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KTM 250 SX-F PRADO 2020 Owner's Manual

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OWNER'S MANUAL
2020
250 SX-F
250 XC‑F
250 SX‑F PRADO
Art. no. 3214129en

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Summary of Contents for KTM 250 SX-F PRADO 2020

  • Page 1 OWNER'S MANUAL 2020 250 SX-F 250 XC‑F 250 SX‑F PRADO Art. no. 3214129en...
  • 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 PREPARING FOR USE......... 22 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..22 Symbols used ........5 Running in the engine ...... 23 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.33 Removing the fuel tank ....71 shock absorber ......42 11.34 Installing the fuel tank ....73 10.11 Adjusting the riding sag ....43 11.35 Checking for chain dirt 10.12 Checking the basic setting of the accumulation........
  • Page 6 TABLE OF CONTENTS 14.4 Changing main fuse ....... 106 22.7 Fork..........137 14.5 Diagnostics connector ....107 22.7.1 All EU models ......137 22.7.2 SX‑F US........138 15 COOLING SYSTEM ........108 22.7.3 XC‑F US........138 15.1 Cooling system ......108 22.8 Shock absorber ......

  • 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 (all SX‑F models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies 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: Degrees Of Risk And Symbols

    SAFETY ADVICE 2 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • 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: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 12: Important Notes

    Manufacturer and 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 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) E01234-10 Hand brake lever ( p. 15) Clutch lever ( p. 15) Fuel tank filler cap Air filter box cover p. 21) (all SX‑F models) Plug-in stand ( Cold start button ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) E01233-10 Shock absorber compression adjustment Combination switch ( p. 16) Switch-off button ( p. 15) Start button ( p. 16) Throttle grip ( p. 15) Vehicle identification number ( p. 13) Type label ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 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 Engine number is located on the left side of the engine over the engine sprocket.

  • Page 16: Shock Absorber Article Number

    5 SERIAL NUMBERS 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 17: Controls 6

    CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S01192-10 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. S01193-10 Throttle grip The throttle grip...

  • Page 18: Start Button

    6 CONTROLS Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. S01195-10 Combination switch The combination switch is fitted on the left side of the handlebar.

  • Page 19: Service Hour Counter

    CONTROLS 6 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 20: Closing The Fuel Tank Filler Cap

    6 CONTROLS (XC‑F US) – Press release button , turn the fuel tank filler cap coun- terclockwise, and lift it off. F01557-10 6.10 Closing the fuel tank filler cap (all SX‑F models) – Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed.

  • Page 21: Cold Start Button

    CONTROLS 6 6.11 Cold start button (all SX‑F models) The cold start button is fitted to the bottom of the throttle valve body. F01578-10 (XC‑F US) The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low.

  • Page 22: Idle Speed Adjusting Screw

    6 CONTROLS 6.12 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi- cle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 23: Foot Brake Lever

    CONTROLS 6 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand (all SX‑F models) The support for plug-in stand is the left side of the wheel spin- dle.

  • Page 24: Preparing For Use

    When using the motorcycle, remember that others may be disturbed by excessive noise. – Ensure 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 25: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 91) – Adjust the basic position of the shift lever. p. 118) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.

  • Page 26: Preparing The Vehicle For Difficult Operating Conditions

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

  • Page 27: Preparing The Vehicle For Riding On Wet Sand

    Change the piston every 20 operating hours. Preparing the vehicle for riding on wet sand – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. 102137-01 – Clean the chain. Chain cleaner ( p. 145) –...

  • Page 28: Preparing Vehicle For High Temperatures Or Slow Riding

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 109) 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. 102137-01...

  • Page 29: Riding Instructions 8

    RIDING INSTRUCTIONS 8 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 30: Activating Launch Control

    8 RIDING INSTRUCTIONS (all SX‑F models) – Remove plug-in stand H02629-10 (XC‑F US) – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 31: Activating Traction Control

    RIDING INSTRUCTIONS 8 – Press and hold the MAP and TC buttons simultaneously. The malfunction indicator lamp flashes orange rapidly. Info The launch control is deactivated automatically for a few seconds after the vehicle has started. The launch control is also deactivated in the following cases (malfunction indicator lamp no longer flashes): if the throttle valve is closed more than 1/3 of the way H02884-01...

  • Page 32: Shifting, Riding

    If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop. First gear is used for starting off and for steep inclines.

  • Page 33: Stopping, Parking

    RIDING INSTRUCTIONS 8 – Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not over- rev the engine when doing so. This means that significantly less braking is required and the brake system does not overheat.

  • Page 34: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 35 RIDING INSTRUCTIONS 8 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 fuel tank filler cap. ( p.

  • Page 36: 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 37: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● ● Make a service entry in the KTM Dealer.net.
  • Page 38 9 SERVICE SCHEDULE Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours every 12 months ● Perform major engine service including removing and installing the engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the connect- ing rod, conrod bearing and crank pin.

  • Page 39: 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 40: 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 41: 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 42: 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 43: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 Main work – Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090000) Sag gage pin (00029990010) – Note the value as dimension 402415-10 Finishing work –...

  • Page 44: Checking The Riding Sag 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.) Info Note the current adjustment before changing the spring preload -–e.g. measure the spring length.

  • Page 45: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 Main work – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (90129051000) – Measure the total spring length while the spring is not under tension. – Tighten the spring by turning adjusting ring to specified dimension Guideline...

  • Page 46: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS Guideline Spring rate (All EU models) Weight of rider: 65 … 39 N/mm (223 lb/in) 75 kg (143 … 165 lb.) Weight of rider: 75 … 42 N/mm (240 lb/in) 85 kg (165 … 187 lb.) Weight of rider: 85 …...

  • Page 47: 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 (All EU models) 10.4 bar (151 psi)

  • Page 48: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS – Disconnect the fork airpump from the left fork leg. 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.

  • Page 49: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection cap – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the lower end of the right fork leg.

  • Page 50: Adjusting The Handlebar Position

    10 TUNING THE CHASSIS 10.17 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. Preparatory work –...

  • Page 51: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 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 52: Bleeding The Fork Legs

    11 SERVICE WORK ON THE CHASSIS (XC‑F US) – Remove the motorcycle from the lift stand. – Remove the lift stand. – To park the motorcycle, press side stand to the ground with your foot and lean the motorcycle on it. Info When you are riding, the side stand must be folded up and secured with the rubber strap.

  • Page 53: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 Universal oil spray ( p. 146) – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 51) – Remove the motorcycle from the lift stand. ( p.

  • Page 54: Installing The Motor Guard (Prado)

    11 SERVICE WORK ON THE CHASSIS – Remove screw . Take off the motor guard. F02588-10 11.8 Installing the motor guard (PRADO) – Position the motor guard on the frame. – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F02588-11 –...

  • Page 55: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 (SX‑F EU/US, XC-F US) – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. F01559-10 (PRADO) – Loosen screws . Remove the left fork leg. – Loosen screws .

  • Page 56: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS (PRADO) – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Tighten screws Guideline Screw, bottom 12 Nm (8.9 lbf ft) F01832-11 triple clamp – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 57: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 (PRADO) – Open cable holder on the left and detach the wiring harness. – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and place to one side. Info F01833-10 Cover the components to protect them against dam-...
  • Page 58 11 SERVICE WORK ON THE CHASSIS (SX‑F EU/US, XC-F US) – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. F01562-10 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.
  • Page 59 SERVICE WORK ON THE CHASSIS 11 – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Secure the wiring harness with cable holder on the left.

  • Page 60: Checking The Steering Head Bearing Play

    11.13 Checking the steering head bearing play Warning 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.)

  • Page 61: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 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. Preparatory work – Raise the motorcycle with a lift stand.

  • Page 62: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS (PRADO) – Loosen screws – Remove screw – 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 F01841-10 clamp to avoid stresses.

  • Page 63: Installing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.17 Installing the start number plate – Position the brake line in holders on the start number plate. – Position the start number plate. Mount and tighten screw The holding lugs engage in the fender. F01525-10 11.18 Removing front fender...

  • Page 64: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.19 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F01526-10 Finishing work – Install the start number plate. ( p. 61) 11.20 Removing the shock absorber Preparatory work...

  • Page 65: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove screws – Pull off foot brake cylinder from the push rod. F01582-10 – Remove the connecting link of the chain. – Take off the chain. Info Cover the components to protect them against damage. S01222-10 –...
  • Page 66 11 SERVICE WORK ON THE CHASSIS – 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) F01586-10 – Mount the chain. –...

  • Page 67: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 – 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 68: Mounting The Seat

    11 SERVICE WORK ON THE CHASSIS 11.23 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. H02218-11 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 69: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area sideways and take off toward the front. F01589-10 11.25 Installing the air filter box cover Condition The air filter box cover is secured.

  • Page 70: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Preparatory work – Remove the air filter box cover. ( p.

  • Page 71: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.28 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 145) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 72: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the main silencer. F01590-10 11.31 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. –...

  • Page 73: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove all the screws on the main silencer. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.
  • Page 74 11 SERVICE WORK ON THE CHASSIS Main work (all SX‑F models) – Unplug connector of the fuel pump. – Clean quick release coupling thoroughly with com- pressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection F01591-10 valve! –...

  • Page 75: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Remove screw with the rubber bushing. F01565-10 – Remove screws with the collar bushings. F01541-10 – Pull both spoilers laterally off the radiator and lift off the fuel tank. F01542-10 11.34 Installing the fuel tank Danger Fire hazard Fuel is highly flammable.
  • Page 76 11 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 80) – 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 77: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 – Plug in connector for the fuel pump. – Remove the wash cap set. Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –...

  • Page 78: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 145) – After drying, apply chain spray. Off-road chain spray ( p.

  • Page 79: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.38 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 80: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 81 SERVICE WORK ON THE CHASSIS 11 – 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 82: 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 11.42 Checking throttle cable routing Preparatory work –...

  • Page 83: Checking The Rubber Grips

    SERVICE WORK ON THE CHASSIS 11 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 rubber strap of the fuel tank support.

  • Page 84: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.44 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 counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 85: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info Clean up overflowed or spilled brake fluid immediately with water. 11.46 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 86 11 SERVICE WORK ON THE CHASSIS Info Immediately clean up any brake fluid that has over- flowed or spilled with water. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. (XC‑F US) –...

  • Page 87: 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 88: 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 89: 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 90: 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 91 – 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.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 92 12 BRAKE SYSTEM – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated properly. 100397-01 –...

  • Page 93: 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 94: 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 95 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 96: 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 97 BRAKE SYSTEM 12 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. 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.
  • Page 98 12 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 143) – Mount and tighten screw cap with membrane and the O-ring. Info Immediately clean up any brake fluid that has over- flowed or spilled with water.

  • Page 99: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) 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 100: Installing The Front Wheel

    13 WHEELS, TIRES (PRADO) – Remove spacer and brake disc guard H01890-10 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. –...

  • Page 101: Removing The Rear Wheel

    WHEELS, TIRES 13 – Align the brake disc guard so that distance equal in size. S01633-10 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc.

  • Page 102: Installing The Rear Wheel

    13 WHEELS, TIRES Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.

  • Page 103: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 104: Checking Tire Pressure

    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 105 WHEELS, TIRES 13 – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 106: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard 12 V batteries contain environmentally hazardous materials. –...

  • Page 107: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 Finishing work – Mount the seat. ( p. 66) 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. –...

  • Page 108: Changing Main Fuse

    It is also impossible to overcharge the 12 V battery with these battery chargers. The charging time may be longer at low temperatures. These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...

  • Page 109: Diagnostics Connector

    ELECTRICAL SYSTEM 14 Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. – Remove the seat. ( p. 65) Main work – Pull starter relay from the holder. S02303-10 – Take off protection caps –...

  • Page 110: 15 Cooling System

    15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 111: Checking The Coolant Level

    COOLING SYSTEM 15 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 112: Refilling With Coolant

    15 COOLING SYSTEM 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 113: Changing The Coolant

    COOLING SYSTEM 15 Finishing work (PRADO) – Install the motor guard. ( p. 52) 15.6 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 114 15 COOLING SYSTEM – Go for a short test ride. – Check the coolant level. ( p. 109) Finishing work (PRADO) – Install the motor guard. ( p. 52)

  • Page 115: Tuning The Engine 16

    TUNING THE ENGINE 16 16.1 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 3 …...
  • Page 116 16 TUNING THE ENGINE Main work (all SX‑F models) – 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 117: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16 16.3 Adjusting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –...

  • Page 118: Changing The Mapping

    16.5 Adjusting the idle speed Warning 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.)

  • Page 119: Teaching The Throttle Valve Position

    TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 19) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 120: Checking The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 121: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 17.1 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 122: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE 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 effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 123: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE 17 Condition The engine is cold. – Check the engine oil level. The engine oil reaches the middle of level viewer » If the engine oil does not reach the middle of the level viewer: –...
  • Page 124 17 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. E01241-10 – Position oil screen with the O-rings on a pin wrench. –...

  • Page 125: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil. – Fill the oil filter with engine oil and position the oil filter in the housing.
  • Page 126 17 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring. – Add the same engine oil used when the last oil change was carried out. Engine oil (SAE 10W/50) ( p. 143) Info For optimal performance of the engine oil, do not mix different types of engine oil.

  • Page 127: Cleaning, Care 18

    CLEANING, CARE 18 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 128 18 CLEANING, CARE – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 75) – Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 129: Storage 19

    – 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. 49) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 130: Putting Into Operation After Storage

    19 STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 131: Troubleshooting 20

    – Check the electrical system. – Malfunction in the electronic Read out fault memory using the KTM fuel injection diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out fault memory using the KTM fuel injection diagnostics tool.
  • Page 132 Check the wiring for damage and the lights up or flashes fuel injection electrical plug-in connections for corro- sion and damage. – Read out fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 133: Blink Code 21

    BLINK CODE 21 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 Crankshaft speed sensor – circuit fault Error level condition Blink code for malfunction indicator lamp...
  • Page 134 21 BLINK CODE Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 135: Technical Data 22

    TECHNICAL DATA 22 22.1 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 14.4:1 Idle speed 2,250 … 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 136: Engine Tightening Torques

    22 TECHNICAL DATA Starting aid Starter motor 22.2 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 137 TECHNICAL DATA 22 Screw, guide rail 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil filter cover 10 Nm (7.4 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ®...

  • Page 138: Capacities

    22 TECHNICAL DATA Nut, primary gear wheel M18LHx1.5 120 Nm (88.5 lbf ft) Loctite ® 243™ Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft) Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) Fixing nut for main bearing inner M27x1...

  • Page 139: 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 22.7 Fork 22.7.1 All EU models Fork article number 34.18.8T.05...

  • Page 140: Sx-F Us

    22 TECHNICAL DATA Sport 7 clicks Air pressure 10.4 bar (151 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism ml (7.44 fl. oz.) Fork oil (SAE 4) (48601166S1) + 20 + 0.68 − 40 − 1.35 right p.

  • Page 141: Shock Absorber

    TECHNICAL DATA 22 Air pressure 9.8 bar (142 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) + 40 + 1.35 − 20 − 0.68 right p. 144) Oil capacity external mechanism ml (6.76 fl.

  • Page 142: Xc-F Us

    22 TECHNICAL DATA 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 Standard 15 clicks Sport 13 clicks Spring preload 9 mm (0.35 in) Spring rate Weight of rider: 65 …...

  • Page 143: Chassis Tightening Torques

    TECHNICAL DATA 22 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 oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 144) 22.9 Chassis tightening torques Screw, air filter box cover EJOT PT...
  • Page 144 22 TECHNICAL DATA Screw, bottom triple clamp 12 Nm (8.9 lbf ft) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace on engine M8x20 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft) Loctite...

  • Page 145: Substances 23

    SUBSTANCES 23 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 146 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 147) (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 147: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 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 148 24 AUXILIARY SUBSTANCES 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 149: Standards 25

    STANDARDS 25 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 150: 26 Index Of Special Terms

    26 INDEX OF SPECIAL TERMS Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 151: List Of Abbreviations 27

    LIST OF ABBREVIATIONS 27 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 152: 28 List Of Symbols

    28 LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics.

  • Page 153: Index

    INDEX Chain guide INDEX checking ......78 12-V battery Chain tension installing ......104 adjusting .
  • Page 154 INDEX Foot brake lever ......21 Indicator lamps basic position, adjusting ....91 overview .
  • Page 155 INDEX Steering head bearing lubricating ......60 Rear sprocket Steering head bearing play checking ......78 adjusting .
  • Page 156 *3214129en* 3214129en 10/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

This manual is also suitable for:

250 xc-f 2020250 sx-f 2020

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