Related Manuals for KTM 250 XC-F
Summary of Contents for KTM 250 XC-F
- Page 1 OWNER’S MANUAL 2007 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING ART. NR. 3.211.145 EN...
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Page 2: Introduction
KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. -
Page 3: Important Information
IMPORTANT INFORMATION INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. - Page 4 If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer.
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Page 5: Table Of Contents
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......17 Instructions for initial operation ....17 Running in the XC/EXC models . -
Page 6: Serial Number Locations
» SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. -
Page 7: Operation Instruments
» OPERATION INSTRUMENTS Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjust- ing screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. -
Page 8: Headlamp Switch (Xc-W)
OPERATION INSTRUMENTS » Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [1]. Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. -
Page 9: Electronic Speedometer
H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motor- cycles, making the service hour counter a very practical function. -
Page 10: Activating And Deactivating Display Modes
SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press button Changes to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures... - Page 11 OPERATION INSTRUMENTS » LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds.
- Page 12 OPERATION INSTRUMENTS » SPEED / A2 display mode (average speed 2) A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.
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Page 13: Overview Of The Electronic Speedometer Functions
OPERATION INSTRUMENTS display briefly press + button SPEED / H SPEED / CLK starts/stops LAP without SPEED / LAP clearing LAP figure LAP / LAP SPEED / MAX SPEED / ODO SPEED / TR1 SPEED / TR2 increases the TR2 figure SPEED / A1 SPEED / A2 SPEED / S1... -
Page 14: Filler Cap (Bayonet Cap)
OPERATION INSTRUMENTS » Filler cap (bayonet cap) To open the filler cap: Turn the filler cap 45° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. Filler cap (screw cap) To open the filler cap: Turn the filler cap counter-clockwise. To close the filler cap: Put the filler cap on and tighten it by turning it clockwise. -
Page 15: Shift Lever
» OPERATION INSTRUMENTS Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. 2,3,4 (5,6) Kickstarter The kickstarter is mounted on the right side of the engine. -
Page 16: Compression Damping Of Fork
(Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. -
Page 17: Compression Damping Of Shock Absorber (Xc-W, Exc)
OPERATION INSTRUMENTS » Compression damping of shock absorber (XC-W, EXC) The compression damping (during compression) can be adjusted for these shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [1] with a screwdriver. Turning in a clockwise direction will increase the damping, turn- ing in a counterclockwise direction will decrease the damping. -
Page 18: General Tips And Warnings For Starting The Motorcycle
(throttled) version. Avoid extended on-road rides at full throttle. – Wear suitable clothing when driving a motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regard- less of whether driving all day or just for a short trip. -
Page 19: Driving Instructions
If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as com- plete failure of the braking system can be avoided. -
Page 20: Starting When The Engine Is Warm
– Maximal period for continuous starting: 5 seconds. Wait at least 5 sec- onds before trying again. – Don’t ride your motorcycle with full load and don’t rev up the engine when cold because the piston is warming up faster than the water cooled cylin- der and can cause engine damage. -
Page 21: Braking
– In the event that, while riding on your motorcycle, you notice any unusual operation-related noise, stop immediately, turn the engine off, and contact an authorized KTM dealer. Braking Close throttle and apply the hand and foot brakes at the same time. -
Page 22: Periodic Maintenance
Clean Sparkarrestor (XC-W USA) Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. »... - Page 23 Check tightness of screws, nuts and hose clamps regularly 250-F 2007 IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx.
- Page 24 Clean Sparkarrestor (XC-W USA) Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. »...
- Page 25 PERIODIC MAINTENANCE 400/450/525 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary...
- Page 26 PERIODIC MAINTENANCE 400/450/525 2007 IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx. 15 operating hours...
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Page 28: Maintenance Work On Chassis And Engine
OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out. -
Page 29: Basic Suspension Setup For The Weight Of The Driver
EXAMPLE: Motorcycle jacked up (dimension A) .....600 mm Motorcycle on ground, unloaded (dimension B) ... .– 565 mm Static sag . -
Page 30: Checking The Basic Setup Of The Telescopic Fork
The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged. -
Page 31: Breather Plug Front Fork
[1] a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on the road, it will suffice to have this job performed in the course of the periodical maintenance service. -
Page 32: Changing The Fork Offset (Caster) (Xc, Exc Sixdays)
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) (XC, EXC SIXDAYS) * The fork offset [A] in these models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course. -
Page 33: How To Change The Handlebar Position
Tighten all screws and nuts to the specified torques using a torque wrench. Screws or nuts that are not tightened enough can become loose and cause the motorcycle to go out of control while driving. Screws or nuts tightened too firmly can damage the thread and components. -
Page 34: Check Chain Tension
– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. -
Page 35: Chain Maintenance
No lubrication is allowed to reach the rear tire or the brake disks, otherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily lose control. When mounting the chain masterlink clip, the closed side of the masterlink clip must point in running direction. -
Page 36: General Information About Ktm Disc Brakes
Have the brake disk replaced as soon as it reaches the serv- ice limit. – Have any repairs on the brake system be performed by a KTM dealer. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces- sary to top up the brake fluid. -
Page 37: Adjusting The Free Travel At The Hand Brake Lever
If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4]. -
Page 38: Replacing The Front Brake Pads
If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A]. -
Page 39: Checking The Rear Brake Pads
Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen the 2 clamping screws [4] on the left side of the fork fists. -
Page 40: Dismounting And Mounting The Rear Wheel
– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. -
Page 41: Tires, Air Pressure
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – Do not mount tires which have not been approved by KTM. Other tires rear could have adverse effects on the way your motorcycle behaves. -
Page 42: Battery
Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charging device (item no. 58429074000). You can also use this charging device to test the off-load voltage and startability of the battery and generator. It is impossible to overcharge the battery with this device. -
Page 43: Fuse
Replace a blown fuse only with an equivalent one. If a new fuse that has just been installed gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere. Under no circumstances is a stronger fuse allowed to be installed or a fuse allowed to be “repaired”. -
Page 44: Cooling System
Freeze). Using lower-grade antifreeze agents can cause corrosion and coolant foaming. – Extreme climate conditions or stop and go traffic may cause overheating problems. To avoid this, an electric blower [4] is offered (ask your KTM Dealer). Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine... -
Page 45: Bleeding The Cooling System (250-F)
Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to „burn out“. -
Page 46: Cleaning The Air Filter
The XC models do not have a throttle cap. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter maintenance (Bio Dirt Remover and Liquid Bio Power). -
Page 47: Changing The Original Position Of The Clutch Lever
KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch. Do not mix this oil with any other hydraulic oil. Always use original KTM hydraulic oil (available from your authorized KTM workshop) to make sure your clutch operates smoothly. -
Page 48: Carburetor - Adjust Idling (Keihin-Fcrmx 37/39/41)
MAINTENANCE WORK ON CHASSIS AND ENGINE » Carburetor – Adjust idling (Keihin-FCRMX 37/39/41) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel [1] and the mixture control screw [2]. -
Page 49: Draining The Float Chamber Of The Carburetor
Checking the engine oil level The engine oil level can be checked with the engine either warm or cold. Place the motorcycle in an upright position and on a horizontal surface (not on the side stand). If the engine is cold, the engine oil must be visible at the lower edge of the inspection glass [A]. -
Page 50: Engine Oil
Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity or 5W/40 viscosity (see table). Insufficient oil or poor quality oil results in premature wear of the engine. -
Page 51: Changing The Oil Filters
The 250-F engine only has one oil filter insert [3]. Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil. Fill oil filter with oil, place the long oil filter in the front and the short filter in the back of the filter box. -
Page 52: Troubleshooting
We would like to point out that many operations cannot be performed by yourself. In case of uncertainty, please contact a KTM-dealer. TROUBLE CAUSE Engine doesn’t crank (E-starter). - Page 53 Check if fan operates properly. To do this, start the engine, then bypass the connections to the thermoswitch (bottom right radiator), contact a KTM dealer Dislocate i.e. replace non-buckling vetilation hose Check engine oil level and, if necessary, correct it Use thicker engine oil;...
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Page 54: Cleaning
CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre- cautions against the aggressive road salt. -
Page 55: Technical Data - Engine
Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F). - Page 56 Hexagon collar screw, bump part kickstarter Cable retaining bracket (ignition) Allan head screw, kickstarter Hexagon collar screw, shift lever Hexagon screw, engine sprocket Spark plug BASIC CARBURATOR SETTING 250 XC-F USA Type Keihin FCR-MX 3900G Main jet Jet needle OBETP Idling jet...
- Page 57 Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). 400/450/525: KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). 10W/50 Poor oil quality or minor quantity cause early engine-wear.
- Page 58 TECHNICAL DATA – ENGINE BASIC CARBURATOR SETTING 400 XC-W Type Keihin FCR-MX 3900D Keihin FCR-MX 3900E Main jet Jet needle OBDVR Idling jet Main air jet Idling air jet Needle position 1st from top Starting jet Mixture control screw open 1.25 Slide Performance restrictor...
- Page 59 TECHNICAL DATA – ENGINE TIGHTENING TORQUES – ENGINE 400/450/525 Hexagon collar screw, engine case, clutch cover, ignition cover Oil drain plug Allan head plug, oil screen short Hexagon plug, oil screen long Collar screw for oil filter cover Plug pressure valve Jet screw and hollow screw, oil line Screws, oil pump cover Hexagon collar screw, cylinder head top section...
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Page 60: Technical Data - Chassis
Front tires XC, XC-F, XC-W, XCF-W 80/100-21“ Air pressure offroad 1,0 bar Air pressure road 1,5 bar Rear tires 250 XC-F, XCF-W 100/100-18“ Air pressure offroad 1,0 bar Air pressure road 2,0 bar Fuel tank capacity 250 XC-F, XCF-W 250 EXC-F AUS 8,5 liters (2.2 US gal) 7 liters (2 US gal) - Page 61 WP 5018 PDS MCC WP 5018 PDS MCC 12187C04 12187C06 76/250 80/250 5 mm 5 mm 250 XC-F 450/525 XC 250 EXC-F SIXDAYS 450/525 EXC SIXDAYS WP 4860 MXMA + PA WP 4860 MXMA + PA 14187C28 14187C29 4.4 N/mm 4.6 N/mm...
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Page 62: Head Word Index
Fuse ........42 General information about KTM disc brakes ... .35 General tips and warnings for starting the motorcycle . -
Page 64: Wiring Diagram
» SCHALTPLAN WIRING DIAGRAM headlight bl-wh bu-wh ye-bl re-wh re-bl re-bl re-wh multi-func.-digital-speedometer driving light lamp flasher control lamp front brake switch ye-re ye-re ye-re wh-gn rear light/brakelight ye-bl ye-re ye-bl ye-re wh-re black wh-re ye-re... - Page 65 » SCHALTPLAN WIRING DIAGRAM bl-wh bu-wh ye-bl re-wh re-bl headlight re-bl re-wh rear light/brakelight multi-func.-digital-speedometer ye-bl ye-re wh-re black ye-re wh-re ye-re...
- Page 66 » SCHALTPLAN WIRING DIAGRAM ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
- Page 67 » SCHALTPLAN WIRING DIAGRAM ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
- Page 68 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...