KTM 250 EXC-F Owner's Manual
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KTM 250 EXC-F Owner's Manual

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OWNER'S MANUAL
2016
250 EXC‑F EU
250 EXC‑F Six Days EU
250 EXC‑F AU
250 EXC‑F BR
250 XCF‑W US
Art. no. 3213335en

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Summary of Contents for KTM 250 EXC-F

  • Page 1 OWNER'S MANUAL 2016 250 EXC‑F EU 250 EXC‑F Six Days EU 250 EXC‑F AU 250 EXC‑F BR 250 XCF‑W US Art. no. 3213335en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Setting the clock..........21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Viewing the lap time........21 Symbols used ........... 5 Display mode SPEED (speed) ......22 Formats used............ 5 Display mode SPEED/H (service hours) ..... 22 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 11.12 Adjusting the compression damping of the 12.48 Removing the engine guard......77 fork ............... 44 12.49 Installing the engine guard ......77 11.13 Adjusting the rebound damping of the fork ..45 13 BRAKE SYSTEM ............78 11.14 Adjusting the spring preload of the fork 13.1 Checking free travel of hand brake lever ....
  • Page 6 TABLE OF CONTENTS 18.4 Adding engine oil .......... 109 19 CLEANING, CARE ............ 110 19.1 Cleaning the motorcycle ........ 110 19.2 Checks and maintenance steps for winter operation............111 20 STORAGE ..............112 20.1 Storage ............112 20.2 Preparing for use after storage......112 21 TROUBLESHOOTING ..........

  • Page 7: 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 8: Safety Advice

    Use definition - intended use (All EXC‑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 9: Safe Operation

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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.

  • Page 10: 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 11: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) M01021-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Filler cap Side stand ( p. 18) Shift lever ( p. 18) Engine number ( p. 12)

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

    VIEW OF VEHICLE View of vehicle, rear right (example) C00894-10 Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p.

  • Page 14: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label  is fixed to the front of the steering head. 401946-10 Key number (All EXC‑F models)  The key number for the steering lock is stamped onto the key connector.

  • Page 15: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number  The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 0 0 1 401948-10...

  • Page 16: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M00083-10 Hand brake lever The hand brake lever  is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake.

  • Page 17: Horn Button (All Exc-F Models)

    CONTROLS Horn button (All EXC‑F models)  The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 102044-11 Light switch (All EXC‑F models) The light switch ...

  • Page 18: Electric Starter Button (Exc-F Eu/Br, Xcf-W, Six Days)

    CONTROLS 6.11 Electric starter button (EXC‑F EU/BR, XCF-W, Six Days)  The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – the electric starter is actuated in this position. •...

  • Page 19: Closing Filler Cap

    CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 20: Shift Lever

    CONTROLS 6.18 Shift lever  The shift lever is fitted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.19 Kick starter ...

  • Page 21: Steering Lock (All Exc-F Models)

    CONTROLS The side stand is used to park the motorcycle. Info  When you are riding, the side stand must be folded up and secured with the  rubber band 401944-10 6.22 Steering lock (All EXC‑F models) Steering lock  is fitted on the left side of the steering head.

  • Page 22: Speedometer

    SPEEDOMETER Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 23: Setting The Speedometer Functions

    SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display.

  • Page 24: Display Mode Speed (Speed)

    SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –...

  • Page 25: Setup Menu

    SPEEDOMETER Setup menu Condition • The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached.

  • Page 26: Display Mode Speed/Clk (Time)

    SPEEDOMETER 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button The display changes to the Setup menu of the clock. for 2–3 seconds.

  • Page 27: Viewing The Lap Time

    SPEEDOMETER 7.14 Viewing the lap time Condition • The motorcycle is stationary. – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button Press the button The stop watch and the lap time are reset. for 2–3 seconds.

  • Page 28: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) – Repeatedly press the button briefly until TR2 appears at the top right of the dis- play. TR2 (trip master 2) runs constantly and counts up to 999.9. Press the button Clears the values TR2 and A2. for 2–3 seconds.

  • Page 29: Display Mode Speed/A2 (Average Speed 2)

    SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) – Repeatedly press the button briefly until A2 appears at the top right of the dis- play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

  • Page 30: Table Of Functions

    SPEEDOMETER 7.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service...

  • Page 31: Table Of Conditions And Menu Activation

    SPEEDOMETER 7.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •...

  • Page 32: 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 33: Running-In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p. 124) –...

  • Page 34: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (77206920100) Info See the KTM PowerParts fitting instructions. M00999-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006922000) Info See the KTM PowerParts fitting instructions.

  • Page 35: 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 (77206921100) Info See the KTM PowerParts fitting instructions. M01001-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 36: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 106) –...

  • Page 37: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 38: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 39: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 40: Service Schedule

    ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 41: Service Work (As Additional Order)

    SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 135 operating hours Every 70 operating hours after sporting use Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●...

  • Page 42: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to 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 43: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 44: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 49) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover.

  • Page 45: Adjusting The Spring Preload Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to 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 46: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 62) – Remove the motorcycle from the lift stand. ( p. 49) – Check the static sag of the shock absorber. ( p. 42) – Check the riding sag of the shock absorber. ( p.

  • Page 47: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS Guideline Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F EU/AU/BR) –...

  • Page 48: Adjusting The Spring Preload Of The Fork (Exc-F Eu/Au/Br, Xcf-W)

    TUNING THE CHASSIS (XCF‑W) –  Turn adjusting screws clockwise all the way. Info  Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type.

  • Page 49: Handlebar Position

    TUNING THE CHASSIS 11.15 Handlebar position (All EXC‑F models)  On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in)  Hole distance 3.5 mm (0.138 in)  Hole distance The handlebar supports can be mounted in four different positions.
  • Page 50 TUNING THE CHASSIS (All EXC‑F models) –  Remove screws . Take off the handlebar clamps. Remove 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 51: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 52: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS (XCF‑W) –  Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. M00988-11 Finishing work – Remove the motorcycle from the lift stand. ( p. 49) 12.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 53: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS (EXC‑F EU/AU/BR) –  Release screws . Take out the left fork leg. –  Release screws . Take out the right fork leg. K00086-10 (EXC‑F Six Days) –  Release screws . Take out the left fork leg. –...

  • Page 54: Removing The Fork Protector

    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 15 Nm (11.1 lbf ft) M00138-11 (XCF‑W) – Position the fork legs. ...

  • Page 55: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12.8 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, wiring harness, and clamp. Mount and tighten screws –...

  • Page 56: Removing The Lower Triple Clamp (Xcf-W)

    SERVICE WORK ON THE CHASSIS –   Remove O-ring . Remove protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. M01017-10 12.10 Removing the lower triple clamp (XCF‑W) Preparatory work –...
  • Page 57 SERVICE WORK ON THE CHASSIS (EXC‑F EU/AU/BR) – Position the upper triple clamp with the handlebar. – Mount screw  but do not tighten yet. – Position the clutch line, wiring harness, and voltage regulator. Mount and  tighten screws Guideline Remaining screws, chassis 10 Nm...
  • Page 58 SERVICE WORK ON THE CHASSIS (EXC‑F Six Days) – Position the upper triple clamp with the handlebar. – Mount screw  but do not tighten yet. – Position the clutch line, wiring harness, and voltage regulator. Mount and  tighten screws Guideline Remaining screws, chassis 10 Nm...

  • Page 59: Installing The Lower Triple Clamp (Xcf-W)

    SERVICE WORK ON THE CHASSIS –  Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount the cable binder. –  Position the brake line, wiring harness, and clamp. Mount and tighten screws K00088-11 Finishing work –...
  • Page 60 SERVICE WORK ON THE CHASSIS – Position the fork legs.  Bleeder screws are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 61: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (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- aged over time.

  • Page 62: Adjusting The Play Of The Steering Head Bearing (Xcf-W)

    SERVICE WORK ON THE CHASSIS – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –  Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) –  Mount and tighten screw Guideline Loctite ®...

  • Page 63: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12.16 Greasing the steering head bearing (XCF‑W) – Remove the lower triple clamp. p. 54) – Install the lower triple clamp. p. 57) (All EXC‑F models) – Remove the lower triple clamp. p. 53) – Install the lower triple clamp.

  • Page 64: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12.19 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 49) Main work –  Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel.

  • Page 65: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12.23 Removing the air filter box cover –  Pull off the air filter box cover in area sideways and remove it toward the front. M01011-10 12.24 Installing the air filter box cover – Insert the air filter box cover into rear area ...

  • Page 66: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS – Insert both parts together, position them and fasten them using the air filter hold-  ing bracket The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 67: Removing Main Silencer

    SERVICE WORK ON THE CHASSIS 12.29 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. –  Disconnect spring Spring hooks (50305017000) –...

  • Page 68: Changing Glass Fiber Yarn Filling In The Main Silencer

    SERVICE WORK ON THE CHASSIS 402269-10 Main work –    Remove screws and take off silencer cap with O-ring Warning Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen. –...
  • Page 69 SERVICE WORK ON THE CHASSIS Main work (All EXC‑F models) –  Remove screws –   Take off silencer cap with O-ring – Remove old glass fiber yarn filling. – Clean the parts that need to be reinstalled and check for damage. –...

  • Page 70: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12.33 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 71: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS (XCF‑W) –  Remove screws with the collar bushings. K00146-10 –  Remove screw with the rubber bushing. K00104-10 (EXC‑F EU/AU/BR, XCF‑W) – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.
  • Page 72 SERVICE WORK ON THE CHASSIS – Make sure that the throttle cable or other cables or are not trapped or damaged. (EXC‑F Six Days) – Position the fuel tank and fit the two spoilers to the sides between the radiator and radiator shield.

  • Page 73: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12.35 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 71) 400678-01 12.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 74: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding component upwards to measure chain  tension Info  The lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain ...

  • Page 75: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS 12.39 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 49) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...

  • Page 76: Checking The Frame

    If the frame exhibits cracking 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. 401340-01...

  • Page 77: Checking The Swingarm

    » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. 401341-01 12.42 Checking throttle cable routing Preparatory work – Remove the seat. ( p.

  • Page 78: Additionally Securing The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12.44 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 75) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip.

  • Page 79: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –  Remove screws –   Remove cover with membrane M00208-10 –  Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 80: Brake System

    BRAKE SYSTEM 13.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.

  • Page 81: Checking The Brake Discs

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 82: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Changing The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

  • Page 84: 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 the pin, and mount the cotter pins. Info Always change the brake linings in pairs.

  • Page 85: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 86: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 87: Changing The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 88 BRAKE SYSTEM –   Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.

  • Page 89: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 49) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 90: Removing The Rear Wheel

    WHEELS, TIRES (EXC‑F Six Days) –   Align the brake disc guard so that gaps are the same size. M01022-10 –  Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 91: Installing The Rear Wheel

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle.

  • Page 92: Checking The Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 93 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.

  • Page 94: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 95: Charging 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 96: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover.

  • Page 97: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat.

  • Page 98: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM (XCF‑W) –  Detach plug-in connector and take off the headlight mask with the head- light. K00143-10 15.7 Refitting the headlight mask with the headlight Main work (All EXC‑F models) –  Connect plug-in connectors K00118-11 (XCF‑W) – ...

  • Page 99: Checking The Headlight Setting

    ELECTRICAL SYSTEM –  Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 120) – Insert the protection cap with the bulb socket into the reflector and turn it clock- wise all the way. Info ...

  • Page 100: Changing The Turn Signal Bulb (All Exc-F Models)

    ELECTRICAL SYSTEM 15.11 Changing the turn signal bulb (All EXC‑F models) Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 101 ELECTRICAL SYSTEM –  Position protection cap and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with washers. K00135-10 Finishing work –...

  • Page 102: Cooling System

    COOLING SYSTEM 16.1 Cooling system  The 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 103: Checking The Coolant Level

    COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 104: Refilling Coolant

    COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal- lowed, contact a physician immediately.

  • Page 105: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and  forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…...

  • Page 106: Adjusting The Idle Speed

    TUNING THE ENGINE 17.3 Adjusting the idle speed –  Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 2,050…...
  • Page 107 TUNING THE ENGINE – Mount and tighten screw with the washers. Guideline Screw, shift lever 14 Nm Loctite ® 243™ (10.3 lbf ft)

  • Page 108: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 109: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE 18.3 Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 110 SERVICE WORK ON THE ENGINE –  Remove screws . Take off the oil filter cover with the O-ring. L02482-10 –  Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...

  • Page 111: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work –  Remove the oil filler plug with the O-ring from the clutch cover. –...

  • Page 112: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 113: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 114: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 49) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 115: Troubleshooting

    – Check the electrical system. switch defective – 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 116 – Check the cabling for damage and the electri- cal plug-in connectors for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.

  • Page 117: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)
  • Page 118 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition EXC‑F EU, EXC‑F BR, EXC‑F Six Days Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit EXC‑F EU, EXC‑F BR, EXC‑F Six Days Lambda sensor heater cylinder 1, sensor 1 - input signal too high...

  • Page 119: Technical Data

    TECHNICAL DATA 23.1 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 12.8:1 Idle speed 2,050… 2,150 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)
  • Page 120 TECHNICAL DATA Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Nut, cylinder head 10 Nm (7.4 lbf ft) Lubricated with engine oil Nut, water-pump wheel 5 Nm (3.7 lbf ft)

  • Page 121: Capacities

    TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 124) Alternative engine oil for harsh Engine oil (SAE 10W/60) operating conditions and (00062010035) ( p. 124) increased performance 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant (...

  • Page 122: Electrical System

    Metzeler MCE 6 Days Extreme (XCF‑W) 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 23.7 Fork 23.7.1 EXC‑F EU/AU/BR, XCF‑W Fork part number 14.18.7P.67...

  • Page 123: Exc-F Six Days

    TECHNICAL DATA Weight of rider: 65… 75 kg (143… 165 lb.) 510 mm (20.08 in) Weight of rider: 75… 85 kg (165… 187 lb.) 510 mm (20.08 in) Weight of rider: 85… 95 kg (187… 209 lb.) 510 mm (20.08 in) Spring rate Weight of rider: 65…...

  • Page 124: Chassis Tightening Torques

    TECHNICAL DATA Spring length 250 mm (9.84 in) Gas pressure 10 bar (145 psi) Static sag 33… 35 mm (1.3… 1.38 in) Riding sag 105… 115 mm (4.13… 4.53 in) Fitted length 417 mm (16.42 in) Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p.
  • Page 125 TECHNICAL DATA Loctite ® 2701™ Screw, top shock absorber 80 Nm (59 lbf ft) – Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –...

  • Page 126: Substances

    128) – SAE ( p. 128) (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 127 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 128) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 128: Auxiliary Substances

    Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ®...
  • Page 129 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 130: 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 131: 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 132: Lisy Of Symbols

    LISY OF SYMBOLS 28.1 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. EFI 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 133: Index

    INDEX fluid, changing ......76 INDEX Clutch lever ........14 Accessories .
  • Page 134 INDEX bleeding ....... . . 49 dust boots, cleaning ......50 Main fuse installing .
  • Page 135 INDEX removing ....... . . 62 riding sag, checking ......42 View of vehicle spring preload, adjusting .
  • Page 136 *3213335en* 3213335en 04/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

250 exc-f six days250 xcf-w350 xcf-w six days

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