KTM 250 SX 2024 Owner's Manual
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KTM 250 SX 2024 Owner's Manual

KTM 250 SX 2024 Owner's Manual

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OWNER'S MANUAL
2024
250 SX
300 SX
250 XC
300 XC
Art. no. 3214833en

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Summary of Contents for KTM 250 SX 2024

  • Page 1 OWNER'S MANUAL 2024 250 SX 300 SX 250 XC 300 XC Art. no. 3214833en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.15 Foot brake lever ....... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 6.16 Plug-in stand (All SX models).... 20 Symbols used ........5 6.17 Side stand (All XC models)....21 Formats used........5 PREPARING FOR USE......... 22 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.9 Adjusting the spring preload of the 11.31 Preparing air filter box cover for shock absorber ......39 securing ........68 10.10 Adjusting the riding sag ....40 11.32 Removing the main silencer ....68 10.11 Air suspension XACT ......41 11.33 Installing the main silencer....
  • Page 6 TABLE OF CONTENTS 14 ELECTRICAL SYSTEM ....... 100 23.3.2 Coolant ........132 23.3.3 Fuel ......... 132 14.1 Removing the 12-V battery ..100 23.4 Chassis ......... 132 14.2 Installing the 12-V battery ... 101 23.5 Electrical system......133 14.3 Charging the 12-V battery ...

  • Page 7: Means Of Representation 1

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (All SX models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – 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.

  • Page 10: Work Rules

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) I00379-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Air filter box cover Shift lever ( p. 19)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) I00380-10 Shock absorber compression adjuster Combination switch ( p. 16) Stop button ( p. 15) Start button ( p. 16) Throttle grip ( p. 15) Fork compression adjuster Vehicle identification number ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Steering head label The steering head label is attached to the front of the steering head. 401946-10 Engine number Engine number is embossed on the left side of the engine above the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever (All SX models) Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself auto- matically. S05507-10 (All XC models) Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself auto- matically.

  • Page 17: Throttle Grip

    CONTROLS 6 Throttle grip (All SX models) The throttle grip is fitted on the right side of the handle- bar. S05509-11 (All XC models) The throttle grip is fitted on the right side of the handle- bar. S05510-11 Stop button (All SX models) The stop button is located on the right side of the handle-...

  • Page 18: Start Button

    6 CONTROLS Start button (All SX models) Start button is fitted on the right side of the handlebar. S05511-11 (All XC models) Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed –...

  • Page 19: Overview Of Indicator Lights (All Xc Models)

    CONTROLS 6 Overview of indicator lights (All XC models) Possible states Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics. lights up white – STANDARD map- Indicator lamp ping is activated. lights up green – ADVANCED map- Indicator lamp ping is activated.

  • Page 20: Closing The Fuel Tank Filler Cap

    6 CONTROLS Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. (All SX models) – Turn fuel tank filler cap counterclockwise and lift it off.

  • Page 21: Cold Start Button

    CONTROLS 6 6.12 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 22: Foot Brake Lever

    6 CONTROLS (All SX models) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-13 (All XC models) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears.

  • Page 23: Side Stand (All Xc Models)

    CONTROLS 6 6.17 Side stand (All XC models) The side stand is located on the left of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10...

  • Page 24: Preparing For Use

    When using the motorcycle, remember that others may be disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 25: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 88) – Adjust the basic position of the shift lever. p. 117) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.

  • Page 26: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    – Riding at low temperatures and in snow. ( p. 26) Preparing the vehicle for rides on dry sand – Mount the air filter dust cover. Air filter dust cover (A46006920000) Info Observe the fitting instructions for KTM PowerParts. F03669-01...

  • Page 27: Preparing The Vehicle For Rides On Wet Sand

    PREPARING FOR USE 7 – Mount the air filter sand cover. Air filter sand cover (A46006922000) Info Observe the fitting instructions for KTM PowerParts. F03670-01 – Clean the chain. Chain cleaner ( p. 140) – Mount the steel sprocket. –...

  • Page 28: Preparing The Vehicle For Rides On Wet And Muddy Circuits

    Preparing the vehicle for rides on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (A46006921000) Info Observe the fitting instructions for KTM PowerParts. F03668-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 29: Riding Instructions 8

    RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use 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 it is being operated. –...

  • Page 30: Starting Off

    8 RIDING INSTRUCTIONS (All SX models) – Remove plug-in stand H02629-10 (All XC models) – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 31: Shifting, Riding

    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 32: Stopping, Parking

    8 RIDING INSTRUCTIONS – Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not over- rev the engine when doing so. This means that significantly less braking is required and the brake system does not overheat.

  • Page 33: Refueling

    RIDING INSTRUCTIONS 8 (All SX models) – Switch off the engine. – Mount plug-in stand on the fork legs. Plug-in stand (79029094000) Info The plug-in stand is included. Make sure the brake line runs in front of the plug-in stand and does not become wedged. H02628-01 –...
  • Page 34 8 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline 35 mm (1.38 in) Measurement of Total fuel tank 7.2 l Super unleaded capacity, approx. (All (1.9 US gal) (95 octane) mixed SX models) with 2-stroke engine oil (1:60) p.

  • Page 35: Service Schedule 9

    Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
  • Page 36 ● ● Take a test ride. ○ ● ● ● ● Read out the fault memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ●...

  • Page 37: Tuning The Chassis 10

    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 effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock...

  • Page 38: Adjusting The High-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 effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.

  • Page 39: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjuster clockwise up to the last perceptible click.

  • Page 40: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 48) 10.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 37) – Hold the motorcycle upright with aid of an assistant. –...

  • Page 41: Adjusting The Spring Preload 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 spring length.

  • Page 42: Adjusting The Riding Sag

    10 TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 48) 10.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) – Remove the frame protector. ( p. 52) –...

  • Page 43: Air Suspension Xact

    TUNING THE CHASSIS 10 10.11 Air suspension XACT Air suspension WP XACT is used in the fork. In this system, the suspension is located in the left fork leg and damping in the right fork leg. As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks.

  • Page 44: Adjusting The Fork Air Pressure (All Sx Models)

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 10.5 bar (152 psi)

  • Page 45: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only mount the protection cap by hand. Finishing work – Remove the motorcycle from the lift stand. ( p. 48) 10.14 Adjusting the compression damping of the fork Info...

  • Page 46: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping during compression. 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All SX models) – Turn adjuster clockwise all the way to the stop.

  • Page 47: Handlebar Position

    TUNING THE CHASSIS 10 10.16 Handlebar position The holes on the handlebar support are placed at a distance from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.
  • Page 48 10 TUNING THE CHASSIS Main work – Remove screws . Take off handlebar clamp . Take off the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
  • Page 49 TUNING THE CHASSIS 10 Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)

  • Page 50: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 51: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) Main work (All SX models) – Release bleeder screws Any excess pressure escapes from the interior of the fork.

  • Page 52: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS – Press the dust boots back into their normal position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 50) – Remove the motorcycle from the lift stand. ( p. 48) 11.5 Removing the fork protector –...

  • Page 53: Removing The Engine Guard (All Xc Models)

    SERVICE WORK ON THE CHASSIS 11 11.7 Removing the engine guard (All XC models) – Remove screws with the bushings. – Remove screw . Take off the engine guard. S05522-10 11.8 Installing the engine guard (All XC models) – Position the engine guard on the frame. –...

  • Page 54: Removing The Frame Protector

    11 SERVICE WORK ON THE CHASSIS 11.9 Removing the frame protector – Remove the cable ties. – Remove screws with the bushings. – Take off the left frame protector. – Push the right frame protector to the front and take off at the bottom.

  • Page 55: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.12 Installing the fork legs Main work (All SX models) – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of F03665-11...

  • Page 56: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.13 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) – Remove the front wheel. p. 94) – Remove the fork legs. p. 52) – Remove the start number plate.
  • Page 57 SERVICE WORK ON THE CHASSIS 11 – Position the upper triple clamp and handlebar. – Mount screw , but do not tighten it yet. Guideline Screw, steering head, M20x1.5 12 Nm (8.9 lbf ft) S05332-11 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 58: Checking Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 59: Adjusting Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...

  • Page 60: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.17 Lubricating the steering head bearing – Remove the lower triple clamp. p. 54) – Install the lower triple clamp. p. 54) Info The steering head bearing is cleaned and lubricated in the course of removal and installation. H02387-01 11.18 Removing the start number plate...

  • Page 61: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Remove front fender. S05339-10 11.21 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05339-10 Finishing work –...

  • Page 62: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) – Remove the frame protector. ( p. 52) Main work – Remove screw – Remove fitting Info Raise the swingarm slightly to be able to remove the screws more easily.

  • Page 63: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. S05502-10 11.23 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.

  • Page 64: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on M16x1.5 60 Nm (44.3 lbf ft) angle lever Info Pay attention to flat area S05348-10 – Mount and tighten screw Guideline Screw, bottom...

  • Page 65: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 11.25 Mounting the seat – Attach the seat to the collar bushings at the front and simulta- neously push it back. The holding lugs engage in the recesses at the back. – Make sure the seat is latched in place correctly. S05495-10 –...

  • Page 66: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.27 Installing the air filter box cover (All SX models) Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area Info An air filter box cover with openings for greater airflow and a more direct response is included.
  • Page 67 SERVICE WORK ON THE CHASSIS 11 (All XC models) Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area S05497-10 – Mount and tighten screw Guideline Screw, air filter EJOT PT ®...

  • Page 68: Removing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.28 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 69: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the air filter. p. 67) – Install the air filter box cover. ( p. 64) 11.30 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 70: Preparing Air Filter Box Cover For Securing

    11 SERVICE WORK ON THE CHASSIS 11.31 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p. 63) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in) F03679-10 Finishing work –...

  • Page 71: Changing The Glass Fiber Yarn Filling In The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.34 Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the rock wool escape into the air, and the main silencer “burns out”.
  • Page 72 11 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • Page 73: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Pull both spoilers laterally off the radiator and lift off the fuel tank. S05361-10 11.36 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 74: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05377-11 – Plug in fuel pump connector – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air.

  • Page 75: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Note 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 regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 76: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 48) 11.40 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 77: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.41 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket, and engine sprocket for wear. »...
  • Page 78 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 79: Checking The Frame

    SERVICE WORK ON THE CHASSIS 11 – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Remaining screws, 10 Nm chassis (7.4 lbf ft) Remaining nuts, 10 Nm chassis (7.4 lbf ft)

  • Page 80: Checking The Rubber Grip

    11 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, above the fuel tank bracket on the right of the frame to the throttle valve body. The throttle cable must be secured on the fuel tank bracket with a rub- ber strap.

  • Page 81: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 11.46 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 82: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS 11.48 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid is a harmful substance. – 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 83 SERVICE WORK ON THE CHASSIS 11 – Position the cover with the membrane. Mount and tighten the screws. Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 84: 12 Brake System

    Do not make any adjustments while riding. 12.3 Checking the brake discs Warning 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.)

  • Page 85: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 86: Adding Front Brake Fluid

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 87: Checking That The Brake Linings Of The Front Brake Are Secured

    Checking that the brake linings of the front brake are secured 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 lining thickness ≥...

  • Page 88: Changing The Brake Linings Of The Front Brake

    Changing the brake linings of the front brake Warning Danger of accidents Incorrect servicing 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 is a harmful substance.
  • Page 89 BRAKE SYSTEM 12 – Remove screws – Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc. Carefully pull the brake caliper up and off the brake disc. – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir;...

  • Page 90: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM – Add brake fluid up to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Position cover with membrane – Mount and tighten screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 91: Checking The Rear Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 92: Adding Rear Brake Fluid

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 93: Checking That The Brake Linings Of The Rear Brake Are Secured

    Checking that the brake linings of the rear brake are secured 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 lining thickness ≥...
  • Page 94 – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)
  • Page 95 BRAKE SYSTEM 12 – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.

  • Page 96: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 97: Installing The Front Wheel

    WHEELS, TIRES 13 13.2 Installing the front 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. –...

  • Page 98: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 99 WHEELS, TIRES 13 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 100: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 101: Checking Spoke Tension

    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 102: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is operated. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard 12 V batteries contain environmentally hazardous materials. –...

  • Page 103: Installing The 12-V Battery

    ELECTRICAL SYSTEM 14 14.2 Installing the 12-V battery Main work – Pull up battery holding bracket , insert the 12-V battery into the battery compartment with the terminals facing upwards and secure with battery holding bracket 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 104: Charging The 12-V Battery

    14 ELECTRICAL SYSTEM 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 105: Changing The Main Fuse

    It is also impossible to overcharge the 12-V battery with this battery charger. The charging time may be longer at low temperatures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...

  • Page 106: Changing The Fuse Of The Fuel Pump

    14 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. S05554-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 107: Diagnostics Connector

    ELECTRICAL SYSTEM 14 Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire – Insert the new fuse for the fuel pump. Fuse (58011109105) ( p. 133) – Check that the electrical system is functioning properly. –...

  • Page 108: 15 Cooling System

    15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 109: Checking The Coolant Level

    COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets 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 110: Refilling With Coolant

    15 COOLING SYSTEM Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 111 COOLING SYSTEM 15 – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant ( p. 138) 400243-10 – Remove screw and wait until coolant emerges without bub- bles. – Mount and tighten screw Guideline Bleeder screw, cylin- 10.5 Nm...

  • Page 112: Changing The Coolant

    15 COOLING SYSTEM 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets 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 113 COOLING SYSTEM 15 – Remove screw and wait until coolant emerges without bub- bles. – Mount and tighten screw Guideline Bleeder screw, cylin- 10.5 Nm der head (7.74 lbf ft) G05886-11 – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant (...

  • Page 114: 16 Exhaust Control

    16 EXHAUST CONTROL 16.1 Programming the end positions of the exhaust control Info If work has been carried out on the exhaust control, the end positions must be reprogrammed. Condition The engine is off. Preparatory work – Remove the seat. ( p.
  • Page 115 EXHAUST CONTROL 16 – Mount diagnostics connector on the holder. G05977-10 Finishing work – Mount the seat. ( p. 63)

  • Page 116: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Changing the mapping Info The desired engine characteristic can be altered using the combination switch. Changing the mapping also affects the response of the exhaust control. The setting most recently selected is activated again when restarting. The mapping can also be changed during the ride.

  • Page 117: Adjusting The Play In The Throttle Cable

    17.4 Adjusting the idle speed Warning 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.)

  • Page 118: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE – Run the engine until warm. Guideline Do not allow engine to warm up at idle speed. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine.

  • Page 119: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 17.6 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing.

  • Page 120: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 121: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 18 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 122: Adding The Gear Oil

    18 SERVICE WORK ON THE ENGINE Note 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 regulations. Info Drain the gear oil while the engine is at operating temperature. Preparatory work –...
  • Page 123 SERVICE WORK ON THE ENGINE 18 Main work – Remove gear oil level monitoring screw – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw. Engine oil (15W/50) ( p.

  • Page 124: 19 Cleaning, Care

    19 CLEANING, CARE 19.1 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 125 CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 140) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 126: 20 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 48) – Cover the vehicle with a tarp or a similar cover that is perme-...

  • Page 127: Preparing For Use After Storage

    STORAGE 20 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus- ing engine parts and the exhaust system to rust.

  • Page 128: 21 Troubleshooting

    – Read out the fault memory using the KTM diagnostics tool. – Gear oil exits at the vent hose Too much gear oil added Check the gear oil level. ( p. 119) –...
  • Page 129 Check wiring for damage and electrical fuel injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.

  • Page 130: 22 Blink Code

    22 BLINK CODE Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine control Error level condition unit Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition Crankcase pressure sensor - short circuit to ground...
  • Page 131 BLINK CODE 22 Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil – circuit fault Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – synchronization faulty Error level condition Crankshaft speed sensor –...

  • Page 132: 23 Technical Specifications

    23 TECHNICAL SPECIFICATIONS 23.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement (All 250 models) 249 cm³ (15.19 cu in) Displacement (All 300 models) 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole (All 250 models) 66.4 mm (2.614 in) Hole (All 300 models) 72 mm (2.83 in)

  • Page 133: Engine Tightening Torques

    TECHNICAL SPECIFICATIONS 23 23.2 Engine tightening torques EJOT DELTA PT Screw, inner membrane sheets ® 3.5x25 1 Nm (0.7 lbf ft) EJOT DELTA PT Screw, membrane support plate ® 3x12 1 Nm (0.7 lbf ft) EJOT DELTA PT ® Screw, outer membrane sheets 1 Nm (0.7 lbf ft) Nut, axle for control flap 5 Nm (3.7 lbf ft)

  • Page 134: Capacities

    23 TECHNICAL SPECIFICATIONS Screw, balancer shaft 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, cylinder head 27 Nm (19.9 lbf ft) Nut, cylinder base 38 Nm (28 lbf ft) Screw, drive chain engine sprocket 60 Nm (44.3 lbf ft) Loctite ®...

  • Page 135: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM 23.7 Fork 23.7.1...

  • Page 136: All Xc Models

    23 TECHNICAL SPECIFICATIONS Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Air pressure 10.5 bar (152 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism ml (8.11 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 −...

  • Page 137: All Xc Models

    TECHNICAL SPECIFICATIONS 23 Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 42 N/mm (240 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 45 N/mm (257 lb/in) Weight of rider: 85 …...

  • Page 138: Chassis Tightening Torques

    23 TECHNICAL SPECIFICATIONS 23.9 Chassis tightening torques Hose clamp, radiator 2.4 Nm (1.77 lbf ft) Hose clip, inlet sleeve to throttle 2.8 Nm (2.07 lbf ft) valve body Screw, air filter box, on subframe EJOT PT ® K60x20AL 5 Nm (3.7 lbf ft) Screw, combination switch EJOT PT ®...
  • Page 139 TECHNICAL SPECIFICATIONS 23 Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, seat fixing 8 Nm (5.9 lbf ft) Screw, starter cable to starter relay M6x8 6 Nm (4.4 lbf ft) Screw, throttle grip 5 Nm (3.7 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw...

  • Page 140: 24 Substances

    24 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 141 SUBSTANCES 24 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 142) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 142: 25 Auxiliary Substances

    25 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...
  • Page 143 AUXILIARY SUBSTANCES 25 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – Klüberfood NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 144: 26 Standards

    26 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 145: Index Of Special Terms 27

    INDEX OF SPECIAL TERMS 27 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 146: 28 List Of Abbreviations

    28 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 147: List Of Symbols 29

    LIST OF SYMBOLS 29 29.1 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. Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics.

  • Page 148: Index

    INDEX cleaning ......72 INDEX Chain guide 12-V battery checking ......75 charging .
  • Page 149 INDEX Filling up free travel, checking ....82 fuel ......31 Handlebar position .
  • Page 150 INDEX checks and maintenance measures when Steering head label ..... . 12 preparing for use ....27 Stop button .
  • Page 151 *3214833en* 3214833en 14.03.2023 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

This manual is also suitable for:

300 sx 2024250 xc 2024300 xc 2024

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