2005-2008 KTM 250 SX-F, EXC-F, EXC-F Six Days, XCF-W, XC-F, SXS-F Motorcycle Service & Repair Manual

REPAIR MANUAL 2005-2010 BEDIENUNGSANLEITUNG OWNER’S MANUAL MANUALE O’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES REPARATURANLEITUNG REPAIR MANUAL MANUALE DI REPARAZIONE MANUEL DE REPARATION MANUAL DE REPARACION GABEL FORK FORCELLA FOURCHE HORQUILLA FEDERBEIN SHOCK ABSORBER AMMORTIZZATORE AMMORTISSEUR AMORTIGUADOR

OWNERS MANUAL 2009/10 2009 2010

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

CONTENTS 2 CONTENTS MEANS OF REPRESENTATION ............................................ 5 IMPORTANT NOTES ............................................................ 6 VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example) ................. 8 View of the vehicle from the right rear (example) ................ 9 LOCATION OF SERIAL NUMBERS ...................................... 10 Chassis number ............................................................. 10 Type label ..................................................................... 10 Key number (EXC-F, EXC‑F SIX DAYS)............................. 10 Engine number.............................................................. 10 Fork part number........................................................... 10 Shock absorber part number ........................................... 11 CONTROLS ....................................................................... 12 Clutch lever .................................................................. 12 Hand brake lever ........................................................... 12 Short circuit button (XCF‑W, XC‑F, SX‑F) ......................... 12 Short circuit button (EXC-F, EXC‑F SIX DAYS) .................. 12 Emergency OFF switch (250 EXC-F AUS) ........................ 12 Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 13 Electric starter button (250 EXC-F AUS) .......................... 13 Light switch (EXC-F, EXC‑F SIX DAYS) ............................ 13 Light switch (XCF‑W) ..................................................... 13 Horn button (EXC-F, EXC‑F SIX DAYS)............................. 13 Flasher switch (EXC-F, EXC‑F SIX DAYS) ......................... 14 Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) ...... 14 CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) ...................... 15 Speedometer................................................................. 15 Speedometer activation and test ..................................... 15 Tripmaster switch .......................................................... 15 Setting kilometers or miles ............................................. 15 Setting the clock ........................................................... 16 Adjusting the speedometer functions ............................... 16 Querying the lap time .................................................... 17 SPEED display mode (speed) .......................................... 17 SPEED/H display mode (service hours) ............................ 17 SPEED/CLK display mode (time) ..................................... 18 SPEED/LAP display mode (lap time) ................................ 18 SPEED/ODO display mode (odometer) ............................. 18 SPEED/TR1 display mode (trip master 1)......................... 18 SPEED/TR2 display mode (trip master 2)......................... 19 SPEED/A1 display mode (average speed 1) ...................... 19 SPEED/A2 display mode (average speed 2) ...................... 19 SPEED/S1 display mode (stop watch 1) ........................... 20 SPEED/S2 display mode (stop watch 2) ........................... 20 CONTROLS ....................................................................... 22 Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) .............. 22 Fuel tap (SX‑F) .............................................................. 22 Opening filler cap .......................................................... 22 Closing filler cap ........................................................... 23 Choke (EXC-F EU, EXC‑F SIX DAYS) ................................ 23 Choke (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) .......................... 23 Shift lever ..................................................................... 23 Foot brake pedal ........................................................... 24 Kickstarter .................................................................... 24 Side stand (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) .......... 24 Plug-in stand (SX‑F) ...................................................... 24 Steering lock (EXC-F, EXC‑F SIX DAYS) ........................... 25 Locking the steering (EXC-F, EXC‑F SIX DAYS) ................. 25 Unlocking the steering (EXC-F, EXC‑F SIX DAYS).............. 25 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 26 Advice on first use ......................................................... 26 Running in the engine.................................................... 27 RIDING INSTRUCTIONS .................................................... 28 Checks before putting into operation ............................... 28 Starting ........................................................................ 28 Starting up ................................................................... 29 Shifting, riding .............................................................. 29 Braking ........................................................................ 29 Stopping, parking .......................................................... 30 Refueling...................................................................... 30 SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)........ 32 Important maintenance work to be carried out by an authorized KTM workshop. ............................................. 32 Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. 33 SERVICE SCHEDULE (XC‑F, SX‑F) ...................................... 34 Important maintenance work to be carried out by an authorized KTM workshop. ............................................. 34 Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. 35 SERVICE SCHEDULE FOR RIDER ....................................... 36 Important checks and maintenance work to be carried out by the rider. ............................................................ 36 MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 37 Jacking up the motorcycle .............................................. 37 Removing the motorcycle from the work stand .................. 37 Checking the basic chassis setting with the rider's weight .......................................................................... 37 Compression damping of shock absorber.......................... 37 Adjusting high-speed compression damping of the shock absorber ....................................................................... 37 Adjusting the low-speed compression damping of the shock absorber .............................................................. 38 Adjusting the rebound damping of the shock absorber....... 39 Measuring rear wheel sag unloaded ................................. 40 Checking the static sag of the shock absorber .................. 40 Checking the riding sag of the shock absorber .................. 41 Adjusting the spring preload of the shock absorber x ...... 41 Adjusting the riding sag x............................................. 42 Removing the shock absorber x..................................... 42 Installing the shock absorber x ..................................... 42 Checking basic setting of fork ......................................... 43 Adjusting the compression damping of the fork ................ 43 Adjusting the rebound damping of fork ............................ 44 Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... 45 Bleeding fork legs .......................................................... 45 Cleaning dust boots of fork legs ...................................... 46 Loosening the fork protection.......................................... 46 Positioning the fork protection ........................................ 46 Checking play of steering head bearing ............................ 46 Adjusting play of steering head bearing x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. 47 Adjusting play of steering head bearing x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ..................... 47 Fork offset (XCF‑W USA, XC‑F, SX‑F) ............................... 48 Setting the fork offset x (XCF‑W USA, XC‑F, SX‑F) .......... 48 Removing the fork legs................................................... 48 Installing the fork legs x............................................... 49 Removing the fork protector x ....................................... 50 Installing the fork protector x ....................................... 50

CONTENTS 3 Removing the lower triple clamp x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ................................................ 50 Removing the lower triple clamp x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. 51 Installing the lower triple clamp x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ................................................ 51 Installing the lower triple clamp x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. 52 Greasing the steering head bearing x ............................. 53 Dismounting the front fender .......................................... 53 Installing the front fender ............................................... 53 Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) .......................................... 53 Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) .......................................... 54 Dismount the start number plate (XCF‑W USA, XC‑F, SX‑F)............................................................................ 54 Installing the start number plate (XCF‑W USA, XC‑F, SX‑F)............................................................................ 54 Handlebar position ........................................................ 54 Adjusting the handlebar position x ................................ 55 Checking gas Bowden cable route ................................... 56 Checking play in the gas Bowden cable ........................... 56 Adjusting the gas Bowden cable play x .......................... 57 Checking for chain dirt accumulation .............................. 57 Cleaning the chain......................................................... 57 Checking the chain tension ............................................ 58 Checking the chain tension when fitting rear wheel ........... 58 Checking the rear sprocket / engine sprocket for wear ....... 59 Checking chain wear ...................................................... 59 Adjusting the chain tension ............................................ 59 Adjusting chain tension - after checking .......................... 60 Adjusting chain tension - fitting rear wheel ...................... 61 Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 61 Adjusting the chain guide x (SX‑F) ................................ 62 Adjusting basic position of clutch lever ............................ 62 Checking the fluid level of hydraulic clutch ...................... 62 Changing the hydraulic clutch fluid x ............................ 63 Checking the brake discs................................................ 64 Checking free travel of hand brake lever........................... 64 Adjusting basic position of handbrake lever (XCF‑W, XC‑F, SX‑F) ...................................................... 64 Adjusting free travel of handbrake lever (EXC-F, EXC‑F SIX DAYS) ............................................... 65 Checking the front brake fluid level ................................. 65 Adding front brake fluid x ............................................ 65 Checking the front brake linings...................................... 66 Removing the front brake linings x ................................ 66 Installing the front brake linings x................................. 67 Changing the front brake linings x................................. 67 Checking free travel of foot brake lever ............................ 68 Adjusting basic position of footbrake lever x................... 68 Checking the rear brake fluid level .................................. 69 Adding brake fluid for the rear brake x .......................... 69 Checking the rear brake linings ....................................... 70 Removing rear brake linings x ....................................... 70 Installing the rear brake linings x .................................. 70 Changing the rear brake linings x .................................. 71 Removing the front wheel x .......................................... 72 Installing the front wheel x ........................................... 72 Removing rear wheel x ................................................. 73 Installing the rear wheel x ............................................ 73 Tire condition checking .................................................. 74 Checking tire air pressure ............................................... 75 Checking spoke tension.................................................. 75 Removing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 75 Installing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 76 Recharging the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 76 Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)............................................................................ 77 Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)............................................................................ 77 Removing the seat ......................................................... 77 Mounting the seat ......................................................... 78 Dismounting the fuel tank x ......................................... 78 Installing the fuel tank x .............................................. 79 Cooling system .............................................................. 79 Checking antifreeze and coolant level .............................. 80 Checking the coolant level .............................................. 80 Draining the coolant x.................................................. 81 Refilling coolant x ....................................................... 81 Glass fiber yarn filling of main silencer ............................ 81 Removing main silencer ................................................. 82 Installing the main silencer ............................................ 82 Dismounting the air filter box lid ..................................... 82 Installing the air filter box lid.......................................... 82 Removing the air filter x............................................... 83 Installing the air filter x ............................................... 83 Cleaning air filter x ...................................................... 83 Carburetor - idle ............................................................ 84 Carburetor - adjusting idle x ......................................... 84 Emptying the carburetor float chamber x ....................... 85 Checking the engine oil level .......................................... 86 Changing the engine oil and oil filter, cleaning the oil screen x ..................................................................... 86 Draining the engine oil x .............................................. 86 Cleaning the oil screens x ............................................ 87 Removing the oil filter x ............................................... 88 Installing the oil filter x ............................................... 88 Filling up with engine oil x ........................................... 89 Adding engine oil .......................................................... 89 TROUBLESHOOTING......................................................... 90 CLEANING........................................................................ 92 Cleaning motorcycle ...................................................... 92 STORAGE ......................................................................... 93 Storage......................................................................... 93 Putting into operation after storage ................................. 93 TECHNICAL DATA - ENGINE .............................................. 94 Capacity- engine oil ....................................................... 95 Capacity - coolant .......................................................... 95 TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 96 TECHNICAL DATA - CARBURETOR ..................................... 98 EXC-F, EXC‑F SIX DAYS ................................................. 98 XCF‑W, 250 XC-F USA ................................................... 98 SX‑F............................................................................. 98 TECHNICAL DATA - CHASSIS ............................................ 99 Lighting equipment ..................................................... 100 Tires .......................................................................... 100 Capacity - fuel............................................................. 100

CONTENTS 4 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 ............................................................ 103 250 SX-F EU .............................................................. 104 250 SX-F USA ............................................................ 104 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 105 WIRING DIAGRAM .......................................................... 106 Wiring diagram (EXC-F EU, EXC‑F SIX DAYS) ................. 106 Wiring diagram (250 EXC-F AUS) ................................. 110 Wiring diagram (XCF‑W, 250 XC-F USA) ........................ 112 Wiring diagram (SX‑F) .................................................. 114 SUBSTANCES ................................................................. 116 AUXILIARY SUBSTANCES................................................ 117 STANDARDS ................................................................... 119 INDEX ............................................................................ 120

MEANS OF REPRESENTATION 5 1MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). 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. Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained in the following. Specific name Identifies a specific name. Name ® Identifies a protected name. Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 6 2IMPORTANT NOTES Use definition (EXC-F, EXC‑F SIX DAYS) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on secluded property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use. Use definition (XCF‑W, XC‑F, SX‑F) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle must be used only on secluded property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use. Maintenance A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break- age of components. Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached. Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle. Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's service 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. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com Work rules When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash- ers) must be replaced with new parts. Where thread lockers are used on screw connections (e.g., Loctite ® ), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle. Transport Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running. – Do not place the vehicle where there are flammable or explosive substances. – Switch off the engine.

IMPORTANT NOTES 7 (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) – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten- tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others. Notes/warnings Be sure to pay attention to the notes and warnings given here. Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are miss- ing, you or others may not recognize dangers and may therefore be injured. Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death. Warning Danger that will probably lead to severe and permanent injury or death. Note Danger of serious damage to machine or material. Warning Risk of environmental damage. OWNER'S MANUAL – It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle. – The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE 8 3VIEW OF VEHICLE 3.1 View of the vehicle from the left front (example) 600657-10 1 Hand brake lever 2 Filler cap 3 Clutch lever 4 Fuel tap 5 Shift lever 6 Air filter box lid 7 Chain guide

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2005-2008 KTM 250 SX-F, EXC-F, EXC-F Six Days, XCF-W, XC-F, SXS-F Motorcycle Service & Repair Manual

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