KTM 250 EXC-F EU 2010 Owner's Manual
Hide thumbs
Also See for 250 EXC-F EU 2010:
- Owner's manual (136 pages) ,
- Owner's manual (130 pages) ,
- Owner's manual (112 pages)
Related Manuals for KTM 250 EXC-F EU 2010
Summary of Contents for KTM 250 EXC-F EU 2010
- Page 1 OWNER'S MANUAL 2010 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF-W ZA 250 SX-F EU 250 SX-F USA Art. no. 3211465en...
- 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
Emergency OFF switch (EXC‑F AUS) ....... 12 Important maintenance work to be carried out by an Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, authorized KTM workshop (as additional order)....36 XCF‑W)................. 13 SERVICE SCHEDULE (SX‑F)..........37 Electric starter button (EXC‑F AUS)......... 13 Important maintenance work to be carried out by an Light switch (EXC-F, EXC‑F SIX DAYS) ...... - Page 5 TABLE OF CONTENTS Mounting the seat ............77 Installing the fork protector ........52 Removing the front fender ..........52 Dismounting the fuel tank ......... 77 Installing the front fender..........53 Installing the fuel tank ..........78 Removing headlight mask with headlight (EXC‑F, Cooling system ..............
- Page 6 TABLE OF CONTENTS WIRING DIAGRAM ............106 Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)....106 Wiring diagram (EXC‑F AUS) ........110 Wiring diagram (XCF-W) ..........112 Wiring diagram (SX‑F) ..........114 SUBSTANCES..............116 AUXILIARY SUBSTANCES..........117 STANDARDS..............119 INDEX ................120...
-
Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 8: Important Information
Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle. - Page 9 IMPORTANT INFORMATION 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 become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances.
-
Page 10: View Of Vehicle
VIEW OF VEHICLE View of the vehicle from the left front (example) 600874-10 Hand brake lever Filler cap Clutch lever Fuel tap Shift lever Air filter box lid Chain guide... -
Page 11: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) 600873-10 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 12: 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 (EXC-F, EXC‑F SIX DAYS) The key number is stamped on the key strap. -
Page 13: 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 14: 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 15: Electric Starter Button (Exc-F Eu, Exc-F Six Days, Xcf-W)
CONTROLS Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W) 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 electric starter is actuated. •... -
Page 16: Overview Of Indicator Lamps (Exc-F, Exc-F Six Days)
CONTROLS Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) 5.11 Possible states High beam indicator lamp lights up blue – High beam is switched on. Turn signal indicator lamp flashes green – Turn signal light is switched 500147-01... -
Page 17: Controls (Exc-F, Exc-F Six Days, Xcf-W)
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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 18: Setting The Clock
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) – 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 is closed. -
Page 19: Querying The Lap Time
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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. -
Page 20: Display Mode Speed/Clk (Clock)
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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 21: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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 22: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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 23 CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) Table of conditions and activability Display The motorcycle is Menu can be acti- stationary vated Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...
-
Page 24: Controls
CONTROLS Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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 –... -
Page 25: Closing Filler Cap
CONTROLS Closing filler cap – Replace the filler cap and turn clockwise until the release button locks in place. Info Route the fuel tank breather hose without kinking. 400199-11 Choke (EXC-F EU, EXC‑F SIX DAYS) The choke lever is fitted on the left side of the handlebar. -
Page 26: Foot Brake Lever
CONTROLS 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. 600664-10 Kick starter The kick starter is fitted on the right of the engine. ... -
Page 27: Steering Lock (Exc-F, Exc-F Six Days)
CONTROLS Steering lock (EXC-F, EXC‑F SIX DAYS) 7.12 Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible. 500126-10 Locking the steering (EXC-F, EXC‑F SIX DAYS) 7.13 Note Danger of damage The parked vehicle can roll away or fall over. -
Page 28: 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 29: Running-In The Engine
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION (EXC‑F, EXC‑F SIX DAYS, XCF-W) – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. -
Page 30: Preparing For Riding On Wet Sand
Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600871-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Clean the chain. Chain cleaner ( p. 117) –... -
Page 31: Preparing For Riding On Wet And Muddy Surfaces
Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Clean the chain. Chain cleaner ( p. 117) –... -
Page 32: Preparing For Rides At High Temperature And Slow Speed
Fit a waterproofing device on the air filter. Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. -
Page 33: 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 34: Starting Up
Do not change into a low gear at high engine speed. The engine overspeeds 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 35: 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 vehicle is in use. –... - Page 36 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, (2.43 US gal) PON 91) ( p.
-
Page 37: Service Schedule (Exc-F, Exc-F Six Days, Xcf-W)
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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. 87) Replace the spark plug. -
Page 38: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 10.2 Competition use Hobby use S10N S10A S20A S40A S80A S20A S40A S60A S80A Perform a fork service. (EXC‑F, •... -
Page 39: Service Schedule (Sx-F)
SERVICE SCHEDULE (SX‑F) Important maintenance work to be carried out by an authorized KTM workshop 11.1 S10A S30A Engine • • • Change the engine oil and oil filter, clean the oil screen. p. 87) Replace the spark plug. •... -
Page 40: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)
SERVICE SCHEDULE (SX‑F) Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 11.2 S10A S20N S20A S30A S40A S80A • Conduct a major fork service. (SX‑F) Conduct a minor fork service. (SX‑F) • •... -
Page 41: Service Schedule For Rider
SERVICE SCHEDULE FOR RIDER Important checks and maintenance work to be carried out by the rider 12.1 NB1A Check the engine oil level. ( p. 87) • Check the brake fluid level of the front brake. ( p. 62) • Check the rear brake fluid level. -
Page 42: 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 glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 43: 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 glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 44: Adjusting The Rebound Damping Of The Shock Absorber
13.7 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 glad to help.) – Turn adjusting screw clockwise with a screwdriver to the last click. -
Page 45: Checking The Static 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 glad 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 46: Adjusting The Riding Sag
MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Combination wrench (50329080000) Hook wrench (T106S) – Measure the overall spring length when not under tension. – Tighten the spring by turning adjusting ring to measurement ... -
Page 47: Removing The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the shock absorber 13.13 – Jack up the motorcycle. ( p. 40) – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. –... -
Page 48: Adjusting The Rebound Damping Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove protection covers – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. –... -
Page 49: Adjusting The Spring Preload Of The Fork (Exc-F, Exc-F Six Days, Xcf-W)
MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. (SX‑F) – Remove protection covers – Turn adjusting screws clockwise all the way. ... -
Page 50: Bleeding Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding fork legs 13.19 – Jack up the motorcycle. ( p. 40) – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. –... -
Page 51: Checking Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) 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 52: Adjusting The Play Of The Steering Head Bearing (Sx-F, 250 Exc-F Six Days Eu)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play of the steering head bearing (SX‑F, 250 EXC-F SIX DAYS EU) 13.25 – Jack up the motorcycle. ( p. 40) (250 EXC-F SIX DAYS EU) – Loosen screws . Remove screw ... -
Page 53: Installing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE (250 EXC-F SIX DAYS EU) – Loosen screws . Remove the fork leg on the left. – Loosen screws . Remove the fork leg on the right. 100803-10 (SX‑F) – Loosen screws . -
Page 54: Removing The Fork Protector
MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) – Position the brake caliper and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) (EXC‑F, EXC‑F SIX DAYS, XCF-W) –... -
Page 55: Installing The Front Fender
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the front fender 13.31 – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the start number plate or headlight mask. -
Page 56: Removing The Start Number Plate (Sx-F)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the start number plate (SX‑F) 13.34 – Remove screw and take off clamp. – Remove screw with the spacer. Remove the start number plate. 500101-10 Installing the start number plate (SX‑F) 13.35 –... -
Page 57: Checking Throttle Cable Route
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the handlebars. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap width is even. -
Page 58: Adjusting The Play In The Throttle Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play in the throttle cable 13.40 – Dismount the fuel tank. p. 77) – Check throttle cable route. ( p. 55) – Move the handlebar to the straight-ahead position. – Push back bellows ... -
Page 59: Checking The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension 13.43 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. -
Page 60: Checking Chain Wear
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain wear 13.46 – Jack up the motorcycle. ( p. 40) – Shift transmission to neutral. – Pull on the upper part of the chain with the specified weight Guideline 0 0 A Weight of chain wear measurement 10…... -
Page 61: Adjusting Chain Tension - After Checking
MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen nut – 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 adjusting screws on the left and right so that the markings on the left ... -
Page 62: Adjusting Chain Tension - Fitting Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - fitting rear wheel 13.49 – 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 63: Adjusting The Chain Guide (Sx-F)
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement ... -
Page 64: Adjusting Basic Position Of Hand Brake Lever (Xcf-W, Sx-F)
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad 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 glad to help.) -
Page 65: Topping Up The 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 glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 66: Checking 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 glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 67 MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.
-
Page 68: Checking Free Travel Of Foot Brake Lever
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad 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 glad to help.) -
Page 69: Adding Brake Fluid To The Rear Brake Circuit
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 glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 70: 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 glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 71: Removing Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove locking split pins , withdraw bolt , and take out the brake linings. – Clean the brake caliper and brake caliper support. 100808-10 – Check that leaf spring in the brake caliper and sliding plate in the brake ... -
Page 72: 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 operate 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 73: Removing The Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 13.68 – Jack up the motorcycle. ( p. 40) – 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 74: 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 state of wear. »... -
Page 75: 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 glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. -
Page 76: Removing The Battery (Exc-F, Exc-F Six Days, Xcf-W)
– 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 77: Removing A Fuse (Exc-F, Exc-F Six Days, Xcf-W)
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 78: Adjusting The Beam Width Of The Headlight (Exc-F, Exc-F Six Days, Xcf-W)
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 79: Mounting The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 13.81 – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –... -
Page 80: Installing The Fuel Tank
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 13.83 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 81: Checking The Anti-Freeze And Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the anti-freeze and coolant level 13.85 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 82: Draining The Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE Alternative 2 Coolant (mixed ready to use) ( p. 116) – Mount the radiator cap. Draining the coolant 13.87 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –... -
Page 83: Glass Fiber Yarn Filling Of Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Glass fiber yarn filling of main silencer 13.89 The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes. -
Page 84: Removing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 13.94 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 85: Adjusting Basic Position Of Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( p. 117) – Clean the air filter box. – Check carburetor connection boot for damage and tightness. –... -
Page 86: Checking The Basic Position Of The Shift Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! –... -
Page 87: Carburetor - Idle
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. – Mount and tighten the screw. Guideline Screw, shift lever 10 Nm... -
Page 88: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motorcyclist will set the mixture about ¼... -
Page 89: Checking The Engine Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo screw (turn it counterclockwise) a few turns and drain the fuel from the ... -
Page 90: Cleaning The Oil Screens
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove oil drain plug – Completely drain the engine oil. – Thoroughly clean the oil drain plug with the magnet. – Clean the sealing area on the engine. –... -
Page 91: Removing The Oil Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 13.109 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 92: Filling Up With Engine Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with engine oil 13.111 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove screw connection on the clutch cover and fill up with engine oil. ... -
Page 93: 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. 31) (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Battery discharged Recharge the battery. p. 74) – Check the charging voltage. - Page 94 TROUBLESHOOTING Faults Possible cause Action – Engine has a lack of power Air filter severly contaminated Clean the air filter. p. 82) – Exhaust system leaky, deformed or Check exhaust system for damage. too little glass fiber yarn filling in –...
-
Page 95: Cleaning
CLEANING Cleaning the motorcycle 15.1 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, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 96: 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. 40) –... -
Page 97: 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 98: Capacity - Engine Oil
TECHNICAL DATA - ENGINE Capacity - engine oil 17.1 Engine oil 1.10 l (1.16 qt.) Engine oil (SAE 10W/50) ( p. 116) Capacity - coolant 17.2 Coolant 1.2 l (1.3 qt.) Coolant ( p. 116) Coolant (mixed ready to use) ( p. -
Page 99: 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 100 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Nut, inner clutch hub M18x1.5 120 Nm (88.5 lbf ft) Loctite 243™ ® Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite 243™ – Plug for oil screen, long M20x1.5 15 Nm (11.1 lbf ft) –...
-
Page 101: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR EXC-F, EXC‑F SIX DAYS 19.1 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... -
Page 102: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork (EXC‑F, EXC‑F SIX DAYS, XCF-W) WP Suspension Up Side Down 4860 MXMA PA Fork (SX‑F) WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 300 mm (11.81 in) Rear... -
Page 103: Tires
80/100 - 21 51M TT 100/90 - 19 62M TT Bridgestone Bridgestone M59 Bridgestone Bridgestone M70 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 20.3 Total fuel tank capacity, 9.2 l (2.43 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. -
Page 104: Technical Data - Fork
TECHNICAL DATA - FORK EXC‑F, EXC‑F SIX DAYS, XCF-W 21.1 Fork part number 14.18.7J.04 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks... -
Page 105: Sx-F Usa
TECHNICAL DATA - FORK SX‑F USA 21.3 Fork part number 14.18.7J.22 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 492 mm (19.37 in) -
Page 106: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER EXC‑F, EXC‑F SIX DAYS, XCF-W 22.1 Shock absorber part number 12.18.7J.04 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport... -
Page 107: 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) – Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) – Remaining nuts, chassis 15 Nm (11.1 lbf ft) –... -
Page 108: Wiring Diagram
WIRING DIAGRAM Wiring diagram (EXC-F EU, EXC‑F SIX DAYS) 24.1 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... - Page 109 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 110 WIRING DIAGRAM ye-re Yellow-red...
- Page 111 WIRING DIAGRAM...
-
Page 112: Wiring Diagram (Exc-F Aus)
WIRING DIAGRAM Wiring diagram (EXC‑F AUS) 24.2 CE/4 CE/4 CE/4 CE/4 CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 CE/4 AK1/2 DG/4 CW2/2 CW3/2 AH1/2 CX2/2 CX3/2 BP/4 ye-bl BA/1 BF/1 bu-wh ye-re ye-re ye-re bu-wh ye-bl re-wh re-bl ye-re wh-re ye-bl ye-re re-bl wh-re... - Page 113 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor 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 Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay...
-
Page 114: Wiring Diagram (Xcf-W)
WIRING DIAGRAM Wiring diagram (XCF-W) 24.3 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 115 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 116: Wiring Diagram (Sx-F)
WIRING DIAGRAM Wiring diagram (SX‑F) 24.4 re-wh re-bl 600701-01... - Page 117 WIRING DIAGRAM Components CDI controller Throttle position sensor Generator Pulse generator Ignition coil Short circuit button Cable colors Black Brown bu-wh Blue-white Green re-bl Red-black re-wh Red-white ye-bl Yellow-black...
-
Page 118: 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 119: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –... - Page 120 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
-
Page 121: 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 122: Index
INDEX Chassis number ....... 10 INDEX Choke ........23 Accessories . - Page 123 INDEX removing ....... . . 52 Plug-in stand ....... . . 24 Front wheel Putting into operation installing .
- Page 124 INDEX Technical data carburetor ....... . 99 chassis ......100-101 chassis tightening torques .
- Page 125 *3211465en* 3211465en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...