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KTM 2009 250 EXC-F SIX DAYS, Owenrs Manual, Page: 89 / 125

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KTM 2009 250 EXC-F SIX DAYS Owenrs Manual Download Page 89

MAINTENANCE WORK ON CHASSIS AND ENGINE

87

13.115

Cleaning the oil screens

x

Warning

Danger of scalding

 

Engine oil and gear oil get very hot when the motocycle is driven.

–

Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard

 

Problem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

–

Place a suitable container under the engine.

600693-10

–

Remove plug

with oil screen

and the O-rings.

600694-10

–

Remove plug

with oil screen

and the O-rings.

–

Drain the remaining engine oil.

–

Thoroughly clean parts and sealing area.

600695-10

–

Position oil screen

with the O-rings.

–

Mount and tighten plug

with the O-ring.

Guideline

Plug for oil screen, long

M20x1.5

15 Nm
(11.1 lbf ft)

600696-10

–

Position the oil screen with the O-rings.

–

Mount and tighten plug

with the O-ring.

Guideline

Plug for oil screen, short

M16x1.5

10 Nm
(7.4 lbf ft)

lubricated with
engine oil

Summary of Contents for 2009 250 EXC-F SIX DAYS

Page 1: ...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 ...

Page 2: ......

Page 3: ... or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as printing and other errors The models p...

Page 4: ...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 o...

Page 5: ...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 Installi...

Page 6: ...3 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 ...

Page 7: ... 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 na...

Page 8: ...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 ser vice record since otherwise no warranty claims will be...

Page 9: ...rnings 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...

Page 10: ...IEW OF VEHICLE 8 3 VIEW 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 ...

Page 11: ... the right rear example 600656 10 1 Rubber band for the side stand 2 Shock absorber compression adjustment 3 Chassis number 4 Fork protector 5 Shock absorber rebound adjustment 6 Level viewer rear brake fluid 7 Level viewer engine oil 8 Kickstarter ...

Page 12: ...500128 10 The type label is fixed to the front of the steering head 4 3 Key number EXC F EXC F SIX DAYS 500125 10 The key number is stamped on the key strap 4 4 Engine number 600661 12 The engine number is stamped on the left side of the engine under the engine sprocket 4 5 Fork part number 500082 10 The fork part number is stamped on the inner side of the fork stub ...

Page 13: ...LOCATION OF SERIAL NUMBERS 11 4 6 Shock absorber part number 500129 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 14: ...it is interrupted a running engine stops and a non running engine will not start 5 4 Short circuit button EXC F EXC F SIX DAYS 500134 10 The short circuit button is fitted on the left side of the handlebar Possible states Short circuit button in basic position In this position the ignition circuit is closed and the engine can be started Short circuit button pressed In this position the ignition ci...

Page 15: ...to the right In this position the light is switched off Low beam on Light switch is in the central position In this position the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and the tail light are switched on 5 9 Light switch XCF W 500146 10 The light switch is on the right of the speedometer Possible states 250 XCF W ZA Lig...

Page 16: ...her switch is in the central position Flasher light left on Flasher switch turned to the left Flasher light right on Flasher switch turned to the right 5 12 Overview of indicator lamps EXC F EXC F SIX DAYS 500147 01 Possible states High beam indicator lamp lights up blue High beam is switched on Flasher indicator lamp flashes green Flasher light is switched on ...

Page 17: ... displayed briefly Info 2205 mm corresponds to the size of the 21 front wheel with a series produc tion tire The display then changes to the last selected mode 6 3 Tripmaster switch Option Tripmaster switch You can use the trip master switch to control the functions of the speedometer from the handlebar Info The trip master is an optional accessory 6 4 Setting kilometers or miles Info If you chang...

Page 18: ... Press the button for 3 5 seconds The settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu is closed 6 6 Adjusting the speedometer functions Info Upon delivery only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is standing 4...

Page 19: ...edly until SPEED appears on the left side of the display The current speed is displayed in the SPEED display mode The current speed can be displayed in Km h or Mph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 6 9 SPEED H display mode service hours 400316 ...

Page 20: ...it and the stop watch starts the next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly next display mode 6 12 SPEED ODO display mode odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display The total number of kilometers ridden is shown in the ODO display mode Press the button No function ...

Page 21: ...dly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated on the basis of TR1 trip mas ter 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button for 3 5 seconds The TR1 A1 and ...

Page 22: ...lay mode service hours No function No function The display changes to the Setup menu of the speedometer functions next display mode SPEED CLK display mode time No function No function The display changes to the Setup menu of the clock next display mode SPEED LAP display mode lap time Starts or stops the clock Stops the current lap time and saves it and the stop watch starts the next lap The stop w...

Page 23: ... Display Vehicle at a stand still Menu can be acti vated SPEED TR1 display mode trip master 1 SPEED TR2 display mode trip master 2 SPEED A1 display mode average speed 1 SPEED A2 display mode average speed 2 SPEED S1 display mode stop watch 1 SPEED S2 display mode stop watch 2 ...

Page 24: ...ties down to the reserve Reserve fuel supply open RES Fuel can flow from the tank to the carburetor The fuel tank empties completely 7 2 Fuel tap SX F 500178 10 The fuel tap is on the left side of the fuel tank Using tap handle on the fuel tap you can open or close the supply of fuel to the carburetor Possible states Fuel supply closed OFF No fuel can flow from the tank to the carburetor Fuel supp...

Page 25: ...s pulled to the stop Choke function deactivated The choke lever is pushed back to the stop 7 6 Choke EXC F AUS XCF W XC F SX F 600660 10 Choke is fitted on the left side of the carburetor Activating the choke function frees an opening through which the engine can draw extra fuel This gives a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must...

Page 26: ... and even surface Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over To park the motorcycle press the side stand to the ground with your foot and lean th...

Page 27: ... over Always place the vehicle on a firm and even surface Park the motorcycle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 7 14 Unlocking the steering EXC F EXC F SIX DAYS Insert the key in the steering lock t...

Page 28: ...ently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons In...

Page 29: ...ht and the axle loads Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Run the engine in 8 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first 3 service hours 7 000 rpm Maximum en...

Page 30: ...r run the engine in a closed space Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Info If the motorcycle is unwilling to start the cause can be old fuel in the float chamber The flammable elements of the fuel evaporate after a long time of standing If the float chamber is filled with fre...

Page 31: ...he speed hardly drops but the fuel consumption falls considerably Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be...

Page 32: ...t button while the engine is idling until the engine stops EXC F EXC F SIX DAYS Press and hold the short circuit button while the engine is idling until the engine stops 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 Park the motorcycle on firm ground 9 7 Refueling Dang...

Page 33: ...Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx EXC F EXC F SIX DAYS XCF W XC F 9 2 l 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 116 Total fuel tank capacity approx SX F 8 0 l 2 11 US gal Super unleaded ROZ 95 RON 95 PON 91 p 116 Close the filler cap p 23 ...

Page 34: ...les for damage and routing without sharp bends Check the functioning of the electrical equipment Check the headlamp setting Brakes Check the front brake linings p 66 Check the rear brake linings p 70 Check the brake discs p 64 Check the front brake fluid level p 65 Check the rear brake fluid level p 69 Check the brake lines for damage and leakage Check the free travel of the hand brake lever p 64 ...

Page 35: ...tch x Check the cylinder and piston for wear x Check the camshafts x Check the valve spring seat x Check the valves x Change the valves x Check wear of valve guides x Change the valve springs x Check the timing chain tensioner function x Check the crankshaft run out at the bearing pin x Change the conrod bearing x Change the crankshaft main bearing x Fully check the transmission x Check the shift ...

Page 36: ...ront brake linings p 66 Check the rear brake linings p 70 Check the brake discs p 64 Check the front brake fluid level p 65 Check the rear brake fluid level p 69 Check the brake lines for damage and leakage Check the free travel of the hand brake lever p 64 Check the free travel of the foot brake lever p 68 Check the brake system function Check the screws and guide bolts of the brake system for ti...

Page 37: ...of valve guides Change the valve springs x Check the timing chain tensioner function x Check the crankshaft run out at the bearing pin x Change the conrod bearing x Change the crankshaft main bearing x Fully check the transmission x Check the shift mechanism x Check the spring length of the oil pressure regulator valve x Change the glass fiber yarn filling of the main silencer x Change the foot br...

Page 38: ...bles Bleed fork legs p 45 Clean dust boots of fork legs p 46 Clean the chain p 57 Check the chain tension p 58 Check the chain wear p 59 Check the rear sprocket engine sprocket for wear p 59 Clean the air filter x p 83 Check the tire air pressure p 75 Check the tire condition p 74 Check the coolant level p 80 Empty the carburetor float chamber x p 85 Check that all operating elements for smooth op...

Page 39: ...our body weight As delivered KTM offroad motorcycles are adjusted for a standard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 lb If your weight is above or below the standard range you have to adjust the basic setting of the suspension components accord ingly Small weight differences can be compensated by adjusting the spring preload but in the case o...

Page 40: ...ns Standard 1 5 turns Sport 1 turn Compression damping high speed 250 SX F USA Comfort 1 turn Standard 1 turn Sport 3 4 turn Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 13 6 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly co...

Page 41: ...U Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping low speed 250 SX F USA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 13 7 Adjusting the rebound damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled wi...

Page 42: ...ycle p 37 400220 10 Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement Remove the motorcycle from the work stand p 37 13 9 Checking the static sag of the shock absorber 400221 10 Measure distance of rear wheel unloaded p 40 Ask someone to help you by holding the motorcycle upright Measure...

Page 43: ...ock absorber x Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove shock absorber x p 42 After removing the shock a...

Page 44: ...ock absorber p 39 13 13 Removing the shock absorber x Jack up the motorcycle p 37 600668 10 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw push splash protector to the side and remove the shock absorber 13 14 Installing the shock absorber x 600668 11 Push splash protector to the side and p...

Page 45: ...spension behavior 100020 10 EXC F EXC F SIX DAYS XCF W Remove protection covers Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 26 clicks Standard 22 clicks Sport 2...

Page 46: ...e hydraulic rebound damping determines the fork suspension behavior 600670 10 EXC F EXC F SIX DAYS XCF W Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 24 clicks Standard...

Page 47: ... 01 Turn adjusting screws counterclockwise until they stop Info Make the same adjustment on both fork legs Turn back clockwise by the number of turns corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort 0 turn Standard 1 turn Sport 3 turns Info Turn clockwise to increase spring preload turn counterclockwise to reduce spring preload Adjusting the spring preload has no in...

Page 48: ...ork protection 500087 11 Remove screws and take off clamp Remove screws on left fork leg Push the fork protection downwards Remove the screws on the right fork leg Push the fork protection downwards 13 22 Positioning the fork protection 500087 10 Position the fork protection on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft EXC F EXC F SIX DAYS XC...

Page 49: ...move the motorcycle from the work stand p 37 13 24 Adjusting play of steering head bearing x EXC F EU EXC F AUS XCF W ZA Jack up the motorcycle p 37 100022 10 Loosen screws and Loosen and retighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Guideline Screw top triple clamp M8 20 ...

Page 50: ... 13 27 Setting the fork offset x XCF W USA XC F SX F Remove the lower triple clamp x p 50 500104 10 Remove screw Remove the steering stem Clean the parts and check for damage Rotate the steering stem 180 and insert into the triple clamp Mount and tighten screw Guideline Screw bottom steering head M20x1 5 60 Nm 44 3 lbf ft Loctite 243 Install the lower triple clamp x p 51 13 28 Removing the fork le...

Page 51: ... tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Fully tighten screw Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 100023 10 EXC F EU EXC F AUS XCF W ZA Fully tighten screw Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Fully tighten screw Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 500093 11 Position brake caliper mount and tighten screws Guidelin...

Page 52: ...Nm 7 4 lbf ft Install the fork legs x p 49 13 32 Removing the lower triple clamp x EXC F SIX DAYS XCF W USA XC F SX F Remove the fork legs p 48 XCF W USA XC F SX F Dismount the start number plate p 54 250 EXC F SIX DAYS EU Remove the headlight mask with the headlight p 53 Dismount the front fender p 53 500099 10 Remove screws and hang the CDI control unit to the side Info Do not unplug the CDI con...

Page 53: ...clamp with the steering stem Remove the upper steering head bearing 13 34 Installing the lower triple clamp x EXC F SIX DAYS XCF W USA XC F SX F 500098 10 Clean the bearing and sealing elements check for damage and grease Long life grease p 117 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Info Check whether the top steering head seal is correctly posit...

Page 54: ...ower triple clamp with the steering stem Mount the upper steering head bearing Info Check whether the top steering head seal is correctly positioned Push on protective ring 500149 11 Position the upper triple clamp with the steering Mount and tighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 lbf ft Position the clutch line wiring harness and CDI control unit Mount and tighten screw...

Page 55: ...n place 13 38 Installing the front fender 600692 10 Ensure that the spacing sleeves are mounted in the fender Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Take care with the contact between the holding lugs and the start number plate or headlight mask 13 39 Removing headlight mask with headlight EXC F EXC F SIX DAYS XCF W ZA 600703 ...

Page 56: ...3 42 Installing the start number plate XCF W USA XC F SX F 500101 11 Position the start number plate Mount and tighten screw with the spacing sleeve Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Take care with the contact of the holding lug at the fender Position the brake line and cable harness Put the clamp on mount and tighten screw 13 43 Handlebar position 400223 11 On the upper ...

Page 57: ...fo Make sure cables and wiring are positioned correctly Position the handlebar clamp Mount and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even 400343 10 250 EXC F SIX DAYS EU Remove the four screws Remove the handlebar clamps with rubber wash ers and elastomeres Remove the handlebar and lay it to one side Info Protect the mot...

Page 58: ...ws Guideline Screw handlebar clamp M8 16 Nm 11 8 lbf ft Info Make sure the gap width is even 13 45 Checking gas Bowden cable route 600672 10 The two gas Bowden cables must run parallel behind the handlebar down to the frame They must be routed directly on the frame above the tank bearing to the car buretor 13 46 Checking play in the gas Bowden cable 400192 10 Move the handlebar to the straight ahe...

Page 59: ... grip Guideline Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten nut Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in the Bowden cable Tighten nut Push bellows on Check the throttle grip for smooth operation Install the fuel tank x p 79 Check play in the gas Bowden cable p 56 13 48 Checking for chain dirt accumulation 800012 10 Check the ...

Page 60: ...chain positions Chain tension 8 10 mm 0 31 0 39 in If the chain tension does not meet specifications Adjusting chain tension after checking p 60 Remove the motorcycle from the work stand p 37 13 51 Checking the chain tension when fitting rear wheel 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...

Page 61: ...mm 10 71 in If the distance is greater than the specified measurement Replace the chain Info When you replace the chain you should also replace the rear sprocket and the engine sprocket New chains wear out faster on old worn sprockets Remove the motorcycle from the work stand p 37 13 54 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain te...

Page 62: ...issions with the same chain length Chain adjusters can be turned by 180 Remove the motorcycle from the work stand p 37 13 55 Adjusting chain tension after checking 400225 13 Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws left and right Guideline Chain tension 8 10 mm 0 31 0 39 in Turn the adjusting screws left and right so that the markings on the left and right ch...

Page 63: ...ame position relative to the reference marks The rear wheel is then correctly aligned Tighten nuts 13 57 Adjusting the chain guide x EXC F EXC F SIX DAYS XCF W XC F 400252 10 Remove screws and Take off the chain guide Condition Number of teeth 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition Number of...

Page 64: ...nce between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 13 60 Checking the fluid level of hydraulic clutch Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid g...

Page 65: ...ke fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 400339 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane 600683 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 116 On the slave cylinder remove bleeder...

Page 66: ... lever according to specifications 400196 11 XCF W XC F SX F Push the hand brake lever forwards and check free travel Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specifications Adjust the basic position of handbrake lever p 64 400196 13 EXC F EXC F SIX DAYS Push the hand brake to the handlebar and check free travel Free travel of hand brake lever 3 mm 0 12 in If t...

Page 67: ...mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer If the brake fluid is below the MIN mark Add front brake fluid x p 65 13 67 Adding front brake fluid x Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in...

Page 68: ...kshop 400235 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x p 67 13 69 Removing the front brake linings x Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop 500089 11 Press the brake cali...

Page 69: ...c 500089 12 Fit the brake pads insert bolt and mount locking split pins Position the brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 EXC F EXC F SIX DAYS XCF W Mount cable clip Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot 13 71 Changing the front brake linings x Warnin...

Page 70: ...o specifications 600704 10 Disconnect spring Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the footbrake lever x p 68 Reconnect spring 13 73 Adjusting basic position of foot...

Page 71: ...ger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If br...

Page 72: ...he brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove the locking split pins withdraw the bolt and take out the brake pads Clean brake caliper and brake caliper support 13 78 Installing the rear brake linings x Warning Danger of accidents Reduced braking due to oil or grease on the b...

Page 73: ...ue to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil sea...

Page 74: ...raw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 500086 10 Remove spacing sleeves 13 81 Installing the front wheel x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and...

Page 75: ...sc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw the wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Holding the rear wheel withdraw the wheel sp...

Page 76: ...Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Remove the motorcycle from the work stand p 37 13 84 Tire condition checking Info Only mount tires approved 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 behavi...

Page 77: ...time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400228 01 To check spoke tension tap each spoke with a screwdriver Guideline You should hear a high note Spoke nipple front wheel M4 5 5 Nm 3 7 lbf ft Spoke nipple rear wheel M5 5 Nm 3 7 lbf ft Info If you hear different tone frequencies from different spokes this ...

Page 78: ...ning Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Even if th...

Page 79: ...ving a fuse EXC F EXC F SIX DAYS XCF W XC F Switch off all power consumers and switch off the engine Dismount the air filter box lid p 82 400270 10 Remove the protection cover Info The fuse is located in the starter relay under the filter box cover Remove the fuse 13 91 Replacing the fuse EXC F EXC F SIX DAYS XCF W XC F Warning Fire hazard The electrical system can be overloaded by the use of inco...

Page 80: ... a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and ...

Page 81: ...ion the fuel tank and install the two spoilers to the side of the radiator fixing Make sure that no cables or Bowden cables are trapped or damaged 600675 10 Mount the fuel tank vent hose Mount and tighten screw with the collar sleeve Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft EXC F EXC F SIX DAYS Position the horn with the horn bracket 600678 11 Mount and tighten screws with the collar...

Page 82: ...mm 0 39 in If the level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant p 116 Alternative 2 Coolant mixed ready to use p 116 Refit the radiator cap 13 98 Checking the coolant level Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling s...

Page 83: ...p Completely drain the coolant Mount screw with a new seal and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 13 100 Refilling coolant x Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately wi...

Page 84: ...crews and take off main silencer 13 103 Installing the main silencer 600681 10 Mount the main silencer Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Reconnect spring 13 104 Dismounting the air filter box lid 600682 10 Pull off the air filter box lid in area to the side and remove to the front 13 105 Installing the air filter box lid 600682 11 Insert the air filter...

Page 85: ... onto the air filter support Put in both parts together position them and fix them with the air filter support Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Install the air filter box lid p 82 13 108 Cleaning air filter x Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cl...

Page 86: ... there is sufficient ventila tion and do not start or run the engine in a closed space Adjust the idle speed with adjusting screw Guideline Choke function deactivated The choke lever is pushed in to the stop EXC F AUS XCF W XC F SX F p 23 Choke function deactivated The choke lever is pushed back to the stop EXC F EU EXC F SIX DAYS p 23 Idle speed 1 400 1 500 rpm Turn the idle adjusting screw slowl...

Page 87: ...void contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the...

Page 88: ...er x p 88 Fill up with engine oil x p 89 13 114 Draining the engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel clean...

Page 89: ...ubstances brake fluid batteries etc according to regulations Place a suitable container under the engine 600693 10 Remove plug with oil screen and the O rings 600694 10 Remove plug with oil screen and the O rings Drain the remaining engine oil Thoroughly clean parts and sealing area 600695 10 Position oil screen with the O rings Mount and tighten plug with the O ring Guideline Plug for oil screen ...

Page 90: ...ns Place a suitable container under the engine 600687 10 Remove screws Remove oil filter cover with O ring 600688 10 Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area 13 117 Installing the oil filter x 600689 10 Lay the motorcycle on its side and fill the oil filter housing to about ful...

Page 91: ...tila tion and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level p 86 13 119 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 600690 10 Remove screw cap from the clutch cover and fill up with engine oil Engine oil SAE 10W 50 p 116 Mount and tighten screw cap Dange...

Page 92: ...djust the plug gap Guideline Spark plug electrode gap 0 7 mm 0 028 in Defect in ignition system Check the ignition system x Short circuit cable in cable harness frayed short circuit button or emergency OFF switch defective Check the wiring harness visual check Check the electrical system Plug connector of CDI control device pulse generator or ignition coil oxidized Clean the plug connector and tre...

Page 93: ...olant in cooling system Check the cooling system for leakage Check the coolant level p 80 Too little air stream Switch off engine when standing Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 81 Refill the coolant x p 81 Bent radiator hose Change the radiator hose x Thermostat defective Check the thermostat x Guideline Opening temperature 70 C 15...

Page 94: ...p 117 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber x p 85 Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the eng...

Page 95: ...il filter clean the oil screen x p 86 Check the antifreeze and coolant level p 80 Drain the fuel from the tank into a suitable container Empty the carburetor float chamber x p 85 Check the tire air pressure p 75 EXC F EXC F SIX DAYS XCF W XC F Remove the battery x p 75 EXC F EXC F SIX DAYS XCF W XC F Recharge the battery x p 76 Guideline Storage temperature of battery without direct sunlight 0 35 ...

Page 96: ... lubrication Pressure circulation lubrication with two rotary pumps Primary transmission 22 68 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio EXC F EXC F SIX DAYS XCF W 1st gear 13 33 2nd gear 17 33 3rd gear 19 29 4th gear 23 28 5th gear 23 23 6th gear 26 22 Transmission ratio SX F 250 XC F USA 1st gear 13 32 2nd gear 15 30 3rd gear 17 28 4th gear 19 26 5th gear 21 ...

Page 97: ...TECHNICAL DATA ENGINE 95 17 1 Capacity engine oil Engine oil 1 10 l 1 16 qt Engine oil SAE 10W 50 p 116 17 2 Capacity coolant Coolant 1 2 l 1 3 qt Coolant p 116 Coolant mixed ready to use p 116 ...

Page 98: ...ng M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw stator bracket EXC F EXC F SIX DAYS XCF W XC F M6 8 Nm 5 9 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw cylinder head M6 10 Nm 7 4 lbf ...

Page 99: ...TORQUES 97 Nut inner clutch hub M18x1 5 120 Nm 88 5 lbf ft Loctite 243 Nut primary gear M18LHx1 5 150 Nm 110 6 lbf ft Loctite 243 Plug for oil screen long M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft ...

Page 100: ...50 XCF W USA 3rd position from top Needle position 250 XCF W ZA 250 XC F USA 5th position from top Idle mixture adjusting screw 250 XCF W ZA 250 XC F USA Open 1 0 turn Idle mixture adjusting screw 250 XCF W USA Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 168 Jet needle 250 XCF W USA OBEKT Jet needle 250 XCF W ZA 250 XC F USA OBETP Idling jet 42 Idle air jet 100 Cold start jet 85 L...

Page 101: ...ear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure EXC F EXC F SIX DAYS Front 1 5 bar 22 psi Rear 2 0 bar 29 psi Final drive EXC F EXC F SIX DAYS 14 38 13 50 Final drive XCF W 13 52 Final drive SX F 250 XC F USA 13 48 Chain 5 8 x 1 4 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 475 10 mm 58 07 0 39 ...

Page 102: ...4M M S TT Metzeler MEC 6 DAYS EXTREME 120 90 18 M C 65M M S TT Metzeler MEC 6 DAYS EXTREME XCF W 250 XC F USA 80 100 21 51M TT Bridgestone Bridgestone M59 100 100 18 64M TT Bridgestone Bridgestone M402 SX F 80 100 21 51M TT Bridgestone Bridgestone M59 100 90 19 62M TT Bridgestone Bridgestone M70 For further information see the Service section under http www ktm com 20 3 Capacity fuel Total fuel ta...

Page 103: ... N mm 25 1 lb in Fork length 940 mm 37 01 in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in FORK OIL Fork oil SAE 5 p 116 21 2 250 XC F USA Fork part number 14 18 7E 28 Fork WP Suspension 4860 MXMA CC Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping Comfort 22 clicks Standard 21 clicks Sport 21 clicks Spring length with preload spacer s 492 mm 19 37 in Sp...

Page 104: ... 59 fl oz Fork oil SAE 5 p 116 Oil capacity fork tube without cartridge 360 ml 12 17 fl oz Fork oil SAE 5 p 116 21 4 250 SX F USA Fork part number 14 18 7E 22 Fork WP Suspension 4860 MXMA CC Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping Comfort 22 clicks Standard 22 clicks Sport 20 clicks Spring length with preload spacer s 492 mm 19 37 in Spring rate Wei...

Page 105: ...lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 411 mm 16 18 in 22 2 250 XC F USA Shock absorber part number 12 18 7E 28 Shock absorber WP Suspension PDS 5018 DCC Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 1 turn Standard 1 turn Sport 3 4 tu...

Page 106: ... mm 9 84 in Gas pressure 10 bar 145 psi Static sag 33 mm 1 3 in Riding sag 105 mm 4 13 in Fitted length 411 mm 16 18 in 22 4 250 SX F USA Shock absorber part number 12 18 7E 22 Shock absorber WP Suspension PDS 5018 DCC Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 1 turn Standard 1 turn Sport 3 4 turn Rebound damping Comfo...

Page 107: ...riple clamp EXC F EU EXC F AUS XCF W ZA M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw top steering stem EXC F SIX DAYS XCF W USA XC F SX F M8 17 Nm 12 5 lbf ft Loctite 243 Screw top steering stem EXC F EU EXC F AUS XCF W ZA M8 20 Nm 14 8 lbf ft Screw handlebar clamp EXC F EU EXC F AUS XCF W XC F SX F M8 20 Nm 14 8 lbf ft Screw handlebar clamp 250 EXC F SIX DAYS EU M8 16 Nm 11 8 l...

Page 108: ... 3 3 3 2 P1 B3 H13 H15 H18 S2 H4 H11 H7 H2 H9 H3 H5 H1 N2 G2 B1 L1 L2 A6 S5 S6 S7 K2 S8 E6 S10 M1 K1 G1 H14 S1 1 4 1 2 5 6 7 11 10 12 13 14 2 1 2 1 2 1 2 1 4 re wh re bl gn re re gn re bl re wh ye bl br ye bl ye br or pu bl or ye re br re ye gn bu wh bu gn ye re br ye re br ye wh bu ye bl bl ye bu br ye re br bl wh re ye re bl wh re ye re ye bl wh gn br wh bu wh bu wh br gr gr bl wh bl br br br bl...

Page 109: ...gh beam indicator light K1 Starter relay with main fuse K2 Flasher relay L1 Pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light switch S5 Tripmaster switch optional S6 Light switch S7 Horn button short circuit button S8 Flasher switch S10 Electric starter button Cable colors bl Black bl wh Black white br Br...

Page 110: ...WIRING DIAGRAM 108 ye re Yellow red ...

Page 111: ...WIRING DIAGRAM 109 ...

Page 112: ... 1 2 3 3 4 4 3 3 3 2 1 4 1 2 5 6 7 11 10 12 13 14 2 1 2 H3 H9 H5 H1 N2 G1 K1 M1 S1 S8 S10 S11 K2 S7 S6 S5 P1 B3 H15 H18 S2 H4 H11 H7 H2 L2 A6 B1 L1 G2 H13 1 2 1 2 1 re wh re bl gn re re gn re bl re wh ye bl br ye bl ye br or pu bl or ye re br re ye gn bu wh bu gn ye re br ye re br ye wh bu ye bl bl ye bu br ye re br bl wh re ye re bl wh re ye re ye bl wh gn br wh bu wh bu wh br ye re ye wh br bl w...

Page 113: ...y with main fuse K2 Flasher relay L1 Pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light switch S5 Tripmaster switch optional S6 Light switch S7 Horn button short circuit button S8 Flasher switch S10 Electric starter button S11 Emergency OFF switch Cable colors bl Black br Brown br bl Brown black bu Blue bu...

Page 114: ...re wh bu wh br ye bl bl wh br br ye br ye re br ye bl bl bl re bu wh br bu ye bl bl ye bu ye re wh re wh re ye re br wh ye bl wh wh br bl br br br bl br bl ye re H11 B3 P1 S5 N2 H5 G2 L1 B1 A6 L2 S12 S6 S10 E6 H14 M1 K1 G1 H7 WIRING DIAGRAM 112 24 3 Wiring diagram XCF W 250 XC F USA 600700 01 ...

Page 115: ...r fan XCF W ZA K1 Starter relay with main fuse L1 Pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S5 Tripmaster switch optional S6 Light switch S10 Electric starter button S12 Short circuit button Cable colors bl Black bl wh Black white br Brown bu Blue bu wh Blue white gn Green re Red re bl Red black re wh Red white wh White wh re White red ye Yello...

Page 116: ...G 3 C D I AM 3 AR 3 1 2 3 1 2 5 7 6 11 10 12 13 14 re wh re bl re gn bu wh br ye bl bl S12 G2 B1 A6 L2 L1 WIRING DIAGRAM 114 24 4 Wiring diagram SX F 600701 01 ...

Page 117: ...6 CDI controller B1 Throttle position sensor G2 Generator L1 Pulse generator L2 Ignition coil S12 Short circuit button Cable colors bl Black br Brown bu wh Blue white gn Green re Red re bl Red black re wh Red white ye bl Yellow black ...

Page 118: ... Anti corrosion antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 119 SAE p 119 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Synthetic engin...

Page 119: ...mends Motorex products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex products Supplier Motorex Accu Contact High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Specification KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Specification KTM recommends Motorex pr...

Page 120: ...CES 118 Oil for foam air filter Specification KTM recommends Motorex products Supplier Motorex Twin Air Liquid Power Universal oil spray Specification KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 121: ... intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle and ATV engines With most motorcycles and ATVs the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for cla...

Page 122: ...justing 59 checking 58 Chain wear checking 59 Chassis number 10 Choke 23 CLEANING 92 Clutch changing fluid 63 checking fluid level 62 Clutch lever 12 adjusting basic position 62 Compression damping fork adjusting 43 Compression damping high speed shock absorber adjusting 37 Compression damping low speed shock absorber adjusting 38 Coolant draining 81 refilling 81 Coolant level checking 80 Cooling ...

Page 123: ... 56 Plug in stand 24 Putting into operation advice on first use 26 after storage 93 Checks before putting into operation 28 R Rear sprocket engine sprocket checking for wear 59 Rear wheel installing 73 removing 73 Rebound damping fork adjusting 44 shock absorber adjusting 39 Riding sag adjusting 42 S Seat mounting 78 removing 77 Service schedule EXC F EXC F SIX DAYS XCF W 32 33 rider 36 XC F SX F ...

Page 124: ...1 102 shock absorber 103 104 tightening torques chassis 105 tightening torques engine 96 97 Tire air pressure checking 75 Tire condition checking 74 Transport 6 TROUBLESHOOTING 90 91 Type label 10 V View of vehicle left front 8 right rear 9 W Warranty 6 Wiring diagram 106 115 Work rules 6 ...

Page 125: ... 3211348en 3211348en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 06 2008 Photo Mitterbauer ...

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