KTM 250 EXC-F EU Owner's Manual
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KTM 250 EXC-F EU Owner's Manual

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See also: Owenrs Manual
OWNER'S MANUAL
2012
250 EXC-F EU
250 EXC-F AUS
250 EXC-F SIX DAYS EU
250 XCF‑W USA
Art. no. 3211719en

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Summary of Contents for KTM 250 EXC-F EU

  • Page 1 OWNER'S MANUAL 2012 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF‑W USA Art. no. 3211719en...
  • 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

    TABLE OF CONTENTS Running-in the engine ........... 25 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 Preparing the vehicle for difficult riding conditions ... 25 IMPORTANT INFORMATION ..........5 Preparing for rides on dry sand ........26 VIEW OF VEHICLE............... 7 Preparing for rides on wet sand........
  • Page 5 TABLE OF CONTENTS Installing the shock absorber ........51 Installing the battery ..........79 Removing the front fender ..........51 Charging the battery ..........79 Installing the front fender..........51 Changing the main fuse ..........80 Removing the seat ............52 Changing the fuses of individual power consumers....

  • Page 6: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important 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 and in the KTM dealer.net; 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 8 IMPORTANT INFORMATION Transport Note Danger of damage The parked vehicle may 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 9: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 101433-10 Filler cap Air filter box lid Fork compression adjustment Shift lever ( p. 21) Engine number ( p. 9) Side stand ( p. 22)

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

    VIEW OF VEHICLE View of vehicle, rear right (example) 101434-10 Kill switch ( p. 11) Horn button ( p. 12) Light switch ( p. 12) Turn signal switch ( p. 12) Emergency OFF switch ( p. 12) Electric starter button ( p.

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  101289-10 Type label The type label is fixed to the front of the steering head.  101290-10 Key number (All EXC‑F models) The key number is stamped on the key strap.

  • Page 12: Shock Absorber Part Number

    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. 101436-10...

  • Page 13: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 101293-10 Hand brake lever Hand brake lever is located on the right side of the handlebar.  The hand brake lever is used to activate the front brake.

  • Page 14: Horn Button (All Exc-F Models)

    CONTROLS Horn button (All EXC‑F models) The horn button is fitted on the left side of the handlebar.  Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 101297-11 Light switch (All EXC‑F models) The light switch is fitted on the left side of the handlebar.

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

    CONTROLS Electric starter button (XCF‑W, EXC‑F EU, EXC-F SIX DAYS) 5.11 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 (All Exc-F Models)

    CONTROLS Overview of indicator lamps (All EXC‑F models) 5.16 Possible states High beam indicator light lights up blue – High beam is switched on. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The fuel level warning lamp lights up orange –...

  • Page 17: Setting Kilometers Or Miles

    CONTROLS Setting kilometers or miles 5.20 Info If you change the unit of measure, the ODO value is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed. Condition The motorcycle is stationary.

  • Page 18: Adjusting The Speedometer Functions

    CONTROLS Adjusting the speedometer functions 5.22 Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – briefly and repeatedly until H appears at the bottom right of the Press the button display.

  • Page 19: Display Mode Speed (Speed)

    CONTROLS Display mode SPEED (speed) 5.24 – Press the button briefly and repeatedly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Making the setting according to the country.

  • Page 20: Display Mode Speed/Odo (Odometer)

    CONTROLS Press the button Next display mode briefly. Display mode SPEED/ODO (odometer) 5.28 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. The total distance traveled is displayed in the ODO display mode. Press the button .

  • Page 21: Display Mode Speed/A1 (Average Speed 1)

    CONTROLS Display mode SPEED/A1 (average speed 1) 5.31 – Press the button briefly and repeatedly until A1 appears at the top right of the display. A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas- ter 1) and S1 (stop watch 1).

  • Page 22: Opening Filler Cap

    CONTROLS Table of functions Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. Display mode SPEED/H No function No function The display changes to Next display mode (operating hours) the Setup menu of the speedometer functions.

  • Page 23: Closing Filler Cap

    CONTROLS – Press release button , turn filler cap counterclockwise and lift it upwards and  remove. 101305-10 Closing filler cap 5.36 – Replace the filler cap and turn clockwise until the release button locks in place.  Info Route the fuel tank breather hose without kinking.

  • Page 24: Kick Starter

    CONTROLS Kick starter 5.39 The kick starter is fitted on the right of the engine.  The engine can be started with either the kick starter or the electric starter. The upper part of the kick starter can be swung out. Info Before riding, swing the upper part of the kick starter inwards towards the engine.

  • Page 25: Locking The Steering (All Exc-F Models)

    CONTROLS Locking the steering (All EXC‑F models) 5.43 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –...

  • Page 26: Preparing For Use

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

  • Page 27: Running-In The Engine

    – KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p.

  • Page 28: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (59006019000) Info See the KTM PowerParts fitting instructions. 600869-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions.

  • Page 29: Preparing For Rides On Wet And Muddy Surfaces

    Change the radiator cap. – Fit a rain cover on the air filter. Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and the setting. Info 600870-01 The specific carburetor tuning can be recommended by your authorized KTM workshop.

  • Page 30: Preparing For Rides At Low Temperatures Or In Snow

    Preparing for rides at low temperatures or in snow – 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 setting. Info 600870-01 Recommendations on the carburetor setting are available from your autho- rized KTM workshop.

  • Page 31: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 92) –...

  • Page 32: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. 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 33: 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 become very hot when the vehicle is operated. –...
  • Page 34 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 9.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx. (2.51 US gal) 91) ( p. 111) –...

  • Page 35: Service Schedule

    Check that the radiator fan is functioning properly. (EXC-F SIX DAYS) Final check: Check the vehicle for roadworthiness and take a test ride. • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • • •...

  • Page 36: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S15N S45A S105A • Change the front brake fluid. Change the rear brake fluid. • Change the foot brake cylinder seals. (XCF‑W, EXC‑F EU, EXC‑F AUS) • Change the hydraulic clutch fluid. p. 63) •...

  • Page 37: Tuning The Chassis

    Caution 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 38: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution 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 39: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS Measuring rear wheel sag unloaded – Raise the motorcycle with the lift stand. ( p. 42) – Measure the distance – as vertically as possible – between the rear axle and a fixed point, such as a mark on the side cover. –...

  • Page 40: Adjusting The Spring Preload Of The Shock Absorber

    Caution 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 41: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Checking basic setting of fork 9.11 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. –...

  • Page 42: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting the spring preload of the fork 9.14 – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –...
  • Page 43 TUNING THE CHASSIS Info Position the left and right handlebar supports evenly. – 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...

  • Page 44: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels should no longer touch the ground.

  • Page 45: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS – Press the dust boots back into their normal position. – Remove excess oil. – Position the fork protection. ( p. 43) – Remove the motorcycle from the lift stand. ( p. 42) Loosening the fork protector 10.5 –...

  • Page 46: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS Installing the fork legs 10.8 – Position the fork legs. Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws toward the front. ...

  • Page 47: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS Installing the fork protector 10.10 – Position the fork protection on the left fork leg. Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 48: Installing The Lower Triple Clamp (Xcf-W, Exc-F Eu, Exc-F Aus)

    SERVICE WORK ON THE CHASSIS – Remove O-ring . Remove protective ring   – Take out the lower triple clamp with the steering stem. – Take out the upper steering head bearing. 101336-10 Installing the lower triple clamp (XCF‑W, EXC‑F EU, EXC‑F AUS) 10.13 –...
  • Page 49 SERVICE WORK ON THE CHASSIS – Tighten screw  Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 101428-10 – Tighten screw  Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) 101334-11 – Tighten screws  Guideline Screw, top triple clamp 20 Nm...

  • Page 50: Installing The Lower Triple Clamp (Exc-F Six Days)

    SERVICE WORK ON THE CHASSIS Installing the lower triple clamp (EXC-F SIX DAYS) 10.14 – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 112) 0 0 3 – Insert the lower triple clamp with the steering stem. Mount the upper steering head 0 0 2 bearing.

  • Page 51: Checking The 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 ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.

  • Page 52: Adjusting The Play Of The Steering Head Bearing (Xcf-W, Exc-F Eu, Exc-F Aus)

    SERVICE WORK ON THE CHASSIS » If click positions are noticeable: (EXC-F SIX DAYS) – Adjust the play of the steering head bearing. p. 50) (XCF‑W, EXC‑F EU, EXC‑F AUS) – Adjust the play of the steering head bearing. p. 50) –...

  • Page 53: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Removing the shock absorber 10.19 – Raise the motorcycle with the lift stand. ( p. 42) – 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 54: Removing The Seat

    SERVICE WORK ON THE CHASSIS Removing the seat 10.23 – Remove screw  – Lift up the seat at the rear, pull it back and then remove it from above. 101346-10 Mounting the seat 10.24 – 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.

  • Page 55: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Detach air filter holder at the bottom and swing it to one side. Remove the air  filter with the air filter support. – Remove the air filter from the air filter support. 101350-10 Installing the air filter 10.28 –...

  • Page 56: Removing Main Silencer

    SERVICE WORK ON THE CHASSIS Removing main silencer 10.30 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 57: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Mount and tighten the screws. (XCF‑W) 0 0 6 – Remove screws of connecting cap   – Take off the connecting cap with the perforated pipe, O-ring and glass fiber  yarn filling ...

  • Page 58: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings and horn.  101356-10 – Remove screw with the rubber bushing.  101357-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 101358-01 Installing the fuel tank 10.34...

  • Page 59: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Position the horn, and fit and tighten screws with collar bushings.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101356-11 – Connect the electrical plug-in connection  – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 60: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 112) Off-road chain spray ( p. 112) 400725-01 Checking the chain tension 10.37 Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 61: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws 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 ...
  • Page 62 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 63: Adjusting The Chain Guide

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 Checking the swingarm 10.42 –...

  • Page 64: Checking The Throttle Cable Routing

    SERVICE WORK ON THE CHASSIS Checking the throttle cable routing 10.43 – Remove the fuel tank. p. 55) – Check the throttle cable routing. Both throttle cables must be routed to the carburetor side by side behind the handlebars and above the tank bearing. »...

  • Page 65: Checking The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Checking the fluid level of the hydraulic clutch 10.47 Info The fluid level rises with increased wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 66: Removing The Engine Guard (Exc-F Aus, Exc-F Six Days)

    SERVICE WORK ON THE CHASSIS Removing the engine guard (EXC‑F AUS, EXC-F SIX DAYS) 10.49 – Turn quick release counterclockwise until it disengages. Remove the engine  guard. 101451-10 Installing the engine guard (EXC‑F AUS, EXC-F SIX DAYS) 10.50 – Attach the engine guard on the frame at the rear and swing up at the front.

  • Page 67: Brakes

    BRAKES Checking free travel of hand brake lever 11.1 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

  • Page 68: Checking The Brake Discs

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 69: 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 brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 70 Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake 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: Checking The Free Travel Of Foot Brake Lever

    BRAKES – Fit the brake linings, insert the bolt, and mount the locking split pins. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. 100398-10 –...

  • Page 72: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 73: Checking 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 brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 74: 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 brake 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 75 BRAKES – Check that leaf spring in the brake caliper and sliding plate in the brake   caliper support are seated correctly. 100407-10 – Fit the brake linings, insert the bolt, and mount the locking split pins. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 76: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 42) – Press the brake caliper onto the brake disc by hand in order to push 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 77: Removing The Rear Wheel

    WHEELS, TIRES – 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) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 78: Checking The Tire Condition

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

  • Page 79: 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 80 WHEELS, TIRES Torque wrench with various accessories in set (58429094000)

  • Page 81: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 82: Changing The Main Fuse

    – 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 83: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – Remove screw  101395-10 – Lift rear fairing slightly and pull starter relay out of the bracket.   101396-10 – Remove protection caps  – Remove the faulty main fuse  Info A defective fuse can be identified by the burned-out fuse wire ...

  • Page 84: Changing The Fuse Of The Radiator Fan (Exc-F Six Days)

    ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan (optional) Fuse 5 - not used Fuses res - 10 A - spare fuses...

  • Page 85: Removing Headlight Mask With Headlight

    ELECTRICAL SYSTEM Removing headlight mask with headlight 13.7 – Switch off all electrical equipment. – Remove screw and take off clamp.  – Loosen the rubber band . Push up the headlight mask and swing it forwards.  101401-10 – Pull out the electric plug connector and remove the headlight mask with the ...

  • Page 86: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Press headlight bulb into the lamp socket lightly, turn it counterclockwise all the  way and pull it out. – Insert a new headlight bulb. Headlight (S2 / socket BA20d) ( p. 105) – Insert the rubber cap together with the lamp socket into the reflector and turn it clockwise all the way.
  • Page 87 ELECTRICAL SYSTEM – Using a coin, turn locking cap counterclockwise all the way and remove it.  – Remove speedometer battery  – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p. 105) – Check that the O-ring of the locking cap is seated properly.

  • Page 88: Cooling System

    COOLING SYSTEM Cooling system 14.1 Water pump in the engine circulates the coolant.  The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tem- ...

  • Page 89: Checking The Coolant Level

    COOLING SYSTEM Checking the coolant level 14.3 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 90: Refilling Coolant

    COOLING SYSTEM Refilling coolant 14.5 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi- ately.

  • Page 91: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 92: Adjusting The Idle Speed

    TUNING THE ENGINE On the Map‑Select switch for the basic setting: – Pull off rubber cap of Map‑Select.  – Turn adjusting wheel until the desired number is aligned with marking   SOFT: – Set the adjusting wheel to position 1. Soft –...

  • Page 93: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE Adjusting the basic position of the shift lever 15.6 – Remove screw and take off shift lever   101459-10 – 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.

  • Page 94: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level can be checked when the engine is cold or warm. – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 95 SERVICE WORK ON THE ENGINE – Remove screw plug with the long oil screen   101464-10 – Remove screws . Remove the oil filter cover with the O-ring.  101468-10 – Pull oil filter out of the oil filter housing. ...

  • Page 96: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil. – Fill oil filter with engine oil and place it in the oil filter housing. ...

  • Page 97: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 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 98: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Checks and maintenance steps for winter operation 17.2 Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 99: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 42) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

  • Page 100: Troubleshooting

    – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 101 – Check the cabling for damage and the electri- cal plug-in connections for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.

  • Page 102: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)
  • Page 103 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition EXC‑F EU, EXC-F SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit EXC‑F EU, EXC-F SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - input signal too high...

  • Page 104: 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 13.2:1 Idle speed 2,050… 2,150 rpm Control DOHC, four valves controlled via cam lever, drive via tooth-wheel chain Valve diameter, intake 30.0 mm (1.181 in)

  • Page 105: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Jet, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil jet for alternator cooling 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 106 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite 243™ ® Nut, primary gear M18LHx1.5 130 Nm (95.9 lbf ft) Loctite 243™ – Plug for oil screen, long M20x1.5 15 Nm (11.1 lbf ft) –...

  • Page 107: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 20 mm (0.79 in) Shock absorber WP Suspension PDS 5018 DCC Brake system...

  • Page 108: Tires

    80/100 - 21 51M TT 100/100 - 18 59M TT Dunlop GEOMAX MX51 Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 109: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7L.63 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Full payload...

  • Page 110: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7L.63 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns...

  • Page 111: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal 2.5 Nm (1.84 lbf ft) – Screw, intake air temperature sensor 2 Nm (1.5 lbf ft) –...

  • Page 112: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (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 113 SAE ( p. 114) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Supplier ® Motorex – Racing Fork Oil Shock absorber oil (SAE 2.5) (50180342S1)

  • Page 114: 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 Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 115 AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Clean & Polish Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE...

  • Page 116: 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 117: Index

    INDEX Compression damping, low-speed INDEX shock absorber, adjusting ..... 35 Accessories ........5 Coolant Air filter draining .
  • Page 118 INDEX removing ....... . . 44 Map‑Select switch engine characteristics, setting ....89 Frame for the basic setting .
  • Page 119 INDEX battery, changing ......84 clock, setting ......15 function description .
  • Page 120 *3211719en* 3211719en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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