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Related Manuals for KTM 250 SX-F 2016
Summary of Contents for KTM 250 SX-F 2016
- Page 1 OWNER'S MANUAL 2016 250 SX-F 250 XC‑F Art. no. 3213331en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Preparing for rides at low temperature and in TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 snow.............. 21 Symbols used ........... 4 RIDING INSTRUCTIONS..........22 Formats used............ 4 Checks and maintenance before putting into SAFETY ADVICE............5 operation............ - Page 5 TABLE OF CONTENTS 11.21 Mounting the seat ........... 50 15.3 Checking the coolant level ....... 83 11.22 Removing the air filter box cover ...... 50 15.4 Draining the coolant ........83 11.23 Installing the air filter box cover ....... 51 15.5 Refilling coolant ..........
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Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 7: Safety Advice
Use definition – intended use (All SX‑F models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 8: Safe Operation
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. -
Page 9: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left side (example) C00916-10 Hand brake lever ( p. 12) Clutch lever ( p. 12) Filler cap Air filter box lid Engine number ( p. 11) Shift lever ( p. 16) Cold start button ( p. -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) C00917-10 Shock absorber compression adjustment Kill switch ( p. 12) Electric starter button ( p. 12) Map‑Select switch for ride mode ( p. 13) Throttle grip ( p. 12) Type label ( p. -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. -
Page 14: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 102124-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. -
Page 15: Map-Select Switch For The Basic Setting (All Sx-F Models)
CONTROLS Map‑Select switch for the basic setting (All SX‑F models) The Map‑Select switch for the basic setting is fitted under the air filter box cover. Possible states SOFT – The mapping with reduced peak performance for better ride- ability is activated. The Launch Control can be activated. ADVANCED –... -
Page 16: Opening The Filler Cap
CONTROLS 6.10 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 17: Cold Start Button
CONTROLS (XC‑F US) – Replace the filler cap and turn clockwise until release button locks in place. Info Route fuel tank breather hose without kinks. S00849-10 6.12 Cold start button Cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. -
Page 18: Shift Lever
CONTROLS 6.14 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 (All SX‑F models) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 (XC‑F US) The gear positions can be seen in the photograph. -
Page 19: Side Stand (Xc-F Us)
CONTROLS 6.17 Side stand (XC‑F US) The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber ... -
Page 20: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 21: Running In The Engine
For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – Use the specified engine oil when riding under difficult conditions and to enhance performance, as recommended by KTM. Engine oil (SAE 10W/60) (00062010035) ( p. 106) –... -
Page 22: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (79006920000) Info See the KTM PowerParts fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand protection device for air filter (79006922000) Info See the KTM PowerParts fitting instructions. -
Page 23: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 24: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance before putting into operation Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. -
Page 25: Activating Launch Control
Do not change into a low gear at high engine speed. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off and for steep inclines. -
Page 26: Applying The Brakes
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system. -
Page 27: Transport
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment. - Page 28 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline 35 mm (1.38 in) Measurement of Total fuel tank 7.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx. (1.98 US gal) 91) ( p. 107) (All SX‑F models) Total fuel tank 8.5 l...
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Page 29: Service Schedule
Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. -
Page 30: Recommended Work
SERVICE SCHEDULE ○ One-time interval ● Periodic interval Recommended work Annually Every 100 operating hours Every 50 operating hours Every 40 operating hours Once after 20 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. -
Page 31: Tuning The Chassis
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…... -
Page 32: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 33: Adjusting The Rebound Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – ... -
Page 34: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 35: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 36: Adjusting The Riding Sag
TUNING THE CHASSIS – Check the free travel of the foot brake lever. ( p. 68) – Remove the motorcycle from the lift stand. ( p. 39) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. -
Page 37: Adjusting The Fork Air Pressure (Sx-F Eu)
S00861-10 Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 10.6 bar (154 psi) -
Page 38: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS (SX‑F EU) – Turn adjusting screw clockwise all the way. Info The adjusting screw is located at the upper end of the right fork leg. – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping S00860-10... -
Page 39: Handlebar Position
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. – Mount protection cap (SX‑F US, XC‑F US) – Turn red adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in right fork leg REB (red adjusting screw). - Page 40 TUNING THE CHASSIS Main work – Remove screws . Take off the handlebar clamps. Take off the handlebar and lay it to one side. Info Protect the components against damage by covering them. Do not bend the cables and lines. –...
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Page 41: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground. -
Page 42: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS (SX‑F US, XC‑F US) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. 402556-10 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 43: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 11.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws –... -
Page 44: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 102150-11 – Position the brake caliper. Mount and tighten screws Guideline Loctite ®... -
Page 45: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 108) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 46: Checking The Steering Head Bearing Play
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-... -
Page 47: Adjusting The Steering Head Bearing Play
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. -
Page 48: Removing The Start Number Plate
SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove it. 102160-10 11.15 Installing the start number plate – Attach the start number plate to the brake line. –... -
Page 49: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 11.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 102162-10 Finishing work – Install the start number plate. ( p. -
Page 50: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Remove the connecting link of the chain. – Take off the chain. S00857-10 – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. S00703-10 –... -
Page 51: Removing The Seat
SERVICE WORK ON THE CHASSIS – Mount the chain. – Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. S00854-10 – Position the foot brake cylinder. ... -
Page 52: Mounting The Seat
SERVICE WORK ON THE CHASSIS – Raise the rear of the seat, push the seat back, and lift it off. 102174-01 11.21 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. -
Page 53: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area M01370-10 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box cover EJOT PT... -
Page 54: Installing The Air Filter
SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 108) Info Only press the air filter to dry it, never wring it out. –... -
Page 55: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 11.28 Sealing the air filter box Preparatory work – Remove the air filter box cover. ( p. 50) Main work – Seal the air filter box in the marked area S00847-10 Finishing work – Install the air filter box cover. -
Page 56: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove all screws on the main silencer. – Take off silencer cap and O-ring – Take off outer tube and O-ring – Pull glass fiber yarn filling off of inner tube –... -
Page 57: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Disconnect the plug-in connection of the fuel line. Info Remaining fuel may flow out of the fuel hose. – Mount the wash cap set Wash cap set (81212016100) – Pull the hose off the fuel tank breather on the tank lid. M00782-10 –... -
Page 58: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 60) – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. –... -
Page 59: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info The service life of the chain depends largely on its maintenance. Preparatory work –... -
Page 60: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. - Page 61 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) 0 0 A – Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
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Page 62: Checking The Frame
If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. S00867-01 11.40 Checking the swingarm –... -
Page 63: Checking The Rubber Grips
SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band. -
Page 64: Checking/Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 11.44 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. - Page 65 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 106) – Remove bleeder screw – Mount bleeding syringe on the clutch slave cylinder. Info Clean up overflowed or spilt brake fluid immediately with water! M00785-10...
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Page 66: Brake System
Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each ... -
Page 67: Checking The Front Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 68: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ... -
Page 69: Changing The Front Brake Linings
Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –... -
Page 70: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. -
Page 71: Adjusting The Basic Position Of The Foot Brake Lever
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 72: Adding Rear Brake Fluid
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. -
Page 73: Changing The Rear Brake Linings
Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –... - Page 74 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
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Page 75: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 76: Removing The Rear Wheel
WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. -
Page 77: Installing The Rear Wheel
WHEELS, TIRES 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 78: Checking The Tire Condition
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) - Page 79 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diame- ter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions. You should hear a high note.
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Page 80: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries. -
Page 81: Recharging The Battery
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 82: Changing The Main Fuse
ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Maximum charging voltage 14.4 V Maximum charging current 3.0 A Charge the battery regularly when 6 months the motorcycle is not in use Info Never remove cover –... - Page 83 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 49) Main work – Pull the starter relay from the holder. 102224-10 – Remove protection caps – ...
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Page 84: Cooling System
COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 85: Checking The Coolant Level
COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. -
Page 86: Refilling Coolant
COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) -
Page 87: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3…... -
Page 88: Setting The Characteristic Map Of The Throttle Response
TUNING THE ENGINE 16.3 Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –... -
Page 89: Adjusting The Idle Speed
Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm. -
Page 90: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –... -
Page 91: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 92: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen
SERVICE WORK ON THE ENGINE Condition The engine is cold. – Check the engine oil level. The engine oil reaches the middle of level viewer » If the engine oil does not reach the middle of the level viewer: –... - Page 93 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case. S00712-10 –...
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Page 94: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. -
Page 95: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... -
Page 96: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 39) – Cover the vehicle with a tarp or similar cover that is permeable to air. -
Page 97: Putting Into Operation After Storage
STORAGE 19.2 Putting into operation after storage – Install the battery. p. 78) – Remove the motorcycle from the lift stand. ( p. 39) – Perform checks and maintenance steps before putting into operation. ( p. 22) – Take a test ride. 401059-01... -
Page 98: Troubleshooting
– Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 99 TROUBLESHOOTING Faults Possible cause Action – Battery discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the open-circuit current.
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Page 100: Technical Data
TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 14.4:1 Idle speed 2,250… 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in) -
Page 101: Engine Tightening Torques
TECHNICAL DATA 21.2 Engine tightening torques Loctite ® 243™ Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubrication M4 2 Nm (1.5 lbf ft) Loctite ®... -
Page 102: Capacities
TECHNICAL DATA Nut, cylinder head M10x1.25 Tightening sequence: Thread, oiled with engine Tighten diagonally. oil/cone greased 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50 Nm (36.9 lbf ft) Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) -
Page 103: Electrical System
Dunlop GEOMAX MX32 (XC‑F US) 90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork 21.7.1 SX‑F EU Fork part number 34.18.8P.05... -
Page 104: Sx-F Us
TECHNICAL DATA Standard 17 clicks Sport 12 clicks Air pressure 10.6 bar (154 psi) Fork length 950 mm (37.4 in) Oil capacity external mecha- ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 106) +1.35 −20 −0.68 nism right Oil capacity external mecha- ml (6.76 fl. -
Page 105: Shock Absorber
TECHNICAL DATA 21.8 Shock absorber 21.8.1 SX‑F EU Shock absorber part number 18.18.7P.05 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns... -
Page 106: Xc-F Us
TECHNICAL DATA Static sag 40 mm (1.57 in) Riding sag 110 mm (4.33 in) Fitted length 477 mm (18.78 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 107) 21.8.3 XC‑F US Shock absorber article number 18.18.7P.75 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed... - Page 107 TECHNICAL DATA – Screw, electric starter cable connec- 4 Nm (3 lbf ft) tion Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Loctite 243™ Screw, rear brake disc 14 Nm (10.3 lbf ft) ® – Screw, throttle grip 5 Nm (3.7 lbf ft) –...
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Page 108: Substances
109) – SAE ( p. 109) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. Synthetic engine oil... - Page 109 SUBSTANCES Multi-purpose grease (00062010051) Recommended supplier Klüber Lubrication ® – CENTOPLEX 2 EP Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 109) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
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Page 110: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex... -
Page 111: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 112: Index Of Special Terms
INDEX OF SPECIAL TERMS Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes On-board diagnosis Vehicle system that monitors emission- and safety-related values... -
Page 113: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 114: List Of Symbols
LIST OF SYMBOLS 27.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The low fuel warning lamp lights up orange –... -
Page 115: Index
INDEX Characteristic map of the throttle response INDEX adjusting ....... . . 86 Switches Chassis number . - Page 116 INDEX basic setting, checking ..... . . 34 Map‑Select switch bleeding ....... . . 39 for the basic setting .
- Page 117 INDEX spring preload, adjusting ..... . 33 static sag, checking ......32 Shock absorber article number .
- Page 118 *3213331en* 3213331en 04/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...