KTM Freeride 250 R EU Operating instructions

REPAIR MANUAL 2014
Freeride 250 R EU
Freeride 250 R AUS
Art. no. 3206188en

INTRODUCTION 1
INTRODUCTION
It is important that you read this repair manual carefully and completely before the start of work.
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair 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 repair 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.
© 2013 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

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1 Repair Manual .................................................. 6
2.2 Safety advice.................................................... 6
2.3 Degrees of risk and symbols ............................... 6
2.4 Work rules........................................................ 6
3 IMPORTANT NOTES..................................................... 7
3.1 Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Figures ............................................................ 7
4 SERIAL NUMBERS ...................................................... 8
4.1 Chassis number ................................................ 8
4.2 Type label ........................................................ 8
4.3 Key number...................................................... 8
4.4 Engine number ................................................. 8
4.5 Fork part number .............................................. 8
4.6 Shock absorber part number .............................. 9
5 MOTORCYCLE ........................................................... 10
5.1 Raising the motorcycle with the lift stand.......... 10
5.2 Removing the motorcycle from the lift stand...... 10
5.3 Starting.......................................................... 10
5.4 Starting the motorcycle to make checks ............ 11
6 FORK, TRIPLE CLAMP ............................................... 12
6.1 Adjusting the compression damping of the
fork ............................................................... 12
6.2 Adjusting the rebound damping of the fork ........ 12
6.3 Bleeding the fork legs...................................... 12
6.4 Cleaning the dust boots of the fork legs............. 13
6.5 Removing the fork protector ............................. 13
6.6 Installing the fork protector.............................. 13
6.7 Removing the fork legs .................................... 14
6.8 Installing the fork legs..................................... 14
6.9 Performing a fork service ................................. 15
6.10 Disassembling the fork legs.............................. 15
6.11 Disassembling the cartridge ............................. 18
6.12 Disassembling the compression holder.............. 20
6.13 Checking the fork legs ..................................... 20
6.14 Assembling the compression holder .................. 22
6.15 Assembling the cartridge ................................. 22
6.16 Assembling the fork legs.................................. 24
6.17 Greasing the steering head bearing ................... 28
6.18 Removing the lower triple clamp....................... 28
6.19 Installing the lower triple clamp ....................... 29
6.20 Checking the steering head bearing play............ 30
6.21 Adjusting the play of the steering head
bearing .......................................................... 31
7 HANDLEBAR, CONTROLS........................................... 32
7.1 Handlebar position.......................................... 32
7.2 Adjusting the handlebar position ...................... 32
7.3 Adjusting the basic position of the clutch
lever .............................................................. 32
7.4 Checking the throttle cable routing ................... 33
7.5 Checking the play in the throttle cable .............. 33
7.6 Adjusting the play in the throttle cable.............. 34
8 FRAME ..................................................................... 35
8.1 Removing the engine guard.............................. 35
8.2 Installing the engine guard .............................. 35
9 SHOCK ABSORBER, SWINGARM ................................ 36
9.1 Adjusting the high-speed compression
damping of the shock absorber......................... 36
9.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 36
9.3 Adjusting the rebound damping of the shock
absorber......................................................... 37
9.4 Measuring rear wheel sag unloaded................... 37
9.5 Checking the static sag of the shock absorber.... 38
9.6 Checking the riding sag of the shock absorber.... 38
9.7 Adjusting the spring preload of the shock
absorber......................................................... 38
9.8 Adjusting the riding sag................................... 39
9.9 Removing the shock absorber........................... 40
9.10 Installing the shock absorber............................ 40
9.11 Servicing the shock absorber............................ 40
9.12 Removing the spring........................................ 41
9.13 Disassembling the damper ............................... 41
9.14 Disassembling the piston rod ........................... 42
9.15 Disassembling the seal ring retainer.................. 44
9.16 Replacing the pilot bushing ............................. 44
9.17 Checking the damper ...................................... 45
9.18 Removing the heim joint.................................. 46
9.19 Installing the heim joint................................... 47
9.20 Assembling the seal ring retainer...................... 48
9.21 Assembling the piston rod................................ 48
9.22 Assembling the damper ................................... 50
9.23 Bleeding and filling the damper ....................... 52
9.24 Filling the damper with nitrogen....................... 54
9.25 Installing the spring ........................................ 55
10 EXHAUST.................................................................. 57
10.1 Removing the main silencer ............................. 57
10.2 Installing the main silencer.............................. 57
10.3 Changing the glass fiber yarn filling of the
main silencer.................................................. 57
11 AIR FILTER ............................................................... 59
11.1 Removing the air filter housing......................... 59
11.2 Installing the air filter housing ......................... 59
11.3 Removing the air filter..................................... 59
11.4 Installing the air filter...................................... 60
11.5 Cleaning the air filter and air filter housing........ 60
12 FUEL TANK, SEAT, TRIM ........................................... 61
12.1 Opening the filler cap...................................... 61
12.2 Refueling ....................................................... 61
12.3 Closing the filler cap ....................................... 62
12.4 Folding the seat up ......................................... 62
12.5 Locking the seat ............................................. 62
12.6 Removing the seat .......................................... 63
12.7 Mounting the seat........................................... 63
12.8 Taking off the spoiler....................................... 63
12.9 Mounting the spoiler ....................................... 64
12.10 Removing the fuel tank.................................... 65
12.11 Installing the fuel tank .................................... 65
12.12 Fuel tap ......................................................... 66
13 MASK, FENDER......................................................... 67
13.1 Removing the front fender ............................... 67
13.2 Installing the front fender ................................ 67
13.3 Removing the headlight mask with the
headlight........................................................ 67
13.4 Refitting the headlight mask with the
headlight........................................................ 68

TABLE OF CONTENTS 3
14 WHEELS ................................................................... 69
14.1 Checking the tire air pressure........................... 69
14.2 Checking the tire condition .............................. 69
14.3 Checking the brake discs ................................. 70
14.4 Checking the spoke tension.............................. 70
14.5 Front wheel .................................................... 71
14.5.1 Removing the front wheel ............................ 71
14.5.2 Installing the front wheel............................. 71
14.5.3 Removing the brake disc of the front brake.... 72
14.5.4 Installing the brake disc of the front brake .... 72
14.6 Rear wheel ..................................................... 72
14.6.1 Removing the rear wheel ............................. 72
14.6.2 Installing the rear wheel .............................. 73
14.6.3 Removing the brake disc of the rear brake..... 74
14.6.4 Installing the brake disc of the rear brake...... 74
14.6.5 Checking the chain tension.......................... 75
14.6.6 Adjusting the chain tension ......................... 75
14.6.7 Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 76
14.6.8 Checking for chain dirt accumulation............ 77
14.6.9 Cleaning the chain...................................... 77
15 WIRING HARNESS, BATTERY..................................... 79
15.1 Changing the main fuse................................... 79
15.2 Changing the fuses of individual power
consumers...................................................... 79
15.3 Removing the battery ...................................... 80
15.4 Installing the battery ....................................... 81
15.5 Recharging the battery .................................... 81
15.6 Checking the charging voltage.......................... 82
15.7 Checking the quiescent current ........................ 83
15.8 Checking the starter relay ................................ 83
16 BRAKE SYSTEM ........................................................ 84
16.1 Checking the front brake linings ....................... 84
16.2 Changing the front brake linings....................... 84
16.3 Checking the free travel of the hand brake
lever .............................................................. 86
16.4 Adjusting the free travel of the handbrake
lever .............................................................. 86
16.5 Checking the brake fluid level of the front
brake ............................................................. 86
16.6 Adding front brake fluid................................... 87
16.7 Changing the front brake fluid.......................... 87
16.8 Checking the rear brake linings ........................ 89
16.9 Changing the rear brake linings ........................ 89
16.10 Checking the free travel of foot brake lever ........ 91
16.11 Adjusting the basic position of the foot brake
lever .............................................................. 91
16.12 Checking the rear brake fluid level.................... 91
16.13 Adding rear brake fluid.................................... 92
16.14 Changing the rear brake fluid ........................... 93
17 LIGHTING SYSTEM, INSTRUMENTS ........................... 95
17.1 Setting the speedometer.................................. 95
17.2 Setting kilometers or miles............................... 96
17.3 Setting the clock............................................. 96
17.4 Setting the wheel circumference ...................... 96
17.5 Setting the service display ............................... 97
17.6 Checking the headlight setting ......................... 97
17.7 Adjusting the headlight range........................... 98
17.8 Changing the turn signal bulb .......................... 98
17.9 Changing the headlight bulb ............................ 98
17.10 Changing the speedometer battery.................... 99
18 30/ENGINE ............................................................. 101
18.1 Removing the engine..................................... 101
18.2 Installing the engine...................................... 104
18.3 Engine disassembly....................................... 108
18.3.1 Clamping the engine into the engine work
stand....................................................... 108
18.3.2 Draining the gear oil.................................. 109
18.3.3 Removing the clutch push rod.................... 109
18.3.4 Removing the shift lever ............................ 109
18.3.5 Removing the spacer................................. 109
18.3.6 Removing the starter motor........................ 110
18.3.7 Removing the cylinder head....................... 111
18.3.8 Removing the cylinder............................... 112
18.3.9 Removing the piston ................................. 112
18.3.10 Removing the water pump cover................. 113
18.3.11 Removing the clutch cover......................... 113
18.3.12 Removing the clutch discs......................... 113
18.3.13 Removing the clutch basket....................... 114
18.3.14 Removing the shift shaft............................ 115
18.3.15 Removing the shift drum locating unit ........ 115
18.3.16 Removing the locking lever ........................ 115
18.3.17 Removing the rotor.................................... 115
18.3.18 Removing the reed valve housing................ 116
18.3.19 Removing the left engine case section ........ 116
18.3.20 Removing the shift rails............................. 117
18.3.21 Removing the shift drum ........................... 117
18.3.22 Removing the shift forks............................ 117
18.3.23 Removing the transmission shafts............... 117
18.3.24 Removing the crankshaft ........................... 117
18.4 Work on individual parts ................................ 118
18.4.1 Work on the right section of the engine
case ........................................................ 118
18.4.2 Work on the left section of the engine
case ........................................................ 119
18.4.3 Removing the crankshaft bearing inner
race......................................................... 119
18.4.4 Installing the crankshaft bearing inner
race......................................................... 120
18.4.5 Changing the connecting rod, conrod
bearing, and crank pin .............................. 120
18.4.6 Checking the crankshaft run-out at the
bearing pin............................................... 121
18.4.7 Checking/measuring the cylinder ................ 121
18.4.8 Cylinder - Nikasil®coating ......................... 122
18.4.9 Checking/measuring the piston................... 122
18.4.10 Checking the piston ring end gap ............... 123
18.4.11 Piston/cylinder - measuring the mounting
clearance ................................................. 123
18.4.12 Checking the reed valve housing, reed
valve, and intake flange............................. 123
18.4.13 Work on the clutch cover ........................... 124
18.4.14 Checking the clutch .................................. 125
18.4.15 Preassembling the shift shaft..................... 126
18.4.16 Checking the shift mechanism ................... 127
18.4.17 Disassembling the main shaft .................... 128
18.4.18 Disassembling the countershaft.................. 129
18.4.19 Checking the transmission ......................... 129
18.4.20 Assembling the main shaft......................... 130
18.4.21 Assembling the countershaft...................... 131
18.4.22 Checking the electric starter drive .............. 133
18.5 Engine assembly........................................... 134
18.5.1 Installing the crankshaft............................ 134
18.5.2 Installing the transmission shafts ............... 134

TABLE OF CONTENTS 4
18.5.3 Installing the shift forks............................. 135
18.5.4 Installing the shift drum............................ 135
18.5.5 Installing the shift rails ............................. 135
18.5.6 Installing the left engine case section ......... 135
18.5.7 Installing the reed valve housing ................ 136
18.5.8 Installing the rotor .................................... 136
18.5.9 Installing the locking lever......................... 137
18.5.10 Installing the shift drum locating unit ......... 137
18.5.11 Installing the shift shaft ............................ 137
18.5.12 Installing the clutch basket........................ 137
18.5.13 Installing the clutch discs.......................... 138
18.5.14 Installing the clutch cover ......................... 139
18.5.15 Installing the water pump cover.................. 139
18.5.16 Installing the piston .................................. 140
18.5.17 Installing the cylinder................................ 140
18.5.18 Checking the X-distance ............................ 141
18.5.19 Adjusting the X-distance............................ 141
18.5.20 Installing the cylinder head........................ 142
18.5.21 Installing the starter motor......................... 142
18.5.22 Installing the spacer.................................. 144
18.5.23 Installing the shift lever............................. 144
18.5.24 Installing the clutch push rod .................... 145
18.5.25 Installing the gear oil drain plug................. 145
18.5.26 Removing the engine from the work stand ... 145
19 CARBURETOR ......................................................... 146
19.1 Choke .......................................................... 146
19.2 Carburetor - adjusting idle ............................. 146
19.3 Emptying the carburetor float chamber ........... 147
19.4 Removing the carburetor................................ 147
19.5 Installing the carburetor ................................ 148
19.6 Checking/setting the carburetor components.... 149
19.7 Disassembling the carburetor ......................... 149
19.8 Checking the choke slide ............................... 151
19.9 Checking the jet needle ................................. 151
19.10 Checking the throttle slide ............................. 151
19.11 Checking the float needle valve ...................... 152
19.12 Assembling the carburetor ............................. 152
19.13 Checking/adjusting the float level ................... 153
20 CLUTCH.................................................................. 155
20.1 Checking fluid level of the hydraulic clutch ..... 155
20.2 Correcting the fluid level of the hydraulic
clutch.......................................................... 155
20.3 Changing the hydraulic clutch fluid ................ 155
21 WATER PUMP, COOLING SYSTEM ............................ 157
21.1 Checking the antifreeze and coolant level........ 157
21.2 Checking the coolant level ............................. 157
21.3 Draining the coolant...................................... 158
21.4 Refilling coolant ........................................... 158
22 LUBRICATION SYSTEM............................................ 160
22.1 Changing the gear oil..................................... 160
22.2 Draining the gear oil...................................... 160
22.3 Filling in gear oil........................................... 161
22.4 Checking the gear oil level ............................. 161
22.5 Adding gear oil ............................................. 161
23 IGNITION SYSTEM................................................... 163
23.1 Checking the ignition system.......................... 163
23.2 Ignition coil - checking the primary winding..... 164
23.3 Ignition coil - checking the secondary
winding........................................................ 164
23.4 Checking the spark plug connector ................. 165
23.5 Alternator - checking the charging coil of the
ignition ........................................................ 165
23.6 Alternator - checking the battery winding ........ 165
23.7 Alternator - checking the light winding............ 166
23.8 Checking the ignition pulse generator ............. 166
23.9 Removing the stator and crankshaft position
sensor.......................................................... 167
23.10 Installing the stator and crankshaft position
sensor.......................................................... 167
23.11 Cleaning the alternator .................................. 168
24 ELECTRIC STARTER ................................................ 169
24.1 Checking the starter motor............................. 169
25 TECHNICAL DATA.................................................... 170
25.1 Engine ......................................................... 170
25.2 Engine tolerance, wear limits ......................... 170
25.3 Engine tightening torques .............................. 171
25.4 Capacities .................................................... 171
25.4.1 Gear oil.................................................... 171
25.4.2 Coolant .................................................... 171
25.4.3 Fuel ........................................................ 171
25.5 Chassis ........................................................ 172
25.6 Electrical system........................................... 172
25.7 Tires............................................................ 173
25.8 Fork............................................................. 173
25.9 Shock absorber............................................. 173
25.10 Chassis tightening torques ............................. 174
25.11 Carburetor.................................................... 175
25.12 Carburetor tuning.......................................... 176
25.12.1 Carburetor tuning...................................... 176
26 CLEANING, CARE .................................................... 177
26.1 Cleaning the motorcycle ................................ 177
26.2 Checks and maintenance steps for winter
operation...................................................... 178
27 STORAGE................................................................ 179
27.1 Storage ........................................................ 179
27.2 Preparing for use after storage........................ 179
28 SERVICE SCHEDULE ............................................... 180
28.1 Service schedule........................................... 180
28.2 Service work (as additional order) ................... 181
29 WIRING DIAGRAM ................................................... 182
29.1 Page 1 of 5 (Freeride 250 R EU).................... 182
29.2 Page 2 of 5 (Freeride 250 R EU).................... 184
29.3 Page 3 of 5 (Freeride 250 R EU).................... 186
29.4 Page 4 of 5 (Freeride 250 R EU).................... 188
29.5 Page 5 of 5 (Freeride 250 R EU).................... 190
29.6 Page 1 of 5 (Freeride 250 R AUS).................. 192
29.7 Page 2 of 5 (Freeride 250 R AUS).................. 194
29.8 Page 3 of 5 (Freeride 250 R AUS).................. 196
29.9 Page 4 of 5 (Freeride 250 R AUS).................. 198
29.10 Page 5 of 5 (Freeride 250 R AUS).................. 200
30 SUBSTANCES ......................................................... 202
31 AUXILIARY SUBSTANCES ........................................ 204
32 SPECIAL TOOLS ...................................................... 206
33 STANDARDS ........................................................... 215
INDEX ............................................................................ 216

1 MEANS OF REPRESENTATION 5
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 6
2.1 Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
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.
Caution
Identifies a danger that may lead to minor injuries 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 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.

3 IMPORTANT NOTES 7
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 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.
3.3 Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.

4 SERIAL NUMBERS 8
4.1 Chassis number
B01005-10
The chassis number 1is stamped on the right side of the steering head.
4.2 Type label
B01124-10
The type label 1is fixed to the frame at the front right.
4.3 Key number
500125-10
The key number 1for the steering lock is stamped onto the key connector.
4.4 Engine number
B01653-10
The engine number 1is stamped on the left side of the engine under the engine
sprocket.
4.5 Fork part number
B01007-10
The fork part number 1is stamped on the inner side of the axle clamp.

4 SERIAL NUMBERS 9
4.6 Shock absorber part number
B01654-10
The shock absorber part number 1is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

5 MOTORCYCLE 10
5.1 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) ( p. 207)
The wheels must no longer touch the ground.
–Secure the motorcycle against falling over.
5.2 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 1to 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.
5.3 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
The motorcycle has been out of use for more than 1 week
–Empty the carburetor float chamber. ( p. 147)
–Turn handle 1of the fuel tap to the ON position. (Figure B01660-10 p. 66)
Fuel can flow from the fuel tank to the carburetor.

5 MOTORCYCLE 11
B01667-11
–Raise the motorcycle off of the stand and secure the stand with the rubber band 1.
–Shift gear to neutral.
(Freeride 250 R AUS)
–Press the emergency OFF switch into the position .
The engine is cold
–Pull the choke lever out as far as possible.
400733-01
–Press the electric starter button.
Info
Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
Do not open the throttle to start.
5.4 Starting the motorcycle to make checks
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
(Freeride 250 R AUS)
–Press the emergency OFF switch into the position .
400733-01
–Shift gear to neutral.
–Press the electric starter button.
Info
Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
Do not open the throttle to start.

6 FORK, TRIPLE CLAMP 12
6.1 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
B01033-10
–Remove protection caps 1.
–Turn adjusting screws 2clockwise all the way.
Info
Adjusting screws 2are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
–Mount protection caps 1.
6.2 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
B01728-10
–Turn adjusting screws 1clockwise all the way.
Info
Adjusting screws 1are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
6.3 Bleeding the fork legs
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 10)
B01736-10
Main work
–Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
–Tighten the bleeder screws.

6 FORK, TRIPLE CLAMP 13
Finishing work
–Remove the motorcycle from the lift stand. ( p. 10)
6.4 Cleaning the dust boots of the fork legs
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 10)
602788-10
Main work
–Push dust boots 1of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the shaft seal rings behind can start to leak.
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.
–Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 205)
–Press the dust boots back into their normal position.
–Remove excess oil.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 10)
6.5 Removing the fork protector
B01734-10
–Remove screws 1. Take off the clamp.
–Remove screws 2on the left fork leg. Take off the fork protector.
B01735-10
–Remove screws 3on the right fork leg. Take off the fork protector.
6.6 Installing the fork protector
B01735-11
–Position the fork protection on the right fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

6 FORK, TRIPLE CLAMP 14
B01734-11
–Position the fork protection on the left fork leg. Mount and tighten screws 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the brake line, wiring harness, and clamp. Mount and tighten screws 3.
6.7 Removing the fork legs
Preparatory work
–Remove the headlight mask with the headlight. ( p. 67)
–Raise the motorcycle with the lift stand. ( p. 10)
–Remove the front wheel. ( p. 71)
602805-10
Main work
–Remove screws 1and take off the clamp.
–Remove cable binder 2.
–Remove screws 3and the spacers and take off the brake caliper.
–Allow the brake caliper and brake line to hang tension-free to the side.
B01054-10
–Release screws 4. Take out the left fork leg.
–Release screws 5. Take out the right fork leg.
6.8 Installing the fork legs
B01737-10
Main work
–Position the fork legs.
Info
The upper milled groove in the fork leg must be flush with the upper edge of
the upper triple clamp.
Position bleeder screws 1toward the front.
B01054-11
–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)

6 FORK, TRIPLE CLAMP 15
602805-11
–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™
–Mount cable binder 5.
–Position the brake line, wiring harness, and clamp. Mount and tighten screws 6.
Finishing work
–Install the front wheel. ( p. 71)
–Refit the headlight mask with the headlight. ( p. 68)
–Check the headlight setting. ( p. 97)
6.9 Performing a fork service
Condition
The fork legs have been removed.
201467-01
–Disassemble the fork legs. ( p. 15)
–Disassemble the cartridge. ( p. 18)
–Disassemble the compression holder. ( p. 20)
–Check the fork legs. ( p. 20)
–Assemble the compression holder. ( p. 22)
–Assemble the cartridge. ( p. 22)
–Assemble the fork legs. ( p. 24)
6.10 Disassembling the fork legs
Info
The operations are the same on both fork legs.
Condition
The fork legs have been removed.
201423-10
–Remove protection cap A.
–Note down the present state of rebound damping 1and compression damping 2.
–Completely open the adjusters of the rebound damping and compression damping.

6 FORK, TRIPLE CLAMP 16
201424-10
–Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T612S) ( p. 214)
201425-10
–Loosen screw cap 3.
Info
The screw cap cannot be removed yet.
201426-10
–Unclamp the fork leg and clamp it with the axle clamp.
Info
Use soft jaws.
201427-10
–Push the outer tube down.
–Pull the spring downward. Place the special tool on the hexagonal part.
Open-end wrench (T14032) ( p. 212)
Info
Preload spacers 4should be above the special tool.
201428-10
–Clamp the special tool in the bench vise. Loosen screw cap 3.
201429-10
–Remove screw cap 3with preload spacers 4.
–Remove adjusting tube 5.

6 FORK, TRIPLE CLAMP 17
201430-10
–Pull the spring downward. Remove the special tool.
–Remove spring.
201431-10
–Drain the fork oil.
Info
Pull out the piston rod all the way and push it back in several times in order
to pump out the cartridge until it is empty.
201432-10
–Clamp the fork leg with the axle clamp.
Guideline
Use soft jaws.
–Unscrew and remove compression holder 6.
Info
Place a fluid collector beneath it, as usually some oil will drain out.
201433-10
–Remove the cartridge.
201434-10
–Remove dust boot 7.
201435-10
–Remove lock ring 8.
Info
The lock ring has a specially finished end against which the screwdriver can
be placed.

6 FORK, TRIPLE CLAMP 18
201436-10
–Warm up the outer tube in area Bof the lower sliding bushings.
Guideline
50 °C (122 °F)
–Jerk the outer tube out of the inner tube.
Info
The lower sliding bushing 9must be pulled out of its bearing seat when
doing this.
201437-10
–Remove the upper sliding bushing bk.
Info
Without using a tool, pull the stack apart by hand slightly.
201438-10
–Take off the lower sliding bushing 9.
–Take off support ring bl.
–Take off seal ring bm.
–Take off lock ring 8.
–Take off dust boot 7.
–Take out the fork leg.
6.11 Disassembling the cartridge
Info
The steps are identical for both fork legs.
Preparatory work
–Disassemble the fork legs. ( p. 15)
200693-10
Main work
–Clamp the special tool in a bench vise.
Pin (T605) ( p. 214)
–Hitch cartridge 1by using the drilled holes.
200694-10
–Unscrew and remove screw sleeve 2.