KTM 250 SX Setup Instructions
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KTM 250 SX Setup Instructions

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SETUP INSTRUCTIONS
2021
250 SX
Art. no. 3214365en

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Summary of Contents for KTM 250 SX

  • Page 1 SETUP INSTRUCTIONS 2021 250 SX Art. no. 3214365en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Means Of Representation

    1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 5 SETUP 2 Unpacking and setting up the vehicle Package 2 – Remove the box and the plastic packaging. Info To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you have finished. – Remove the separate enclosure and unpack it. Check that the scope of supply is complete using the enclosed pack- E00851-10 ing list.
  • Page 6 2 SETUP – Have a lift stand available. Lift stand (78129955100) – Together with an assistant, take the vehicle off the pallet. – Position the vehicle on a lift stand. – Check the vehicle for transport damage. Info The procedure in the event of transport damage is described in the customer service manual.
  • Page 7 SETUP 2 – Remove screws . Take off the handlebar clamp. 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. – Remove screws . Take off handlebar supports –...
  • Page 8 2 SETUP – Position the controls on the right half of the handlebar. K00938-10 – Position the controls on the left handlebar half. – Mount the cable ties. – Mount the fuel tank breather. – Install the front wheel. ( p.
  • Page 9 SETUP 2 – Position spring as shown. Spring engages in area K00621-10 – Press the spring with special tool Footrest spring plier (79029083000) The special tool is applied to area on the footrest. – Mount pin K00622-10 – Mount the washer and splint –...
  • Page 10 Position all controls in their exact positions on the handlebar. Tighten all screws. – Remove the remaining film, padding, the corrugated card- board, and the other packaging material. – Prepare the vehicle according to the specifications in KTM Dealer.net for handover to the customer.
  • Page 11 WORK 3 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...
  • Page 12 3 WORK 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 upper edge of the upper triple clamp. The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.

  • Page 13: Tighten Screws 3 . Guideline

    WORK 3 – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc.

  • Page 14: Mounting The Seat

    3 WORK Removing the seat – Remove screw K01133-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward.
  • Page 15 WORK 3 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. –...
  • Page 16 3 WORK 3.10 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 17: Technical Data

    TECHNICAL DATA 4 Chassis tightening torques Screw, start button 0.4 Nm (0.3 lbf ft) Screw, stop button 0.4 Nm (0.3 lbf ft) Screw, fixed grip 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, service hour counter 0.8 Nm (0.59 lbf ft) Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
  • Page 18 4 TECHNICAL DATA Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine bracket screw 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, bottom shock absorber 60 Nm (44.3 lbf ft) Loctite ®...
  • Page 19 SUBSTANCES 5 Engine oil, 2-stroke Standard/classification – JASO FD ( p. 19) Guideline – Only use high-grade 2-stroke engine oil from a reputable brand. fully synthetic Recommended supplier MOTOREX ® – Cross Power 2T Super unleaded (ROZ 95) Standard/classification – DIN EN 228 (ROZ 95) Guideline –...

  • Page 20: Auxiliary Substances

    6 AUXILIARY SUBSTANCES Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000...
  • Page 21 STANDARDS 7 JASO FD JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
  • Page 22 *3214365en* 3214365en 02/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.com...

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