KTM 250 SX-F Owner's Manual
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KTM 250 SX-F Owner's Manual

Ktm owner's manual motorcycle 250 sx-f, 450 sx-f
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OWNER'S MANUAL
2007
250 SX-F
450 SX-F
ART. NR. 3.211.146 EN

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  • Page 1 OWNER’S MANUAL 2007 250 SX-F 450 SX-F ART. NR. 3.211.146 EN...
  • Page 2 KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

  • Page 3: Important Information

    » IMPORTANT INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.
  • Page 4 The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule. SPARE PARTS, ACCESSORIES For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. TRANSPORT When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position.

  • Page 5: Table Of Contents

    Shift lever ....... .7 Kickstarter (250 SX-F) ......7 Foot brake pedal .

  • Page 6: Serial Number Locations

    » SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.

  • Page 7: Hand Brake Lever

    OPERATION INSTRUMENTS » Hand brake lever The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see "Maintenance"). Short circuit button The short circuit button [2] turns off the engine.

  • Page 8: Choke

    The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral is located between first and second gear. 2,3,4 (5,6) Kickstarter (250 SX-F) The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right footrest.

  • Page 9: Compression Damping Of Fork

    (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.

  • Page 10: Rebound Damping Of Shock Absorber

    OPERATION INSTRUMENTS » Rebound damping of shock absorber By using the adjusting screw [1], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counter- clockwise to reduce damping during rebounding. STANDARD ADJUSTMENT: –...

  • Page 11: General Tips And Warnings For Starting The Motorcycle

    In the following 12 operating hours, you may load the engine up to 75% of its capacity. – Dress properly for the ride. Smart KTM drivers always wear a helmet, boots, gloves and the right Enduro/Motocross clothing. Protective clothing should be conspicuous to make sure other road users see you in time.

  • Page 12: Driving Instructions

    If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided.

  • Page 13: Starting When The Engine Is Cold

    – Maximal period for continuous starting: 5 seconds. Wait at least 5 seconds before trying again. – Don’t ride your motorcycle with full load and don’t rev up the engine when cold because the piston is warming up faster than the water cooled cylinder and can cause engine damage.

  • Page 14: Starting Off

    In normal racing, the cooling system is sufficient. If you use your motorbike in other conditions, please note that: turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time (more than 2 minutes).

  • Page 15: Periodic Maintenance

    IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. »...
  • Page 16 Check tightness of screws, nuts and hose clamps regularly 250/450 SX-F 2007 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx. 15 operating hours...

  • Page 17: Maintenance Work On Chassis And Engine

    OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out.

  • Page 18: Basic Suspension Setup For The Weight Of The Driver

    EXAMPLE: Motorcycle jacked up (dimension A) .....600 mm Motorcycle on ground, unloaded (dimension B) ... . .– 567 mm Static sag .

  • Page 19: Checking The Basic Setup Of The Telescopic Fork

    The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged.

  • Page 20: Changing The Fork Offset (Caster)

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) * The fork offset [A] in the 250/450 SX-F models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the handling to match the race course.

  • Page 21: Checking And Adjusting The Steering Head Bearing

    Mount the front wheel (see: Dismounting and mounting the front wheel). Checking and adjusting the steering head bearing * Check steering head bearing for play periodically. To check, put the motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward.

  • Page 22: How To Change The Handlebar Position

    The screws [4] must be secured with loctite 243. Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx.

  • Page 23: Correct Chain Tension

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 24: Chain Maintenance

    No lubrication is allowed to reach the rear tire or the brake disks, otherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily lose control. When mounting the chain masterlink clip, the closed side of the masterlink clip must point in running direction.

  • Page 25: General Information About Ktm Disc Brakes

    Have the brake disk replaced as soon as it reaches the service limit. – Have any repairs on the brake system be performed by a KTM dealer. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid.

  • Page 26: Adjusting The Free Travel At The Hand Brake Lever

    If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an authorized KTM dealer immediately. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4].

  • Page 27: Replacing The Front Brake Pads

    If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an authorized KTM dealer immediately. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].

  • Page 28: Changing The Basic Position Of The Foot Brake Pedal

    MAINTENANCE WORK ON CHASSIS AND ENGINE 3-5mm min. 1 mm » Changing the basic position of the foot brake pedal * The basic position of the foot brake pedal can be altered by turning the stop screw [1]. The free play at the foot brake pedal must then be adjusted by means of the piston rod [2].

  • Page 29: Dismounting And Mounting The Front Wheel

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 30: Dismounting And Mounting The Rear Wheel

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 31: Tires, Air Pressure

    – Tire pressure should be checked regularly on a “cold” tire. Proper pressure ensures optimum driving comfort and extends the life of your tires. – Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle behaves.

  • Page 32: Charging The Battery (450 Sx-F)

    Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charging device (item no. 58429074000). You can also use this charging device to test the off-load voltage and startability of the battery and generator. It is impossible to overcharge the battery with this device.

  • Page 33: Cooling System

    Coolant is circulated by a water pump [1] located in the engine. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down. Dirty radiators also reduce the cooling efficiency.

  • Page 34: Replacing The Glassfiber Yarn Packing Of The Silencer

    Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to “burn out“.

  • Page 35: Cleaning The Air Filter

    [3] and filter support [4] out of the filter box. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air filter maintenance (Bio Dirt Remover and Liquid Bio Power).

  • Page 36: Changing The Original Position Of The Clutch Lever

    [4]. The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. 250 SX-F: if necessary, fill up with brake fluid DOT 4 or DOT 5.1 (e.g. Motorex Brake Fluid DOT 5.1) – Never use DOT 5 brake fluid! It is based on silicone oil and of a purple color.

  • Page 37: Carburetor - Adjust Idling

    MAINTENANCE WORK ON CHASSIS AND ENGINE CARBURETOR – Adjust idling (Keihin FCR-MX 39/41) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel [1] and the mixture control screw [2].

  • Page 38: Draining The Float Chamber Of The Carburetor

    250 SX-F: Unscrew the plug [1] and clean it with compressed air. Then, mount the plug together with the gasket, open the fuel tap, and check the float chamber for leaks.

  • Page 39: Cleaning Short/Long Oil Screen

    Check the O-rings for damage and, if necessary, replace them. Mount the oil screen together with the plug again and tighten the plug to 10 Nm (250 SX-F) or 30 Nm (450 SX-F).

  • Page 40: Changing The Oil Filter

    Check the O-ring of the oil filter covers for damage and, if necessary, replace Put the motorcycle on its side and fill the oil filter housing about halfway with engine oil. Fill oil filter with oil, place the oil filter in the filter box.

  • Page 41: Troubleshooting

    We would like to point out that many operations cannot be performed by yourself. In case of uncertainty, please contact a KTM-dealer. TROUBLE Engine doesn’t crank (E-starter).
  • Page 42 Dislocate i.e. replace non-buckling vetilation hose Check engine oil level and, if necessary, correct it Use thicker engine oil; see chapter “Engine oil“ Remove seat and fuel tank and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer.

  • Page 43: Cleaning

    – Before cleaning with water, plug the exhaust pipe to prevent water ingress – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber of the carburetor. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.

  • Page 44: Specifications

    Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F).

  • Page 45: Technical Data - Chassis

    Hexagon collar screw, engine case, clutch cover, ignition cover, water pump cover M6 Hexagon collar screw, engine case, clutch case Oil drain plug Allen head plug, oil screen short (250 SX-F) Hexagon plug, oil screen long (250 SX-F) Plug, oil screen (450 SX-F)
  • Page 46 TECHNICAL DATA – CHASSIS CHASSIS 250 SX-F Frame Central tube chrome-moly-steel frame Fork WP 4860 CC MA Wheel travel front/rear 300/335 mm Rear suspension WP PDS shock absorber 5018 DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø...
  • Page 47 TECHNICAL DATA – CHASSIS TIGHTENING TORQUES – CHASSIS 250/450 SX-F Collar screw, front wheel spindle Brake caliper, front Brake disks Clamping screws, top triple clamp Clamping screws, bottom triple clamp Clamping screws, fork stubs Clamping screw steering stem Steering head screw top Steering head screw bottom Collar nut, swing arm bolt Hexagon collar screw, handlebar clamp...

  • Page 48: Head Work Index

    ......22 Kickstarter (250 SX-F) ......7 Maintenance work on chassis and engine .

  • Page 49: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAM red-white red-black...
  • Page 50 » SCHALTPLAN WIRING DIAGRAM blue-white brown yellow-black green blue yellow black red-white white grey-black grey yellow yellow yellow-black blue yellow black red-white black-white brown black black red-white red-white black-white...
  • Page 51 » SCHALTPLAN WIRING DIAGRAM...
  • Page 52 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

Sx-f 450 2007Sx-f 250 2007250 sx-f 2007450 sx-f 2007

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