1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 250 XCF-W ZA 2010
  6. Owner's manual

KTM 250 XCF-W USA 2010 Owner's Manual

Hide thumbs Also See for 250 XCF-W USA 2010:
Table of Contents

Advertisement

Quick Links

Download this manual
OWNER'S MANUAL
2010
250 EXC-F EU
250 XCF‑W USA
ART. NO. 3211481en

Advertisement

Table of Contents
loading

Related Manuals for KTM 250 XCF-W USA 2010

Summary of Contents for KTM 250 XCF-W USA 2010

  • Page 1 OWNER'S MANUAL 2010 250 EXC-F EU 250 XCF‑W USA ART. NO. 3211481en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    Key number (250 EXC-F EU) ..........9 Important maintenance work to be carried out by an Engine number..............9 authorized KTM workshop (as additional order)....31 Fork part number............. 9 Important checks and maintenance work to be carried Shock absorber part number........... 10 out by the rider.
  • Page 5 CONTENTS Installing the start number plate (250 XCF‑W USA) ..48 Removing main silencer ..........75 Handlebar position ............48 Installing the main silencer ..........75 Dismounting the air filter box lid........76 Adjusting handlebar position ........48 Installing the air filter box lid.......... 76 Checking of the routing of the throttle cable.....

  • Page 6: 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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important Notes

    Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's ser- vice record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
  • Page 8 IMPORTANT NOTES Transport Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components get very hot when the machine is driven. – Do not place the vehicle where there are flammable or explosive substances.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 600657-10 Hand brake lever Filler cap Clutch lever Fuel tap Shift lever Air filter box lid Chain guide...

  • Page 10: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 600656-10 Rubber band for the side stand Shock absorber, compression adjustment Chassis number Fork protector Shock absorber, rebound adjustment Level viewer, rear brake fluid Level viewer, engine oil Kickstarter...

  • Page 11: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  500127-10 Type label The type label is fixed to the front of the steering head.  500128-10 Key number (250 EXC-F EU) The key number is stamped on the key strap.

  • Page 12: Shock Absorber Part Number

    LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above  the adjusting ring on the engine side. 500129-10...

  • Page 13: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 600659-10 Hand brake lever Hand brake lever is located on the right side of the handlebar.  The hand brake lever is used to activate the front brake.

  • Page 14: Light Switch (250 Exc-F Eu)

    CONTROLS Light switch (250 EXC-F EU) The light switch is fitted on the left side of the handlebar.  Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on.

  • Page 15: Controls

    CONTROLS Speedometer – Press the key to change the display mode or change to one of the setup menus. – Press the button to control different functions. – Press the button to control different functions. Info In its condition at delivery, the display mode SPEED/H andSPEED/ODO is acti- vated.

  • Page 16: Setting The Clock

    CONTROLS – Press the button for 3 - 5 seconds. The settings are saved and the Setup menu closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed.

  • Page 17: Querying The Lap Time

    CONTROLS Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. Querying the lap time Info This function can be called only if lap times are measured. Condition The motorcycle is standing.

  • Page 18: Display Mode Speed/Clk (Clock)

    CONTROLS Display mode SPEED/CLK (clock) 6.10 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button .

  • Page 19: Display Mode Speed/Tr2 (Trip Master 2)

    CONTROLS Press the button next display mode briefly. Display mode SPEED/TR2 (trip master 2) 6.14 – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

  • Page 20: Display Mode Speed/S1 (Stop Watch 1)

    CONTROLS Display mode SPEED/S1 (stop watch 1) 6.17 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.
  • Page 21 CONTROLS Table of conditions and activability Display The motorcycle is Menu can be acti- standing vated Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • SPEED/TR1 display mode (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...

  • Page 22: Controls

    CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. Using tap handle on the fuel tap, you can open or close the supply of fuel to the  carburetor. Possible states Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. •...

  • Page 23: Choke (250 Xcf-W Usa)

    CONTROLS Choke (250 XCF‑W USA) Choke is fitted on the left side of the carburetor.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 24: Side Stand

    CONTROLS Side stand Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only.

  • Page 25: Unlocking The Steering (250 Exc-F Eu)

    CONTROLS Unlocking the steering (250 EXC-F EU) 7.12 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 26: General Tips And Hints On Putting Into Operation

    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 record at vehicle handover.

  • Page 27: Running In The Engine

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load...

  • Page 28: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level.

  • Page 29: Starting Up

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can block. 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 or for steep inclines.

  • Page 30: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components get very hot when the machine is driven. –...
  • Page 31 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 9.2 l Super unleaded (ROZ 95 / RON 95 / capacity, approx. (2.43 US gal) PON 91) ( p.

  • Page 32: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. 10.1 S20A S30A Engine • • Change the engine oil and oil filter, clean the oil screen. p. 79) Replace the spark plug. • Check the valve clearance.

  • Page 33: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop (as additional order). 10.2 Competition use Hobby use S20N S40A S10A S20A S40A S80A S20A S40A S80A • • Perform a fork service. Perform a shock absorber service.

  • Page 34: Important Checks And Maintenance Work To Be Carried Out By The Rider

    SERVICE SCHEDULE Important checks and maintenance work to be carried out by the rider. 10.3 NB1A Check the engine oil level. ( p. 79) • Check the brake fluid level of the front brake. ( p. 57) • Check the brake fluid level of the rear brake. ( p.

  • Page 35: Maintenance Work On Chassis And Engine

    Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 36: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 37: Measuring Rear Wheel Sag Unloaded

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise with a screwdriver to the last click.  Info Do not loosen nut  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 400210-10...

  • Page 38: Checking The Riding Sag Of The Shock Absorber

    Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 39: Adjusting The Riding Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the riding sag 11.12 – Remove shock absorber. p. 37) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75…...

  • Page 40: Checking Basic Setting Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking basic setting of fork 11.15 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller weight differences can be compensated by the spring preload.

  • Page 41: Adjusting The Spring Preload Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. Adjusting the spring preload of the fork 11.18 – Turn adjusting screws counterclockwise until they stop. Info Make the same adjustment on both fork legs. –...

  • Page 42: Loosening The Fork Protection

    Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 43: Adjusting Play Of Steering Head Bearing (250 Exc-F Eu)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting play of steering head bearing (250 EXC-F EU) 11.24 – Jack up the motorcycle. ( p. 33) – Loosen screws   – Loosen and retighten screw  Guideline Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –...

  • Page 44: Setting The Fork Offset (250 Xcf-W Usa)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Setting the fork offset (250 XCF‑W USA) 11.27 – Remove the lower triple clamp. p. 44) – Remove screw . Remove the steering stem.  – Clean the parts and check for damage. – Rotate the steering stem 180°...

  • Page 45: Removing The Fork Protector

    MAINTENANCE WORK ON CHASSIS AND ENGINE (250 XCF‑W USA) – Fully tighten screw  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Fully tighten screw  Guideline Screw, bottom triple clamp 12 Nm 500094-11 (8.9 lbf ft) (250 EXC-F EU) –...

  • Page 46: Removing The Lower Triple Clamp (250 Exc-F Eu)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp (250 EXC-F EU) 11.32 – Remove the fork legs. ( p. 42) – Remove the headlight mask with the headlight. ( p. 47) – Dismount the front fender. ( p.

  • Page 47: Installing The Lower Triple Clamp (250 Exc-F Eu)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the lower triple clamp (250 EXC-F EU) 11.34 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 104) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 48: Installing The Lower Triple Clamp (250 Xcf-W Usa)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the lower triple clamp (250 XCF‑W USA) 11.35 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 104) 0 0 3 – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 49: Dismounting The Front Fender

    MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the front fender 11.37 – Remove screws . Remove the front fender.  – Make sure that the distance bushings remain in place. 600692-10 Installing the front fender 11.38 – Ensure that the spacing sleeves are mounted in the fender. –...

  • Page 50: Dismount The Start Number Plate (250 Xcf-W Usa)

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the headlight mask and fix it with the rubber band  Info Take care with the contact of the holding lug at the fender. – Position the brake line and cable harness. Put the clamp on, mount and tighten screw ...

  • Page 51: Checking Of The Routing Of The Throttle Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the four screws . Remove the handlebar clamp. Remove the handlebar  0 0 1 0 0 1 and lay it to one side. 0 0 2 0 0 2 Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

  • Page 52: Checking The Play In The Throttle Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 11.46 – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the gas Bowden cable. Play in throttle cable 3…...

  • Page 53: Cleaning The Chain

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the chain 11.49 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. –...

  • Page 54: Checking The Rear Sprocket / Engine Sprocket For Wear

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Make sure that the chain adjusters are mounted correctly on the adjusting screws. – Push the chain at the end of the chain sliding component upwards to measure the chain tension  Info The upper chain section must be taut.

  • Page 55: Adjusting Chain Tension - After Checking

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the chain at the end of the chain sliding component upwards to measure chain tension  Info The upper chain section must be taut.  Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 56: Adjusting Chain Tension - Fitting Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - fitting rear wheel 11.56 – Loosen nuts  – Adjust the chain tension by turning the adjusting screws left and right.  Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the adjusting screws left and right so that the markings on the left and ...

  • Page 57: Checking Fluid Level Of Hydraulic Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking fluid level of hydraulic clutch 11.59 Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. –...

  • Page 58: Checking The Brake Discs

    Danger of accidents Reduced braking effect due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be pleased to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 59: Adjusting Free Travel Of Handbrake Lever (250 Exc-F Eu)

    Check the brake system and do not continue riding. (Your authorized KTM workshop will be pleased to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.)

  • Page 60: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 61: Checking The Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 62: Changing The Front Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 63: Checking Free Travel Of Foot Brake Lever

    Check the brake system and do not continue riding. (Your authorized KTM workshop will be pleased to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.)

  • Page 64: Adding Brake Fluid For The Rear Brake

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 65: Removing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 66: Changing The Rear Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 67: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.

  • Page 68: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing rear wheel 11.81 – Jack up the motorcycle. ( p. 33) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 69: Tire Condition Checking

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufac- ture. KTM recommends that the tires be changed after five years at the latest, regardless of the actual wear. »...

  • Page 70: Checking Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be pleased to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 71: Removing The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 72: Removing A Fuse

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 73: Removing The Seat

     Replace a burned-out fuse only by an equivalent fuse.  If the new fuse burns out, contact an authorized KTM workshop. – Replace the protection cover. 400273-10 – Install the air filter box lid. ( p.

  • Page 74: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw with the collar sleeve.  – Remove the tube from the fuel tank vent line. 600675-11 – Pull both spoilers to the side of the radiator bracket and take the fuel tank away ...

  • Page 75: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws with the collar sleeve.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the fuel hose. – Mount the seat. ( p. 71) 600678-11 Cooling system 11.95 The water pump in the engine forces the coolant to flow.

  • Page 76: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the coolant level 11.97 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the engine and cooling system cool down first.

  • Page 77: Refilling Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE Refilling coolant 11.99 Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor.

  • Page 78: Dismounting The Air Filter Box Lid

    MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the air filter box lid 11.103 – Pull off the air filter box lid in area to the side and remove to the front.  600682-10 Installing the air filter box lid 11.104 –...

  • Page 79: Cleaning Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Put in both parts together, position them and fix them with the air filter support  Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. –...

  • Page 80: Emptying The Carburetor Float Chamber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline ≥ 5 min Warm-up time Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death. – When running the engine, always make sure there is sufficient venti- lation, and do not start or run the engine in a closed space without an effective exhaust extraction system.

  • Page 81: Checking The Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 82: Draining The Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the engine oil 11.113 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and protective gloves. If you get scalded, immediately flush the affected areas with luke- warm water.

  • Page 83: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen with the O-rings.  – Mount and tighten plug with the O-ring.  Guideline Plug for oil screen, long M20x1.5 15 Nm (11.1 lbf ft) 600695-10 – Position the oil screen with the O-rings. –...

  • Page 84: Installing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the oil filter 11.116 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil. – Fill oil filter with engine oil and place it in the oil filter container. ...

  • Page 85: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 26) – Battery discharged Recharge the battery. p. 69) – Check the charging voltage. – Check the closed current.
  • Page 86 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Air filter very dirty Clean the air filter. p. 77) – Exhaust system leaky, deformed or Check exhaust system for damage. too little glass fiber yarn filling in – Change glass fiber yarn filling of main main silencer silencer.

  • Page 87: Cleaning

    CLEANING Cleaning motorcycle 13.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 88: Storage

    Storage temperature of battery without direct sunlight. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature fluctuations. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 33) –...

  • Page 89: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement 248.60 cm³ (15.1706 cu in) Stroke 54.80 mm (2.1575 in) Bore 76 mm (2.99 in) Compression ratio 12.8:1 Idle speed 1,400… 1,500 rpm Control DOHC, four valves controlled via cam lever, drive via tooth-wheel chain Valve diameter, intake 30.0 mm (1.181 in)

  • Page 90: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil jet, conrod lubrication Loctite 243™ ® Oil jet for cam lever lubrication 4 Nm (3 lbf ft) Loctite 243™ ® Screw, freewheel hub 7 Nm (5.2 lbf ft) Loctite 243™ ® Screw, ignition pulse generator 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 91 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Plug for oil screen, long M20x1.5 15 Nm (11.1 lbf ft) – Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft)

  • Page 92: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR 250 EXC-F EU 17.1 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900H Needle position 3rd position from top Idle mixture adjusting screw Open 1.25 turns Pump diaphragm stop 2.15 mm (0.0846 in) Main jet Jet needle OBDYS (OBETP) Idling jet Idle air jet...

  • Page 93: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset (250 XCF‑W USA) Front marking 18 mm (0.71 in) Rear marking...

  • Page 94: Tires

    80/100 - 21 51M TT 100/100 - 18 64M TT Bridgestone Bridgestone M59 Bridgestone Bridgestone M402 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 18.3 Total fuel tank capacity, 9.2 l (2.43 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 95: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7E.04 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 20 clicks Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Spring preload - Preload Adjuster Comfort 0 turn Standard...

  • Page 96: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7E.04 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 26 clicks...

  • Page 97: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, spoiler on fuel tank M5x12 1.5 Nm (1.11 lbf ft) (250 XCF‑W USA) – Spoke nipple, rear wheel 5…...

  • Page 98: Wiring Diagram

    WIRING DIAGRAM Wiring diagram (250 EXC-F EU) 22.1 CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 AK1/2 DG/4 CW2/2 CW3/2 AH1/2 CX3/2 BP/4 CX2/2 ye-bl bl-wh bu-wh ye-re ye-re ye-re bu-wh ye-bl re-wh re-bl BA2/1 ye-bl ye-re ye-re wh-re re-bl re-wh CR/1 CR1/1 wh-re wh-gn...
  • Page 99 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC-F SIX DAYS) Battery Generator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC-F SIX DAYS)
  • Page 100 WIRING DIAGRAM ye-re Yellow-red...
  • Page 101 WIRING DIAGRAM...

  • Page 102: Wiring Diagram (250 Xcf-W Usa)

    WIRING DIAGRAM Wiring diagram (250 XCF‑W USA) 22.2 ye-bl bl-wh ye-re bu-wh wh-re ye-bl re-wh black re-bl ye-re re-bl wh-re re-wh ye-re 600700-01...
  • Page 103 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XCF-W ZA) Battery Generator Brake/tail light (XCF-W ZA) Parking light (XCF-W ZA) Low beam (XCF-W ZA) Radiator fan (XCF-W ZA) Starter relay with main fuse Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer...

  • Page 104: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 105 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 106: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –...
  • Page 107 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...

  • Page 108: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 109: Index

    INDEX Clutch lever ........11 INDEX adjusting basic position ..... . . 54 Accessories .
  • Page 110 INDEX Fuel tank installing ....... . . 72 Rear sprocket / engine sprocket removing .
  • Page 111 INDEX engine ........87 engine tightening torques .
  • Page 112 *3211481en* 3211481en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

250 exc-f eu 2010

Table of Contents