KTM 250 Duke Repair Manual 2016

2,076 363 89MB

English Pages [262] Year 2018

Author / Uploaded
KTM Sportmotorcycle GmbH

Table of contents :
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