KTM 250 EXC-F EU Owenrs Manual
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KTM 250 EXC-F EU Owenrs Manual

2009 ktm
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OWNER'S MANUAL
2009
250 EXC-F EU
250 EXC-F AUS
250 EXC-F SIX DAYS EU
250 XCF-W USA
250 XCF-W ZA
250 XC-F USA
250 SX-F EU
250 SX-F USA
ART. NO. 3211348en

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Summary of Contents for KTM 250 EXC-F EU

  • Page 1 OWNER'S MANUAL 2009 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF-W USA 250 XCF-W ZA 250 XC-F USA 250 SX-F EU 250 SX-F USA ART. NO. 3211348en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    Hand brake lever ............12 Important maintenance work to be carried out by an Short circuit button (XCF‑W, XC‑F, SX‑F) ......12 authorized KTM workshop (as additional order)....33 Short circuit button (EXC-F, EXC‑F SIX DAYS)....12 SERVICE SCHEDULE (XC‑F, SX‑F) ........34 Emergency OFF switch (250 EXC-F AUS) ......
  • Page 5 CONTENTS Removing the lower triple clamp (EXC‑F SIX DAYS, Installing the rear wheel ..........73 XCF‑W USA, XC‑F, SX‑F) ..........50 Tire condition checking..........74 Removing the lower triple clamp (EXC‑F EU, Checking tire air pressure ..........75 EXC‑F AUS, XCF‑W ZA) ..........51 Checking spoke tension..........
  • Page 6 CONTENTS TECHNICAL DATA - FORK..........101 EXC‑F, EXC‑F SIX DAYS, XCF-W ........101 250 XC-F USA ............101 250 SX-F EU .............. 102 250 SX-F USA ............102 TECHNICAL DATA - SHOCK ABSORBER ......103 EXC‑F, EXC‑F SIX DAYS, XCF-W ........103 250 XC-F USA ............

  • 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 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 9 IMPORTANT NOTES (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 22)  (SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10 p. 22) ...

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE 3 V IEW 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 11: 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 12: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 4 L OCATION 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. ...

  • 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 5 C ONTROLS 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. ...

  • Page 15: Electric Starter Button (Exc-F Eu, Exc-F Six Days, Xcf-W, Xc-F)

    CONTROLS Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W, XC‑F) 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: Flasher Switch (Exc-F, Exc-F Six Days)

    CONTROLS Flasher switch (EXC-F, EXC‑F SIX DAYS) 5.11 Flasher switch is fitted on the left side of the handlebar.  Possible states Flasher light off – Flasher switch is in the central position. Flasher light, left, on – Flasher switch turned to the left. Flasher light, right, on –...

  • Page 17: Controls (Exc-F, Exc-F Six Days, Xcf-W)

    CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 6 C ONTROLS (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. –...

  • 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) – 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 20: Speed/Clk Display Mode (Time)

    CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) Press the button next display mode briefly. SPEED/CLK display mode (time) 6.10 – briefly and repeatedly until CLK appears at the bottom right of Press the button the display. The time is displayed in the CLK display mode. Press the button .

  • Page 21: Speed/Tr2 Display Mode (Trip Master 2)

    CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) SPEED/TR2 display mode (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 to 999.9. The displayed value can be set manually with the button and the button .

  • Page 22: Speed/S1 Display Mode (Stop Watch 1)

    CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) SPEED/S1 display mode (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) shows the trip time on the basis of TR1 and continues running 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 Vehicle at a stand- Menu can be acti- still vated SPEED/TR1 display mode (trip master 1) • SPEED/TR2 display mode (trip master 2) • SPEED/A1 display mode (average speed 1) •...

  • Page 24: Controls

    CONTROLS 7 C ONTROLS Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) 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 ...

  • Page 25: Closing Filler Cap

    CONTROLS Closing filler cap – Replace the filler cap and turn clockwise until the release button locks in place.  Info Run the fuel tank breather hose without kinks.  400199-11 Choke (EXC-F EU, EXC‑F SIX DAYS) The flasher switch is fitted on the left side of the handlebar.

  • Page 26: Foot Brake Pedal

    CONTROLS Foot brake pedal Foot brake pedal is located in front of the right footrest.  The foot brake pedal is used to activate the rear brake. 600664-10 Kickstarter Kickstarter is fitted on the right of the engine.  The engine can be started with either the kickstarter or the electric starter. The upper part of the kickstarter can be swung out.

  • 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 Danger of damage by the vehicle running away or falling 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 – 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 dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution.

  • Page 30: Riding Instructions

    RIDING INSTRUCTIONS 9 R IDING 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. –...

  • Page 31: 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 32: 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 33 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 34: Service Schedule (Exc-F, Exc-F Six Days, Xcf-W)

    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.

  • Page 35: 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 S10A S20A S40A S80A S20A S40A S80A • • Carry out a complete fork service.

  • Page 36: Service Schedule (Xc-F, Sx-F)

    SERVICE SCHEDULE (XC‑F, SX‑F) SERVICE SCHEDULE (XC‑F, 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. 86) • • •...

  • Page 37: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)

    SERVICE SCHEDULE (XC‑F, SX‑F) Important maintenance work to be carried out by an authorized KTM workshop (as additional order). 11.2 S10A S20A S40A S80A • • Carry out a complete fork service. Carry out a complete shock absorber service. •...

  • Page 38: Service Schedule For Rider

    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. 86) • Check the front brake fluid level. ( p. 65) •...

  • Page 39: Maintenance Work On Chassis And Engine

    For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set- tings of the suspension components must match your body weight. – As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Guideline Standard rider weight 75…...

  • Page 40: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise with a ring wrench until it stops.  Info Do not loosen nut  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed (EXC‑F, EXC‑F SIX DAYS, XCF-W) 600667-10...

  • Page 41: Adjusting The Rebound Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed (EXC‑F, EXC‑F SIX DAYS, XCF-W) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, low-speed (250 XC-F USA) Comfort 17 clicks Standard...

  • Page 42: Measuring Rear Wheel Sag Unloaded

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (EXC‑F, EXC‑F SIX DAYS, XCF-W) Comfort 26 clicks Standard 24 clicks Sport 22 clicks Rebound damping (250 XC-F USA) Comfort 25 clicks Standard...

  • Page 43: Checking The Riding Sag Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the riding sag of the shock absorber 13.10 – Measure distance of rear wheel unloaded. ( p. 40)  – With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out.

  • Page 44: Adjusting The Riding Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the riding sag 13.12 – Remove shock absorber. p. 42) – 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 45: Checking Basic Setting Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking basic setting of fork 13.15 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 46: Adjusting The Rebound Damping Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping (250 XC-F USA) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping (250 SX-F EU) Comfort 14 clicks Standard...

  • Page 47: Adjusting The Spring Preload Of The Fork (Exc-F, Exc-F Six Days, Xcf-W)

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping (250 XC-F USA) Comfort 22 clicks Standard 21 clicks Sport 21 clicks Rebound damping (250 SX-F EU) Comfort 21 clicks Standard...

  • Page 48: Cleaning Dust Boots Of Fork Legs

    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 49: Adjusting Play Of Steering Head Bearing (Exc-F Eu, Exc-F Aus, Xcf-W Za)

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) –...

  • Page 50: Fork Offset (Xcf-W Usa, Xc-F, Sx-F)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fork offset (XCF‑W USA, XC‑F, SX‑F) 13.26 You can see the currently set offset if you remove screw  The fork offset has an impact on the handling of the vehicle. It is calculated from ...

  • Page 51: Installing The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Loosen screw . Remove the fork leg on the left.  – Loosen screw . Remove the fork leg on the right.  100023-11 Installing the fork legs 13.29 –...

  • Page 52: Removing The Fork Protector

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork protector 13.30 – Remove the fork legs. ( p. 48) – Remove screws on the left fork leg. Remove the fork protector upwards.  – Remove the screws on the right fork leg. Remove the fork protector upwards. 500105-10 Installing the fork protector 13.31...

  • Page 53: Removing The Lower Triple Clamp (Exc-F Eu, Exc-F Aus, Xcf-W Za)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) 13.33 – Remove the fork legs. ( p. 48) – Remove the headlight mask with the headlight. ( p. 53) – Dismount the front fender. ( p.

  • Page 54: Installing The Lower Triple Clamp (Exc-F Eu, Exc-F Aus, Xcf-W Za)

    MAINTENANCE WORK ON CHASSIS AND ENGINE (250 EXC-F SIX DAYS EU) – Refit the headlight mask with the headlight. ( p. 54) – Install the fork legs. p. 49) – Mount and tighten screw  Guideline Screw, top steering stem 17 Nm Loctite ®...

  • Page 55: Greasing The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE Greasing the steering head bearing 13.36 (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) – Remove the lower triple clamp. p. 50) – Install the lower triple clamp. p. 51) (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) –...

  • Page 56: Refitting The Headlight Mask With The Headlight (Exc-F, Exc-F Six Days, Xcf-W Za)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) 13.40 – Connect the electric plug connector  600702-11 – Position the headlight mask and fix it with the rubber band ...

  • Page 57: Adjusting The Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar position 13.44 (EXC‑F EU, EXC‑F AUS, XCF‑W, XC‑F, SX‑F) 0 0 1 0 0 1 – Remove the four screws . Remove the handlebar clamp. Remove the handle-  bar and lay it to one side. 0 0 2 0 0 2 Info...

  • Page 58: Checking Gas Bowden Cable Route

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount lower shells  – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position handlebar clamps with rubber washers and elastomeres    Elastomer kit green - soft quality (SXS05125203) Elastomer kit yellow - medium quality (standard) (SXS05125204) Elastomer kit red - hard quality (SXS05125205) Info...

  • Page 59: Adjusting The Gas Bowden Cable Play

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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 ventila- tion, and do not start or run the engine in a closed space. –...

  • Page 60: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 117) Offroad chain spray ( p. 117) Checking the chain tension 13.50 Warning...

  • Page 61: Checking The Rear Sprocket / Engine Sprocket For Wear

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear sprocket / engine sprocket for wear 13.52 – Check the rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Replace rear sprocket / engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).

  • Page 62: Adjusting Chain Tension - After Checking

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the left and right adjusting screws  Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the left and right adjusting screws so that the markings on the left and ...

  • Page 63: Adjusting Chain Tension - Fitting Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - fitting rear wheel 13.56 – 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 64: Adjusting The Chain Guide (Sx-F)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain guide (SX‑F) 13.58 – Loosen screw . Remove screw . Push the chain guide down.   Condition Number of teeth: ≤ 44 teeth – Insert collar sleeve in hole . Position the chain guide. ...

  • Page 65: Changing The Hydraulic Clutch Fluid

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt fluid immediately with water. Changing the hydraulic clutch fluid 13.61 Warning Skin irritations Brake fluid can cause skin irritation on contact. –...

  • Page 66: Checking The Brake Discs

    Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 67: Adjusting Free Travel Of Handbrake Lever (Exc-F, Exc-F Six Days)

    Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 68: Checking The Front Brake Linings

    Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

  • Page 69: Installing 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 70: Checking Free Travel Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the front brake linings. p. 66) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

  • Page 71: Checking The Rear Brake Fluid Level

    Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –...

  • Page 72: Checking 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 73: Changing The Rear Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 74: Removing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the front wheel 13.80 – Jack up the motorcycle. ( p. 37) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 75: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw  Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.

  • Page 76: Tire Condition Checking

    13.84 Info Only mount tires approved or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

  • Page 77: Checking Tire Air Pressure

    Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 78: Installing The Battery (Exc-F, Exc-F Six Days, Xcf-W, Xc-F)

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect the negative (minus) cable of the battery.  – Pull back the plus pole cover and disconnect the positive (plus) cable of the bat-  tery. – Hang the rubber band out to the bottom. ...

  • Page 79: Removing A Fuse (Exc-F, Exc-F Six Days, Xcf-W, Xc-F)

     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 80: Mounting The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 13.93 – 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 81: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 13.95 Danger Fire hazard Fuel can easily catch fire. – Never fill up 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.

  • Page 82: Checking Antifreeze And Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking antifreeze and coolant level 13.97 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 83: Draining The Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the coolant 13.99 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 84: Removing Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing main silencer 13.102 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Disconnect spring ...

  • Page 85: Removing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 13.106 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 Problem materials cause environmental damage.

  • Page 86: Carburetor - Idle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - idle 13.109 The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

  • Page 87: Emptying The Carburetor Float Chamber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust the idle speed with adjusting screw  Guideline Choke function deactivated – The choke lever is pushed in to the stop. (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) ( p. 23) Choke function deactivated – The choke lever is pushed back to the stop. (EXC- F EU, EXC‑F SIX DAYS) ( p.

  • Page 88: Checking The Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the engine oil level 13.112 – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. – Check the engine oil level. The engine oil level is at the bottom edge of level viewer ...

  • Page 89: Cleaning The Oil Screens

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the oil screens 13.115 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 90: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 13.116 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 91: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with engine oil 13.118 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 92: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (electric Operating error Go through the steps of starting the starter). engine. ( p. 28) EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F – Battery discharged Recharge the battery. p. 76) –...
  • Page 93 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power. Fuel feed interrupted Check the fuel tank breather. – Clean the fuel tap. – Check/adjust the carburetor compo- nents. – Air filter very dirty Clean the air filter. p. 83) –...

  • Page 94: Cleaning

    CLEANING CLEANING Cleaning 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, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 95: 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. 37) –...

  • Page 96: Technical Data - Engine

    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 97: 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 98: Technical Data - Engine Tightening Torques

    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, locking lever 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 99 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 100: Technical Data - Carburetor

    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 membrane stop 2.15 mm (0.0846 in) Main jet Jet needle OBDYS (OBETP)

  • Page 101: Technical Data - Chassis

    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 4860 MXMA PA Fork (250 XC-F USA) WP Suspension 4860 MXMA CC Fork (250 SX-F EU) WP Suspension 4860 MXMA CC Fork (250 SX-F USA) WP Suspension 4860 MXMA CC...

  • Page 102: Lighting Equipment

    80/100 - 21 51M TT 100/90 - 19 62M TT Bridgestone Bridgestone M59 Bridgestone Bridgestone M70 For further information, see 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 103: Technical Data - Fork

    TECHNICAL DATA - FORK TECHNICAL DATA - FORK EXC‑F, EXC‑F SIX DAYS, XCF-W 21.1 Fork part number 14.18.7E.04 Fork WP Suspension 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 20 clicks Rebound damping Comfort 24 clicks Standard 22 clicks Sport...

  • Page 104: 250 Sx-F Eu

    TECHNICAL DATA - FORK 250 SX-F EU 21.3 Fork part number 14.18.7E.03 Fork WP Suspension 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 21 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s) 492 mm (19.37 in) Spring rate...

  • Page 105: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER EXC‑F, EXC‑F SIX DAYS, XCF-W 22.1 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...

  • Page 106: 250 Sx-F Eu

    TECHNICAL DATA - SHOCK ABSORBER 250 SX-F EU 22.3 Shock absorber part number 12.18.7E.03 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 1.5 turns Standard 1.5 turns Sport 1 turn...

  • Page 107: Technical Data - Chassis Tightening Torques

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

  • Page 108: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM Wiring diagram (EXC-F EU, EXC‑F SIX DAYS) 24.1 CX/2 DB/4 CZ/3 CW/2 DA/4 CY/3 AK1/2 DG/4 CW2/2 CW3/2 AH1/2 BP/4 CX2/2 CX3/2 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...
  • Page 109 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC-F SIX DAYS) Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC-F SIX DAYS) Flasher indicator light High beam indicator light Starter relay with main fuse...
  • Page 110 WIRING DIAGRAM ye-re Yellow-red...
  • Page 111 WIRING DIAGRAM...

  • Page 112: Wiring Diagram (250 Exc-F Aus)

    WIRING DIAGRAM Wiring diagram (250 EXC-F AUS) 24.2 CX/2 DB/4 CZ/3 CW/2 DA/4 CY/3 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-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re CR/1 CR1/1...
  • Page 113 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Flasher indicator light High beam indicator light Starter relay with main fuse Flasher relay Pulse generator...

  • Page 114: Wiring Diagram (Xcf-W, 250 Xc-F Usa)

    WIRING DIAGRAM Wiring diagram (XCF‑W, 250 XC-F USA) 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 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 120 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Power Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...

  • Page 121: Standards

    STANDARDS STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle and ATV engines.With most motorcycles and ATVs, the gearbox and the clutch are lubricated with the same oil as the engine.

  • Page 122: Index

    INDEX Clutch lever ........12 INDEX adjusting basic position ..... . . 62 Accessories .
  • Page 123 INDEX removing ....... . . 53 Plug-in stand ....... . . 24 Front wheel Putting into operation installing .
  • Page 124 INDEX Storage ........93 Technical data carburetor .
  • Page 125 *3211348en* 3211348en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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