KTM 250 EXC-F Owner's Manual
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- Owner's manual (136 pages) ,
- Owner's manual (68 pages) ,
- Owner's manual (125 pages)
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Summary of Contents for KTM 250 EXC-F
- Page 1 OWNER'S MANUAL 2015 250 EXC‑F EU 250 EXC‑F Six Days EU 250 EXC‑F Factory Edition EU 250 EXC‑F AU 250 EXC‑F BR 250 XCF‑W US Art. no. 3213234en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.25 Side stand............19 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.26 Steering lock (All EXC‑F models) ...... 20 Symbols used ........... 5 6.27 Locking the steering (All EXC‑F models) .... 20 Formats used............ 5 6.28 Unlocking the steering (All EXC‑F models).. - Page 5 TABLE OF CONTENTS 11.4 Adjusting the high-speed compression 12.36 Checking for chain dirt accumulation ....68 damping of the shock absorber......41 12.37 Cleaning the chain .......... 68 11.5 Adjusting the rebound damping of the shock 12.38 Checking the chain tension ......69 absorber............
- Page 6 TABLE OF CONTENTS 15.11 Changing the turn signal bulb (All EXC‑F models)............95 15.12 Changing the speedometer battery ....95 16 COOLING SYSTEM ............. 97 16.1 Cooling system ..........97 16.2 Checking the antifreeze and coolant level ..97 16.3 Checking the coolant level .......
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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) L02474-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Filler cap Shift lever ( p. 18) Engine number ( p. 12) Side stand ( p. 19) -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) L02473-10 Kill switch ( p. 15) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 16) Emergency OFF switch ( p. 16) 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 Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. -
Page 17: Kill Switch (Xcf-W)
CONTROLS Kill switch (XCF‑W) Kill switch is fitted on the left side of the handlebar. Possible states in basic position – the ignition circuit is closed in this position and • Kill switch the engine can be started. pressed – the ignition circuit is open in this position, the engine •... -
Page 18: Light Switch (Xcf-W)
CONTROLS 6.11 Light switch (XCF‑W) The light switch is located to the left of the speedometer. Possible states Light off – Light switch is pressed in up to the stop. In this position, the light is • switched off. Light on –... -
Page 19: Electric Starter Button (Exc-F Au)
CONTROLS 6.16 Electric starter button (EXC‑F AU) 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 20: Closing Filler Cap
CONTROLS – Press release button , turn filler cap counterclockwise and lift it upwards and remove. M00150-10 6.20 Closing filler cap – Replace the filler cap and turn clockwise until the release button locks in place. Info Route the fuel tank breather hose without kinking. -
Page 21: Kick Starter
CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.23 Kick starter The kick starter is fitted on the right of the engine. The engine can be started with either the kick starter or the electric starter. The upper part of the kick starter can be swung out. -
Page 22: Steering Lock (All Exc-F Models)
CONTROLS 6.26 Steering lock (All EXC‑F models) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible. S00462-10 6.27 Locking the steering (All EXC‑F models) Note Danger of damage The parked vehicle may roll away or fall over. -
Page 23: 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 24: 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 25: 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 26: Setting The Unit Of Measurement
SPEEDOMETER Briefly press the Activates the flashing display and changes to the next display button Press the button No function for 2–3 seconds. Briefly press the Deactivates the flashing display and changes to the next dis- button play Press the button No function for 2–3 seconds. -
Page 27: Setting The Clock
SPEEDOMETER 7.12 Setting the clock Condition • The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. Press the button Increases the value for 2–3 seconds. -
Page 28: Display Mode Speed/Odo (Odometer)
SPEEDOMETER 7.15 Display mode SPEED/ODO (odometer) – Repeatedly press the button briefly until ODO appears at the bottom right of the display. The total traveled distance is shown in display mode ODO. Press the button No function for 2–3 seconds. Briefly press the Next display mode button... -
Page 29: Display Mode Speed/A1 (Average Speed 1)
SPEEDOMETER Info The TR2 value can also be corrected manually during the journey with the but- and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the button Increases value of TR2. for 2–3 seconds. Briefly press the Increases value of TR2. -
Page 30: Display Mode Speed/S1 (Stop Watch 1)
SPEEDOMETER 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the dis- play. S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor. -
Page 31: Table Of Conditions And Menu Activation
SPEEDOMETER 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 stop watch Next display Stops the clock. Starts the stop SPEED/LAP (lap and the 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. 120) –... -
Page 34: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. 600869-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) 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 (77206921000) Info See the KTM PowerParts fitting instructions. 600870-01 – 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. 102) –... -
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 you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off 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
Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in KTM Dealer.net and in the service record. -
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 when used for motorsports 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. 48) 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. 61) – Remove the motorcycle from the lift stand. ( p. 48) – 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 15 clicks Standard 13 clicks Sport 11 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, XCF‑W) –... -
Page 48: Adjusting The Spring Preload Of The Fork (Exc-F Eu/Au/Br, Exc-F Factory Edition, Xcf-W)
TUNING THE CHASSIS (EXC‑F Six Days) – Turn the red adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in the right fork leg REB (red adjusting screw). -
Page 49: Handlebar Position
TUNING THE CHASSIS Info Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload. -
Page 50: 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 (54829055000) Neither wheel is in contact with the ground. -
Page 51: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS (EXC‑F Six Days) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. S00636-10 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 52: Loosening The Fork Protector
SERVICE WORK ON THE CHASSIS 12.5 Loosening the fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg. Push the fork protection downwards. – Remove the screws on the right fork leg. Push the fork protection downwards. M00094-10 12.6 Positioning the fork protector... -
Page 53: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work (EXC‑F EU/AU/BR, XCF‑W) – 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 second milled groove (from the top) must be flush with the top edge of the upper triple clamp. -
Page 54: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS – Position the brake caliper and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount cable binder. – Position the brake line, wiring harness, and clamp. Mount and tighten screws M00234-10 Finishing work –... -
Page 55: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS Main work – Open the cable holder in front of the right radiator and detach the wiring harness. – Remove screws and hang the voltage regulator to one side. – Release screw and remove screw . -
Page 56: Installing The Lower Triple Clamp (Exc-F Eu/Au/Br, Xcf-W)
SERVICE WORK ON THE CHASSIS 12.13 Installing the lower triple clamp (EXC‑F EU/AU/BR, XCF‑W) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 122) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. - Page 57 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) M00098-11 – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Secure the wiring harness with cable holder L02470-11 –...
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Page 58: (Exc-F Factory Edition, Exc-F Six Days)
SERVICE WORK ON THE CHASSIS 12.14 Installing the lower triple clamp (EXC‑F Factory Edition, EXC‑F Six Days) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 122) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. - Page 59 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) S00638-10 (EXC‑F Six Days) – Position the fork legs. Position bleeder screws toward the front. Info The rebound damping is located in the right fork leg REB (red adjusting screw).
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Page 60: 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 61: Adjusting The Play Of The Steering Head Bearing (Exc-F Eu/Au/Br, Xcf-W)
SERVICE WORK ON THE CHASSIS 12.16 Adjusting the play of the steering head bearing (EXC‑F EU/AU/BR, XCF‑W) Preparatory work – Raise the motorcycle with the lift stand. ( p. 48) Main work – Loosen screws – Loosen and retighten screw ... -
Page 62: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) Finishing work – Check the steering head bearing play. ( p. 58) – Remove the motorcycle from the lift stand. ( p. -
Page 63: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B01603-11 Finishing work – Refit the headlight mask with the headlight. ( p. 93) – Check the headlight setting. ( p. -
Page 64: Mounting The Seat
SERVICE WORK ON THE CHASSIS 12.24 Mounting the seat – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –... -
Page 65: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 12.28 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 122) L00943-10 – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. -
Page 66: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 12.30 Sealing the air filter box Preparatory work – Remove the air filter box lid. ( p. 62) Main work – Seal the air filter box in the marked area 401527-10 Finishing work – Install the air filter box lid. - Page 67 SERVICE WORK ON THE CHASSIS Main work (All EXC‑F models) – Remove screws – Take off silencer cap with O-ring – Remove the old glass fiber yarn filling. – Clean the parts that need to be reinstalled and check for damage. –...
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Page 68: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS 12.34 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 69: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. M00182-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. M00207-10 12.35 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. –... -
Page 70: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS (XCF‑W) – Position the collar bushings, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00626-11 – Plug in connector of the fuel pump. – Remove the wash cap set. –... -
Page 71: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 122) Off-road chain spray ( p. 122) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 72: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws ... -
Page 73: Nm (7.4 Lbf Ft)
SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt 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 74: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 12.42 Checking the swingarm –... -
Page 75: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.44 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn or loose: – Change and secure the rubber grip. -
Page 76: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 12.48 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 77: 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 78: 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 79: 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 80: 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 81: 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 82: 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 83: 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 84: 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 85 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.
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Page 86: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 48) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 87: Removing The Rear Wheel
WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle 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 88: 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 89: 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 90: Nm (4.4 Lbf Ft)
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 91: 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 92: 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 93: 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 94: 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 95: Refitting The Headlight Mask With The Headlight
ELECTRICAL SYSTEM (All EXC‑F models) – Detach plug-in connectors and take off the headlight mask with the head- light. M00589-10 (XCF‑W) – Detach plug-in connector and take off the headlight mask with the head- light. S00646-10 15.7 Refitting the headlight mask with the headlight Main work (All EXC‑F models) –... -
Page 96: Changing The Headlight Bulb
ELECTRICAL SYSTEM 15.8 Changing the headlight bulb 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. Preparatory work –... -
Page 97: Adjusting The Headlight Range
ELECTRICAL SYSTEM 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 94) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the headlight setting). - Page 98 ELECTRICAL SYSTEM – Using a coin, turn protection cap all the way counterclockwise and remove it. – Remove speedometer battery – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p. 116) – Check the O-ring of the protection cap for correct seating.
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Page 99: 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 100: 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 101: 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 coolant is swal- lowed, contact a physician immediately. -
Page 102: 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 103: 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 104: 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 105: 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 106: Nm (7.4 Lbf Ft)
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 107: 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 108: 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 109: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. 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 110: 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. 48) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion. -
Page 111: 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 112 – 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.
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Page 113: 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 114 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 Factory Edition, 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 Factory Edition, EXC‑F BR, EXC‑F Six Days Lambda sensor heater cylinder 1, sensor 1 - input signal too high...
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Page 115: 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 116: Nm (4.4 Lbf Ft) Loctite
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 6 Nm (4.4 lbf ft) -
Page 117: Capacities
TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.2 l (1.3 qt.) Engine oil (SAE 10W/50) ( p. 120) Alternative engine oil for harsh Engine oil (SAE 10W/60) operating conditions and (00062010035) ( p. 120) increased performance 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant (... -
Page 118: Electrical System
(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, EXC‑F Factory Edition, XCF‑W Fork part number 14.18.7L.67... -
Page 119: Exc-F Six Days
TECHNICAL DATA Standard 2 turns Sport 2 turns Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 513 mm (20.2 in) Weight of rider: 75… 85 kg (165… 187 lb.) 513 mm (20.2 in) Weight of rider: 85… 95 kg (187… 209 lb.) 513 mm (20.2 in) Spring rate Weight of rider: 65…... -
Page 120: Chassis Tightening Torques
TECHNICAL DATA Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in) Spring length 250 mm (9.84 in) Gas pressure... - Page 121 TECHNICAL DATA – Engine attachment bolt 60 Nm (44.3 lbf ft) – Remaining nuts, chassis 45 Nm (33.2 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, handlebar holder 40 Nm (29.5 lbf ft) Loctite ® 243™ –...
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Page 122: Substances
124) – SAE ( p. 124) (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 123 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 124) (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 –...
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Page 124: Auxiliary Substances
Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® –... - Page 125 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 126: 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 127: Index
INDEX Clutch lever ........14 INDEX basic position, adjusting ..... . 73 Accessories . - Page 128 INDEX dust boots, cleaning ......49 removing ....... 52-53 installing .
- Page 129 INDEX removing ....... . . 61 riding sag, checking ......42 View of vehicle spring preload, adjusting .
- Page 130 *3213234en* 3213234en 11/2014 KTM Motorrad AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...