KTM 250 EXC-F 2019 Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 250 EXC-F 2019
  6. Owner's manual

KTM 250 EXC-F 2019 Owner's Manual

Hide thumbs Also See for 250 EXC-F 2019:
Table of Contents

Advertisement

Quick Links

Download this manual
OWNER'S MANUAL
2019
250 EXC‑F
250 EXC‑F Six Days
Art. no. 3213881en

Advertisement

Table of Contents
loading

Related Manuals for KTM 250 EXC-F 2019

Summary of Contents for KTM 250 EXC-F 2019

  • Page 1 OWNER'S MANUAL 2019 250 EXC‑F 250 EXC‑F Six Days Art. no. 3213881en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy riding this motorcycle! Please enter the serial number of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.16 Shift lever ........21 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.17 Foot brake lever ....... 21 Symbols used ........6 6.18 Side stand........21 Formats used........6 6.19 Steering lock ........22 SAFETY ADVICE..........7 6.20 Locking the steering ......
  • Page 5 TABLE OF CONTENTS Preparing vehicle for rides on wet 11.16 Adjusting the handlebar position ..60 and muddy circuits ......40 12 SERVICE WORK ON THE CHASSIS....63 Preparing vehicle for high temperatures or slow riding ....40 12.1 Raising the motorcycle with the lift Preparing vehicle for low stand ..........
  • Page 6 TABLE OF CONTENTS 12.39 Checking the chain, rear sprocket, 15.7 Installing the headlight mask with engine sprocket, and chain guide ..89 the headlight ......... 121 12.40 Checking the frame ...... 91 15.8 Changing the headlight bulb ... 122 12.41 Checking the swingarm ....
  • Page 7 TABLE OF CONTENTS 23.2 Engine tightening torques ....151 23.3 Capacities ........153 23.3.1 Engine oil ......... 153 23.3.2 Coolant ........153 23.3.3 Fuel ......... 153 23.4 Chassis ......... 153 23.5 Electrical system......154 23.6 Tires ..........154 23.7 Fork..........155 23.7.1 EXC‑F EU/AU/AR/BR ....

  • Page 8: 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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Tampering Warning

    An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 11: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 12: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void.
  • Page 13 IMPORTANT NOTES 3 A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00336-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Filler cap Engine number ( p. 14) Side stand ( p. 21) Shift lever ( p. 21)

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) A00337-10 Kill switch ( p. 16) Horn button ( p. 17) Light switch ( p. 17) Turn signal switch ( p. 17) Emergency OFF switch ( p. 17) Electric starter button ( p.

  • Page 16: Serial Numbers

    5 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 The key number for the steering lock is stamped onto the key connector.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. A00345-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 19: Horn Button

    CONTROLS 6 Horn button 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 posi- • Horn button tion. S01303-10 Light switch The light switch is fitted on the left side of the handlebar.

  • Page 20: Electric Starter Button

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 21: Opening Filler Cap

    CONTROLS 6 6.12 Opening 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 22: Cold Start Button

    6 CONTROLS 6.14 Cold start button Cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. To help the engine burn the increased amount of fuel, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 23: Shift Lever

    CONTROLS 6 6.16 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 6.17 Foot brake lever The foot brake lever...

  • Page 24: Steering Lock

    6 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 6.19 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 25: Unlocking The Steering

    CONTROLS 6 6.21 Unlocking the steering – Insert the key in the steering lock ( p. 22), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 26: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument 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. V00799-01 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 27: Adjusting The Combination Instrument

    COMBINATION INSTRUMENT 7 – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10 -12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 28: Setting The Clock

    7 COMBINATION INSTRUMENT 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. The hour display flashes. – Set the hour display with the button and/or button –...

  • Page 29: Display Mode Speed (Speed)

    COMBINATION INSTRUMENT 7 Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 30: Setting The Unit Of Measurement

    7 COMBINATION INSTRUMENT Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 31: Display Mode Speed/Clk (Time)

    COMBINATION INSTRUMENT 7 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 but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 32: Viewing The Lap Time

    7 COMBINATION INSTRUMENT Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 33: Display Mode Speed/Tr1 (Trip Master 1)

    COMBINATION INSTRUMENT 7 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 34: Display Mode Speed/A1 (Average Speed 1)

    7 COMBINATION INSTRUMENT Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 35: Display Mode Speed/S1 (Stop Watch 1)

    COMBINATION INSTRUMENT 7 Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 36: Table Of Functions

    7 COMBINATION INSTRUMENT 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 37: Table Of Conditions And Menu Activation

    COMBINATION INSTRUMENT 7 Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Setting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • Page 38: 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 39: Running-In The Engine

    PREPARING FOR USE 8 – Adjust the basic position of the foot brake lever. p. 102) – Set the basic position of the shift lever. p. 135) – Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip. Info When off road, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.

  • Page 40: Starting Power Of Lithium-Ion Batteries At Low Temperatures (Exc-Feu/Au/Ar, Exc-F Six Days)

    8 PREPARING FOR USE Starting power of lithium-ion batteries at low temperatures (EXC‑F EU/AU/AR, EXC‑F Six Days) Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batter- ies.

  • Page 41: Preparing Vehicle For Rides On Dry Sand

    Preparing vehicle for rides on dry sand – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info Observe fitting instructions for KTM PowerParts. 102136-01 – Mount a sand cover on the air filter. Sand cover for air filter (79006922000) Info Observe fitting instructions for KTM PowerParts.

  • Page 42: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe fitting instructions for KTM PowerParts. 102137-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 43: Preparing Vehicle For Low Temperatures Or Snow

    PREPARING FOR USE 8 Preparing vehicle for low temperatures or snow – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe fitting instructions for KTM PowerParts. 102137-01...

  • Page 44: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 45: Activating Traction Control (Exc-F Six Days)

    RIDING INSTRUCTIONS 9 – Take the motorcycle off side stand and secure the side stand with rubber band – Shift transmission to neutral. – Turn the emergency OFF switch to the position Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 46: Starting Off

    Do not change into a low gear at high engine speed. 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 47: Braking

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 48: Transporting

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 49 RIDING INSTRUCTIONS 9 Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open the filler cap. ( p.

  • Page 50: 10 Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 51: Recommended Work

    Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval 10.3...
  • Page 52 10 SERVICE SCHEDULE Annually Every 135 operating hours Every 70 operating hours when used for motorsports Once after 20 operating hours Once after 10 operating hours ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector.

  • Page 53: Tuning The Chassis 11

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 54: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 55: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 56: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 53) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.

  • Page 57: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 58: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) – Remove shock absorber. p. 77) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring.

  • Page 59: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (EXC‑F EU/AU/AR/BR) – Turn white adjusting screw clockwise as far as it will Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 60: Adjusting The Rebound Damping Of The Fork

    11 TUNING THE CHASSIS 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F EU/AU/AR/BR) – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the right fork leg.

  • Page 61: Adjusting The Spring Preload Of The Fork (Exc-F Six Days)

    TUNING THE CHASSIS 11 11.14 Adjusting the spring preload of the fork (EXC‑F Six Days) Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Turn the adjusting wings counterclockwise all the way. The marking +0 aligns with the right wing. Info Make the adjustment by hand only.

  • Page 62: Handlebar Position

    11 TUNING THE CHASSIS 11.15 Handlebar position (EXC‑F EU/AU/AR/BR) On the upper triple clamp, there are 2 holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center.
  • Page 63 TUNING THE CHASSIS 11 (EXC‑F EU/AU/AR/BR) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
  • Page 64 11 TUNING THE CHASSIS (EXC‑F Six Days) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 65: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 66: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) – Remove the fork protector. ( p. 64) Main work – Push dust boots of both fork legs downward.

  • Page 67: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 68: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work (EXC‑F EU/AU/AR/BR) – 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 402556-10 triple clamp.

  • Page 69: Removing The Lower Triple Clamp (Exc-F Eu/Au/Ar/Br)

    SERVICE WORK ON THE CHASSIS 12 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws K00546-10 Finishing work...

  • Page 70: Removing The Lower Triple Clamp (Exc-F Six Days)

    12 SERVICE WORK ON THE CHASSIS 12.10 Removing the lower triple clamp (EXC‑F Six Days) Preparatory work – Remove the headlight mask with the headlight. ( p. 121) – Raise the motorcycle with the lift stand. ( p. 63) – Remove the front wheel.

  • Page 71: Installing The Lower Triple Clamp (Exc-F Eu/Au/Ar/Br)

    SERVICE WORK ON THE CHASSIS 12 12.11 Installing the lower triple clamp (EXC‑F EU/AU/AR/BR) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 161) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 72 12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head V00465-11 – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem V00465-10 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp –...

  • Page 73: Installing The Lower Triple Clamp (Exc-F Six Days)

    SERVICE WORK ON THE CHASSIS 12 12.12 Installing the lower triple clamp (EXC‑F Six Days) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 161) – Position the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 74 12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head E00387-10 – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) Loctite 243™ ® steering stem E00388-10 –...

  • Page 75: Checking The Play Of The Steering Head Bearing

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

  • Page 76: Adjusting The Steering Head Bearing Play (Exc-F Six Days)

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen screws – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. K00544-10 –...

  • Page 77: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12 12.16 Greasing the steering head bearing (EXC‑F EU/AU/AR/BR) – Remove the lower triple clamp. p. 67) – Install the lower triple clamp. p. 69) (EXC‑F Six Days) – Remove the lower triple clamp. p. 68) –...

  • Page 78: Installing Front Fender

    12 SERVICE WORK ON THE CHASSIS – Remove screws . Take off front fender. S01321-10 12.18 Installing front fender Main work (EXC‑F EU/AU/AR/BR) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-10 –...

  • Page 79: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12 – Check the headlight setting. ( p. 122) 12.19 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel.

  • Page 80: Mounting The Seat

    12 SERVICE WORK ON THE CHASSIS 12.22 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. – Make sure that the seat is correctly locked in. V00343-10 –...

  • Page 81: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.24 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area K00554-12 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 82: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS 12.26 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. 161) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 83: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Install the air filter. p. 80) – Install the air filter box cover. ( p. 79) 12.28 Sealing the air filter box Preparatory work – Remove the air filter box cover. ( p.

  • Page 84: Installing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS – Detach spring Spring hook (5030501700004) – Remove screws and take off the main silencer. K00575-10 12.31 Installing the main silencer – Position the main silencer. Mount screws but do not tighten yet. – Attach spring Spring hook (5030501700004) –...

  • Page 85: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 Main work – 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 dam- age. – Fit new glass fiber yarn filling into the main silencer.
  • Page 86 12 SERVICE WORK ON THE CHASSIS Main work – Unplug connector of the fuel pump. – Remove the hose from the fuel tank breather. K00555-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 87: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 12.34 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 88: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS – Plug in connector for the fuel pump. – Remove the wash cap set. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 89: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 90: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.38 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 91: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 12.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Shift the transmission to idle. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 92 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 93: Checking The Frame

    If the swingarm shows signs of damage, cracking, or defor- mation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 12.42 Checking throttle cable routing Preparatory work – Remove the seat. ( p.

  • Page 94: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.

  • Page 95: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 12.44 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 96: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( p. 159) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 97: Removing The Engine Guard (Exc-F Au, Exc-F Six Days)

    SERVICE WORK ON THE CHASSIS 12 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 159) – On the clutch slave cylinder, remove the protection cap, remove bleeder screw and mount bleeding syringe S01327-10 –...

  • Page 98: 13 Brake System

    Do not make any adjustments while riding! 13.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 99: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 100: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 101: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 102 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 103: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 – 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 cot- ter pins. Info Always change the brake linings in pairs.

  • Page 104: Adjusting The Basic Position Of The Foot Brake Lever

    KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 105: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 106: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 107 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 108 13 BRAKE SYSTEM – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and brake caliper support. E00351-10 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. E00352-10 –...

  • Page 109: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 110: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 111: Installing The Rear Wheel

    WHEELS, TIRES 14 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 112 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 113: Checking The Tire Condition

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

  • Page 114: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 115: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the battery Note Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 116: Installing The Battery

    15 ELECTRICAL SYSTEM (EXC‑F BR) 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 safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 117: Recharging The Battery

    ELECTRICAL SYSTEM 15 Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal. Finishing work – Mount the seat. ( p. 78) 15.3 Recharging the battery Note Environmental hazard Batteries contain environmentally-hazardous materials.
  • Page 118 15 ELECTRICAL SYSTEM Main work (EXC‑F EU/AU/AR, EXC‑F Six Days) Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. F01568-10 – Only charge batteries in well-ventilated rooms. –...
  • Page 119 ELECTRICAL SYSTEM 15 Info If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed. If the battery is left in a discharged state for an extended period, it will become over- discharged and sulfated, destroying the bat- tery.

  • Page 120: Changing The Main Fuse

    15 ELECTRICAL SYSTEM Info If the charging current, charging voltage and charg- ing time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity. If the battery is left in a discharged state for an extended period, over-discharge and sulfating occurs, destroying the battery.

  • Page 121: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p.
  • Page 122 15 ELECTRICAL SYSTEM (EXC‑F AU/BR) Fuse 1 ‑ 10 A – EFI control unit, combination instru- ment, combination switch (optional), fuel injection, diagnostics connector, fuse 4 Fuse 2 - 10 A - high beam, low beam, position light, tail light, license plate lamp Fuse 3 –...

  • Page 123: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 15.6 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask. – Release rubber bands . Slide the headlight mask up and swing it forward. V00458-10 – Detach plug-in connectors and take off the headlight mask with the headlight.

  • Page 124: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM 15.8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 125: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider. » If the light-dark border does not meet specifications: – Adjust the headlight range. ( p. 123) 15.10 Adjusting the headlight range Preparatory work –...

  • Page 126: Changing The Combination Instrument

    15 ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully take off diffuser – Lightly squeeze orange cap in the area of the holding lugs and take it off. – Press the turn signal bulb lightly into the socket, turn it coun- terclockwise by about 30°, and take it out of the socket.

  • Page 127: Diagnostics Connector

    ELECTRICAL SYSTEM 15 – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...

  • Page 128: 16 Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 129: Checking The Coolant Level

    COOLING SYSTEM 16 – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 130: Draining The Coolant

    16 COOLING SYSTEM 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 131: Refilling Coolant

    COOLING SYSTEM 16 16.5 Refilling coolant Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...

  • Page 132: 17 Tuning The Engine

    17 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. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 133: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 17 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 134: Changing The Mapping (Exc-F Six Days)

    17 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 135: Adjusting The Idle Speed

    Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm.

  • Page 136: Teaching The Throttle Valve Position

    17 TUNING THE ENGINE 17.6 Teaching the throttle valve position Info If the control unit detects that the throttle valve idle position needs to be retaught, then the malfunction indicator lamp flashes 2x per second. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.

  • Page 137: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 17.8 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing.

  • Page 138: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 139: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 18 – Start the engine and check the response. 18.2 Checking the engine oil level Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 140 18 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surfaces. K00568-10 – Position oil screen with the O-rings on a pin wrench. –...

  • Page 141: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 – Lay the motorcycle on its right side and fill the oil filter hous- ing approx. ⅓ full with engine oil. – Place the oil filter into the oil filter housing. – Oil the O-ring of the oil filter cover and mount it together with oil filter cover –...
  • Page 142 18 SERVICE WORK ON THE ENGINE Main work – Remove oil filler plug with the O-ring from the clutch cover. – Fill engine oil to the middle of the level viewer. Engine oil (SAE 10W/50) ( p. 159) Info In order to achieve optimal engine performance, it is not advisable to mix different engine oils.

  • Page 143: Cleaning, Care 19

    CLEANING, CARE 19 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 144: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 161) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 145: Storage 20

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 63) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 146: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 63) – Install the battery. p. 114) – Perform checks and maintenance measures when preparing for use. ( p. 42) – Take a test ride. 401059-01...

  • Page 147: Troubleshooting 21

    Check the electrical system. tive – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool.
  • Page 148 – Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
  • Page 149 TROUBLESHOOTING 21 Faults Possible cause Action – The high beam, low beam, tail Fuse 2 blown Change the fuses of individual power light, position light, and license consumers. ( p. 119) plate lamp are not working – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual power nal, and radiator fan (optional)

  • Page 150: 22 Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short...
  • Page 151 BLINK CODE 22 Blink code for malfunction indicator lamp 22 Malfunction indicator lamp flashes 2x long, 2x short Error level condition Gear position sensor - input voltage too high Gear position sensor - input voltage too low Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Error level condition...

  • Page 152: 23 Technical Data

    23 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 153: Engine Tightening Torques

    TECHNICAL DATA 23 23.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) Loctite ®...
  • Page 154 23 TECHNICAL DATA Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 155: Capacities

    TECHNICAL DATA 23 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) p. 159) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 159) 23.3.3 Fuel Total fuel tank capacity, approx. 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 156: Electrical System

    90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...

  • Page 157: Fork

    TECHNICAL DATA 23 23.7 Fork 23.7.1 EXC‑F EU/AU/AR/BR Fork article number 14.18.8S.67 WP SuspensionXplor 48 Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 …...

  • Page 158: Shock Absorber

    23 TECHNICAL DATA 23.8 Shock absorber Shock absorber article number 12.18.7S.63 WP Suspension 5018 PDS DCC Shock absorber Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort...
  • Page 159 TECHNICAL DATA 23 Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring Screw, turn signal switch 1 Nm (0.7 lbf ft) Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ball joint of push rod on...
  • Page 160 23 TECHNICAL DATA 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™ Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite 2701™...

  • Page 161: Substances 24

    SUBSTANCES 24 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 162 24 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 163) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 163: Auxiliary Substances 25

    AUXILIARY SUBSTANCES 25 Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 164 25 AUXILIARY SUBSTANCES Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 165: Standards 26

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

  • Page 166: 27 Index Of Special Terms

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

  • Page 167: List Of Abbreviations 28

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

  • Page 168: 29 List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 169: Index

    INDEX Chain guide INDEX checking ......89 Accessories ......10 Chain tension Air filter adjusting .
  • Page 170 INDEX Engine number ......14 Headlight light range, adjusting ....123 Engine oil Headlight bulb adding .
  • Page 171 INDEX Oil screen Spoke tension cleaning ......137 checking ......112 Operating substances .
  • Page 172 INDEX View of vehicle front left ......12 rear right ......13 Warranty .
  • Page 173 *3213881en* 3213881en 03/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

250 exc-f six days 2019

Table of Contents