KTM Freeride 250 R 2016 Manual

SETUP INSTRUCTIONS 2016
Freeride 250 R
Art. no. 3213438en

INTRODUCTION 1
*3213438en*
3213438en
11/2015
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.
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2015 KTM Sportmotorcycle GmbH, 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 GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
Freeride 250 R EU (F7303P4)
Freeride 250 R AU (F7360P4)
Freeride 250 R US (F7375P4)

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.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
M00075-10
Package 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 (78929955100)
–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.
M00075-11
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 (78929955100)
–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. 7)

2 SETUP 4
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.
M01029-11
–Remove screws . Take off the handlebar clamps.
–Remove screws . Take off the handlebar supports.
–Place the handlebar supports in the required 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.
B02301-01
–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. 8)
S00979-01
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.

2 SETUP 5
B02302-01
–Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
B02303-10
(EU/AU)
–Mount the connector retainer and speedometer on the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Position turn signal indicator lamp .
–Connect all plug-in connectors to the connector retainer.
B02000-10
–Remove the fuel tank. ( p. 9)
–Disconnect the plug-in connector on 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 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 ties.
Info
The routing of the wiring harness is shown in the figure.
–Install the fuel tank. ( p. 10)
402148-01
–Mount the turn signal switch and connect the plug-in connector on the wiring
harness.
–Mount the handlebar cushion.
–Install the front fender. ( p. 13)
–Refit the headlight mask with the headlight. ( p. 14)

2 SETUP 6
M00695-01
–Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers for footrest spring (58429083000)
B02002-01
(EU/AU)
–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.
B02304-01
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.
–Maintain the minimum clearance to inflammable materials while charg-
ing.
Minimum clearance 1 m (3 ft)
–Over-discharged batteries with a charge of less than 9 V are not permit-
ted to be charged. They must be disposed of.
–Recharge the battery. ( p. 11)
Info
Read the notes in the battery package.
–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).
B02305-01
(EU/AU)
–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. 16)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 SERVICE WORK ON THE CHASSIS 7
3.1 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.
401942-01
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78929955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 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.
401943-10
–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.
3.3 Removing the shock absorber
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 7)
–Fold the seat up. ( p. 9)
B02282-10
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.
3.4 Installing the shock absorber
B02282-11
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®2701™
–Mount and tighten screw .

3 SERVICE WORK ON THE CHASSIS 8
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 or with any other lubricants. Lubricants
dissolve the Teflon coating, thereby drastically reducing the service life.
–Mount and tighten screw .
Guideline
Screw, upper subframe M10 45 Nm
(33.2 lbf ft)
Loctite®243™
Finishing work
–Lock the seat. ( p. 9)
–Remove the motorcycle from the lift stand. ( p. 7)
3.5 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.
B01046-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the front wheel bearing.
–Clean and grease the shaft seal rings and contact surface of the spacers.
Long-life grease ( p. 19)
–Insert the spacers.
B02290-11
–Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
–Mount and tighten screw .
Guideline
Screw, front wheel spindle 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. ( p. 7)
–Pull the front brake and compress the fork forcefully a few times.
The fork legs straighten.
–Tighten screw .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)