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KTM 2005 250 EXC-F SIX DAYS, Repair Manual

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KTM 2005 250 EXC-F SIX DAYS Repair Manual Download Page 47

SERVICING INDIVIDUAL COMPONENTS

Repair manual  KTM 250 -F

Art.-No.  3.206.052-E            

LEFT CASING HALF  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
RIGHT CASING HALF  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
BYPASS VALVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
CLUTCH COVER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
CRANKSHAFT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
MEASURING THE OUTSIDE DIMENSION OF THE CRANKSHAFT WEBS  . . . . . . . . . .5-6
CRANKSHAFT BEARINGS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
AXIAL CLEARANCE OF THE CRANKSHAFT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
CYLINDER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
MEASURING THE PISTON AND CYLINDER, MOUNTING CLEARANCE  . . . . . . . . . . .5-7
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
PISTON RING END GAP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
CHECKING THE OIL PUMPS FOR WEAR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
LUBRICATING SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
CAMSHAFT BEARING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
CAMSHAFTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
AUTOMATIC DECOMPRESSION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
CAMSHAFT BEARING BRIDGES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
TIMING TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
CYLINDER HEAD  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
CLUTCH  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
KICKSTARTER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
PRE-MOUNTING THE KICKSTARTER SHAFT  . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
SHIFT MECHANISM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
PRE-MOUNTING THE SHIFT SHAFT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
GENERAL INFORMATION ON SERVICING THE TRANSMISSION  . . . . . . . . . . . . . .5-21
ASSEMBLING THE MAIN SHAFT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
ASSEMBLING THE COUNTERSHAFT   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

INDEX

5-1

5

Summary of Contents for 2005 250 EXC-F SIX DAYS

Page 1: ...250 SX F EXC F EXC F SIX DAYS SIX DAYS XCF W XC F SXS F REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN ART NR 3 206 052 E REPAIRMANUAL2005 2008 ...

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Page 3: ...REPAIRMANUAL2005 2008 250 SX F EXC F EXC F Six Days XCF W XC F SXS F KTM Group Partner ...

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Page 5: ...3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS 13 14 15 16 ...

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Page 7: ...ocket provided for this purpose on the inside of the binder or insert this page at the beginning of the manual Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page Example page no 3 5 3 chapter 3 5 page 5 For example All pages with a page number that begins with the digit 3 must be put under t...

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Page 9: ...ar 2005 06 Engine number with first digit 5 and 6 3 206 052 E Updating of Rep Manual 3 206 027 E 10 2007 Model year 2007 08 Engine number with first digit 7 and 8 Modification Updating Technical Details Models EXC XC W XC 2007 08 Technical Specifications Tightening torques Periodic Maintenance Schedule ...

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Page 11: ...NTS OUT USEFUL TIPS Use only ORIGINAL KTM SPARE PARTS when replacing parts The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality KTM Sportmotorcycle AG rese...

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Page 13: ...s missing technical data or torques inaccurate or incorrect translations or wording etc please enter the error s in the table below and fax the completed form to us at 0043 7742 6000 5349 NOTE to table Enter the complete item no for the repair manual in column 1 e g 3 206 052 E You will find the number on the cover page or in the left margin on each right page of the manual Enter the corresponding...

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Page 15: ...pair manual KTM 250 F Art No 3 206 052 E 2 1 2 BLEEDING THE COOLING SYSTEM 2 2 CHANGING THE OIL FILTER 2 2 OIL CIRCUIT 2 3 BLEEDING OF THE HYDRAULIC CLUTCH 2 4 ADJUSTING THE THROTTLE CABLES 2 4 SPECIAL TOOLS ENGINE 2 5 INDEX ...

Page 16: ......

Page 17: ...il filter insert 4 out of the case Clean the oil filter cover the sealing area on the O ring and the engine case Check the O ring in the oil filter cover for damage and replace if necessary Lay the motorcycle down and fill the oil filter case about half full with engine oil Fill the oil filter up with oil and insert the oil filter in the case Grease the O ring in the oil filter cover and mount the...

Page 18: ...to the conrod bearing 6 and sprayed onto the piston 8 from below through a jet 7 Two other oil ducts lead into the cylinder head One duct supplies the hydraulic chain tensioner 9 the other duct leads to the camshaft bearing bridge bk where the camshaft bearings and the cam lever are supplied with oil via spraying nozzles The second oil pump bl draws the engine oil out of the crankcase through the ...

Page 19: ...is discharged from the bore A of the master cylinder in a bubble free state Make sure that the oil does not overflow CAUTION HAVING COMPLETED THE BLEEDING PROCEDURE YOU HAVE TO VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT FOR FILLING OF THE MASTER CYLINDER USE SAE 10 BIODEGRADABLE HYDRAULIC OIL MOTOREX KUPPLUNGS FLUID 75 ONLY NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OIL...

Page 20: ...2 5 SPECIAL TOOLS ENGINE 250 F 4 2 bk bl bm bn bo bp bq br bs 1 3 5 6 7 8 9 25 20 30 15 10 12 5 3 5 bt ck cl ...

Page 21: ... Magneto extractor 9 600 29 015 000 Piston ring mounting tool 10 584 29 037 037 Mounting tool for inner rings of crankshaft bearings 11 510 12 012 000 Chain sprocket holder 12 510 12 011 000 Circlip pliers 13 590 29 019 000 Valve spring mounter 14 770 29 041 000 Valve spring mounter 15 590 29 033 000 Puller for camshaft bearings 16 503 29 003 000 Clutch holder 17 590 29 041 000 Feeler gauge for va...

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Page 23: ...REMOVING AND REFITTING ENGINE Repair manual KTM 250 F Art No 3 206 052 E DISMOUNTING THE ENGINE 3 2 MOUNTING THE ENGINE 3 6 INDEX 3 1 3 ...

Page 24: ......

Page 25: ... the chain and remove Dismount the foot brake cylinder 1 you do not need to loosen the line to the rear wheel brake Detach the return spring on the foot brake lever Remove the upper shock absorber screw 2 Loosen the nut on the swing arm pivot knock out the swing arm pivot with a suitable driver and completely remove the swing arm shock absorber and rear wheel from the motorcycle Detach the exhaust...

Page 26: ...sel Loosen the hose clamp 1 and pull the radiator hoses off of the engine Disconnect the spark plug connector 2 Unscrew the chain securing guide 3 on the clutch slave cylinder and tilt up Unscrew the clutch slave cylinder 4 and let it hang down on the side NOTE do not actuate the clutch lever as long as the clutch slave cylinder is dismounted 3 3 1 1 1 2 3 4 ...

Page 27: ...vent 5 and remove from the motorcycle together with the hose NOTE only pull the connection upwards otherwise it can easily break Loosen the carburetor connection boots 6 Dismount the carburetor towards the right and let it hang down CAUTION DO NOT PLACE THE CARBURETOR IN THE AIR FILTER BOX SINCE THE AIR FILTER WILL ABSORB ANY LEAKING FUEL 3 4 Repair manual KTM 250 F Art No 3 206 052 E 1 2 3 4 5 6 ...

Page 28: ...sen the chain guide 1 and tilt upwards Remove the front 2 and lower 3 engine fixing screws and lift the engine out of the frame from the left side CAUTION MAKE SURE THE MOTORCYCLE CANNOT TIP OVER 3 5 1 2 3 ...

Page 29: ...on and screw in the lower 1 and the front 2 engine fixing screws but do not tighten them yet Mount the chain guide 3 and tighten the screw Place the carburetor into the boots Tighten the carburetor connection boots 4 3 6 Repair manual KTM 250 F Art No 3 206 052 E 2 3 1 4 4 ...

Page 30: ...nto the carburetor Connect the generator connector 4 and throttle potentiometer connector 5 Attach the wiring harnesses with cable clips Mount the clutch slave cylinder 6 screw in both front screws M6x20 and tighten to 10 Nm Position the chain securing guide 7 mount the M6x25 screw and tighten to 10 Nm Tighten the screw on the chain roller Connect the spark plug connector 8 3 7 3 1 2 4 5 6 7 8 ...

Page 31: ... sleeve 4 Attach the exhaust springs 5 Position the rear wheel with the swing arm and shock absorber in the frame Insert the swing arm pivot and tighten the nut Tighten the upper shock absorber screw 6 to 70 Nm Tighten the nut on the swing arm pivot to 100 Nm Tighten the nuts on the two engine braces to 33 Nm Tighten the front and lower engine fixing screws to 60 Nm 3 8 Repair manual KTM 250 F Art...

Page 32: ...foot brake lever Mount the chain and chain joint CAUTION WHEN YOU MOUNT THE CHAIN JOINT MAKE SURE THE CLOSED SIDE OF THE GUIDE POINTS IN THE RUNNING DIRECTION To adjust the chain tensioning see Owner s Manual Mount both sides of the frame protector To fill and bleed the cooling system see Chapter 2 Mount the seat and tank with the spoiler and take the motorcycle off the assembly stand 3 9 1 ...

Page 33: ...N 4 3 REMOVING THE CAMSHAFTS 4 4 REMOVING THE CYLINDER HEAD AND PISTON 4 5 REMOVING THE CLUTCH COVER 4 7 DISMANTLING THE CLUTCH 4 8 REMOVING THE CHAIN DRIVE AND PRIMARY GEAR 4 9 DISMANTLING THE SHIFT MECHANISM 4 10 REMOVING THE OIL PUMPS 4 11 SEPARATINGTHECASINGHALVES REMOVINGTHECRANKSHAFTANDTRANSMISSIONSHAFTS 4 12 INDEX 4 1 4 ...

Page 34: ......

Page 35: ...in the oil filter cover and the seal ring on the oil drain plug Use suitable pliers circlip pliers 510 12 011 000 to pull out the oil filter and discard Unscrew the spark plug Dismount the ignition cover 1 Unscrew the pulse generator 2 pull the rubber duct out of the recess and remove the pulse generator Remove the plug 3 and pull out the oil screen Discard the seal rings on the plug and on the oi...

Page 36: ...nkshaft until the two marks 1 on the camshaft gears are aligned and precisely above the dividing line 2 between the two camshaft bearing bridges Unscrew the engine locking screw 3 remove the seal ring and screw the engine locking screw back in tightening torque 20 Nm 4 3 1 2 3 ...

Page 37: ...g bridge 4 and carefully remove the camshaft bearing bridge NOTE the screws on the timing chain guide rail 5 have distance bushings 6 be careful not to lose them Turn the exhaust camshaft up along the timing chain and towards the intake camshaft take the timing chain off the camshaft gear Also remove the intake camshaft let the timing chain fall into the timing chain compartment 4 4 Repair manual ...

Page 38: ...ed to check the valve clearance after assembling if valves or other parts in the valve control or replaced the valve clearance will need to be readjusted Remove the screws from the chain guide 2 the cylinder head 3 and the cylinder base 4 Pull the timing chain guide 5 out of the timing chain compartment Loosen the cylinder head crews crosswise and remove together with the washers 4 5 1 2 3 3 4 5 ...

Page 39: ...ntion to the chain tensioning rail Discard the cylinder base gasket remove the dowels Carefully remove the piston pin retainer from the groove NOTE for easier demounting mounting remove the piston pin retainer opposite the timing chain compartment Carefully push the piston pin out of the piston remove the piston 4 6 Repair manual KTM 250 F Art No 3 206 052 E ...

Page 40: ...special tool from the rotor again Removing the clutch cover Remove the water pump cover 1 Use a suitable wrench 510 12 011 000 to remove the lock ring 2 pull the water pump wheel off the shaft and take the needle roller out of the cross bore Remove all of the screws from the big clutch cover as well as both of the upper screws and the lower right screw on the outer clutch cover Remove the dowels a...

Page 41: ...he outer clutch hub Remove the pressure piece 1 and bend up the lock washer on the driving nut Hold the driver with the special tool 503 29 003 000 and unscrew the driving nut A F 27 Remove the driving nut together with the lock washer Remove the driver together with the stop disk under the driver NOTE the stop disk usually adheres to the driver 4 8 Repair manual KTM 250 F Art No 3 206 052 E 1 ...

Page 42: ... stop disk and remove the woodruff key 3 Slip off the timing chain NOTE mark the running direction if you plan to use the timing chain again Remove the timing chain tensioning rail and the chain securing guide Loosen the nut on the primary pinion A F 27 LH thread and remove together with the detent edged lock washer Remove the primary gear NOTE if you cannot remove the primary gear by hand use a s...

Page 43: ...go of the locking lever Remove the locking lever Detach the kickstarter spring 5 and pull the kickstarter shaft all the way out being careful not to lose the washer and spring underneath NOTE slightly turn the kickstarter shaft in a counterclockwise direction while you pull it out Remove the lock ring and washer from the starter idler 6 pull off the kickstarter idler 4 10 Repair manual KTM 250 F A...

Page 44: ...ll out the oil pump shaft and remove the needle roller Take both pressure pump rotors 4 out of the engine case Remove the screws and lift the pump cover off the suction pump 5 discarding the O ring Remove both suction pump rotors 6 out of the engine case do not lose the needle roller for the inner rotor NOTE the pressure pump rotors are narrower than the suction pump rotors 4 11 1 3 2 4 4 5 6 6 ...

Page 45: ... ring NOTE the main shaft has a stop disk which usually adheres to the bearing be careful not to lose it Lift the crankshaft out of the bearing First pull out the upper springs 2 in the shift rails and then pull out the shift rails 3 Tilt the shift forks 4 aside and pull out the shift drum 5 remove the shift forks If the lower springs do not stick to the shift rails remove them with a suitable too...

Page 46: ......

Page 47: ...R MOUNTING CLEARANCE 5 7 PISTON 5 8 PISTON RING END GAP 5 8 CHECKING THE OIL PUMPS FOR WEAR 5 8 LUBRICATING SYSTEM 5 9 CAMSHAFT BEARING 5 10 CAMSHAFTS 5 11 AUTOMATIC DECOMPRESSION 5 11 CAMSHAFT BEARING BRIDGES 5 12 TIMING CHAIN TENSIONER 5 13 TIMING TRAIN 5 14 CYLINDER HEAD 5 15 CLUTCH 5 17 KICKSTARTER 5 18 PRE MOUNTING THE KICKSTARTER SHAFT 5 18 SHIFT MECHANISM 5 20 PRE MOUNTING THE SHIFT SHAFT 5...

Page 48: ...ves must be placed on a suitably large plane surface supporting the whole of the sealing surface without damaging it A wooden panel is best used as a base Bearings or shaft seal rings should not be hammered into their seats If no suitable press is available use a suitable mandrel and hammer them in with great care Cold bearings will practically drop into their seats at an engine housing temperatur...

Page 49: ...iver from the outside Press in a new bearing from the inside up to the stop Needle bearing for the shift shaft 4 Press in the needle bearing from the outside Press in a new needle bearing from the inside until flush Shaft seal ring for the crankshaft 5 Press in a new shaft seal ring from the outside open side on the inside until flush Shaft seal ring for the countershaft 6 Press in a new shaft sea...

Page 50: ...tside with a suitable driver Press in a new grooved ball bearing from the inside up to the stop Needle bearing for the shift shaft 5 Press in the needle bearing from the outside Press in a new needle bearing from the inside until flush Needle bearing for the timing train idler shaft 6 Pull the Needle bearing out of the casing half with a bearing extractor Press in a new bearing up to the stop Shaf...

Page 51: ... of the kickstarter shaft 2 press in a new shaft seal ring open side on the inside up to the stop Pry the shaft seal ring 3 out of the water pump Press the grooved ball bearing 4 out of the timing train idler shaft from the outside to the inside Press in a new grooved ball bearing from the inside to the outside up to the stop Press a new shaft seal ring into the water pump open side on the outside...

Page 52: ...BEARING WILL NOT BE SUPPLIED WITH ENGINE OIL WHICH WILL RESULT IN DAMAGE TO THE BEARINGS If you will continue to use the crankshaft check the crankshaft journal for runout Place the crankshaft on a roller stand or similar support and use a dial gauge to check the crankshaft journal for runout Crankshaft journal runout max 0 15 mm Check the conrod bearing for radial and axial clearance Radial clear...

Page 53: ...ing measure the axial clearance of the crankshaft CAUTION NEVER CLAMP THE CRANKSHAFT INTO A VISE WITH THE CRANKSHAFT JOURNAL AND TRY TO STRIKE THE INNER BEARING RING THE CRANKSHAFT WEB WILL BE PRESSED TOGETHER AND RENDER THE CRANKSHAFT USELESS Axial clearance of the crankshaft Insert the crankshaft in the right casing half and mount the left casing half Mount the casing screws around the crankcase...

Page 54: ...tablishing the mounting clearance of the piston To establish the wear to the cylinder use a micrometer to measure the cylinder in the middle of the bearing surface Measure the diameter of the cylinder in the X and the Y axis to detect any ovality Cylinder diameter Size I 76 000 76 012 mm Size II 76 013 76 025 mm NOTE mark the cylinder size 1 on the side of the cylinder the piston size 2 on the pis...

Page 55: ... in the conrod and check for clearance Piston ring end gap Insert the piston ring in the cylinder and align with the piston approx 10 mm under the upper edge of the cylinder Use a feeler gauge A to measure the end gap Compression ring max 0 80 mm Oil scraper ring max 1 00 mm If the end gap is larger than indicated above check the cylinder for wear If the cylinder wear is within the tolerance limit...

Page 56: ...maged Thoroughly clean the magnet on the oil drain plug 5 each time you change the oil filter Check the oil pump rotors 6 see pages 5 8 Thoroughly clean the oil pump rotors before remounting Check the inside of the oil pump covers 7 for seizing marks and replace if necessary replace the O ring 8 Place the oil pump shaft 9 on an even surface and check for eccentricity Check whether the toothing on ...

Page 57: ...ositioning pin The positioning pin can be knocked out through this hole with a suitable driver Pull off the camshaft bearing using the extractor 590 29 033 000 and pressure tool 770 29 035 000 Slide on a new camshaft bearing if necessary knock on the inner ring with a suitable pipe NOTE the positioning ring 2 for the camshaft bearing must face up as shown in the photo If the camshaft bearing is mo...

Page 58: ...on spring 6 and automatic decompression weight 7 Check all parts for damage and wear Assemble in the reverse order Perform a function test The spring should turn the automatic decompression shaft back to the stop if not increase the preload or replace Camshafts Check pivot points 1 and cams 2 for wear and damage Check the toothing of the camshaft gears 3 for wear and damage Replace the camshaft be...

Page 59: ... installation position Check the cam lever shafts and cam lever 2 for wear seizing marks and damage Blow into the oil bore 3 with compressed air or a cleansing spray to make sure the oil jets 4 are not clogged If the oil jets 50 were removed apply Loctite 243 and tighten to 3 Nm Install the cam lever according to the original installation position and slide into the cam lever shafts NOTE the cam l...

Page 60: ...y again it may not be mounted in this state since the locking mechanism will not function Press down on the timing chain tensioner to ensure smooth operation To prepare the timing chain tensioner for installation place 2 spacing washers or similar implements with a thickness of 2 2 5 mm next to the piston of the timing chain tensioner This will ensure that the piston cannot be completely retracted...

Page 61: ...timing chain guide 3 for seizing marks and damage Check the timing chain clip 4 for seizing marks and damage Check the timing chain 5 for damage and wear make sure the chain links operate smoothly NOTE The smooth operation of the chain links can easily be checked by simply letting the timing chain hang down the chain links should align in a row Replace the timing chain if the chain links do not al...

Page 62: ...ainers if still mounted Dismount the valve keys using the special tools 590 29 019 000 and 770 29 041 000 and relieve the valve springs NOTE Used valves must be remounted in the same valve guide as before We suggest that you place the valves in a carton in the position they were previously mounted in the cylinder head see illustration ...

Page 63: ... should be in the center of the valve seat The valve stem is hard plated wear usually appears at the valve guide Check the valve springs for ruptures or wear visual check measure the length with a sliding gauge Minimum length 38 5 mm Replace the spring if it is shorter Always replace the valve stem seal if dismounting the valves Measure the thickness of the valve spring retainers minimum thickness...

Page 64: ...ces 5 minimum thickness 2 9 mm The lining disks must be flat Clutch disks 7 pieces 6 must be flat check for mechanical damage Replace the clutch disks if they have score shaped breakout Check the driver 7 for seizing marks and damage Check the pressure cap mounting face 8 for damage Check the thrust face 9 of the outer clutch hub and the lining disks for wear If the depressions are larger than 0 5...

Page 65: ...mounting the kickstarter shaft Clamp the kickstarter shaft in a vise with the toothed end facing up use protective jaws Mount the stop disk 5 and kickstarter pinion with the lock toothing facing down Mount the stop disk 6 and circlip 7 with the sharp edge facing up Mount the kickstarter spring 8 inserting the inner end in the hole in the kickstarter shaft Mount the driving hub 9 pushing the recess...

Page 66: ...5 19 1 2 3 4 4 5 5 4 A D 6 7 8 9 C E B 1 1 ...

Page 67: ...t rails Check the shift rail 6 at the contact areas C for wear Check the return surface D on the shift rail for wear replace in case of severe indentation Check the guide bolt E for a tight fit and wear Pre mount the shift shaft and check the clearance F between the shift rail 6 and the shift quadrant The clearance must lie between 0 40 0 80 mm F 7 bk 6 8 9 bl Pre mounting the shift shaft Clamp th...

Page 68: ...never you repair the transmission Assembling the main shaft Clamp the main shaft in the vise with the toothed end facing down use protective jaws Carefully oil all parts before mounting Mount the split needle bearing 1 mount the 5 speed idler gear 2 with the shift dogs facing up Mount the stop disk 3 22x28 5x1mm and circlip 4 with the sharp edge facing up Slip on the 3rd 4th gear sliding gear 5 wi...

Page 69: ...down use protective jaws Carefully oil all parts before mounting Mount the idler gear sleeve 25x28x9 7mm 1 and the 2nd gear idler gear 2 on the countershaft with the recess for the shift dogs facing up Mount the thrust washer 3 25x35x1mm and the lock ring 4 with the sharp edge facing up Mount the 6th gear sliding gear 5 with the shift groove facing up Mount the lock ring 6 and the stop disk 7 25 2...

Page 70: ......

Page 71: ... 2 MOUNTING THE OIL PUMPS 6 4 MOUNTING THE SHIFT MECHANISM 6 6 MOUNTING THE PRIMARY PINION AND THE CHAIN DRIVE 6 7 MOUNTING THE CLUTCH 6 8 MOUNTING THE CLUTCH COVER 6 9 MOUNTING THE PISTON AND CYLINDER HEAD 6 10 MOUNTING THE CAMSHAFTS 6 13 MOUNTING THE CHAIN TENSIONER 6 14 CHECKING THE VALVE CLEARANCE 6 14 ASSEMBLING THE ENGINE 6 15 INDEX 6 1 6 ...

Page 72: ......

Page 73: ...rshaft The one sided shift fork 2 is inserted on the bottom the symmetrical shift fork 3 on top The needle rollers on the shift forks must point towards the shift drum Mount the shift drum and allow the needle rollers on the shift forks to engage NOTE the shift drum has a groove A without curves around its edge no shift fork can engage in this shift groove Attach the lower springs to the shift rai...

Page 74: ...stic hammer if necessary Turn in the screws as illustrated and tighten to 10 Nm CAUTION DO NOT PULL THE CASING HALVES TOGETHER BY TIGHTENING THE SCREWS NOTE use the M6x45 screw to fasten the hose retaining clip up to model 2007 Unscrew the nuts on the engine work stand holder again Grease a new O ring 2 for the countershaft and insert in the collar 3 of the bushing mount the bushing with the colla...

Page 75: ...ble Fill the oil pump with engine oil Mount the pressure pump cover Apply Loctite 222 to the screws and tighten to 6 Nm Insert the needle roller 2 in the oil pump shaft and mount the oil pump gear 3 Mount the stop disk 4 and lock washer 5 holding the oil pump shaft on the other side Slide on the thrust washer 6 and oil pump idler 7 mount the thrust washer 8 and the lock ring 9 Check the wheels for...

Page 76: ...rotor Fill the oil pump with engine oil Insert a new O ring 3 and mount the oil pump cover 4 Apply Loctite 222 to the screws and tighten to 6 Nm Insert the preassembled kickstarter shaft in the seat of the engine case slightly turn the kickstarter shaft in a clockwise direction until the kickstarter ratchet gear 5 stops behind the stop plate 6 Attach the kickstarter spring again 1 2 3 4 5 6 ...

Page 77: ...k NOTE the flat surfaces on the shift lock are not symmetrical Apply Loctite 243 to the shift lock and tighten to 10 Nm Mount the preassembled shift shaft in the case do not forget the stop disk press the shift rail back and allow to engage in the shift lock Mount the shift lever and shift through the gears while turning the main shaft remove the shift lever again 6 6 Repair manual KTM 250 F Art N...

Page 78: ...Apply Loctite 243 to the screws and tighten to 10 Nm NOTE Make sure you only apply Loctite 243 to the screw thread otherwise the timing chain tensioning rail will block and can break The chain securing guide must rest against the stop A Slip on the timing chain Pay attention to the running direction if using a used chain Place the stop disk 3 on the bearing 4 of the timing train idler shaft 5 Posi...

Page 79: ...43 to the driving nut 5 and mount with a new lock washer 6 Hold the driver with special tool 503 29 003 000 and tighten the driving nut to 120 Nm A F 27 Turn down the lock washer the driving nut Insert the pressure piece 7 Thoroughly oil all lining disks Starting with lining disk 8 insert all 8 lining disks and all 7 clutch disks 9 in the outer clutch hub ending with a lining disk on top 6 8 Repai...

Page 80: ... a new gasket and the clutch cover do not forget the dowels Turn in the screws as illustrated and tighten to 10 Nm Insert the needle roller in the shaft mount the water pump wheel and lock ring Mount the water pump cover with a new gasket and tighten the screws to 10 Nm 6 9 M6x55 M6x35 M6x25 Cu M6x35 M6x25 M6x55 M6x25 M6x25 M6x20 M6x25 ...

Page 81: ...BE ABLE TO PUSH THE PISTON INTO THE CYLINDER BY TAPPING LIGHTLY WITH THE HAMMER HANDLE EXCESSIVE FORCE USUALLY DAMAGES THE PISTON RINGS Mount a new cylinder base gasket and thrust bushing Slide the piston out of the bottom of the cylinder until you can push in the piston pin NOTE You should easily be able to push the piston pin into the conrod bearing The arrow mark 1 on the piston must point to t...

Page 82: ...l oiled cylinder head screws and washers and tighten crosswise to 40 Nm in the first stage Tighten crosswise to 50 Nm in the second stage Tighten the 3 screws to 10 Nm Insert the guide rail with the nose 1 resting in the recess 2 in the securing guide Align the hole in the guide rail with the hole in the cylinder head Apply Loctite 243 to the thread of the bearing bolt 3 mount the bearing bolt wit...

Page 83: ...ing adjust the valve clearance if valves or other parts in the valve control were replaced Mount the thrust bushings and pull the timing chain up Fold all 4 cam levers 1 up and mount the lower camshaft bearing bridge positioning the timing chain over the nose 2 Remove the cable clip from the timing chain Oil the screws 3 on the lower camshaft bearing bridge turn in and tighten to 18 Nm ...

Page 84: ...e Run the timing chain over the rear sprocket of the exhaust camshaft and press the exhaust camshaft into the bearing seat NOTE The lock ring on the camshaft ball bearing must engage in the groove in the camshaft bearing bridge If mark 3 on the exhaust camshaft is not positioned over the dividing edge 2 of the camshaft bearing bridge lift the exhaust camshaft out again and turn it accordingly Moun...

Page 85: ...h oil pressure has been built up yet CAUTION IF THE CHAIN TENSIONER IS NOT LOCKED AND RELIEVED AFTER ASSEMBLY AS DESCRIBED IN CHAPTER 5 THE TIMING CHAIN WILL SKIP WHEN THE ENGINE IS STARTED RESULTING IN ENGINE DAMAGE Checking the valve clearance Use the feeler gauge 590 29 041 000 to measure the valve clearance Intake valves 0 10 0 20 mm Exhaust valves 0 12 0 22 mm Write down any deviations from t...

Page 86: ...ECT AND LEAD TO EXCESSIVE ENGINE WEAR Push in the pushrod Mount the pulse generator 2 apply Loctite 243 to the screws and tighten to 6 Nm Press the cable guide into the recess in the case Mount the ignition cover with dowels and a new gasket Tighten the screws to 10 Nm NOTE longer screws M6x35 instead of M6x30 are used at the dowel positions Fill the oil filter case approx 1 3 full with engine oil...

Page 87: ...HE STATOR 7 3 MAIN FUSE 7 3 CHECKING THE STARTER 7 4 CHECKING THE START RELAY 7 4 DISMOUNTING AND MOUNTING THE BATTERY 7 4 CHARGING THE BATTERY 7 4 CHECKING THE CHARGING VOLTAGE 7 5 CHECKING FOR LOSS OF CURRENT 7 5 ENGINE CHARACTERISTIC 250 EXC F EU 7 5 MEASURING WITH THE PEAK VOLTAGE ADAPTER STATIC IGNITION VALUES 7 4 STATIC GENERATOR VALUES 7 7 THROTTLE VALVE SENSOR ADJUSTING 8 11 CHECKING 8 12 ...

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Page 89: ...oltage adapter If the ignition is being supplied with voltage but no spark is visible check The ground connection from the CDI unit and ignition coil The cable from the CDI unit to the ignition coil The pulse generator The stator The ignition coil The short circuit button NOTE the CDI unit cannot be tested with simple devices It can only be tested on an ignition test bench CDI unit Check the cable...

Page 90: ...tator in the ignition cover Degrease the thread of all 3 screws and apply Loctite 243 Mount the screws and tighten tightening torques see chapter 10 Run the wiring harness stress free and fix with the retaining bracket Don t forget the cable socket Main fuse The main fuse 10 amperes is located under the filter box cover in the starter engine relay The main fuse 2 is visible after you remove the fi...

Page 91: ...d or defective parts Dismounting and mounting the battery Remove the seat First disconnect the negative terminal then the positive terminal from the battery Remove the filter box cover detach the rubber strap 5 and remove the battery The battery is mounted in the reverse order paying attention to the following points Replace any damaged or defective parts Connect the positive terminal then the neg...

Page 92: ...e regulator Checking for loss of current Check for loss of current before you check the voltage regulator Disconnect the ground wire from the battery Connect an ammeter between the ground wire and the negative terminal on the battery Setpoint value max 0 2 mA If this value is higher than specified look for the power consumers Engine characteristic 250 EXC F Two ignition curves performance and soft...

Page 93: ...d red cables Apply the red measuring tip of the peak voltage adapter 584 29 042 000 to the green cable and the black measuring tip to the red cable disconnect plug 4 to disconnect the CDI unit Multimeter display 4 5 volts 0 5 volt Same measurement with CDI unit connected Multimeter display 3 volts 0 5 volt Check the generator charging coil for ignition capacitor charge two pole plug 5 with black r...

Page 94: ...e measurement with connector 2 connected Multimeter display 14 volts 1 volt NOTE The black measuring lead S of the peak voltage adapter must be applied to the ground 1 2 S Measuring with the peak voltage adapter 584 29 042 000 static generator values Measuring conditions cold engine seat and tank removed all connectors and the ground connection in a non corroding condition connectors tightly conne...

Page 95: ...CELERATOR PUMP 8 7 CHECKING THE JET NEEDLE 8 7 CHECKING THE FLOAT NEEDLE VALVE 8 7 CHECKING THE THROTTLE VALVE 8 7 ASSEMBLING THE CARBURETOR 8 8 ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR 8 11 CHECKING THE THROTTLE VALVE SENSOR 8 12 DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR 8 12 CARBURETOR ADJUSTING IDLING 8 13 CHECKING ADJUSTING THE FLOAT HEIGHT 8 14 INDEX 8 1 8 ...

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Page 97: ...8 2 Repair manual KTM 250 F Art No 3 206 052 E 550 mm 630 mm 630 mm 550 mm 400 mm CARBURATOR KEIHIN FCR MX 39 ...

Page 98: ...oot and remove from the left side To mount the carburetor insert in the connection boot and attach with the hose clamps Make sure the carburetor is mounted vertically Attach Adjust both throttle cables and check the throttle grip for smooth operation Connect the throttle sensor connector screw in the hot start control Run the carburetor vent hoses through the retainer on the rear of the engine Sta...

Page 99: ... the carburetor in perfect order Dismount the carburetor and remove any coarse dirt Loosen both screws 1 and remove all of the vent hoses from the carburetor Remove both screws 2 and remove the slide cover and gasket from the carburetor Remove screw 3 and pull the jet needle out of the throttle slide Remove screw 4 Pull the throttle slide arm up and take the throttle slide roller 5 and the slide s...

Page 100: ...e float together with the float needle valve Remove the main jet 2 Remove the screw 3 and use pliers to carefully extract the seat of the float needle valve from the carburetor Screw out the idling jet 4 the starting jet 5 and the needle jet 6 Turn in the mixture control screw 7 down to the stop count the number of turns and write it down Turn out the mixture control screw and dismount it together...

Page 101: ... and pull the connecting piece out of the carburetor Remove the 2 screws and take the intake trumpet together with the O ring 4 off the carburetor Unscrew the idle air jet 5 and the main air jet 6 Thoroughly clean all jets and other parts and blow compressed air through them Clean the carburetor housing and blow compressed air through all the ducts in the carburetor Check all gaskets for damage an...

Page 102: ...ccelerator pump Check the membranes for cracking or brittleness Check gaskets for damage Check if the bores 2 are unobstructed Checking the jet needle Check the jet needle for bending and wear Checking the float needle valve Check the sealing surface of the needle valve for notches There must not be any dirt between the valve seat and the float needle Checking the throttle valve The rollers 3 at t...

Page 103: ... knob 6 and actuate several times checking for smooth operation Also make sure the choke and the hot start knob lock into place Thread the spring the washer and the O ring onto the mixture control screw 7 and screw the mixture control screw in as far as it will go Now unscrew the mixture control screw the number of turns written down during disassembly NOTE See the Technical Specifications for the...

Page 104: ...labeling facing upwards and the spring into the pump housing Place the O ring 6 into the groove Secure the sealing ring 7 with some grease in the cover and fasten the cover by means of 3 screws Mount the throttle valve sensor such that the flat spot at the carburetor engages the groove of the throttle valve sensor and secure it by means of the screw Pull up the throttle slide arm push the throttle...

Page 105: ...6 052 E Apply Loctite 243 to the screw 1 and tighten Mount the jet needle and fix with the screw 2 Position the slide cover with the gasket and fasten with the 2 screws 3 Fix the vent hoses on the float chamber with the 2 screws 4 1 2 3 3 4 4 ...

Page 106: ...esistance bl s 5 kΩ Throttle valve sensor resistance ge s 5 kΩ x 0 15 750 Ω 50 Ω Connect the multimeter measuring range Ω x100 to the yellow and the black cable of the throttle valve sensor and measure the throttle valve sensor resistance with the throttle grip closed According to the above example this value should be 750 Ω 50 Ω If the value measured does not correspond to the desired value loose...

Page 107: ... open the throttle grip slowly the resistance must change evenly Resistance of throttle valve sensor 0 5 kΩ 1 kΩ while opening the throttle grip Dismounting and installing the throttle valve sensor Disconnect the plug and socket connection of the throttle valve sensor and remove the screws 1 Take the throttle valve sensor off the carburetor When mounting the throttle valve sensor make sure that th...

Page 108: ...fied in 4 Serious competitive racers will choose a setting approx 1 4 turn clockwise leaner than this ideal value because their engine will heat up more when used in competitions NOTE If you fail to obtain a satisfying result by following the procedure described above an incorrectly dimensioned idling nozzle may be the cause If a the mixture control screw has been screwed in up to the stop without...

Page 109: ...at needle valve but not compress it In this position the edge of the float should be parallel with the float chamber sealing surface see illustration If the float height does not correspond to the desired value check the float needle valve and if necessary replace it If the float needle valve is o k you can adjust the float height by bending the float lever 1 Mount the float chamber install the ca...

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Page 111: ...TROUBLE SHOOTING Repair manual KTM 250 F Art No 3 206 052 E TROUBLE SHOOTING 9 2 INDEX 9 1 9 ...

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Page 113: ...er is filled with new fuel Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if fuel leaks out the carburetor may need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap Clean and dry the spark plug or exchange it respectively Clean and dry the spark plug or exchange it respectively Adjust spark plug electrode gap to 0 6 mm Dismount spark plug c...

Page 114: ...l Engine takes air out of control Clean and check fuel system and carburettor Check rubber sleeve and carburetor for tight fit Engine gets too hot Insufficient cooling liquid Not enough air stream Cooling system has not been bled Radiators very dirty Foam formation in cooling system Bent cooling hose Refill cooling liquid see maintenace work check cooling system for leaks Drive on briskly Bleed co...

Page 115: ... 06 11 3 CHASSIS 250 SXS F MODEL 2006 11 3 CHASSIS 250 SX F SXS F MODEL 2007 11 4 ENGINE 250 XC F XCF W EXC F MODEL 2007 11 5 CHASSIS 250 XC F XCF W EXC F MODEL 2007 11 6 ENGINE 250 SX F XC F XCF W EXC F MODEL 2008 11 7 CHASSIS 250 SX F XC F XCF W EXC F MODEL 2008 11 8 MOUNTING CLEARANCES WEAR LIMITS 11 10 TIGHTENING TORQUES ENGINE 11 11 CHASSIS 11 12 INDEX 10 1 10 ...

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Page 117: ...ulation lubrication with 2 rotor pumps Engine oil full synthetic oil Motorex Power Synt 4T 10W 50 Quantity of engine oil 1 1 liters Primary drive 22 68 Transmission claw shifted 6 speed 1st gear 13 32 2nd gear 15 30 3rd gear 17 28 4th gear 19 26 5th gear 21 25 6th gear 22 24 Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator no generator Spark plug NGK CR...

Page 118: ...s Final drive ratio 13 48 Z Chain X ring 5 8 x 1 4 Steering head angle 63 5 Wheel base 1481 10 mm Seat height unloaded 925 mm Ground clearance unloaded 380 mm STANDARD ADJUSTMENT FORK 250 SX F 2005 250 SX F 2006 250 SXS F 2006 WP 4860 MA PA WP 4860 MA PA WP 4860 MA PA 14 18 7A 03 14 18 7B 03 14 18 7B 15 Compression adjuster 22 20 22 Rebound adjuster 20 18 24 Spring 4 4 N mm Spring preload 5 mm 5 5...

Page 119: ...r Fuel tank capacity 8 liters 2 1 US gall Final drive ratio 13 48 Chain 5 8 x 1 4 Available final sprockets 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheel base 1475 10 mm Seat height unloaded 925 mm Ground clearance unloaded 380 mm Weight without fuel approx 98 2 kg STANDARD ADJUSTMENT FORK 250 SX F 250 SXS F WP 4860 CC MA 14 18 7C 03 WP 4860 CC MA 14 18 7C 15 Compression adjuster 15 Re...

Page 120: ...perated brake fluid DOT 5 1 Transmission claw shifted 6 speed 6 speed 1st gear 13 32 13 33 2nd gear 15 30 17 33 3rd gear 17 28 19 29 4th gear 19 26 23 28 5th gear 21 25 23 23 6th gear 22 24 26 22 Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator 12 V 150 W Spark plug NGK CR 9 EBK Cooling system liquid cooled permanent rotation of cooling liquid through m...

Page 121: ... 5 8 x 1 4 Available final sprockets 38 40 42 45 48 49 50 51 52 Bulbs EXC headlight 12V 35 35W socket BA20D parking light 12V 5W socket W2 1x9 5d brake rear light 12V 21 5W socket BaY15d flasher light 12V 10W socket Ba15s Battery maintenance free battery 12V 4Ah Steering head angle 63 5 Wheel base 1475 10 mm Seat height unloaded 925 mm Ground clearance unloaded 380 mm Weight without fuel approx 10...

Page 122: ... speed 6 speed 1st gear 13 32 13 33 2nd gear 15 30 17 33 3rd gear 17 28 19 29 4th gear 19 26 23 28 5th gear 21 25 23 23 6th gear 22 24 26 22 Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator 12 V 80 W at 5000 rpm SX F without generator Spark plug NGK CR 9 EBK Cooling system liquid cooled permanent rotation of cooling liquid through mechanically driven wa...

Page 123: ... 100 90 19 100 100 18 120 90 18 Air pressure offroad Air pressure road 1 0 bar 2 0 bar Fuel tank capacity 250 SX F 7 2 liters 250 XC F XCF W EXC F 9 2 liters 2 liters Reserve Final drive ratio 250 SX F XC F 250 XCF W EXC F Six Days 250 EXC F 13 48 13 52 14 38 13 52 Chain 5 8 x 1 4 Available final sprockets 38 40 42 45 48 49 50 51 52 Bulbs 250 XCF W ZA 250 EXC F Six Days headlight 12V 35 35W socket...

Page 124: ...turns Air chamber length 110 mm 110 mm Fork oil SAE 5 SAE 5 SAE 5 SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER 250 SX F 250 XC F 250 XCF W EXC F 250 EXC F Six Days WP 5018 PDS DCC 12 18 7D 03 WP 5018 PDS DCC 12 18 7D 28 WP 5018 PDS DCC 12 18 7D 04 WP 5018 PDS DCC 12 18 7D 34 Compression adjuster 14 LS low speed 1 0 HS high speed 15 LS low speed 1 0 HS high speed 15 LS low speed 1 5 HS high speed 15 LS...

Page 125: ...size I 0 030 0 052 mm assembly clearance size II 0 032 0 055 mm wear limit 0 070 mm Piston ring end gap compression ring max 0 80 mm oil scraper ring max 1 00 mm Valves seat sealing intake max 1 50 mm seat sealing exhaust max 1 50 mm spring washer 0 90 mm Valve springs minimum length 38 50 mm Oil pumps clearance outer rotor housing max 0 20 mm clearance outer rotor inner rotor max 0 20 mm axial cl...

Page 126: ...rew shift roller lock M6 Loctite 243 10 Nm HH collar screw locking lever M5 Loctite 243 6 Nm Lock screw on shift drum bearing M6 Loctite 243 6 Nm Lock screw on main shaft bearing M6 Loctite 243 6 Nm HH collar screw on securing guide tensioning rail M6 Loctite 243 10 Nm Plug on chain tensioner M24x1 5 25 Nm Bearing bolt for chain guide rail M8 Loctite 243 10 Nm HH collar screws on stator M5 Loctite...

Page 127: ...ping screw steering stem M8 Loctite 243 17 Nm Clamping screws fork stubs M8 15 Nm Hexagon nut swing arm bolt M16x1 5 100 Nm Hexagon collar screw handlebar clamp M8 20 Nm Allan head srew handlebar support M10 Loctite 243 40 Nm Shock absorber top M12 Loctite 243 80 Nm Shock absorber bottom M12 Loctite 243 80 Nm Collar nut swing arm bolt M20x1 5 80 Nm Sprocket Screws M8 Loctite 243 35 Nm Ball joint f...

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Page 129: ...PERIODIC MAINTENANCE SCHEDULE Repair manual KTM 250 F Art No 3 206 052 E MODEL 2005 12 2 MODEL 2006 12 4 MODEL 2007 12 6 MODEL 2008 250 SX F XC F 12 8 250 XCF W EXC F 12 10 INDEX 11 1 11 ...

Page 130: ... handbrake foot brake lever z z Check the screws and guide bolts on the brake system for a tight fit z z CHASSIS Check shock absorber and fork for leaks and function z z Clean fork dust bellows z Bleed fork legs z Check swing arm bearings z Check adjust steering head bearings z z Check tightness of chassis screws triple clamps fork leg axle passage swingarm shock aborber z z WHEELS Check adjust st...

Page 131: ... operating hours every 10 hours 70 liter every 20 hours 140 liter every 40 hours 270 liter every 60 hours 400 liter every 80 hours 540 liter Check the clutch disks for wear z z z z Check the length of the clutch springs z z z z Check the clutch drive for indentations z z Check the outer clutch hub for indentations z z Check the cylinder and piston for wear z z Check the groove on the piston pin re...

Page 132: ... handbrake foot brake lever z z Check the screws and guide bolts on the brake system for a tight fit z z CHASSIS Check shock absorber and fork for leaks and function z z Clean fork dust bellows z Bleed fork legs z Check swing arm bearings z Check adjust steering head bearings z z Check tightness of chassis screws triple clamps fork leg axle passage swingarm shock aborber z z WHEELS Check adjust st...

Page 133: ... operating hours every 10 hours 70 liter every 20 hours 140 liter every 40 hours 270 liter every 60 hours 400 liter every 80 hours 540 liter Check the clutch disks for wear z z z z Check the length of the clutch springs z z z z Check the clutch drive for indentations z z Check the outer clutch hub for indentations z z Check the cylinder and piston for wear z z Check the groove on the piston pin re...

Page 134: ...Check brake lines for damage and leaks z z Check function smooth operation and adjust free travel of handbrake foot brake lever z z Check the screws and guide bolts on the brake system for a tight fit z z CHASSIS Check shock absorber and fork for leaks and function z z Clean fork dust bellows z Bleed fork legs z Check swing arm bearings z Check adjust steering head bearings z z Check tightness of ...

Page 135: ... THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING FOR HOBBY USE SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP COMPETITIVE A 100 liter fuel consumption RACING is equivalent to approx 15 operating hours HOBBY USE every 10 hours 70 liter every 20 hours 140 liter every 20 hours 140 liter every 40 hours 270 liter every 40 hours 270 liter every 80 hours 540 liter every 80 hours 540 liter Check the clut...

Page 136: ...Check brake lines for damage and leaks z z Check function smooth operation and adjust free travel of handbrake foot brake lever z z Check the screws and guide bolts on the brake system for a tight fit z z CHASSIS Check shock absorber and fork for leaks and function z z Clean fork dust bellows z Bleed fork legs z Check swing arm bearings z Check adjust steering head bearings z z Check tightness of ...

Page 137: ...TIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING FOR HOBBY USE SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP A 100 liter fuel consumption is equivalent to approx 15 operating hours every 10 hours 70 liter every 20 hours 140 liter every 40 hours 270 liter every 60 hours 400 liter every 80 hours 540 liter Check the clutch disks for wear z z z z Ch...

Page 138: ...adlamp setting z Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button z z BRAKES Check brake fluid level lining thickness brake discs z z Check brake lines for damage and leaks z z Check function smooth operation and adjust free travel of handbrake foot brake lever z z Check the screws and guide bolts on the brake...

Page 139: ...ST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING FOR HOBBY USE SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP COMPETITIVE A 100 liter fuel consumption RACING is equivalent to approx 15 operating hours HOBBY USE every 10 hours 70 liter every 20 hours 140 liter every 20 hours 140 liter every 40 hours 270 liter every 40 hours 270 liter every 80 hours 540 liter every 80 hours 540 li...

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Page 141: ...12 1 12 MODEL 2005 250 SX F 13 2 250 EXC F USA 13 3 MODEL 2006 250 SX F 13 2 250 EXC F USA 13 3 250 EXC F EU 13 4 MODEL 2007 250 SX F 13 5 250 EXC F EU 13 4 250 XC F XCF W 13 6 MODEL 2008 250 SX F 13 7 250 XC F XCF W 13 8 250 EXC F 13 9 CABLE COLORS 13 10 INDEX ...

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Page 143: ...0 0 2 F X S 0 5 2 5 0 0 2 2 0 0 2 p u k c i p G 3 r o t a r e n e g n o t t u b p o t s C D I l i o c n o i t i n g i 0 0 0 2 3 0 9 3 4 9 5 s s e n r a h I D C red white red black d e r n e e r g e t i h w e u l b n w o r b k c a l b w o l l e y k c a l b ...

Page 144: ... t a b y a l e r t r a t s r o t o m r e t r a t s n o t t u b t r a t s black h c t i w s t h g i l h c t i w s p o t s C D I headlight U r e i f i t c e r r o t a l u g e r multi func digital speedometer n a f g n i l o o c e r e y e y h w r b h w r b wh ye re wh re bl gn re re gn re bl re wh bu wh br ye bl bl wh br br ye r b e r e y r b l b e y l b l b e r u b h w r b bu ye bl bl ye bu ye re wh...

Page 145: ...r o t a r e n e g rear light brakelight v r o s n e s d e e p s h c t i w s r a b e l d n a h l a n o i t p o S P T M A 0 1 y r e t t a b y a l e r t r a t s r o t o m r e t r a t s n o t t u b t r a t s black C D I U r e i f i t c e r r o t a l u g e r headlight multi func digital speedometer n a f g n i l o o c e r e y e y h w r b r b l b h w n g h w r b r b u p wh ye re wh re bl gn re re gn re ...

Page 146: ... 2 4 0 8 0 p u k c i p G 3 r o t a r e n e g n o t t u b p o t s C D I l i o c n o i t i n g i 0 0 0 2 3 0 9 3 4 9 5 s s e n r a h I D C red white red black d e r n e e r g e t i h w e u l b n w o r b k c a l b w o l l e y k c a l b ...

Page 147: ... S P T M A 0 1 y r e t t a b y a l e r t r a t s r o t o m r e t r a t s n o t t u b t r a t s black h c t i w s t h g i l h c t i w s p o t s C D I headlight U r e i f i t c e r r o t a l u g e r multi func digital speedometer n a f g n i l o o c e r e y e y h w r b h w r b wh ye re wh re bl gn re re gn re bl re wh bu wh br ye bl bl wh br br ye r b e r e y r b l b e y l b l b e r u b h w r b bu y...

Page 148: ...o c n o i t i n g i 3 M A _ C 3 R A _ C n o i t i s o p e l t t o r h t r o s n e s 1 2 3 0 0 1 2 3 0 9 3 4 9 5 s s e n r a h I D C 1 2 7 5 6 1 1 0 1 2 1 4 1 3 1 red white red black d e r n e e r g e t i h w e u l b n w o r b k c a l b w o l l e y k c a l b 250 SX F 2008 ...

Page 149: ...y a l e r t r a t s r o t o m r e t r a t s n o t t u b t r a t s black h c t i w s t h g i l h c t i w s p o t s C D I headlight U r e i f i t c e r r o t a l u g e r multi func digital speedometer n a f g n i l o o c 0 0 1 2 3 0 9 3 4 9 5 s s e n r a h I D C e r e y e y h w r b h w r b wh ye re wh re bl gn re re gn re bl re wh bu wh br ye bl bl wh br br ye r b e r e y r b l b e y l b l b e r u b...

Page 150: ... t c e r r o t a l u g e r C_CE 4 C_CA 4 headlight C_BP 4 C_DG 4 C D I 8 1 U B _ C multi func digital speedometer C_CY 3 C_CZ 3 C_DA 4 C_DB 4 C_CW 2 C_CX 2 C_CW 2 C_CX 2 C_CW1 2 C_CX1 2 C_CW2 2 C_CX2 2 C_CW3 2 C_CX3 2 licence plate lamp 1 2 C_DI 2 rear light brake light C_AJ 3 C_BG 3 2 V B _ C 2 S B _ C 1 2 3 1 2 2 2 1 I E _ C 1 H E _ C 1 1 2 1 2 4 1 3 2 2 2 2 1 2 T A _ C n a f g n i l o o c 1 1 2...

Page 151: ...13 10 Repair manual KTM 250 F Art No 3 206 052 E Cable colours bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple ...

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