KTM 250 XC 2019 Owner's Manual
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KTM 250 XC 2019 Owner's Manual

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OWNER'S MANUAL
2019
250 SX
250 XC
300 XC
Art. no. 3213848en

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Summary of Contents for KTM 250 XC 2019

  • Page 1 OWNER'S MANUAL 2019 250 SX 250 XC 300 XC Art. no. 3213848en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy riding this motorcycle! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 23 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on first use ......23 Symbols used ........5 Running in the engine ...... 24 Formats used........5 Preparing the vehicle for difficult SAFETY ADVICE..........6 operating conditions......
  • Page 5 TABLE OF CONTENTS 10.12 Checking the basic setting of the 11.36 Adjusting the chain tension....74 fork ..........46 11.37 Checking the chain, rear sprocket, 10.13 Adjusting the fork air pressure... 47 engine sprocket, and chain guide ..75 10.14 Adjusting the compression damping 11.38 Checking the frame ......
  • Page 6 TABLE OF CONTENTS 15.2 Checking the antifreeze and 21.3.3 Carburetor - basic setting for coolant level ........105 sandy surfaces (All SX models)..136 15.3 Checking the coolant level ....106 21.3.4 250 XC US ....... 137 15.4 Draining the coolant ....

  • 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 models) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehi- cle complies with the currently valid regulations and categories of the top international motorsport organiza- tions.

  • 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 Special tools are necessary for certain tasks.

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

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) K01222-10 Hand brake lever ( p. 16) Kill switch ( p. 16) Clutch lever ( p. 16) Air filter box cover Plug-in stand Shift lever ( p. 20) Choke ( p.

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) K01223-10 Seat Filler cap Throttle grip ( p. 16) Kick starter ( p. 21) Foot brake lever ( p. 21) Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment...

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing 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 17: 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. 0 0 1 401948-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. 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 19: Electric Starter Button (All Xc Models)

    CONTROLS 6 Electric starter button (All XC models) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the elec- • Electric starter button tric starter is actuated.

  • Page 20: Closing The Filler Cap

    6 CONTROLS (All XC models) – Press release button , turn the filler cap counterclock- wise, and lift it off. K01200-11 Closing the filler cap (All SX models) – Mount filler cap and turn it clockwise until the fuel tank is tightly closed. Info Run the fuel tank breather hose without kinks.

  • Page 21: Fuel Tap (All Sx Models)

    CONTROLS 6 Fuel tap (All SX models) 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 22: Choke

    6 CONTROLS 6.10 Choke (All SX models) Choke is fitted on the left side of the carburetor. K01203-10 (All XC models) Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel.

  • Page 23: Kick Starter

    CONTROLS 6 (All SX models) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 6.12 Kick starter Kick starter is fitted on the right side of the engine. The top part of the kick starter pivots.

  • Page 24: Side Stand (All Xc Models)

    6 CONTROLS 6.15 Side stand (All XC models) Side stand is located on the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 401944-10 6.16...

  • Page 25: Preparing For Use 7

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 26: Running In The Engine

    7 PREPARING FOR USE – Adjust the basic position of the foot brake lever. p. 89) – Set the basic position of the shift lever. p. 116) – Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip. Info Your motorcycle is not approved for use on public roads.

  • Page 27: Preparing Vehicle For Rides On Dry Sand

    Change the radiator cap. – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info Observe fitting instructions for KTM PowerParts. M01104-01 – Mount a sand cover on the air filter. Sand cover for air filter (79006922000) Info Observe fitting instructions for KTM PowerParts.

  • Page 28: Preparing Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Clean the chain. Chain cleaner ( p. 149) – Mount the steel sprocket. – Grease the chain.

  • Page 29: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Waterproofing device for air filter (79006921000) Info Observe fitting instructions for KTM PowerParts. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Clean the chain. Chain cleaner ( p. 149) –...

  • Page 30: Preparing Vehicle For High Temperatures Or Slow Riding

    7 PREPARING FOR USE – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Mount the steel sprocket. – Clean the motorcycle. ( p. 124) – Straighten bent radiator fins carefully.

  • Page 31: Preparing Vehicle For Low Temperatures Or Snow

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

  • Page 32: 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 33: Starting Off

    RIDING INSTRUCTIONS 8 Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable ele- ments of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. The motorcycle has been out of use for more than 1 week –...

  • Page 34: Shifting, Riding

    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 35: Stopping, Parking

    RIDING INSTRUCTIONS 8 – Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.

  • Page 36: Refueling

    8 RIDING INSTRUCTIONS (All SX models) – Switch off the engine. – Mount plug-in stand on the fork legs. Plug-in stand (79029094000) Info The plug-in stand is included. Make sure the brake line runs in front of the plug-in stand and does not become wedged. H02628-01 –...
  • Page 37 RIDING INSTRUCTIONS 8 – Fill the fuel tank with fuel up to measurement Guideline 35 mm (1.38 in) Measurement of Total fuel tank 7.5 l Super unleaded capacity, approx. (All (1.98 US gal) (95 octane) mixed SX models) with 2-stroke engine oil (1:60) p.

  • Page 38: 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 39: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Book- let. ○ One-time interval ● Periodic interval Recommended work...
  • Page 40 9 SERVICE SCHEDULE Every 40 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours / Every 20 operating hours Once after 10 operating hours / Every 10 operating hours ●...

  • Page 41: 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 42: Compression Damping Of The Shock Absorber

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

  • Page 43: Adjusting The High-Speed Compression Damping Of The Shock Absorber

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

  • Page 44: 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 45: Checking The Static Sag Of The Shock Absorber

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

  • Page 46: Checking The Riding Sag Of The Shock Absorber

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

  • Page 47: Adjusting The Riding Sag

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

  • Page 48: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS Guideline Spring rate (250 SX EU) 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 49: Adjusting The Fork Air Pressure

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure (250 SX EU) 10.1 bar (146 psi)

  • Page 50: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS – Disconnect the fork pump 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 pump indicator switches off automatically after 80 seconds.

  • Page 51: 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 52: 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 53 TUNING THE CHASSIS 10 Finishing work – Mount the handlebar cushion.

  • Page 54: 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 55: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 52) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 56: 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. 52) – Remove the front wheel. p. 95) Main work – Remove screws and take off the clamp. –...

  • Page 57: 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 clamp. Mount and tighten screws K01143-11 Finishing work –...

  • Page 58: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Pull off the upper triple clamp with the handlebar and hang to the side. Info Protect the components against damage by covering them. K01149-10 Do not kink the cables and lines. –...
  • Page 59 SERVICE WORK ON THE CHASSIS 11 – Position the fork legs. Air release 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 60: Checking The Play Of The Steering Head Bearing

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

  • Page 61: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 52) 11.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 52) – Remove the handlebar cushion.

  • Page 62: 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 63: 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. 52) Main work – Remove the cable ties. – Remove screws with the washers. – Remove screw –...

  • Page 64: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. K01138-10 – 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 65 SERVICE WORK ON THE CHASSIS 11 – Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) K01147-10 – Mount the chain. –...

  • Page 66: Removing The Seat

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

  • Page 67: 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 68: 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 69: 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 70: 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. 149) 102178-10 – Insert the air filter and position the top retaining pin bushing The air filter is correctly positioned.

  • Page 71: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 – Remove screws with the washers. – Pull off the main silencer from the manifold at rubber sleeve A00025-10 11.29 Installing the main silencer – Position the main silencer with rubber sleeve – Mount and tighten screws with the washers.

  • Page 72: 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 73: 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 (All SX models) – Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the tank lid. K01190-10 (All XC models) –...
  • Page 74 11 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 75: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Mount the seat. ( p. 64) 11.33 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p.

  • Page 76: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.35 Checking 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 77: 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 to the 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 78 11 SERVICE WORK ON THE CHASSIS – Pull at the top part 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 79 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 80: Checking The Frame

    – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S02305-01 11.40 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 81: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. The throttle cable must be fixed on the fuel tank bracket with a rubber band.

  • Page 82: Adjusting Basic Position Of Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.42 Adjusting basic position of clutch lever – Adjust the basic setting 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 83: 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 84 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 85: 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 86: 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 87: 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 88: 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 89 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 90 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 pin , pull out pin , and remove the brake linings. – Clean the brake caliper and brake caliper support. 101737-10 –...

  • Page 91: 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 92: 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 93 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 94: 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 95 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 96 12 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 147) – 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 97: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 52) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 98: 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 99: Installing The Rear Wheel

    WHEELS, TIRES 13 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 100 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 surface of the spacers. Long-life grease ( p.

  • Page 101: 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 102: 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 103: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the battery (All XC models) Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...

  • Page 104: Recharging The Battery (All Xc Models)

    14 ELECTRICAL SYSTEM Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal. Finishing work – Mount the seat. ( p. 64) 14.3 Recharging the battery (All XC models) Warning Risk of injury Batteries contain harmful substances.
  • Page 105 It is also impossible to overcharge the bat- tery 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 106: Changing The Main Fuse (All Xc Models)

    14 ELECTRICAL SYSTEM 14.4 Changing the main fuse (All XC models) Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat.

  • Page 107: Cooling System 15

    COOLING SYSTEM 15 15.1 Cooling system (All SX models) Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 108: Checking The Coolant Level

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

  • Page 109: Draining The Coolant

    COOLING SYSTEM 15 15.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 110: Refilling With Coolant

    15 COOLING SYSTEM 15.5 Refilling with coolant Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...
  • Page 111 COOLING SYSTEM 15 (All XC models) – Make sure that screw is tightened. – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant ( p. 147) K01209-10 – Loosen screw until coolant escapes without bubbles. – Mount and tighten screw Guideline Bleeder screw, 10 Nm (7.4 lbf ft)

  • Page 112: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to determine the play in throttle cable Play in throttle cable 2 …...

  • Page 113: Carburetor Setting

    TUNING THE ENGINE 16 – Turn barrel adjuster so that there is play in the throttle cable at the throttle grip. Guideline Play in throttle cable 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 114 16 TUNING THE ENGINE Idling jet IJ The idling jet has the greatest influence in the low to mid throttle slide range. If the engine stutters when idling or accelerating with a partially open throttle slide, a smaller idling jet must be used.

  • Page 115: Carburetor - Idle

    TUNING THE ENGINE 16 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 carburation.

  • Page 116: Carburetor - Adjusting The Idle Speed

    16 TUNING THE ENGINE (250 XC US) Height above sea 0 … 300 m (0 … 984 ft) level Ambient tempera- 6 … 15 °C (43 … 59 °F) ture Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p.

  • Page 117: Plug-In Connector Of Ignition Timing Map Adjustment

    TUNING THE ENGINE 16 Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to sat- isfactory results, the cause may be a wrongly dimen- sioned idling jet.

  • Page 118: Changing The Ignition Timing Map

    16 TUNING THE ENGINE 16.7 Changing the ignition timing map Switching the ignition timing map from Performance to Soft (All SX models) – Disconnect plug-in connector of the ignition timing map adjustment. (Figure K01214-10 p. 115) Soft – better rideability (All XC models) –...

  • Page 119: Engine Characteristic - Auxiliary Spring

    TUNING THE ENGINE 16 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. 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 120 16 TUNING THE ENGINE Main work (All SX models) – 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 121 TUNING THE ENGINE 16 – 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. 117) adjusting spring and position them together in the clutch cover.

  • Page 122: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 123: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 17 17.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Detach the foot brake lever spring. –...

  • Page 124: Adding Gear Oil

    17 SERVICE WORK ON THE ENGINE Main work – Remove the gear oil drain plug with magnet – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug with magnet. – Clean the sealing surface on the engine. –...
  • Page 125 SERVICE WORK ON THE ENGINE 17 Main work – Remove screw for checking gear oil level K01220-10 – Remove the filler plug with the O-ring – Add gear oil until it emerges from the drill hole of the gear oil monitoring screw.

  • Page 126: 18 Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 127 CLEANING, CARE 18 – Treat bare metal parts (except for brake discs and exhaust sys- tem) with anti-corrosion materials. Preserving materials for paints, metal and rubber p. 150) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p.

  • Page 128: 19 Storage

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

  • Page 129: Preparing For Use After Storage

    STORAGE 19 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. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus- ing engine parts and the exhaust system to rust.

  • Page 130: 20 Troubleshooting

    20 TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked Operating error Carry out the start procedure. (electric starter) p. 30) (All XC models) – Battery discharged Recharge the battery. p. 102) – Check the charging voltage. – Check the closed current.
  • Page 131 TROUBLESHOOTING 20 Faults Possible cause Action – Engine has too little power Fuel feed interrupted Check the fuel tank breather. – Clean the fuel tap. – Check/set the carburetor components. – Air filter very dirty Clean the air filter and air filter box. p.

  • Page 132: 21 Technical Data

    21 TECHNICAL DATA 21.1 Engine 21.1.1 All SX models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Exhaust valve, beginning of adjustment 5,500 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing...

  • Page 133: Xc Us

    TECHNICAL DATA 21 Z distance (height of control flap) 49.0 mm (1.929 in) Primary transmission 26:73 Clutch Multidisc clutch in oil bath/hydraulically activated Transmission 6-gear, claw shifted Transmission ratio First gear 15:31 Second gear 16:25 Third gear 20:25 Fourth gear 22:23 Fifth gear 25:22...

  • Page 134: Engine Tightening Torques

    21 TECHNICAL DATA Starting aid Kick starter and electric starter 21.2 Engine tightening torques 21.2.1 All SX models Screw, inner membrane sheets EJOTDELTA PT ® 35x25 1 Nm (0.7 lbf ft) Screw, membrane support plate EJOTDELTA PT ® 30x12 1 Nm (0.7 lbf ft) Screw, outer membrane sheets EJOTDELTA PT ®...

  • Page 135: All Xc Models

    TECHNICAL DATA 21 Screw, balancer shaft 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, cylinder head 27 Nm (19.9 lbf ft) Screw, kick starter 25 Nm (18.4 lbf ft) Loctite ® 2701™ Nut, cylinder base 35 Nm (25.8 lbf ft) Screw, drive chain engine sprocket 60 Nm (44.3 lbf ft) Loctite...
  • Page 136 21 TECHNICAL DATA Screw, intermediate clutch cover 10 Nm (7.4 lbf ft) Screw, kick starter idler gear steel 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, kick starter stop plate 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, outer clutch cover 8 Nm (5.9 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft)

  • Page 137: Carburetor

    TECHNICAL DATA 21 21.3 Carburetor 21.3.1 All SX models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 87 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) Starting jet Needle jet S‑1...

  • Page 138: Carburetor - Basic Setting For Sandy Surfaces (All Sx Models)

    21 TECHNICAL DATA TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. 21.3.3 Carburetor - basic setting for sandy surfaces (All SX models) Idle air adjusting screw Open 1.5 turns Idling jet...

  • Page 139: 250 Xc Us

    TECHNICAL DATA 21 21.3.4 250 XC US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 85 Needle position 2nd position from top Jet needle 6BFY43‑75 (6BFY42‑75) Main jet 470 (450, 460, 480) Idling jet 35 (30/32.5) Starting jet Needle jet S‑4 Idle air adjusting screw...
  • Page 140 21 TECHNICAL DATA Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain.

  • Page 141: 300 Xc Us

    TECHNICAL DATA 21 21.3.6 300 XC US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 80 Needle position 2nd position from top Jet needle 6BFY43-75 (6BFY42-75) Main jet 450 (430, 440, 460) Idling jet 25 (22.5/27.5) Starting jet Needle jet S‑4 Idle air adjusting screw...

  • Page 142: Capacities

    21 TECHNICAL DATA Idling jet Needle Needle position from top Main jet Needle jet Info Do not use on sandy terrain. 21.4 Capacities 21.4.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 147) 21.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant (...

  • Page 143: Electrical System

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

  • Page 144: Sx Us

    21 TECHNICAL DATA 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 left p. 148) Oil capacity external mechanism ml (7.44 fl. oz.) Fork oil (SAE 4) (48601166S1) + 20 + 0.68...

  • Page 145: Shock Absorber

    TECHNICAL DATA 21 Oil capacity external mechanism ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) + 40 + 1.35 − 20 − 0.68 left p. 148) Oil capacity external mechanism ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) + 40 + 1.35 −...

  • Page 146: All Xc Models

    21 TECHNICAL DATA Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 7 mm (0.28 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75 …...

  • Page 147: Chassis Tightening Torques

    TECHNICAL DATA 21 21.10 Chassis tightening torques Screw, E-starter button 1 Nm (0.7 lbf ft) Screw, kill switch 1 Nm (0.7 lbf ft) Screw, fixed grip 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, service hour counter 1 Nm (0.7 lbf ft) Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
  • Page 148 21 TECHNICAL DATA Screw, subframe 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, top steering stem 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis...

  • Page 149: Substances 22

    SUBSTANCES 22 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 150 22 SUBSTANCES Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 151) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 151: Auxiliary Substances 23

    AUXILIARY SUBSTANCES 23 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 152 23 AUXILIARY SUBSTANCES Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ®...

  • Page 153: Standards 24

    STANDARDS 24 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 154: 25 List Of Abbreviations

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

  • Page 155: Index

    INDEX Chain guide INDEX checking ......75 Accessories ......10 Chain tension Air filter adjusting .
  • Page 156 INDEX Filling up plug-in connector ....115 fuel ......34 Implied warranty .
  • Page 157 INDEX Rubber grip Throttle cable play checking ......79 adjusting ......110 checking .
  • Page 158 *3213848en* 3213848en 03/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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