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2014 KTM 250 Freeride Repair Manual

2014 KTM 250 Freeride Repair Manual

Online PDF 2014 KTM 250 Freeride Repair Manual

Read this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was 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 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 the repair work will be performed by a fully trained mechanic.

Ail specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical speciticetions, 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 speccial equipment that does not belong to the regular scope of supply.

10  2014 KTM 250 Freeride manual EXHAUST. ...  83
10.1  2014 KTM 250 Freeride manual Removing the manifold. .    83
10.2  2014 KTM 250 Freeride manual Installing the manifold. ....   83
10.3  2014 KTM 250 Freeride manual Removing main silencer. .... 84
10.4  2014 KTM 250 Freeride manual Installing the main silencer. .....  84
10.5  2014 KTM 250 Freeride manual Changing the glass fiber yarn filling of the main silencer. .  84

11  2014 KTM 250 Freeride manual
2014 KTM 250 Freeride manual AIR FILTER. . 86
11.1  2014 KTM 250 Freeride manual Removing the air filter box lid. .. 86
11.2  2014 KTM 250 Freeride manual Installing the air filter box lid. ... 86
11.3  2014 KTM 250 Freeride manual Sealing the air filter box. ..  86
11.4  2014 KTM 250 Freeride manual Removing the air filter. ....  86
11.5  2014 KTM 250 Freeride manual Installing the air filter. .  87
11.6  2014 KTM 250 Freeride manual Cleaning the air filter and air filter box. .  87 

12  2014 KTM 250 Freeride manual FUEL TANK, SEAT, TRIM. . 89
12.1  2014 KTM 250 Freeride manual Opening filler cap. ...   89
12.2  2014 KTM 250 Freeride manual Closing filler cap. ..  89
12.3  Removing the seat.  89
12.4  2014 KTM 250 Freeride manual Mounting the seat. .  90
12.5  2014 KTM 250 Freeride manual Removing the fuel tank. ..... 90
12.6  2014 KTM 250 Freeride manual Installing the fuel tank. ....  91
12.7  2014 KTM 250 Freeride manual Changing the fuel screen. .  92
12.8  2014 KTM 250 Freeride manual Changing the fuel filter. ..... 93
12.9  2014 KTM 250 Freeride manual Changing the fuel pump. ..  95
12.10  2014 KTM 250 Freeride manual Checking the fuel pressure.    96 

13  2014 KTM 250 Freeride manual MASK, FENDER.. . .. 98
13.1  2014 KTM 250 Freeride manual Removing the front fender. .. 98
13.2  2014 KTM 250 Freeride manual Installing the front fender.  98
13.3  2014 KTM 250 Freeride manual Removing headlight mask with headlight. .... 98
13.4  2014 KTM 250 Freeride manual Refitting the headlight mask with the headlight.  99

14  2014 KTM 250 Freeride manual WHEELS. ..  100
14.1 2014 KTM 250 Freeride manual Checking the tire air pressure. . 100
14.2 2014 KTM 250 Freeride manual Checking the tire condition. ....  100
14.3 2014 KTM 250 Freeride manual Checking the brake discs. .. 101
14.4 2014 KTM 250 Freeride manual Checking spoke tension. .  101
14.5  2014 KTM 250 Freeride manual Front wheel. .  102
14.5.1  2014 KTM 250 Freeride manual Removing the front wheel. .. 102
14.5.2  2014 KTM 250 Freeride manual Installing the front wheel. ...  102
14.5.3  2014 KTM 250 Freeride manual Removing the front brake disc. .... 103
14.5.4  2014 KTM 250 Freeride manual Installing the front brake disc. .... 103
14.6  2014 KTM 250 Freeride manual Rear wheel. .... 103
14.6.1  2014 KTM 250 Freeride manual Removing the rear wheel. ...  103
14.6.2  2014 KTM 250 Freeride manual Installing the rear wheel. ....  104
14.6.3  2014 KTM 250 Freeride manual Removing the rear brake disc. ..... 105
14.6.4  2014 KTM 250 Freeride manual Installing the rear brake disc.  105
14.6.5  2014 KTM 250 Freeride manual Checking the chain tension. ..  106
14.6.6  2014 KTM 250 Freeride manual Adjusting the chain tension. .  106
14.6.7  2014 KTM 250 Freeride manual Checking the chain, rear sprocket, engine sprocket and chain guide. ...  107
14.6.8  2014 KTM 250 Freeride manual Checking for chain dirt accumulation. ....  109
14.6.9  2014 KTM 250 Freeride manual Cleaning the chain. ..... 109 

15  2014 KTM 250 Freeride manual WIRING HARNESS, BATTERY. .... 110
15.1  2014 KTM 250 Freeride manual Changing the main fuse. .  110
15.2  2014 KTM 250 Freeride manual Changing the fuses of individual power consumers.  . Ill
15.3  2014 KTM 250 Freeride manual 2014 KTM 250 Freeride manual Removing the battery. ..... 112
15.4  2014 KTM 250 Freeride manual Installing the battery.  112
15.5  2014 KTM 250 Freeride manual Checking the charging voltage. ..  113
15.6  2014 KTM 250 Freeride manual Checking the quiescent current.  113 

16  2014 KTM 250 Freeride manual BRAKE SYSTEM.   114
16.1  2014 KTM 250 Freeride manual Checking the front brake linings. ..... 114
16.2  2014 KTM 250 Freeride manual Changing the front brake linings. ..... 114
16.3  2014 KTM 250 Freeride manual Checking free travel of hand brake lever. ... 116
16.4  2014 KTM 250 Freeride manual Adjusting the basic position of the hand brake lever (XC-W). ..  116
16.5  2014 KTM 250 Freeride manual Adjusting free travel of hand brake lever (all EXC models). .  116
16.6  2014 KTM 250 Freeride manual Checking the brake fluid level of the front brake.    117
16.7 2014 KTM 250 Freeride manual Adding front brake fluid. .  117
16.8 2014 KTM 250 Freeride manual Changing the front brake fluid. ..  118
16.9 2014 KTM 250 Freeride manual Checking the rear brake linings.  119
16.10 2014 KTM 250 Freeride manual Changing the rear brake linings.  119
16.11 2014 KTM 250 Freeride manual Checking the free travel of foot brake lever. ..... 121
16.12  2014 KTM 250 Freeride manual Adjusting the basic position of the foot brake lever.    121
16.13  2014 KTM 250 Freeride manual Checking the rear brake fluid level. .  122
16.14  2014 KTM 250 Freeride manual Adding rear brake fluid. ..  122
16.15  2014 KTM 250 Freeride manual Changing the rear brake fluid. . 123 

17  2014 KTM 250 Freeride manual LIGHTING SYSTEM, INSTRUMENTS. ..  125
17.1  2014 KTM 250 Freeride manual Checking the headlight setting. .  125
17.2  2014 KTM 250 Freeride manual Adjusting the headlight range. . 125
17.3  2014 KTM 250 Freeride manual EXC EU/AUS/USA, XC-W. .. 125
17.3.1  2014 KTM 250 Freeride manual Speedometer overview. .. 125
17.3.2  2014 KTM 250 Freeride manual Activation and test. ..... 126
17.3.3  2014 KTM 250 Freeride manual Setting kilometers or miles. ..  126
17.3.4  2014 KTM 250 Freeride manual Adjusting the speedometer functions. ... 126
17.3.5 2014 KTM 250 Freeride manual Setting the clock. . 127
17.3.6 2014 KTM 250 Freeride manual Setting the wheel circumference. .... 127
17.3.7 2014 KTM 250 Freeride manual Querying lap time . .....  128
17.4  2014 KTM 250 Freeride manual EXC SIX DAYS. ...  128
17.4.1  2014 KTM 250 Freeride manual Speedometer overview. .. 128
17.4.2  2014 KTM 250 Freeride manual Activation and test. ..... 129
17.4.3 2014 KTM 250 Freeride Setting kilometers or miles. ..  129
17.4.4 2014 KTM 250 Freeride Setting the speedometer functions.   129
17.4.5 2014 KTM 250 Freeride Setting the clock. .  130
17.4.6  2014 KTM 250 Freeride Activating the additional functions.   130
17.4.7  2014 KTM 250 Freeride Setting the wheel circumference. .... 131
17.4.8  2014 KTM 250 Freeride Viewing the lap time. .   131 

18 2014 KTM 250 Freeride ENGINE. ...  133
18.1  2014 KTM 250 Freeride Removing the engine.  133
18.2  2014 KTM 250 Freeride Installing the engine. .  137
18.3  2014 KTM 250 Freeride Engine disassembly. ..  142
18.3.1  2014 KTM 250 Freeride Preparations. ..  142
18.3.2  2014 KTM 250 Freeride Draining the engine oil. . 142
18.3.3  2014 KTM 250 Freeride Removing the clutch push rod. ...  143
18.3.4  2014 KTM 250 Freeride Removing the oil filter. .. 143
18.3.5  2014 KTM 250 Freeride Removing the starter motor. ..  144
18.3.6  2014 KTM 250 Freeride Removing the kickstarter. ... 144
18.3.7  2014 KTM 250 Freeride Removing the spark plug. ... 144
18.3.8  2014 KTM 250 Freeride Removing the valve cover. ... 144
18.3.9  2014 KTM 250 Freeride Removing the alternator cover. .... 145
18.3.10  2014 KTM 250 Freeride Positioning the engine at ignition top dead center. . 145
18.3.11  2014 KTM 250 Freeride Removing the timing chain tensioner. ... 146

Managing the Vehicle Damage Repair Process
In the event that your vehicle requires damage repairs, GM recommends that you take an active role in its repair. If you have a pre-determined repair facility of choice, take your vehicle there, or have it towed there. Specify to the facility that any required replacement collision parts be original equipment parts, either new Genuine GM parts or recycled original GM parts. Remember, recycled parts will not be covered by your GM vehicle warranty.

Insurance pays the bill for the repair, but you must live with the repair. Depending on your policy limits, your insurance company may initially value the repair using aftermarket parts. Discuss this with your repair professional, and insist on Genuine GM parts. Remember if your vehicle is leased you may be obligated to have the vehicle repaired with Genuine GM parts, even if your insurance coverage does not pay the full cost.

If another party’s insurance company is paying for the repairs, you are not obligated to accept a repair valuation based on that insurance company’s collision policy repair limits, as you have no contractual limits with that company. In such cases, you can have control of the repair and parts choices as long as cost stays within reasonable limits.

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