KTM 250 SX 2021 Owner's Manual
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KTM 250 SX 2021 Owner's Manual

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OWNER'S MANUAL
2021
250 SX
Art. no. 3214210en

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Summary of Contents for KTM 250 SX 2021

  • Page 1 OWNER'S MANUAL 2021 250 SX Art. no. 3214210en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Running in the engine ...... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Preparing the vehicle for difficult Symbols used ........5 operating conditions......20 Formats used........5 Preparing the vehicle for riding on dry sand.......... 21 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.14 Adjusting the compression damping 11.38 Checking the frame ...... 70 of the fork ........41 11.39 Checking the link fork ....70 10.15 Adjusting the rebound damping of 11.40 Checking throttle cable routing..70 the fork........... 41 11.41 Checking the rubber grip ....
  • Page 6 TABLE OF CONTENTS 15.5 Carburetor - adjusting the idle speed ........103 15.6 Plug-in connector of ignition timing map adjustment......104 15.7 Changing the ignition timing map ..104 15.8 Checking the basic position of the shift lever........104 15.9 Adjusting the basic position of the shift lever ........

  • Page 7: Means Of Representation 1

    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 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V01533-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) 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 4 View of vehicle, rear right (example) V01534-10 Seat Fuel tank filler cap Switch-off button ( p. 14) Throttle grip ( p. 14) Kick starter lever ( p. 17) Foot brake lever ( p. 17) Shock absorber compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear...

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification 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: Shock Absorber Article Number

    SERIAL NUMBERS 5 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. 401948-10...

  • Page 16: 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. 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.

  • Page 17: Opening Fuel Tank Filler Cap

    CONTROLS 6 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 18: Fuel Tap

    6 CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. Open or close the fuel supply to the carburetor using tap han- on the fuel tap. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank •...

  • Page 19: Kick Starter Lever

    CONTROLS 6 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 6.10 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled.

  • Page 20: Service Hour Counter

    6 CONTROLS 6.13 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. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 21: Preparing For Use 7

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 22: Running In The Engine

    7 PREPARING FOR USE – Adjust the basic position of the foot brake lever. p. 81) – Adjust the basic position of the shift lever. p. 104) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more chal- lenging trips.

  • Page 23: Preparing The Vehicle For Riding On Dry Sand

    – In the event of scalding, rinse the area affected immediately with lukewarm water. – Change the radiator cap. – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for KTM PowerParts. M01104-01...

  • Page 24: Preparing The Vehicle For Riding On Wet Sand

    7 PREPARING FOR USE – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for KTM PowerParts. M01105-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning.
  • Page 25 Change the radiator cap. – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 26: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 27: Preparing The Vehicle For Low Temperatures Or Snow

    Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 28: Riding Instructions

    8 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 29: 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 autho- rized KTM workshop. First gear is used for starting off and for steep inclines. –...

  • Page 30: 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 31: Transporting

    RIDING INSTRUCTIONS 8 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 32: Refueling

    8 RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.

  • Page 33: Service Schedule 9

    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 34: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● ● Make a service entry in the KTM Dealer.net. ○ One-time interval ● Periodic interval Recommended work Every 40 operating hours After 20 operating hours / Every 20 operating hours...

  • Page 35: Tuning The Chassis 10

    – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 36: 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 compression adjuster can be seen in slow to normal compression of the shock absorber.

  • Page 37: 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 compression adjuster can be seen in fast compression of the shock absorber.

  • Page 38: Measuring The Rear Wheel Dimension Unloaded

    10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.7 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 39: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 36) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 40: 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 41: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the shock absorber. p. 53) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 42: 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 airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 10.4 bar (151 psi)

  • Page 43: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only mount the protection cap by hand. Finishing work –...

  • Page 44: Handlebar Position

    10 TUNING THE CHASSIS Guideline Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance from the center.
  • Page 45 TUNING THE CHASSIS 10 Main work – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws .

  • Page 46: 11 Service Work On The Chassis

    11 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 47: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. H01182-12 Finishing work – Remove the motorcycle from the lift stand. ( p. 44) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 48: Removing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.5 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the front wheel. p. 87) Main work – Remove screws and take off the clamp. –...

  • Page 49: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Position the brake line and the clamp. Mount and tighten screws K01143-11 Finishing work –...

  • Page 50: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage. Do not kink the cables and lines. K01149-10 –...
  • Page 51 SERVICE WORK ON THE CHASSIS 11 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info The air suspension AER valve is located in the left fork leg.

  • Page 52: Checking Steering Head Bearing Play

    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 53: Adjusting Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 44) 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the handlebar cushion. Main work –...

  • Page 54: Removing The Start Number Plate

    11 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 55: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Remove the cable ties. – Remove screws with the washers. – Remove screw –...

  • Page 56: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS – Remove nut and pull out the swingarm pivot. – Push the link fork back and secure it against falling over. V01526-10 – Hold the shock absorber and remove screw K01139-10 – Remove the shock absorber carefully at the bottom. K01140-10 11.19 Installing the shock absorber...
  • Page 57 SERVICE WORK ON THE CHASSIS 11 – Position the link fork and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) V01527-10 – Mount the chain. –...

  • Page 58: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Position the left frame protector. – Insert the right frame protector from below and push it to the rear. – Mount and tighten screws with the washers. Guideline Screw, frame protec- 3 Nm (2.2 lbf ft) –...

  • Page 59: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01133-10 11.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p.

  • Page 60: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area K01227-11 – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 61: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Take off air filter from air filter support. K01156-10 11.25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 62: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.26 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. 126) 102178-10 – Insert the air filter and position the top retaining pin bushing The air filter is correctly positioned.

  • Page 63: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 – Remove screws with the washers. – Pull off the main silencer from the manifold at exhaust sleeve K01187-10 11.29 Installing the main silencer – Position the main silencer in exhaust sleeve – Mount and tighten screws with the washers.

  • Page 64: Removing The Fuel Tank

    11 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 dam- age.

  • Page 65: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws K01189-10 – Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the fuel tank lid. K01190-10 –...

  • Page 66: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 70) – Position the fuel tank and fit the two spoilers laterally to the radiator. – Make sure that no cables or throttle cables are trapped or dam- aged.

  • Page 67: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11 11.34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 68: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Guideline Lower chain section must be taut. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 69: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 70 11 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.
  • Page 71 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 72: Checking The Frame

    If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S02305-01 11.40 Checking throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 73: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11 Main work – Check 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. The throttle cable must be secured on the fuel tank bracket with a rubber strap.

  • Page 74: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.42 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 counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 75: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info Clean up overflowed or spilled brake fluid immediately with water. 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 76 11 SERVICE WORK ON THE CHASSIS – Now inject the liquid into the system until it emerges from the drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 77: Brake System 12

    Do not make any adjustments while riding. 12.3 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 78: Checking The Front Brake Fluid Level

    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.) Preparatory work –...

  • Page 79: 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 80: 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 81 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 82 12 BRAKE SYSTEM Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and brake caliper bracket. 101737-10 –...

  • Page 83: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 12.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 84: Checking The Rear Brake Fluid Level

    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.) Preparatory work –...
  • Page 85 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 86: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake 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 87 BRAKE SYSTEM 12 Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
  • Page 88 12 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 124) – Mount and tighten screw cap with membrane and the O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. K01185-10...

  • Page 89: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Manually press the brake caliper toward the brake disc 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 pistons.

  • Page 90: Installing The Front Wheel

    13 WHEELS, TIRES 13.2 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 91: Installing The Rear Wheel

    WHEELS, TIRES 13 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 92 13 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 surfaces of the spacers. Long-life grease ( p.

  • Page 93: 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 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 94: 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 95: Cooling System 14

    COOLING SYSTEM 14 14.1 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 96: Checking The Coolant Level

    14 COOLING SYSTEM 14.3 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 97: Refilling With Coolant

    COOLING SYSTEM 14 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. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 98 14 COOLING SYSTEM – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant ( p. 124) 400243-10 – Loosen screw and wait until coolant escapes without bub- bles. – Mount and tighten screw Guideline Bleeder screw, cylin- 10 Nm (7.4 lbf ft)

  • Page 99: Changing The Coolant

    COOLING SYSTEM 14 14.6 Changing 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 100 14 COOLING SYSTEM – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant ( p. 124) 400243-10 – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 101: Tuning The Engine 15

    TUNING THE ENGINE 15 15.1 Checking throttle cable play – 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 Throttle cable play 2 …...

  • Page 102: Carburetor Tuning

    15 TUNING THE ENGINE – Turn barrel adjuster so that there is play in the throttle cable at the throttle grip. Guideline Throttle cable play 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 103 TUNING THE ENGINE 15 Idling jet IJ The idling jet has the greatest influence in the low to mid throttle slide range. If the engine stutters at idle speed or when accelerating with a partially open throttle slide, a smaller idling jet must be used.

  • Page 104: Carburetor Idle Control

    15 TUNING THE ENGINE 402674-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 corresponds to a needle which is half a clip richer. Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the mixture preparation.

  • Page 105: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE 15 15.5 Carburetor - adjusting the idle speed – Screw in idle air adjusting screw all the way and turn it to the specified basic setting. Info The basic adjustment is shown under the respective model. – Run the engine until warm.

  • Page 106: Plug-In Connector Of Ignition Timing Map Adjustment

    15 TUNING THE ENGINE 15.6 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map •...

  • Page 107: Engine Characteristic - Auxiliary Spring

    TUNING THE ENGINE 15 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
  • Page 108 15 TUNING THE ENGINE Main work – Remove screws K01218-10 – 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 ( p.

  • Page 109: Service Work On The Engine 16

    SERVICE WORK ON THE ENGINE 16 16.1 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 110: Checking The Gear Oil Level

    16 SERVICE WORK ON THE ENGINE 16.2 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 111: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 16 Guideline Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft) with magnet – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.80 l Engine oil (0.85 qt.) (15W/50) p.
  • Page 112 16 SERVICE WORK ON THE ENGINE Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 113: Cleaning, Care 17

    CLEANING, CARE 17 17.1 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 114 17 CLEANING, CARE – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 65) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 115: Storage 18

    91) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 44) – Cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 116: Preparing For Use After Storage

    18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 44) – Perform checks and maintenance measures when preparing for use. ( p. 26) – Make a test ride. 401059-01...

  • Page 117: Troubleshooting 19

    TROUBLESHOOTING 19 Faults Possible cause Action – Engine turns but does not start Operating error Carry out start procedure. ( p. 26) – The motorcycle has been in dis- Empty the carburetor float chamber. use for an extended period and p.
  • Page 118 19 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into Engine takes in bad air Check the intake flange and carburetor the carburetor for tightness. – The connector or ignition coil is Clean the connector and treat it with loose or oxidized contact spray.

  • Page 119: Technical Data 20

    TECHNICAL DATA 20 20.1 Engine 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 control - setting measurement mm (0.071 + 0.2 + 0.008 −...
  • Page 120 20 TECHNICAL DATA Screw, locking lever 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket of exhaust 6 Nm (4.4 lbf ft) Loctite ® 2701™ control Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Bleeder screw, cylinder head 10 Nm (7.4 lbf ft) Nut, water pump impeller 5 Nm (3.7 lbf ft)

  • Page 121: Carburetor

    TECHNICAL DATA 20 20.3 Carburetor Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 89 Needle position 3rd position from top Jet needle 6BFY42-71 (6BFY43-71) Main jet 450 (430, 440, 460, 470) Idling jet 35 (30 / 32.5 / 37.5 / 40) Choke nozzle Needle jet S‑1...

  • Page 122: Carburetor - Basic Setting For Sandy Surfaces

    20 TECHNICAL DATA Info Do not use on sandy terrain. 20.3.2 Carburetor - basic setting for sandy surfaces Idle air adjusting screw Open 1.5 turns Idling jet 37.5 Jet needle 6BFY43‑71 Needle position 3rd position from top Main jet Info If the engine is not running smoothly, use a smaller main jet.

  • Page 123: Electrical System

    110/90 - 19 62M TT Dunlop GEOMAX MX33F Dunlop GEOMAX MX33 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 20.8 Fork Fork article number 34.18.8U.03 WP XACT 5448...

  • Page 124: Shock Absorber

    20 TECHNICAL DATA 20.9 Shock absorber Shock absorber article number 18.18.7U.03 WP XACT 5750 Shock absorber Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks...
  • Page 125 TECHNICAL DATA 20 Screw, chain sliding guard 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, throttle grip 5 Nm (3.7 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft)

  • Page 126: 21 Substances

    21 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 corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 127 SUBSTANCES 21 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 128) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 128: 22 Auxiliary Substances

    22 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...
  • Page 129 AUXILIARY SUBSTANCES 22 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier MOTOREX ®...

  • Page 130: 23 Standards

    23 STANDARDS 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 131: List Of Abbreviations 24

    LIST OF ABBREVIATIONS 24 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 132: Index

    INDEX Chain tension INDEX adjusting ......66 Accessories ......9 checking .
  • Page 133 INDEX article number ..... . 12 basic setting, checking ....39 Link fork Fork legs checking .
  • Page 134 INDEX Service ....... 9 Transporting ......29 Service hour counter .
  • Page 135 *3214210en* 3214210en 04/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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