KTM 250 SX 2018 Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 250 SX 2018
  6. Owner's manual

KTM 250 SX 2018 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
OWNER'S MANUAL
2018
250 SX
250 XC
300 XC
Art. no. 3213637en

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 250 SX 2018 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for KTM 250 SX 2018

Summary of Contents for KTM 250 SX 2018

  • Page 1 OWNER'S MANUAL 2018 250 SX 250 XC 300 XC Art. no. 3213637en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS RIDING INSTRUCTIONS..........25 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Checks and maintenance measures when Symbols used ........... 5 preparing for use..........25 Formats used............ 5 Starting............25 SAFETY ADVICE............6 Starting off............. 26 Use definition – intended use......6 Shifting, riding ..........
  • Page 5 TABLE OF CONTENTS 11.23 Installing the air filter box cover ....... 53 16 TUNING THE ENGINE..........88 11.24 Removing the air filter ......... 54 16.1 Checking the play in the throttle cable ....88 11.25 Cleaning the air filter and air filter box ..
  • Page 6 TABLE OF CONTENTS 25 LIST OF ABBREVIATIONS......... 124 INDEX ................125...

  • 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

    SAFETY ADVICE Use definition – intended use (All SX models) 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 Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Safe Operation

    – 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. The tools are not contained in the vehicle but can be ordered under the number in paren- theses.

  • 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

    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. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) A00031-10 Hand brake lever ( p. 13) Kill switch ( p. 13) Clutch lever ( p. 13) Air filter box cover Plug-in stand Shift lever ( p. 16) Choke ( p. 16) Fuel tap...

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

    VIEW OF VEHICLE View of vehicle, rear right (example) A00033-10 Seat Filler cap Throttle grip ( p. 13) Kick starter ( p. 17) Foot brake lever ( p. 17) Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment...

  • Page 14: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 15: Controls

    CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. F00009-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. F00001-10 Throttle grip Throttle grip...

  • Page 16: Opening The Filler Cap

    CONTROLS Opening the 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 17: Fuel Tap (All Sx Models)

    CONTROLS (All XC models) – Mount filler cap and turn it clockwise until the release button engages. Info Run the fuel tank breather hose without kinks. K00508-11 Fuel tap (All SX models) Fuel tap is on the left of the fuel tank. Open or close the supply of fuel to the carburetor using tap handle on the fuel tap.

  • Page 18: Choke

    CONTROLS 6.10 Choke (All SX models) Choke is fitted on the left side of the carburetor. A00017-10 (All XC models) Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel.

  • Page 19: Kick Starter

    CONTROLS 6.12 Kick starter Kick starter is fitted on the right side of the engine. The top part of the kick starter pivots. Info 0 0 1 Before riding, swing the top part of the kick starter inward toward the engine. 401954-10 6.13 Foot brake lever...

  • Page 20: Service Hour Counter

    CONTROLS 6.16 Service hour counter The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off.

  • Page 21: 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 22: Running In The Engine

    PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –...

  • Page 23: Preparing For Rides On Dry Sand

    Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. M01105-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Clean the chain. Chain cleaner ( p. 121) –...

  • Page 24: Preparing For Rides On Wet Sand

    Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Clean the chain. Chain cleaner ( p. 121) –...

  • Page 25: Preparing For Rides On Wet And Muddy Surfaces

    Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. 99) –...

  • Page 26: Preparing For Rides At Low Temperature Or In Snow

    Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01...

  • Page 27: Riding Instructions

    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 28: Starting Off

    Do not change into a low gear at high engine speed. 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 and for steep inclines.

  • Page 29: Applying The Brakes

    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 30: Transport

    RIDING INSTRUCTIONS Transport Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. –...
  • Page 31 RIDING INSTRUCTIONS Engine oil, 2-stroke ( p. 119) – Close the filler cap. ( p. 14)

  • Page 32: Service Schedule

    ○ ○ ● ● ● ● Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet.

  • Page 33: Recommended Work

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval Recommended work Every 40 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours / Every 20 operating hours Once after 10 operating hours / Every 10 operating hours ●...

  • Page 34: Tuning The Chassis

    For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…...

  • Page 35: Adjusting The Low-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 low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 36: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 37: Measuring The Rear Wheel Dimension Unloaded

    TUNING THE CHASSIS 10.7 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender.

  • Page 38: Checking The Riding Sag 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 pretension, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 39: Adjusting The Riding Sag

    TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 42) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the shock absorber. p. 50) – After removing the shock absorber, clean it thoroughly.

  • Page 40: Adjusting The Fork Air Pressure

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure (250 SX EU) 10.3 bar (149 psi)

  • Page 41: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the upper end of the right fork leg. –...

  • Page 42: Handlebar Position

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions.
  • Page 43 TUNING THE CHASSIS – Tighten screws evenly. Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Finishing work – Mount the handlebar cushion.

  • Page 44: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 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 45: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws.

  • Page 46: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS – Unscrew screws . Take out the left fork leg. – Unscrew screws . Take out the right fork leg. F00011-10 11.6 Installing the fork legs Main work – Position the fork legs. Bleeder screw of the right fork leg is positioned to the front.

  • Page 47: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11.8 Installing the fork protector – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws –...

  • Page 48: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 121) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 49: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages 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 50: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...

  • Page 51: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw – Disconnect the brake line at the start number plate. Take off the start number plate. F00012-10 11.15 Installing the start number plate – Connect the brake line at the start number plate. –...

  • Page 52: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Remove screws with the washers and remove screws – Remove the cable ties and remove the frame protectors on the left and right. A00024-10 –...

  • Page 53: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. A00004-10 – Hold the shock absorber and remove screw A00005-10 – Remove the shock absorber carefully at the bottom. A00006-10 11.19 Installing the shock absorber...

  • Page 54: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Mount the chain. – Connect the chain with the connecting link. Guideline The closed side of the chain joint lock must face in the direction of travel. M01149-01 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder.

  • Page 55: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11.21 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. F00016-10 –...

  • Page 56: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box cover EJOT PT ® 3 Nm EJOT PT screw K60x20-Z (2.2 lbf ft) (0017060204) A00009-10 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 57: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Clean the air filter box. – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 55) – Install the air filter box cover. ( p.

  • Page 58: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.29 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. – Remove screws with the washers.

  • Page 59: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Remove screws . Pull out inner tube – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. – Fit the new glass fiber yarn filling into the inner tube.

  • Page 60: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws F00021-10 (All SX models) – Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the tank lid. F00032-10 (All XC models) –...

  • Page 61: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 63) – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. F00033-02 (All SX models) –...

  • Page 62: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 63: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 61) Finishing work – Remove the motorcycle from the lift stand. ( p. 42) 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.
  • Page 64 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 65: Checking The Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. K00519-01 11.40 Checking the swingarm –...

  • Page 66: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS (All XC models) – Turn handle of the fuel tap to the OFF position. (Figure A00023-10 p. 15) – Remove the fuel tank. p. 57) Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor.

  • Page 67: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11.44 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
  • Page 68 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane H01330-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 69: Brake System

    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.) – Check the thickness of the front and rear brake discs at multiple points on each...

  • Page 70: Checking The Front Brake Fluid Level

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – 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 Old brake fluid reduces the braking effect.

  • Page 71: Checking The Front Brake Linings

    69) H01333-10 12.7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 72 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 73: 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 74: Checking The Rear Brake Fluid Level

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – 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 Old brake fluid reduces the braking effect.

  • Page 75: Adding Rear Brake Fluid

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.

  • Page 76: Changing The Rear Brake Linings

    Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 77 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 78: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 79: Removing The Rear Wheel

    WHEELS, TIRES – Clean and grease the wheel spindle. Long-life grease ( p. 121) – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5...

  • Page 80: Installing The Rear Wheel

    WHEELS, TIRES 13.4 Installing the rear 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. Main work –...

  • Page 81: Checking The Tire Condition

    The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. 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 82 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diame- ter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions. You should hear a high note.

  • Page 83: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery (All XC models) 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. – Only charge batteries in well-ventilated rooms. –...

  • Page 84: Recharging The Battery (All Xc Models)

    ELECTRICAL SYSTEM 14.3 Recharging the battery (All XC models) 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. – Only charge batteries in well-ventilated rooms. –...

  • Page 85: Changing The Main Fuse (All Xc Models)

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the quiescent current, the start ability of the battery, and the alternator. With this device, you cannot overcharge the battery.

  • Page 86: Cooling System

    COOLING SYSTEM 15.1 Cooling system (All SX models) 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 operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 87: Checking The Coolant Level

    COOLING SYSTEM – Mount the radiator cap. 15.3 Checking the coolant level 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 88: Refilling With Coolant

    COOLING SYSTEM – Place a suitable container under the water pump cover. (All SX models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) K00867-10...
  • Page 89 COOLING SYSTEM – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 90: Tuning The Engine

    TUNING THE ENGINE 16.1 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 determine the play in throttle cable Play in throttle cable 2…...

  • Page 91: Carburetor Setting

    TUNING THE ENGINE Finishing work – Check the throttle grip for smooth operation. – Install the fuel tank. p. 58) – Mount the seat. ( p. 53) – Check the play in the throttle cable. ( p. 88) 16.3 Carburetor setting Effects of the carburetor setting H01400-01 The different carburetor components must be tuned both to one another and for the use intended.
  • Page 92 TUNING THE ENGINE Influence of throttle slide adjustment K00495-01 The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence. When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influ- ence.

  • Page 93: Carburetor - Idle

    TUNING THE ENGINE Info The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1 corresponds to the leanest. The optimal carburetor tuning is shown under the respective model. Clip position 1...

  • Page 94: Plug-In Connector Of Ignition Timing Map Adjustment

    TUNING THE ENGINE – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

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

    TUNING THE ENGINE – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in) edge of boot »...
  • Page 96 TUNING THE ENGINE Preparatory work – Tilt the motorcycle to the left and secure against falling in this position. Guideline Angle of title approx. 45° Main work (All SX models) – Remove screws K00877-10 – Remove cap , adjusting spring , auxiliary spring , and spring insert...
  • Page 97 TUNING THE ENGINE – Remove cap , adjusting spring , auxiliary spring , and spring insert from the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring and adjusting spring and position them together in the clutch cover.

  • Page 98: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Emptying the carburetor float chamber 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 99: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 17.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Detach the foot brake lever spring. –...

  • Page 100: Adding Gear Oil

    SERVICE WORK ON THE ENGINE – Remove filler plug and fill up with gear oil. Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 119) – Mount and tighten the oil filler plug. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 101: Cleaning, Care

    CLEANING, CARE 18.1 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 102: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 42) –...

  • Page 103: Preparing For Use After Storage

    STORAGE 19.2 Preparing for use after storage (All XC models) – Install the battery. p. 81) – Remove the motorcycle from the lift stand. ( p. 42) – Perform checks and maintenance measures when preparing for use. ( p. 25) –...

  • Page 104: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 25) tric starter) – Battery discharged Recharge the battery. p. 82) (All XC models) – Check the charging voltage. –...
  • Page 105 TROUBLESHOOTING Faults Possible cause Action (All SX models) Engine stalls or is popping into the Lack of fuel – carburetor Turn handle of the fuel tap to the ON position. (Figure A00016-10 p. 15) (All XC models) – Turn handle of the fuel tap to the ON position.

  • Page 106: Technical Data

    TECHNICAL DATA 21.1 Engine 21.1.1 All SX models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Exhaust valve, beginning of adjustment 5,125 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing...

  • Page 107: Xc Us

    TECHNICAL DATA Fifth gear 25:22 Sixth gear 26:20 Ignition system Contactless controlled, fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK BR 7 ES Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 21.1.3 300 XC US Design...

  • Page 108: All Xc Models

    TECHNICAL DATA Loctite ® 2701™ Screw, retaining bracket of exhaust 7 Nm (5.2 lbf ft) control Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Loctite 243™ Screw, water pump impeller 6 Nm (4.4 lbf ft) ® – Bleeder screw, cylinder head 10 Nm (7.4 lbf ft) –...
  • Page 109 TECHNICAL DATA – Screw, gear oil level check 10 Nm (7.4 lbf ft) – Screw, intake flange/reed valve housing M6 6 Nm (4.4 lbf ft) – Screw, intermediate clutch cover 10 Nm (7.4 lbf ft) Screw, kick starter idler gear steel pin 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 110: Carburetor

    TECHNICAL DATA 21.3 Carburetor 21.3.1 All SX models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 84 Needle position 3rd position from top Jet needle 6BFY43-73 (6BFY44-73) Main jet 440 (430, 450, 460) Idling jet 42.5 (37.5 / 40 / 45 / 47.5) Starting jet Needle jet S‑1...

  • Page 111: Carburetor Tuning (All Sx Models)

    TECHNICAL DATA 21.3.3 Carburetor tuning (All SX models) 402893-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain.

  • Page 112: Xc Us

    TECHNICAL DATA 21.3.4 250 XC US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 85 Needle position 2nd position from top Jet needle 6BFY43‑75 (6BFY42‑75) Main jet 470 (450, 460, 480) Idling jet 35 (32.5/37.5) Starting jet Needle jet S‑4 Idle air adjusting screw Open...
  • Page 113 TECHNICAL DATA Needle Needle position from top Main jet Info Do not use on sandy terrain.

  • Page 114: Xc Us

    TECHNICAL DATA 21.3.6 300 XC US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 80 Needle position 2nd position from top Jet needle 6BFY43-75 (6BFY42-75) Main jet 450 (430, 440, 460) Idling jet 25 (22.5/27.5) Starting jet Needle jet S‑4 Idle air adjusting screw Open...

  • Page 115: Capacities

    TECHNICAL DATA Needle Needle position from top Main jet Info Do not use on sandy terrain. 21.4 Capacities 21.4.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 119) 21.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 116: Electrical System

    110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 21.8 Fork 21.8.1 250 SX EU Fork article number 34.18.8R.03...

  • Page 117: All Xc Models

    TECHNICAL DATA Sport 7 clicks Air pressure 10.5 bar (152 psi) Fork length 950 mm (37.4 in) Oil capacity external mecha- ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 120) +1.35 −20 −0.68 nism left Oil capacity external mecha- ml (6.76 fl.

  • Page 118: Sx Us

    TECHNICAL DATA Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 35 mm (1.38 in) Riding sag 105 mm (4.13 in) Fitted length 477 mm (18.78 in) Shock absorber fluid ( p. 120) SAE 2.5 21.9.2 250 SX US Shock absorber article number...

  • Page 119: Chassis Tightening Torques

    TECHNICAL DATA Weight of rider: 75… 85 kg (165… 187 lb.) 42 N/mm (240 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 45 N/mm (257 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 35 mm (1.38 in) Riding sag...
  • Page 120 TECHNICAL DATA Loctite ® 243™ Screw, handlebar support 40 Nm (29.5 lbf ft) Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701™ – Nut, frame on linkage lever M14x1.5 80 Nm (59 lbf ft) – Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) –...

  • Page 121: Substances

    SUBSTANCES 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 corre- sponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 122 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 123) (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 123: Auxiliary Substances

    AUXILIARY SUBSTANCES 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 Motorex...
  • Page 124 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 125: Standards

    STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.
  • Page 126 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
  • Page 127 INDEX Chassis number ....... 12 INDEX Choke ........16 Accessories .
  • Page 128 INDEX installing ....... . . 44 removing ....... . . 56 removing .
  • Page 129 INDEX Steering head bearing greasing ....... . . 48 Steering head bearing play adjusting .
  • Page 130 *3213637en* 3213637en 03/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

250 xc 2018300 xc 20183213637en

Table of Contents