Torque values:

• Rear axle – 90nm
• Front axle – 45nm
• Fork screws – 15nm
• Oil drain plug (magnet) – 20nm
• Oil screen plug – 15nm
• Oil filter cover – 6nm

Fuses:

• Fuse 1 – 10A – ignition, combination instrument, clock, EFI, control unit
• Fuse 2 – 10A – ignition, combination instrument, EFI, control unit
• Fuse 3 – 10A – fuel pump
• Fuse 4 – 10A – radiator fan
• Fuse 5 – 10A – horn, brake light, turn signal
• Fuse 6 – 15A – high beam, low beam, parking light, tail light, license plate lamp
• Fuse 7 – 10A – for auxiliary equipment (permanent positive)
• Fuse 8 – 10A – for supplementary equipment (accessories connected with ignition switch)
• Fuse 9 – 10A – ABS
• Fuse 10 – not used
• Fuse SPARE – 10A/15A – spare fuses

Basic info:

• Engine oil capacity – 1.7L
• Engine oil type – SAE 10W60 (or 10W50)
• Coolant capacity – 1.2L
• Fuel tank capacity – 12L + 2.5L
• Fuel filter 30 micron “Mahle KL 97” (original KTM 81207090000) or “Mahle KL15” (cheaper option) in-tank filter.
• Fuel pump – A new identical built fuel pump for a Vespa 300 GTS (30 Euro) vs original KTM fuel pump (330 Euro). Both Pumps were made in China. Or Japanese KEMSO-13001 replacement pump. Or Quantum HFP 389 102419. Or Taco Moto 3000hr. Or AllBalls fuel pump kit.
• Brake wear limit – 4.5mm (front/rear)
• Tire pressure offroad – 1.5 bar
• Tire pressure road – 1.8 bar
• Tire pressure pax/luggage – 2.2 bar
• Battery – YTZ10S
• Tire sizes – 90/90-21 & 140/80-18
• Chain slack – 30mm
• Spark plug inside – NGK LKAR8BI-9
• Spark plug outside – NGK LMAR7A-9
• Spark plug gap – 0.9mm

Common issues and weak points:

• Rocker arms bearing failure
• Fuel pump failure
• Fuel filler cap overfill/dirt build-up
• Fuel filter cracking
• Fuel filter blockage
• Engine overheating
• Fan housing (the brackets gain clearance over the time and then the housing is slowly rattling/eating its way into the radiator and damage it till cooling fluid leaks)
• Sub-frame bolts moving and cracking brackets

Fixes and upgrades:

• Replace rocker arms with post-2015 parts
• Rocker arms:
  • SF13 –
  • SF14 –
  • SF15 – roller axle improved design – incorporated 2016+
  • Still advised to make sure roller bearing is OK every valve check.
  • Replacement at 25k km.
  • Book spec: 0.07-0.013
  • Lyndon Poskitt spec: 0.04-0.09 inlet & outlet
  • Puncturing the rocker arm bearings for preventing the axles from moving/destroying the valve train
• Installing stronger sub frame bolts from Rally Raid or NiceCNC
• Sub-frame reinforcement bushing and bolt sleeve
• Adding additional holes to the fuel pump housing for better cooling of the pump in low fuel situations
• Mount a 88° Degree Celsius fan-switch for keeping engine temperatures lower (original switch turns the fan on at 102° Degrees Celsius) Rallyraid (RRP027) or NiceCNC or Suzuki (17680-50F00) or Suzuki p/n 17680-50F70
• Neoprene fork covers
• Fuel pre-filter Twin Air
• (cosmetic) Polisport (Fender 125-500 (EXC, SMR, SX, XC) 23-25)
• Stainless steel oil pressure hose
• Fuel filler cap NiceCNC
• Fuel filter under seat in-line 11 micron Wix 33095 or NAPA 3095 (OEM is 10 micron). Other options: Golan High Flow Compact Fuel Filters (10 micron). Note: 2013 models and older do not have this, make sure to include it before fuel hits the injector
• Two cable ties between the ABS-Pump bracket and the ventilator housing to pull back the fan housing in the direction of the ABS-Pump bracket, eliminate vibration

Torque values:

• Rear axle – 180nm
• Front axle –
• Oil drain plug –
• Oil filter bolts –

Fuses

• Regulator – 40A
• Injection relay – 20A
• Stop light, horn, flasher – 20A
• Key sense – 7.5A
• Control unit power supply – 3A
• High and low beams – 15A
• Instrument panel – 3A
• Key on – 7.5A

Basic info:

• Engine oil capacity – 3.4L
• Engine oil type – SAE 10W40
• Coolant capacity – 2.3L
• Fuel tank capacity – 15.5L of which 3L reserve
• Brake wear limit – 4 mm (front), 4.5mm (rear)
• Tire pressure front – 2.1 bar
• Tire pressure rear – 2.2 bar
• Tire sizes – 120/70-17 & 190/50-17
• Chain slack –
• Spark plug – NGK CR9EK
• Spark plug gap – 0.7-0.8mm

Common issues and weak points:

Fixes and upgrades:

Torque values:

Basic info:

• Brake pads front 06451-KZZ-902
• Brake pads rear 06435-KZZ-902
• Oil filter 15410-KYJ-902 / HF103
• Oil filter gasket 15412-KYJ-901
• Oil sump gasket 11394-K87-A30
• Spark plug SIMR8A9 31916-MEH-003

Common issues and weak points:

• Clutch plate failure

Fixes and upgrades:

• Clutch plate kit PN 22210K87305
• EBC – CK1313 – Clutch plates (CRF250 only)
• EBC – CSK188 – Clutch springs (CRF250 only)
• Barkbusters BHG-091-00-NP

Torque values:

• Rear axle – 100nm
• Front axle – 60nm
• Front axle pinch bolts – 22nm
• Oil drain plug – 30nm
• Spark plugs – 22nm
• Front brake caliper mounting bolt – 45nm
• Rear brake caliper mounting bolt – 22nm
• Rear brake pad pin – 17nm

Fuses:

• Main fuse – 30A
• FI fuse – 15A
• ABS Main fuse – 30A
• Sub fuse – 20Ax1, 10Ax1, 7.5Ax6

Basic info:

• Engine oil capacity – 3.9 liter, 4.1 liter (oil filter), 4.9 liter (disassembly)
• Engine oil type – SAE 10W-30
• Oil filter – HF204
• Coolant capacity – 1.63 liters
• Coolant – Ethylene glycol antifreeze containing silicate-free corrosion inhibitors
• Fuel tank capacity – 18.8L
• Fuel filter –
• Fuel pump –
• Brake wear limit – 4.5mm (front/rear)
• Tire pressure offroad – 1.7
• Tire pressure road – 2.0/2.5
• Tire pressure pax/luggage – 2.0/2.8
• Battery – YTZ14S
• Tire sizes – 90/90-21M/C 54H & 150/70R18M/C 70H
• Chain slack – 35mm-45mm
• Chain – DID525HV3-124LE
• Spark plug – SILMAR8A9S (NGK)
• Spark plug gap – 0.8 – 0.9 mm

Common issues and weak points:

• Rectifiers
• Fuel pump
• Windscreen navigation bar cracking at weld joints
• The rear right side wheel bearing will most likely fail early, as early as 25,000 klms. Especially so if you are heavily loaded and/or ride in hash conditions. Corrugated roads, dust, water crossing etc. It’s a very common 6204, carry spares or modify to a sealed double row 4204 bearing like I have.
• Well known issue of worn sliders on the std el-cheapo Showa forks. Won’t cause a failure, but there you go.
• Whilst on the forks, many have experienced blown fork seals. Do as I have and use neoprene fork gaitors to exclude most dust. Oh I’ve also swapped over to Ohlins. Infinately superior to the originals.
• Corroding spokes. Well known issue. Also spokes will work loose. Keep an eye on them
• Front disc carrier bobbins flogging out. Another known problem. Honda has at times replaced these under warrantly.
• Failed coolant pump. Usually presents itself early in the bikes life. Issue can be identified when coolant can be seen from the weep/witness hole on the right side of the crank case.
• Keep your air box drain tubes clear. Drain every 10-20000 klms. Found on each side of the lower edge of the tank.

Fixes and upgrades:

• Engine bars
• Crash bars
• Frame protectors
• Reinforced windscreen bracket Ali

Torque values:

• Rear axle –
• Front axle –
• Front axle clamp bolts –
• Oil drain plug –
• Spark plugs –
• Rocker arm adjusting screw –
• Steering head bearing adjuster nut –
• Steering stem nut –
• Top yoke fork clamp bolts –
• Shock absorber mounting bolts –
• Front fork top bolt –
• Front fork clamp bolts (top yoke) –
• Front fork clamp bolts (bottom) –
• Swingarm pivot bolt nut –
• Brake disc bolts –
• Brake hose banjo bolts –

Fuses:

Basic info:

• Engine oil capacity –
• Engine oil type –
• Coolant capacity –
• Fuel tank capacity –
• Fuel filter –
• Fuel pump –
• Brake wear limit – 4.5mm (front/rear)
• Tire pressure offroad –
• Tire pressure road –
• Tire pressure pax/luggage –
• Battery –
• Tire sizes – 90/90-21 & 140/80-18
• Chain slack –
• Spark plug inside –
• Spark plug outside –
• Spark plug gap –

Common issues and weak points:

• Rectifiers
• Fuel pump

Fixes and upgrades:

Torque values:

• Rear axle – 95nm
• Front axle – 64nm
• Front axle clamp bolts – 12nm
• Oil drain plug – 34nm
• Spark plugs – 14nm
• Rocker arm adjusting screw – 23nm
• Steering head bearing adjuster nut – 11nm
• Steering stem nut – 128nm
• Top yoke fork clamp bolts – 27nm
• Shock absorber mounting bolts – 44nm
• Front fork top bolt – 23nm
• Front fork clamp bolts (top yoke) – 27nm
• Front fork clamp bolts (bottom) – 33nm
• Swingarm pivot bolt nut – 106nm
• Brake disc bolts – 43nm
• Brake hose banjo bolts – 34nm

Fuses:

• Fuse 1 – 10A – ignition, combination instrument, clock, EFI, control unit
• Fuse 2 – 10A – ignition, combination instrument, EFI, control unit
• Fuse 3 – 10A – fuel pump
• Fuse 4 – 10A – radiator fan
• Fuse 5 – 10A – horn, brake light, turn signal
• Fuse 6 – 15A – high beam, low beam, parking light, tail light, license plate lamp
• Fuse 7 – 10A – for auxiliary equipment (permanent positive)
• Fuse 8 – 10A – for supplementary equipment (accessories connected with ignition switch)
• Fuse 9 – 10A – ABS
• Fuse 10 – not used
• Fuse SPARE – 10A/15A – spare fuses

Basic info:

• Engine oil capacity –
• Engine oil type –
• Coolant capacity –
• Fuel tank capacity –
• Fuel filter –
• Fuel pump –
• Brake wear limit – 4.5mm (front/rear)
• Tire pressure offroad –
• Tire pressure road –
• Tire pressure pax/luggage –
• Battery –
• Tire sizes – 90/90-21 & 140/80-18
• Chain slack –
• Spark plug inside –
• Spark plug outside –
• Spark plug gap –

Common issues and weak points:

• Rectifiers
• Fuel pump

Fixes and upgrades: