 Nm (3.7… 4.4 lbf ft)
–
Screw, battery terminal
M5
2.5 Nm (1.84 lbf ft)
–
Screw, shock absorber adjusting ring
M5
5 Nm (3.7 lbf ft)
–
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
–
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
Screw, ball joint of push rod on foot
brake cylinder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
Loctite® 243™
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite® 243™
Screws, throttle grip
M6
3 Nm (2.2 lbf ft)
–
Fuel connection on fuel pump
M8
10 Nm (7.4 lbf ft)
–
Nut, foot brake lever stop
M8
20 Nm (14.8 lbf ft)
–
Nut, rear sprocket screw
M8
35 Nm (25.8 lbf ft)
Loctite® 243™
Nut, rim lock
M8
10 Nm (7.4 lbf ft)
–
Remaining nuts, chassis
M8
25 Nm (18.4 lbf ft)
–
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
–
Screw of rear brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, bottom triple clamp
M8
18 Nm (13.3 lbf ft)
–
Screw, chain sliding piece
M8
15 Nm (11.1 lbf ft)
–
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
–
Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, fuel tank
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
–
Screw, side stand attachment
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, subframe
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, top steering stem
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
Screw, top triple clamp
M8
22 Nm (16.2 lbf ft)
–
Engine bracket screw
M10
60 Nm (44.3 lbf ft)
–
Nut, fuel tank attachment
M10
10 Nm (7.4 lbf ft)
–
Remaining nuts, chassis
M10
45 Nm (33.2 lbf ft)
–
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
–
Screw, cross bar
M10
45 Nm (33.2 lbf ft)
–
Screw, foot brake lever
M10
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, footrest bracket
M10
45 Nm (33.2 lbf ft)
Loctite® 243™
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite® 243™
Screw, upper subframe
M10
45 Nm (33.2 lbf ft)
Loctite® 243™
Nut, fuel pump fixation
M12
15 Nm (11.1 lbf ft)
–
Screw, bottom shock absorber
M12
80 Nm (59 lbf ft)
Loctite® 243™
Screw, top shock absorber
M12
80 Nm (59 lbf ft)
Loctite® 243™
Nut, swingarm pivot
M14x1.5
75 Nm (55.3 lbf ft)
–
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
–
Screw, front wheel spindle
M20x1.5
35 Nm (25.8 lbf ft)
–
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
–
18
6
SUBSTANCES
19
2-stroke engine oil
Standard/classification
– JASO FC ( p. 21)
Guideline
– Only use high grade 2-stroke engine oil of a reputable brand.
Fully synthetic
Recommended supplier
Motorex®
– Cross Power 2T
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–
Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:80)
Standard/classification
– DIN EN 228
–
JASO FC (
p. 21) (1:80)
Mixture ratio
1:80
Recommended supplier
Motorex®
– Cross Power 2T
2-stroke engine oil ( p. 19)
Super unleaded (ROZ 95/RON 95/PON 91) (
p. 19)
7
AUXILIARY SUBSTANCES
Long-life grease
Recommended supplier
Motorex®
– Bike Grease 2000
20
8
STANDARDS
21
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.
*3213149en*
3213149en
01/2014
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM
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