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

2012
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See also: Owenrs Manual
OWNER'S MANUAL
2012
250 SX‑F EU
250 SX‑F ROCZEN REPLICA EU
250 SX‑F USA
250 XC-F USA
Art. no. 3211813en

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Summary of Contents for KTM 250 SX-F EU

  • Page 1 OWNER'S MANUAL 2012 250 SX‑F EU 250 SX‑F ROCZEN REPLICA EU 250 SX‑F USA 250 XC-F USA Art. no. 3211813en...
  • 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 Checking the basic setting of the fork......29 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 Adjusting the compression damping of the fork ....29 IMPORTANT INFORMATION ..........5 Adjusting the rebound damping of the fork....... 30 VIEW OF VEHICLE...............
  • Page 5 TABLE OF CONTENTS Checking the brake discs..........54 TECHNICAL DATA - SHOCK ABSORBER ......93 Checking the front brake fluid level ......... 55 All SX‑F EU models ............93 SX‑F USA ..............93 Adding front brake fluid ..........55 XC‑F................94 Checking the front brake linings........

  • 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 performed by an authorized KTM workshop! There, your motorcycle will be ser- viced 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 claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
  • Page 8 IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob- lems and conflicts do not have to occur.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 101282-10 Hand brake lever ( p. 10) Clutch lever ( p. 10) Filler cap Fork rebound adjustment Idle speed adjusting screw ( p. 12) Shift lever ( p. 12) Air filter box lid Plug-in stand ( p.

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

    VIEW OF VEHICLE View of vehicle, rear right (example) 101283-10 Kill switch ( p. 10) Electric starter button ( p. 10) Throttle grip ( p. 10) Fork compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment Shock absorber compression adjustment Level viewer, engine oil Foot brake lever ( p.

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. B00262-10 Type label The type label is fixed to the front of the steering head. B00262-20 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 12: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 100904-10 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. B00369-11 Throttle grip The throttle grip...

  • Page 13: Overview Of Indicator Lamps

    CONTROLS Overview of indicator lamps Possible states FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagnosis) has identified an emissions- or safety-critical fault. (XC‑F) Fuel level warning lamp lights up orange – Fuel level has reached the reserve mark. 101081-10 Opening the filler cap Danger...

  • Page 14: Factory Start (Sx-F Roczen Replica)

    CONTROLS Factory Start (SX‑F ROCZEN REPLICA) The Factory Start is mounted on the right fork protector. Possible states Factory Start is deactivated – The fork is in the normal operating mode. • Factory Start is activated – The fork is compressed and the front of the motor- •...

  • Page 15: Kick Starter (Xc-F)

    CONTROLS Kick starter (XC‑F) 5.12 The kick starter is fitted on the right side of the engine. The upper part of the kick starter can be folded in. Info Before riding, fold the upper part of the kick starter toward the engine. 100910-10 Foot brake lever 5.13...

  • Page 16: Service Hour Counter (Sx-F Roczen Replica)

    CONTROLS Service hour counter (SX‑F ROCZEN REPLICA) 5.16 The service hour counter is attached to the battery below the seat. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off.

  • Page 17: 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 18: 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 19: Preparing For Rides On Dry Sand

    – Fit a dust protection device on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. B00435-01 – Fit a sand protection device on the air filter. Sand protection device for air filter (77206922000) Info See the KTM PowerParts fitting instructions.

  • Page 20: Preparing For Rides On Wet And Muddy Surfaces

    Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. B00437-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 21: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance before putting into operation Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.

  • Page 22: 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 23: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 24: Service Schedule

    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. • • • • Make the service entry in KTM DEALER.NET and in the service record.

  • Page 25: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S20N S40A S50A S100A • Change the front brake fluid. Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 52) • Grease the steering head bearing. p. 38) • Service the shock absorber. •...

  • Page 26: 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 27: 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 28: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound 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.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 29: Checking The Static Sag 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 30: Adjusting The Riding Sag

    TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) – Measure the overall spring length while the spring is not under tension. –...

  • Page 31: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS Subsequent work – Install the shock absorber. p. 40) – Install the main silencer. ( p. 43) – Check the static sag of the shock absorber. ( p. 27) – Check the riding sag of the shock absorber. ( p.

  • Page 32: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS Adjusting the rebound damping of the fork 9.13 Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

  • Page 33: Activating The Factory Start (Sx-F Roczen Replica)

    TUNING THE CHASSIS Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Mount and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Activating the Factory Start (SX‑F ROCZEN REPLICA)

  • Page 34: 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. The wheels must no longer touch the ground.

  • Page 35: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS Cleaning the dust boots of the fork legs 10.4 Preliminary work – Raise the motorcycle with the lift stand. ( p. 32) – Loosen the fork protection. ( p. 33) Main work – Push dust boots of both fork legs downwards.

  • Page 36: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS Removing the fork legs 10.7 Preliminary work – Raise the motorcycle with the lift stand. ( p. 32) – Remove the front wheel. p. 62) Main work – Remove screws and take off the clamp. –...

  • Page 37: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS Removing the fork protector 10.9 Preliminary work – Raise the motorcycle with the lift stand. ( p. 32) – Remove the front wheel. p. 62) – Remove the fork legs. p. 34) Main work – Remove screws on the left fork leg.

  • Page 38: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Installing the lower triple clamp 10.12 Main work – Clean the bearing and sealing elements, check for damage, and grease. 0 0 3 High viscosity grease ( p. 98) – 0 0 2 Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 39: 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 40: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Main work – 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: –...

  • Page 41: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS Removing the start number plate 10.16 – Remove screw and take off the clamp. – Remove screw . Take off the start number plate. 101278-10 Installing the start number plate 10.17 – Position the start number plate. Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 42: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw cap 100914-10 – Press angle lever toward the rear. – Press linkage lever downward. 100915-10 – Detach springs Spring hooks (50305017000) – Remove screw – Press the shock absorber toward the rear and remove the exhaust manifold. 100916-10 –...

  • Page 43: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten screw cap Guideline Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) – Mount and tighten screw Guideline Screw, bottom shock 60 Nm Loctite ®...

  • Page 44: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS Removing the air filter 10.26 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 45: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 98) Info Only press the air filter to dry it, never wring it out. –...

  • Page 46: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS (SX‑F EU/USA, XC‑F) – Remove all screws from the main silencer. Remove locking cap and outer tube – Pull the glass fiber yarn filling from inner tube – Clean the parts that are to be reinstalled. –...

  • Page 47: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Disconnect electric plug-in connection of the fuel pump. – Thoroughly clean plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve.

  • Page 48: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately.

  • Page 49: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS Cleaning the chain 10.35 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 50: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Adjusting the chain tension 10.37 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load.
  • Page 51 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) 0 0 A – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 52: 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. 500284-01...

  • Page 53: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 500285-01 Checking the throttle cable routing 10.42 Preliminary work –...

  • Page 54: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS Adjusting the basic position of the clutch lever 10.45 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

  • Page 55: Removing The Engine Guard (Sx-F Roczen Replica)

    SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from hole of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. –...

  • Page 56: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk...

  • Page 57: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to 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 58: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to 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 59 BRAKES Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 60: Checking The Free Travel Of Foot Brake Lever

    BRAKES – Add brake fluid to level Guideline Dimension (brake fluid level below 5 mm (0.2 in) top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 96) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 61: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to 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 62: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to 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 63 BRAKES Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 64: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 Preliminary work – Raise the motorcycle with the lift stand. ( p. 32) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 65: Removing The Rear Wheel

    WHEELS, TIRES (SX‑F ROCZEN REPLICA) – Align the brake disc guard so that gaps are the same size. 101075-10 – 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 66: Installing The Rear Wheel

    12.5 Info Only mount tires approved and/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 67: Checking The 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 causes wheel imbalance and rapidly leads to more loose spokes.
  • Page 68 WHEELS, TIRES » If the spoke tension varies: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)

  • Page 69: 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 70: Recharging The Battery

    – 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 71: Changing The Main Fuse

    ELECTRICAL SYSTEM Changing the main fuse 13.4 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is located in the starter relay housing under the filter box cover. Preliminary work –...

  • Page 72: 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- perature will not result in a risk of malfunctions.

  • Page 73: Draining The Coolant

    COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: –...
  • Page 74 COOLING SYSTEM – Make sure that screw is tightened. – Position the motorcycle upright. – Pour coolant in up to measurement above the radiator fins. Guideline Dimension over the radiator fins 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 75: 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. Throttle cable play 3…...

  • Page 76: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE Checking the basic position of the shift lever 15.4 – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...

  • Page 77: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Changing the fuel screen 16.1 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 78: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.2 Info The engine oil level can be checked when the engine is cold or warm. Preliminary work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 79 SERVICE WORK ON THE ENGINE – Remove screw plug with the long oil screen 100940-10 – Remove screws . Remove the oil filter cover with the O-ring. 100941-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) –...

  • Page 80: 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 the oil filter with engine oil and place it in the oil filter container. –...
  • Page 81 SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight.

  • Page 82: 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 83: 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. 32) – Cover the vehicle with a tarp or a cover that is permeable to air.

  • Page 84: 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 85 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Piston and cylinder worn Piston/cylinder - determine the mounting clear- ance. – Battery discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the open-circuit current.

  • Page 86: 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 87: 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 (SX‑F EU/USA, XC‑F) 13.2:1 Compression ratio (SX‑F ROCZEN REPLICA) 13.7:1 Idle speed 2,150… 2,250 rpm Control DOHC, four valves controlled via cam lever, drive via tooth-wheel chain...

  • Page 88: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE Capacity - engine oil 21.1 Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 96) Alternative engine oil for harsh Engine oil (SAE 10W/60) operating conditions and (00062010035) ( p. 96) increased performance Capacity - coolant 21.2 Coolant...

  • Page 89: 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 nozzle for conrod bearing lubrica- 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 90 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Plug for oil screen, short M16x1.5 10 Nm (7.4 lbf ft) Lubricated with engine oil ® 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™...

  • Page 91: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 300 mm (11.81 in) Suspension travel (All SX‑F EU models) Rear 330 mm (12.99 in) Suspension travel (SX‑F USA, XC‑F) Rear 317 mm (12.48 in)

  • Page 92: Tires

    100/100 - 18 64M TT (XC‑F) Dunlop GEOMAX MX51F Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 7.5 l (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 93: Technical Data - Fork

    TECHNICAL DATA - FORK All SX‑F EU models 24.1 Fork part number 14.18.7L.05 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s)

  • Page 94: Xc-F

    TECHNICAL DATA - FORK XC‑F 24.3 Fork part number 14.18.7L.75 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 492 mm (19.37 in) Spring rate...

  • Page 95: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER All SX‑F EU models 25.1 Shock absorber part number 18.18.7L.05 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport...

  • Page 96: Xc-F

    TECHNICAL DATA - SHOCK ABSORBER Fitted length 486 mm (19.13 in) Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 97) XC‑F 25.3 Shock absorber part number 18.18.7L.75 WP Suspension 5018 BAVP DCC Shock absorber Compression damping, low-speed Comfort 17 clicks Standard...

  • Page 97: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal 2.5 Nm (1.84 lbf ft) –...

  • Page 98: 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 99 SAE ( p. 100) (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 100: 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 101 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 102: 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 103: Index

    INDEX Compression damping, low-speed INDEX shock absorber, adjusting ..... 24 Accessories ........5 Coolant Air filter draining .
  • Page 104 INDEX Front fender checks and maintenance before putting into operation . . 19 installing ....... . . 39 removing .
  • Page 105 INDEX Technical data chassis ....... . 89-90 chassis tightening torques ..... 95 engine .
  • Page 106 *3211813en* 3211813en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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