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KTM 2010 250 EXC-F AUS, Owner'S Manual, Page: 60 / 125

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KTM 2010 250 EXC-F AUS Owner'S Manual Download Page 60

MAINTENANCE WORK ON CHASSIS AND ENGINE

58

13.46

Checking chain wear

–

Jack up the motorcycle. (

p. 40)

0

0

0

B

B

0

0

A

A

1   2   3

16 17 18

400226-10

–

Shift transmission to neutral.

–

Pull on the upper part of the chain with the specified weight

.

Guideline

Weight of chain wear measurement

10… 15 kg (22… 33 lb.)

–

Measure the distance

of 18 chain links in the lower chain section.

Info

Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Maximum distance

at the longest

chain section

272 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 rear sprocket
and engine sprocket.
New chains wear out faster on old, worn sprockets.

–

Remove the motorcycle from the work stand. (

p. 40)

13.47

Adjusting chain tension

Warning

Danger of accidents

 

Danger caused by incorrect chain tension.

–

If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

–

Jack up the motorcycle. (

p. 40)

400213-10

–

Push the chain up at the rear edge of the chain guide to measure the chain ten-
sion

.

Info

The upper chain section

must be taut.

Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Summary of Contents for 2010 250 EXC-F AUS

Page 1: ...OWNER S MANUAL 2010 250 EXC F EU 250 EXC F AUS 250 EXC F SIX DAYS EU 250 XCF W ZA 250 SX F EU 250 SX F USA Art no 3211465en ...

Page 2: ......

Page 3: ...modify 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 misprints and other errors The m...

Page 4: ...ding on dry sand 27 Preparing for riding on wet sand 28 Preparing for riding on wet and muddy surfaces 29 Preparing for rides at high temperature and slow speed 30 Preparing for rides at low temperatures or in snow 30 RIDING INSTRUCTIONS 31 Checks before putting into operation 31 Starting 31 Starting up 32 Shifting riding 32 Braking 32 Stopping parking 33 Refueling 33 SERVICE SCHEDULE EXC F EXC F ...

Page 5: ...the battery x EXC F EXC F SIX DAYS XCF W 74 Recharging the battery x EXC F EXC F SIX DAYS XCF W 74 Removing a fuse EXC F EXC F SIX DAYS XCF W 75 Replacing the fuse EXC F EXC F SIX DAYS XCF W 75 Adjusting the beam width of the headlight EXC F EXC F SIX DAYS XCF W 76 Checking the headlight adjustment EXC F EXC F SIX DAYS XCF W 76 Removing the seat 76 Mounting the seat 77 Dismounting the fuel tank x ...

Page 6: ...NTENTS 4 WIRING DIAGRAM 106 Wiring diagram EXC F EU EXC F SIX DAYS 106 Wiring diagram EXC F AUS 110 Wiring diagram XCF W 112 Wiring diagram SX F 114 SUBSTANCES 116 AUXILIARY SUBSTANCES 117 STANDARDS 119 INDEX 120 ...

Page 7: ...derstanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained in the following Specific name Identifies...

Page 8: ...rescribed running in period inspection and maintenance intervals Observing these rules will vastly increase the service life of your motorcycle Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer s service record otherwise all warranty claims will be void No warranty claim can be honored for damage resulting from...

Page 9: ...e rights of others Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are miss ing you or others may not recognize potential hazards and may therefore be injured Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permane...

Page 10: ...VIEW OF VEHICLE 8 3 1 View of the vehicle from the left front example 600874 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 600873 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: ...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: ...nterrupted 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 circuit i...

Page 15: ...le states Light off Light switch is turned 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 Horn button EXC F EXC F SIX DAYS 500134 11 The horn button is fitted o...

Page 16: ...11 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 Turn signal indicator lamp flashes green Turn signal light is switched on ...

Page 17: ... 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 change the unit of meas...

Page 18: ...tings 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 stationary 400318 01 Press the button briefly and r...

Page 19: ...urrent 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 Display mode SPEED H service hours 400316 01 Condition The motorcycle is stationary Press the button bri...

Page 20: ...t 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 Display mode SPEED ODO odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display In ODO display mode the total number of kilometers ridden is displayed Press the button No function P...

Page 21: ...325 01 Press the button briefly and repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated using TR1 trip master 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...

Page 22: ...ton briefly Display mode SPEED H service hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK clock No function No function The display changes to the Setup menu of the clock Next display mode Display mode SPEED LAP lap time Starts or stops the clock Stops the current lap time and saves it and the stop watch start...

Page 23: ...onary Menu can be acti vated Display mode SPEED CLK clock Display mode SPEED LAP lap time Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Disply mode SPEED A1 average speed 1 Display mode SPEED A2 average speed 2 Display mode SPEED S1 stop watch 1 Display mode SPEED S2 stop watch 2 ...

Page 24: ...e 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 supply open ON Fuel...

Page 25: ...r is pulled to the stop Choke function deactivated The choke lever is pushed back to the stop 7 6 Choke XCF W SX F EXC F AUS 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 b...

Page 26: ...irm 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...

Page 27: ...ce the vehicle on a firm and even surface 400732 01 Park the vehicle 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 400731 01 Insert the key in the steering lock ...

Page 28: ...ur foot off the foot brake lever if you do not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible 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 Info When using your motorcycle remember that others may...

Page 29: ...he first 3 service hours 50 During the next 12 service hours 75 Avoid fully opening the throttle 8 3 Preparing vehicle for arduous riding conditions Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train or brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached Ardu...

Page 30: ...uretor tuning set tings 600868 01 Clean the chain Chain cleaner p 117 Fit the steel sprocket Tip Do not grease the chain Clean radiator fins Straighten bent radiator fins carefully 8 5 Preparing for riding on wet sand 600872 10 Check the radiator cap Value on radiator cap 1 8 bar 26 psi If the displayed value does not correspond to specifications Warning Danger of scalding During motorcycle operat...

Page 31: ...chain Clean radiator fins Straighten bent radiator fins carefully 8 6 Preparing for riding on wet and muddy surfaces Seal the air filter box x Tip Seal the air filter box along the edges to prevent the ingress of dirt Clean the air filter x p 82 Info Check the air filter approx every 30 minutes 600870 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 59006021000 I...

Page 32: ...he air filter x p 82 Info Check the air filter approx every 30 minutes 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive Clean the chain Chain cleaner p 117 Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 79 8 8 Preparing for ri...

Page 33: ...in an enclosed space without an effective exhaust extraction system 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...

Page 34: ...hicle speed but lowers fuel consumption 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 stationary f...

Page 35: ...al XCF W SX F Press and hold the short circuit 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 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 moto...

Page 36: ...nt Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx EXC F EXC F SIX DAYS XCF W 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 37: ...al equipment Check the headlight setting Brakes Check the front brake linings p 64 Check the rear brake linings p 67 Check the brake discs p 61 Check the brake fluid level of the front brake p 62 Check the rear brake fluid level p 66 Check the brake lines for damage and leakage Check the free travel of the hand brake lever p 61 Check the free travel of the foot brake lever p 66 Check the brake sys...

Page 38: ... 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 bear ing x Fully check the transmission x Check the shift mechanism x Check the sprin...

Page 39: ...he brake discs p 61 Check the brake fluid level of the front brake p 62 Check the rear brake fluid level p 66 Check the brake lines for damage and leakage Check the free travel of the hand brake lever p 61 Check the free travel of the foot brake lever p 66 Check the brake system function Check the screws and guide bolts of the brake system for tightness Chassis Check the shock absorber and fork fo...

Page 40: ...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 brake cylinder seals x Check adjust the carburetor components ...

Page 41: ...Bleed fork legs p 48 Clean the dust boots of the fork legs p 48 Clean the chain p 56 Check the chain tension p 57 Check the chain wear p 58 Check rear sprocket engine sprocket for wear p 57 Clean the air filter x p 82 Check the tire air pressure p 73 Check the tire condition p 72 Check the coolant level p 79 Empty the carburetor float chamber x p 86 Check all controls for smooth operation Check br...

Page 42: ...djusted 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 of large weight differences the springs must be replaced 13...

Page 43: ...Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The low speed setting can be seen during the slow to normal compression of the shock absorber 600667 11 Turn adjusting screw clockwise with a screwdriver to the last click Info Do no...

Page 44: ...unterclockwise by the number of clicks corresponding to the shock absorber type Guideline EXC F EXC F SIX DAYS XCF W Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks SX F Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 13 8 Measuring rear wheel sag unloaded Jack up the motorcyc...

Page 45: ...cle in the normal seating position with feet on the footrests Then depress and release the rear of the motorcycle repeat edly so that the rear suspension is returned to the normal operating position The other person now measures the distance between the rear axle and the fixed point again Make a note of the value as measurement Info The riding sag is the difference between measurements and Check t...

Page 46: ...ting the riding sag x Remove shock absorber x p 45 After removing the shock absorber clean it thoroughly Choose and mount a suitable spring Guideline EXC F EXC F SIX DAYS XCF W Spring rate Weight of rider 65 75 kg 143 165 lb 66 N mm 377 lb in Weight of rider 75 85 kg 165 187 lb 69 N mm 394 lb in Weight of rider 85 95 kg 187 209 lb 72 N mm 411 lb in SX F Spring rate Weight of rider 65 75 kg 143 165...

Page 47: ...M12 80 Nm 59 lbf ft Loctite 243 Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Remove the motorcycle from the work stand p 40 13 15 Checking basic setting of fork Info For various reasons no exact riding sag can be determine...

Page 48: ...e 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 SX F EU Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks SX F USA Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping turn counterclockwis...

Page 49: ...se by the number of clicks corresponding to the fork type Info Turn clockwise to increase damping turn counterclockwise to reduce damping Mount protection covers 13 18 Adjusting the spring preload of the fork EXC F EXC F SIX DAYS XCF W 600671 01 Turn the adjusting screws counterclockwise all the way Info Make the same adjustment on both fork legs Turn back clockwise by the number of turns correspo...

Page 50: ...f oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 118 Press the dust boots back into their normal position Remove excess oil Position the fork protection p 48 Remove the motorcycle from the work stand p 40 13 21 Loosening the fork protector 600875 11 Remove screws and remove the clamp Remove sc...

Page 51: ...t play of the steering head bearing x p 49 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable SX F 250 EXC F SIX DAYS EU Adjust the play of the steering head bearing x p 50 EXC F EU EXC F AUS XCF W ZA Adjust play of the steering head bearing...

Page 52: ...s Remove screw 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 screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Check the steering head bearing play p 49 13 26 Removin...

Page 53: ...must be flush to the upper edge of the upper triple clamp Position bleeder screws toward the front 100804 11 EXC F EU EXC F AUS XCF W ZA Fully tighten screws Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Fully tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 100803 11 250 EXC F SIX DAYS EU Fully tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Ful...

Page 54: ... x Remove the fork legs p 50 600878 10 Remove screws on the left fork leg Remove the fork protector upwards Remove the screws on the right fork leg Remove the fork protector upwards 13 29 Installing the fork protector x 600878 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 Position the fork protection on the righ...

Page 55: ...Switch off all electrical equipment Remove screw and take off clamp Loosen the rubber band Push up the headlight mask and swing it forwards 600702 10 Pull out the electric plug connector and remove the headlight mask with the headlight 13 33 Refitting the headlight mask with the headlight EXC F EXC F SIX DAYS XCF W 600702 11 Connect the electric plug connector 600703 11 Position the headlight mask...

Page 56: ...e holes on the handlebar support are placed at a distance of from the center Distance between holes 3 5 mm 0 138 in The handlebar supports can be mounted in 4 different positions 13 37 Adjusting handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handle bar 0 0 2 2 0 0...

Page 57: ... the handlebar to the straight ahead position Move the throttle grip back wards and forwards to ascertain the play in the throttle cable Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable x p 56 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When...

Page 58: ...n the throttle cable p 55 13 41 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 56 13 42 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grea...

Page 59: ...on If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and b...

Page 60: ...on old worn sprockets Remove the motorcycle from the work stand p 40 13 47 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain...

Page 61: ...issions with the same chain length Chain adjusters can be turned by 180 Remove the motorcycle from the work stand p 40 13 48 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 62: ...e same position relative to the reference marks The rear wheel is then correctly aligned Tighten nuts 13 50 Adjusting the chain guide x EXC F EXC F SIX DAYS XCF W 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 t...

Page 63: ... KTM workshop will be glad to help A A 400257 10 Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the ...

Page 64: ... screw by hand only and do not apply any force Do not make any adjustments while riding 13 55 Adjusting free travel of hand brake lever EXC F EXC F SIX DAYS 400196 12 Check the free travel of the hand brake lever p 61 Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjustment screw clockwise to reduce free travel The pressure point moves away from the handlebar Tu...

Page 65: ... immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicabl...

Page 66: ...front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Bra...

Page 67: ...ocking split pins withdraw bolt and take out the brake linings Clean the brake caliper and brake caliper support 0 0 7 7 0 0 6 6 0 0 100397 01 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly 100398 10 Fit the brake linings insert the bolt and mount the locking split pins Operate the hand brake lever repeatedly until the brake linings ...

Page 68: ...ver according to specifications 600705 10 Disconnect spring Loosen nut and with push rod turn it back until you have maximum free travel To adjust the basic position of the foot brake lever individually lossen nut and turn screw accordingly Info The range of adjustment is limited Turn push rod accordingly until you have free travel If necessary adjust the basic position of the footbrake lever Guid...

Page 69: ...aused by old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid This is based on ...

Page 70: ...m with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake lin...

Page 71: ... lever repeatedly until the brake linings lie on the brake disc and there is a pressure point 400233 10 Correct the brake fluid quantity to marking Brake fluid DOT 4 DOT 5 1 p 116 Mount screw cap with membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water 13 66 Removing front wheel x Jack up the motorcycle p 40 100809 01 Press the brake caliper by hand on to t...

Page 72: ...ree of oil and grease and clean them with brake cleaner when necessary 500086 11 Clean and grease shaft seal rings and bearing surface of the spacers Long life grease p 117 Insert the spacers 500084 11 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Operate the hand brake lever several...

Page 73: ... Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 400260 11 Remove spacers 13 69 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep t...

Page 74: ...e tires all have an important impact on the riding behavior of the motorcycle The front and rear wheels must be mounted with tires with similar profiles Worn tires have a negative effect on riding behavior especially on wet surfaces 400602 10 Examine the front and rear tires for cuts foreign bodies and other damage If you find cuts foreign bodies or other damage on a tire Change the tires Check th...

Page 75: ...ct spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Tap each spoke with a screwdriver Info The sound frequency...

Page 76: ... 4Ah battery YTX5L BS p 100 Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat p 77 13 75 Recharging the battery x EXC F EXC F SIX DAYS XCF W Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with ...

Page 77: ...cycle s electronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the battery and to test the generator With this device you cannot overcharge the bat tery Info Never remove the lid Charge the battery with at most 10 of the capacity specified on the ba...

Page 78: ...light beam width Tighten screw 13 79 Checking the headlight adjustment EXC F EXC F SIX DAYS XCF W 0 0 A A 0 0 B B 400726 10 On a light colored wall behind a horizontal area make a mark as high as the center of the headlight Make a second mark at distance of under the first mark Guideline Distance 5 cm 2 in Stand the motorcycle upright in front of the wall at distance The driver in full protective ...

Page 79: ...th 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 keep it...

Page 80: ...fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no 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 sleeve Guideline Remaining...

Page 81: ...the radiator Coolant level above radiator fins 10 mm 0 39 in If the level of the coolant 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 86 Checking the coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radi...

Page 82: ...ut of the reach of children Condition The engine is cold 600679 11 Stand the vehicle upright Place a suitable container under the water pump cover Remove screw Remove radiator cap 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 88 Refilling coolant x Warning Danger of poisoning Coolant is poisonous and a health hazard ...

Page 83: ...very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 600681 11 Disconnect spring Remove screws and take off main silencer 13 91 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 92 Removing the air filter box lid 600682 10 Pull off the ai...

Page 84: ...he air filter x 301262 10 Mount the clean air filter onto the air filter support Apply grease to the section of the air filter Long life grease p 117 500107 10 Put in both parts together position them and fix them with air filter holder 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 81 13 96 Cleaning...

Page 85: ...y with water and contact a doctor immediately Info The fluid level rises with increasing wear of the clutch lining disc Avoid contact between brake fluid and painted parts Brake fluid is corrosive 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 Check the fluid lev...

Page 86: ...er without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level under top level of container 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt fluid immediately with...

Page 87: ... adjustment screw 13 103 Carburetor adjusting idle x 600684 10 Screw in the idle adjusting screw until it stops and then to the prescribed basic setting Guideline Idle mixture adjusting screw EXC F EXC F SIX DAYS SX F Open 1 25 turns Idle mixture adjusting screw XCF W Open 1 0 turn Adjustment tool for mixture control screw 77329034000 Run the engine until warm Guideline Warm up time 5 min Danger D...

Page 88: ...ture or altitude changes adjust the idle speed again 13 104 Emptying the carburetor float chamber x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can esc...

Page 89: ...edge of level viewer If the engine oil level is below the specified level Add engine oil p 90 13 106 Changing the engine oil and oil filter cleaning the oil screen x 301489 10 Drain the engine oil x p 87 Clean the oil screens x p 88 Remove the oil filter x p 89 Install the oil filter x p 89 Fill up with engine oil x p 90 13 107 Draining the engine oil x Warning Danger of scalding Engine oil and ge...

Page 90: ...ediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 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 ...

Page 91: ...Place a suitable container under the engine 600687 10 Remove screws Remove oil filter cover with the 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 surface 13 110 Installing the oil filter x 600689 10 Lay the motorcycle on its side and fill the oil filter housing to about...

Page 92: ... enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Check the engine oil level p 87 13 112 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 93: ...n system Check the ignition system x Short circuit cable in wiring harness frayed short circuit button or emer gency OFF switch defective Check the wiring harness visual check Check the electrical system Plug connector of CDI control device pulse generator or ignition coil oxi dized Clean the plug connector and treat it with con tact spray Water in carburetor or jets blocked Check adjust the carbu...

Page 94: ... for leaks Check the coolant level p 79 Insufficient airflow Switch off engine when stationary Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 80 Refill the coolant x p 80 Bent radiator hose Change the radiator hose x Thermostat defective Check the thermostat x Guideline Opening temperature 70 C 158 F Defect in radiator fan system XCF W 250 EXC F...

Page 95: ...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 86 Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning take a short ride until the engine reaches operating temperature Info The heat produced cau...

Page 96: ...l and oil filter clean the oil screen x p 87 Check the anti freeze and coolant level p 79 Drain the fuel from the tank into a suitable container Empty the carburetor float chamber x p 86 Check the tire air pressure p 73 EXC F EXC F SIX DAYS XCF W Remove the battery x p 74 EXC F EXC F SIX DAYS XCF W Recharge the battery x p 74 Guideline Storage temperature of battery without direct sunlight 0 35 C ...

Page 97: ...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 1st gear 13 32 2nd gear 15 30 3rd gear 17 28 4th gear 19 26 5th gear 21 25 6th gear 22...

Page 98: ...TECHNICAL DATA ENGINE 96 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 99: ...XCF W M6 10 Nm 7 4 lbf ft Screw stator bracket EXC F EXC F SIX DAYS XCF W M6 8 Nm 5 9 lbf ft Loctite 243 Screw timing chain securing guide M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 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 Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Nut camshaft bearing bri...

Page 100: ...TORQUES 98 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 101: ...Carburetor type KEIHIN FCR MX 39 Carburetor identification number 3900K Needle position 5th position from top Idle mixture adjusting screw Open 1 0 turn Pump membrane stop 2 15 mm 0 0846 in Main jet 168 Jet needle OBETP Idling jet 42 Idle air jet 100 Cold start jet 85 Leakage nozzle 50 19 3 SX F Carburetor type KEIHIN FCR MX 39 Carburetor identification number 3925I Needle position 4th position fr...

Page 102: ...XC F SIX DAYS 14 38 13 50 Final drive XCF W 13 52 Final drive SX F 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 in Seat height unloaded 985 mm 38 78 in Ground clearance unloaded 380 mm 14 96 in Weight without fuel approx EXC F EXC F SIX DAYS 105 7 kg 233 lb Weight without fuel approx XCF W 102 6 kg 226 2 lb Weig...

Page 103: ... 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 Additional information is available in the Service section under http www ktm com 20 3 Capacity fuel Total fuel tank capacity approx EXC F EXC F SIX DAYS XCF W 9 2 l 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 116 Total fuel tank capacity approx SX F ...

Page 104: ... in Weight of rider 85 95 kg 187 209 lb 4 4 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 per fork leg 635 ml 21 47 fl oz Fork oil SAE 5 p 116 21 2 SX F EU Fork part number 14 18 7J 03 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standa...

Page 105: ... 10 clicks Spring length with preload spacer s 492 mm 19 37 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6 N mm 26 3 lb in Weight of rider 85 95 kg 187 209 lb 4 8 N mm 27 4 lb in Fork length 940 mm 37 01 in Gas pressure 1 2 bar 17 psi Oil capacity per cartridge 195 ml 6 59 fl oz Fork oil SAE 5 p 116 Oil capacity fork leg without cartr...

Page 106: ... 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 SX F Shock absorber part number 12 18 7J 03 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 2 turns Standard 1 5 turns Sport 1 turn Rebound damping...

Page 107: ...handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand fixing M8 40 Nm 29 5 lbf ft Loctite 243 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 243 Screw top steering stem SX F 250 EXC F SIX DAYS EU 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 top triple clamp SX F 250 EXC F SIX DAYS EU M8 17 Nm 12 5 lbf ft Screw top triple clamp EXC F E...

Page 108: ...1 2 2 3 4 2 6 2 5 1 1 3 1 1 1 1 2 2 1 2 2 2 2 CR1 1 CR 1 1 1 1 2 3 3 4 4 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...

Page 109: ...H18 High beam indicator light K1 Starter relay with main fuse K2 Turn signal 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 Turn signal switch S10 Electric starter button Cable colors bl Black bl wh Bla...

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

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

Page 112: ... DG 4 M A 10 AF 4 AM 3 AR 3 G 3 BK 4 BR 4 BF 1 BA 1 1 2 3 4 1 4 1 3 2 2 2 2 1 AT 2 1 1 AT1 2 AL 2 AL1 2 2 3 2 3 4 2 6 2 5 1 1 3 1 1 1 1 1 2 2 2 1 2 2 2 2 CR1 1 CR 1 1 1 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 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 r...

Page 113: ...r relay with main fuse K2 Turn signal 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 Turn signal switch S10 Electric starter button S11 Emergency OFF switch Cable colors bl Black br Brown br bl Brown bl...

Page 114: ...ye wh br wh br wh ye re wh re bl gn re re gn re bl 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 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: ...WIRING DIAGRAM 114 24 4 Wiring diagram SX F 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 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: ...corrosion inhibitor 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 e...

Page 119: ... products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact Long life grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube...

Page 120: ...AUXILIARY SUBSTANCES 118 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 121: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles 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 classifying oils...

Page 122: ... 85 Chain cleaning 56 Chain guide adjusting 60 61 Chain tension adjusting 58 checking 57 Chain wear checking 58 Chassis number 10 Choke 23 Cleaning 93 Clutch fluid level checking 83 fluid changing 83 Clutch lever 12 adjusting basic position 83 Compression damping fork adjusting 45 Compression damping high speed shock absorber adjusting 40 Compression damping low speed shock absorber adjusting 41 C...

Page 123: ...ng 56 checking 55 Plug in stand 24 Putting into operation advice on first use 26 after storage 94 checks before putting into operation 31 R Rear sprocket engine sprocket checking for wear 57 Rear wheel installing 71 removing 71 Rebound damping fork adjusting 46 shock absorber adjusting 42 Riding sag adjusting 44 S Seat mounting 77 removing 76 Service schedule EXC F EXC F SIX DAYS XCF W 35 36 rider...

Page 124: ...ing torques 97 98 fork 102 103 shock absorber 104 Throttle cable route checking 55 Tire condition checking 72 Tire pressure checking 73 Transport 7 Troubleshooting 91 92 Turn signal switch 13 Type label 10 U Use definition 6 V View of vehicle left front 8 right rear 9 W Warranty 6 Wiring diagram 106 115 Work rules 6 ...

Page 125: ... 3211465en 3211465en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 04 2009 Photo Mitterbauer ...

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