ENGLISH

KTM 250 Duke Repair Manual 2016

By KTM Sportmotorcycle GmbH

Book information

Publisher
KTM Sportmotorcycle GmbH
Year
2018
Language
english
Format
PDF
Filesize
89 MB (93019015 bytes)
Pages
\262
Time added
2021-06-07 18:58:36

Description

1 MEANS OF REPRESENTATION............. 6 1.1 Symbols used........................ 6 1.2 Formats used........................ 6 2 SAFETY ADVICE....................... 7 2.1 Repair Manual....................... 7 2.2 Safety advice....................... 7 2.3 Degrees of risk and symbols......... 7 2.4 Work rules.......................... 7 3 IMPORTANT NOTES..................... 8 3.1 Manufacturer and implied warranty... 8 3.2 Operating and auxiliary substances.. 8 3.3 Spare parts, accessories............ 8 3.4 Figures............................. 8 4 SERIAL NUMBERS...................... 9 4.1 Chassis number...................... 9 4.2 Type label.......................... 9 4.3 Key number.......................... 9 4.4 Engine number....................... 9 5 MOTORCYCLE.......................... 10 5.1 Raising the motorcycle with the rear lifting gear........................ 10 5.2 Removing the rear of the motorcycle from the lifting gear.............. 10 5.3 Lifting the motorcycle with the front lifting gear...................... 10 5.4 Taking the motorcycle off the front lifting gear...................... 11 5.5 Raising the motorcycle with the work stand............................. 11 5.6 Removing the motorcycle from the work stand........................ 13 5.7 Starting.......................... 13 5.8 Starting the motorcycle to make checks............................ 14 6 FORK. TRIPLE CLAMP................ 15 6.1 Cleaning the dust boots of the fork legs.............................. 15 6.2 Removing the fork legs............. 15 6.3 Installing the fork legs........... 16 6.4 Disassembling the fork legs........ 18 6.5 Checking the fork legs............. 21 6.6 Assembling the fork legs........... 22 6.7 Removing the lower triple clamp.... 25 6.8 Installing the lower triple clamp.. 27 6.9 Checking the play of the steering head bearing...................... 30 6.10 Adjusting the steering head bearing play.............................. 31 7 HANDLEBAR. CONTROLS................ 33 7.1 Checking the play in the throttle cable................................... 33 7.2 Adjusting the play in the throttle cable................................... 33 7.3 Checking the clutch lever play..... 33 7.4 Adjusting play in the clutch lever. 34 8 FRAME.................................... 35 8.1 Checking the frame................ 35 9 SHOCK ABSORBER. SWINGARM................. 36 9.1 Measuring the rear wheel dimension unloaded......................... 36 9.2 Checking the static sag of the shock absorber................................ 36 9.3 Adjusting the spring preload of the shock absorber.......................... 36 9.4 Removing the shock absorber........ 37 9.5 Installing the shock absorber...... 37 9.6 Removing the spring............... 38 9.7 Installing the spring............. 39 9.8 Checking the swingarm............. 40 10 EXHAUST............................ 41 10.1 Removing the exhaust manifold...... 41 10.2 Installing exhaust manifold........ 42 10.3 Removing the main silencer......... 43 10.4 Installing the main silencer....... 44 11 AIR FILTER........................ 46 11.1 Removing the air filter........... 46 11.2 Installing the air filter......... 46 12 FUEL TANK. SEAT. TRIM............. 48 12.1 Opening the filler cap............ 48 12.2 Closing the filler cap............ 48 12.3 Removing the seat................. 49 12.4 Mounting the seat................. 49 12.5 Removing the passenger seat........ 50 12.6 Mounting the passenger seat........ 50 12.7 Removing the fuel tank cover....... 50 12.8 Installing the fuel tank cover..... 53 12.9 Removing the fuel tank............ 56 12.10 Installing the fuel tank......... 57 12.11 Removing the front spoiler....... 59 12.12 Fitting front spoiler............ 60 12.13 Removing front fender............ 60 12.14 Installing front fender.......... 61 12.15 Checking the fuel pressure....... 61 12.16 Changing the fuel filter......... 63 12.17 Replacing the fuel pump.......... 64 13 WHEELS.................................. 67 13.1 Checking the tire air pressure..... 67 13.2 Checking the tire condition....... 67 13.3 Checking the brake discs.......... 68 13.4 Front wheel....................... 69 13.4.1 Removing the front wheel.......... 69 13.4.2 Installing the front wheel........ 69 13.4.3 Changing the front brake disc..... 70 13.5 Rear wheel........................ 71 13.5.1 Removing the rear wheel........... 71 13.5.2 Installing the rear wheel......... 71 13.5.3 Changing the rear brake disc...... 73 13.5.4 Checking the chain tension........ 74 13.5.5 Adjusting the chain tension....... 74 13.5.6 Checking the chain, rear sprocket, and engine sprocket........... 75 13.5.7 Cleaning the chain............. 77 13.5.8 Checking the rear hub rubber dampers................................. 78 14 WIRING HARNESS, BATTERY.................. 79 14.1 Removing the battery.............. 79 14.2 Installing the battery............ 80 14.3 Disconnecting the negative cable of the battery.............................. 80 14.4 Reconnecting the negative cable of the battery.............................. 81 14.5 Recharging the battery............ 81 14.6 Checking the charging voltage........ 82 14.7 Checking the open-circuit current.... 83 14.8 Changing the fuses of individual power consumers.......................... 83 15 BRAKE SYSTEM............................ 85 15.1 Checking the front brake linings..... 85 15.2 Changing the front brake linings..... 85 15.3 Checking the brake fluid level of the front brake.............................. 88 15.4 Adding front brake fluid.......... 88 15.5 Changing the front brake fluid....... 90 15.6 Checking the rear brake linings...... 92 15.7 Changing the rear brake linings...... 92 15.8 Checking the free travel of foot brake lever.................................... 95 15.9 Adjusting the free travel of the foot brake lever.............................. 95 15.10 Checking the rear brake fluid level. 96 15.11 Adding rear brake fluid.......... 97 15.12 Changing the rear brake fluid....... 98 16 LIGHTING SYSTEM, INSTRUMENTS................ 101 16.1 Setting the kilometers or miles...... 101 16.2 Adjusting the shift speed RPM1....... 101 16.3 Adjusting the shift speed RPM2....... 102 16.4 Setting the clock............. 102 16.5 Resetting the service interval display................................ 103 16.6 Checking the headlight setting..... 103 16.7 Adjusting the headlight range...... 104 16.8 Changing the parking light bulb.... 105 16.9 Changing the headlight bulb........ 107 17 ENGINE................................. 109 17.1 Removing the engine............. 109 17.2 Installing the engine........... 114 17.3 Engine disassembly.............. 120 17.3.1 preparations.................. 120 17.3.2 Draining the engine oil.......... 120 17.3.3 Removing the chain securing guide......................... 121 17.3.4 Removing the valve cover......... 121 17.3.5 Removing the spark plug.......... 122 17.3.6 Removing the clutch cover........ 122 17.3.7 Setting the engine to ignition top dead center............... 123 17.3.8 Removing the timing chain tensioner..................... 124 17.3.9 Removing the camshaft......... 124 17.3.10 Removing the cylinder head.... 125 17.3.11 Removing the piston........ 126 17.3.12 Removing the starter motor.... 126 17.3.13 Removing the timing chain..... 126 17.3.14 Removing the water pump wheel......................... 127 17.3.15 Removing the alternator cover. 127 17.3.16 Removing the rotor......... 128 17.3.17 Removing the starter drive.... 128 17.3.18 Removing the drive wheel of the balancer shaft................ 129 17.3.19 Removing the gear position sensor........................ 130 17.3.20 Removing the suction pump..... 130 17.3.21 Removing the clutch cage...... 131 17.3.22 Removing the primary gear..... 132 17.3.23 Removing the force pump....... 133 17.3.24 Removing the shift shaft...... 135 17.3.25 Removing the shift drum locating...................... 135 17.3.26 Removing the locking lever.... 135 17.3.27 Removing the oil filter.... 135 17.3.28 Removing the left engine case. 136 17.3.29 Removing the shift rails...... 137 17.3.30 Removing the shift drum....... 138 17.3.31 Removing the shift forks...... 138 17.3.32 Removing the transmission shafts........................ 138 17.3.33 Removing the balancer shaft... 138 17.3.34 Removing the crankshaft....... 139 17.4 Working on individual parts........ 139 17.4.1 Working on the left section of the engine case................. 139 17.4.2 Working on the right section of the engine case................. 140 17.4.3 Changing the shaft seal ring of the water pump.................. 141 17.4.4 Checking the radial play of the lower conrod bearing............ 142 17.4.5 Changing the conrod bearing..... 143 17.4.6 Changing the balancer shaft bearing......................... 145 17.4.7 Work on the cylinder head....... 145 17.4.8 Checking the cylinder head...... 146 17.4.9 Checking the pivot point of the camshafts....................... 147 17.4.10 Checking/measuring the cylinder........................ 148 17.4.11 Checking the piston ring end gap............................. 148 17.4.12 Checking/measuring the piston.... 149 17.4.13 Checking the piston/cylinder mounting clearance.............. 150 17.4.14 Checking the oil pump........... 150 17.4.15 Checking the oil pressure regulator valve................. 151 17.4.16 Checking the clutch............. 151 17.4.17 Checking the shift mechanism .... 152 17.4.18 Preassembling the shift shaft... 153 17.4.19 Disassembling the main shaft.... 154 17.4.20 Disassembling the countershaft.................... 155 17.4.21 Checking the transmission....... 155 17.4.22 Assembling the main shaft....... 157 17.4.23 Assembling the countershaft..... 157 17.4.24 Checking the timing assembly.... 159 17.4.25 Changing the stator............. 160 17.4.26 Checking the electric starter drive........................... 161 17.4.27 freewheel, checking............. 162 17.5 Engine assembly.................... 162 17.5.1 Installing the crankshaft....... 162 17.5.2 Installing the balancer shaft... 162 17.5.3 Installing the transmission shafts.......................... 163 17.5.4 Installing the shift forks...... 163 17.5.5 Installing the shift drum....... 163 17.5.6 Installing the shift rails...... 164 17.5.7 Installing the left engine case. 164 17.5.8 Installing the oil filter....... 166 17.5.9 Installing the locking lever.... 166 17.5.10 Installing the shift drum locating........................ 167 17.5.11 Installing the shift shaft...... 167 17.5.12 Installing the oil pump......... 167 17.5.13 Installing the primary gear...... 169 17.5.14 Installing the clutch basket..... 170 17.5.15 Installing the spacer............. 172 17.5.16 Installing the suction pump...... 172 17.5.17 gear position sensor, installing.... 173 17.5.18 Installing the balancer shaft drive wheel....................... 173 17.5.19 Installing the starter drive..... 174 17.5.20 Installing the rotor.............. 175 17.5.21 alternator cover, installing...... 175 17.5.22 Installing the water pump cover............................. 176 17.5.23 Installing the timing chain...... 176 17.5.24 Installing the starter motor..... 177 17.5.25 Installing the piston............. 177 17.5.26 Installing the cylinder head..... 179 17.5.27 Installing the camshafts......... 180 17.5.28 Installing the timing chain tensioner......................... 180 17.5.29 Checking the valve clearance..... 181 17.5.30 Adjusting the valve clearance.... 182 17.5.31 Installing the clutch cover...... 183 17.5.32 Installing the spark plug........ 184 17.5.33 Installing the valve cover....... 184 17.5.34 Installing the chain securing guide............................. 185 17.5.35 Installing the oil screen........ 185 17.5.36 engine, removing from the engine assembly stand............ 186 18 SHIFT MECHANISM.................... 187 18.1 Adjusting the shift lever............. 187 19 WATER PUMP, COOLING SYSTEM.................. 188 19.1 Draining the coolant.................. 188 19.2 Filling/bleeding the cooling system...................................... 188 19.3 Checking the antifreeze and coolant level............................... 190 19.4 Checking the coolant level........... 191 19.5 Changing the coolant.................. 192 20 LUBRICATION SYSTEM........................... 194 20.1 Oil circuit........................... 194 20.2 Checking the engine oil level..... 194 20.3 Checking the engine oil pressure.. 194 20.4 Changing the engine oil and oil filter, cleaning the oil screens........... 197 20.5 Adding engine oil.................. 198 21 IGNITION SYSTEM.............................. 200 21.1 Alternator - checking the stator winding..................................... 200 22 TECHNICAL DATA...................... 203 22.1 Engine........................ 203 22.2 Tolerance, engine wear limits... 204 22.3 Engine tightening torques....... 204 22.4 Capacities.................... 206 22.4.1 Engine oil.................. 206 22.4.2 Coolant..................... 206 22.4.3 Fuel........................ 206 22.5 Chassis....................... 206 22.6 Electrical system............. 207 22.7 Tires......................... 207 22.8 Fork.......................... 208 22.9 Shock absorber................ 208 22.10 Chassis tightening torques...... 208 23 CLEANING/PROTECTIVE TREATMENT......... 211 23.1 Cleaning the motorcycle....... 211 23.2 Checks and maintenance steps for winter operation............... 212 24 STORAGE............................. 213 24.1 Storage....................... 213 24.2 Preparing for use after storage. 214 25 SERVICE SCHEDULE.................... 215 25.1 Additional information........ 215 25.2 Required work................. 215 25.3 Recommended work.............. 216 26 WIRING DIAGRAM...................... 218 26.1 Pagel of 9.................... 218 26.2 Page 2 of 9................... 220 26.3 Page 3 of 9................... 222 26.4 Page 4 of 9................... 224 26.5 Page 5 of 9................... 226 26.6 Page 6 of 9................... 228 26.7 Page 7 of 9................... 230 26.8 Page 8 of 9................... 232 26.9 Page 9 of 9................... 234 27 SUBSTANCES.......................... 236 28 AUXILIARY SUBSTANCES................ 238 29 SPECIAL TOOLS....................... 240 30 STANDARDS........................... 253 31 INDEX OF SPECIAL TERMS.............. 254 32 LIST OF ABBREVIATIONS............... 255 INDEX.................................... 256

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