KTM 250 Duke — Example photo: Dennis Bratland, CC BY-SA 4.0, Wikimedia Commons

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KTM · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

250 Duke

Library entry covers 2015-2026

38 factory 40 guideline

Published source

KTM 250 Duke Owner's Manual 2016, Service Schedule pp.72-73

Factory owner's handbook. Covers 2016 owner's manual (art. no. 3213414en).

78 items for a 2022 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2022 KTM 250 Duke

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 12 months

5 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 4,650 mi or 12 months

28 items

Change engine oil

Engine

Factory

Manual: Change the engine oil and oil filter and clean the oil screens. Factory: After 1,000 km (620 mi); then every 7,500 km (4,650 mi) or year
Check that the electrical system is functioning properly.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check that the radiator fan is functioning properly.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check the antifreeze. (9.3 Recommended work, p.74)

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every year
Check the coolant level.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check the screws and nuts for tightness. (9.3 Recommended work, p.74)

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every year; ● Every four years
Clean oil strainers / mesh screens

Engine

Factory

Manual: Change the engine oil and oil filter and clean the oil screens. Factory: Done with oil change
Final check: Check the vehicle for roadworthiness and take a test ride.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Read out the fault memory using the KTM diagnostics tool after a test ride.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Read out the fault memory using the KTM diagnostics tool.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Replace oil filter

Engine

Factory

Manual: Change the engine oil and oil filter and clean the oil screens. Factory: Done with oil change
Reset the service interval display.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and correct routing. (9.3 Recommended work, p.74)

Fuel and air

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every year; ● Every four years
Check the chain tension.

Final drive

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. (9.3 Recommended work, p.74)

Final drive

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every year; ● Every four years
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Check the chain, rear sprocket, and engine sprocket.. Factory: Every 7,500 km or year
Check steering head bearing adjustment

Front end

Factory

Manual: Check the play of the steering head bearing.. Factory: After 1,000 km; every 7,500 km or year
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Check the shock absorber and fork for leaks.. Factory: Every 7,500 km or year
Check brake pads and discs

Brakes

Factory

Manual: Check the front / rear brake linings.. Factory: Every 7,500 km or year
Check the brake discs.

Brakes

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check the brake fluid level of the front brake.

Brakes

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year
Check the brake lines for damage and leakage.

Brakes

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check the rear brake fluid level.

Brakes

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year
Check the tire air pressure.

Wheels and tires

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check the tire condition.

Wheels and tires

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.

Controls and cables

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years
Check the cables for damage and routing without sharp bends.

Controls and cables

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi); ● Every year; ● Every two years

Every 4,650 mi

5 items

Check the headlight setting.

Engine

Factory

Factory: As printed: ○ After 1,000 km (620 mi); ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi)
Replace air filter element

Fuel and air

Factory

Manual: Change the air filter. Clean the air filter box.. Factory: Every 7,500 km and 15,000 km columns; no time column
Clean the dust boots of the fork legs.

Front end

Factory

Factory: As printed: ● Every 7,500 km (4,650 mi); ● Every 15,000 km (9,300 mi)
Check the swingarm bearing. (9.3 Recommended work, p.74)

Rear suspension and frame

Factory

Factory: As printed: ● Every 7,500 km (4,650 mi)
Check the wheel bearing for play. (9.3 Recommended work, p.74)

Wheels and tires

Factory

Factory: As printed: ● Every 7,500 km (4,650 mi)

Every 6,000 mi or 12 months

7 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,300 mi

1 item

Replace spark plugs

Engine

Factory

Manual: Check the valve clearance, change the spark plugs.. Factory: Every 15,000 km (9,300 mi)

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

3 items

Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

5 items

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Change the rear brake fluid.

Brakes

Factory

Factory: Printed per the re-read doubt: 'Change the rear brake fluid.' ● Every two years only, a separate row from the front brake fluid. (From the re-read doubt notes: KTM 250 Duke, printed line or second operation stated in the DOUBT line.)
Replace brake fluid

Brakes

Factory

Manual: Change the front brake fluid.. Factory: Every two years

Every 4 years

4 items

Change the coolant. (9.3 Recommended work, p.74)

Engine

Factory

Factory: As printed: ● Every four years
Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

1 item

Check valve clearances (shim adjusted)

Engine

Factory

Manual: Check the valve clearance.. Factory: Every 15,000 km (9,300 mi); one-time check after 1,000 km

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.