KTM 250 EXC-F 2018 Setup Instructions Download

Page: 48 / 48

*3213717en*

3213717en

04/2017

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria

http://www.ktm.com

Photo: Mitterbauer/KTM

Summary of Contents for 250 EXC-F 2018

Page 1: ...SETUP INSTRUCTIONS 2018 250 EXC F 250 EXC F Six Days Art no 3213717en ...

Page 2: ......

Page 3: ...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 figures and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2017 KTM Sportmo...

Page 4: ... or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates a resistance measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand availa...

Page 5: ...npack it Check that the scope of supply is complete using the enclosed pack ing list Have a lift stand available Lift stand 78129955100 Carefully loosen and remove the tension belt of the footrest mount Info An assistant prevents the motorcycle from falling over 402050 01 Together with an assistant take the vehicle off the pallet Position the vehicle on a lift stand Check the vehicle for transport...

Page 6: ...clamp Have a lift stand available Lift stand 78129955100 402051 01 Together with an assistant take the vehicle off the pallet Position the vehicle on a lift stand Check the vehicle and attachments for transport damage Install the shock absorber p 22 H01768 10 Position the turn signal indicator lamp 1 in the speedometer bracket 402736 10 Position the connector retainer and speedometer on the upper ...

Page 7: ...paired handlebar poses a safety risk If the handlebar is bent or straightened the mate rial becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is dam aged or bent Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position the handlebar clamps Mount and tighten the screws evenly Guideline Screw handlebar clamp M8 20 Nm 14 8...

Page 8: ...ired handlebar poses a safety risk If the handlebar is bent or straightened the mate rial becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is dam aged or bent Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position the handlebar clamps Mount and tighten the screws evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 l...

Page 9: ...se and the insurance coverage If the combination switch is installed the vehicle s approval for road use is invalidated Only operate the vehicle in closed off areas remote from public road traffic if the combina tion switch is installed Optional Mount combination switch on the left side Info The figure shows a possible installation position of the left side combination switch S01410 01 EXC F US Po...

Page 10: ...e tie S01411 01 EXC F Six Days Warning Voiding of the government approval for road use and the insurance coverage If the combination switch is installed the vehicle s approval for road use is invalidated Only operate the vehicle in closed off areas remote from public road traffic if the combina tion switch is installed Optional Remove the protection cap and join the plug in connector of the left c...

Page 11: ...2 SETUP 9 S01412 10 Route the cable without tension and secure with cable ties and cable holder H01060 01 Mount the mirror clamps on both sides E00474 01 Mount both rear mirrors with the adapter ...

Page 12: ...d right F01077 10 Mount the left hand guard Mount the right hand guard E00482 01 Secure the handlebar cushion with two cable ties Install front fender p 25 Install the front wheel p 24 EXC F EU AU US EXC F Six Days Remove the battery p 26 Recharge the battery p 29 ...

Page 13: ...and battery gases get into the eyes Fill the battery Info Read the notes in the battery package Recharge the battery p 30 EXC F US Install the headlight mask with the headlight p 20 Install the battery p 28 EXC F EU AU BR EXC F Six Days Remove the fuel tank p 32 S01393 10 Position turn signal cable harness Insert the indicator lamp with the black and violet cable colors into socket 4 E00484 10 Pos...

Page 14: ... and secure turn signal cable harness using cable ties to the main wiring harness under the rubber bands of fuel tank support E00494 10 Remove screw 6 Remove screw 7 Pull off the side cover in area A and area B and remove it toward the rear E00487 10 Detach spring 8 Spring hook 50305017000 Remove screws 9 with the washers and take off the main silencer S01417 10 Pull off engine electronics control...

Page 15: ... contact disk S01416 10 Remove screws bo Carefully pull the tail light cable out of the frame paying attention to the plug as you do so Take off license plate holder with tail light toward the rear E00491 10 Remove screws bp and hang the tail light to the side Drill a hole at the marking C to the size of the marking ...

Page 16: ...gnal cable harness on the license plate holder and pass turn signal cable harness through the drill hole Position tail light on license plate holder and mount and tighten screws bp E00495 10 Carefully pass the tail light cable through the frame pay ing attention to the plug as you do so Position license plate holder on the rear Mount and tighten screws bo ...

Page 17: ...nector Mount engine electronics control unit on the holder Info The wiring harness runs under the engine electron ics control unit E00487 10 Position the main silencer Mount screws 9 with the washers but do not tighten yet Attach spring 8 Spring hook 50305017000 Tighten screws 9 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft E00494 10 Attach the side cover in area A and engage it in area B...

Page 18: ...10 Position license plate holder on the license plate holder Join the plug in connector of the license plate lamp Connect the plug in connector of the left turn signal which is marked red Connect the plug in connector of the right turn signal which is marked green Mount and tighten screws bo D02151 10 Position the right footrest and pin Info Only insert the pin to the extent that the spring can st...

Page 19: ...00 The special tool is applied to area F on the footrest Mount pin bt S01397 10 Mount the washer and split pin ck S01398 10 Position the left footrest and pin Info Only insert the pin to the extent that the spring can still be mounted S01399 10 Position spring as shown Spring G engages in area H ...

Page 20: ...2 lbf ft Mount the cable tie s EXC F AU EXC F Six Days Install the engine guard p 37 Unpack and mount the KTM PowerParts included in the deliv ery optional Info Read the accompanying KTM PowerParts fitting instruc tions Apply the sticker included in the delivery optional Set kilometers or miles p 39 Adjust the combination instrument p 40 Set the clock p 40 Refuel p 38 Position all controls in thei...

Page 21: ...te Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info While riding the side stand must be folded up and secured with the rubber band 3 3 Removing the headlight mas...

Page 22: ...ht mask up and swing it forward V00459 10 Detach plug in connectors 2 and take off the headlight mask with the headlight 3 4 Installing the headlight mask with the headlight E00356 11 Main work EXC F EU AU BR EXC F Six Days Connect plug in connectors 1 V00458 11 Position the headlight mask and fix it with rubber bands 2 The holding lugs engage in the fender Position the brake line and wiring harne...

Page 23: ...tal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle vertically at a distance A away from the wall Guideline Distance A 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary bet...

Page 24: ...e vehicle may require a correc tion of the headlight range Tighten screw 1 3 7 Installing the shock absorber V00806 11 Main work Push splash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Mount and tighten screw 3 Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Info The hei...

Page 25: ...line Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 402556 10 EXC F Six Days Position the fork legs Bleeder screws 1 are positioned toward the front Info The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COM white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove fro...

Page 26: ... H00935 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 1 and contact surface A of the spacers Long life grease p 45 Insert the spacers Clean and grease the wheel spindle Long life grease p 45 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned V00364 11 ...

Page 27: ...t and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00576 10 EXC F Six Days Position front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S01321 10 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 20 Check the headlight setting p 21 ...

Page 28: ...ews chassis M6 10 Nm 7 4 lbf ft 3 13 Removing the battery Warning Environmental hazard Batteries contain environmentally hazardous materials Do not dispose of batteries as household waste Dispose of batteries at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc corre...

Page 29: ... well ventilated rooms Maintain a minimum clearance from inflammable materials when charging batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged batteries if charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the mini mum voltage correctly Disconnect negative cable 1 from the battery Pull back positive...

Page 30: ...gases get into the eyes Disconnect negative cable 1 from the battery Pull back positive terminal cover 2 and disconnect the positive cable from the battery Remove screw 3 Pull holding bracket 4 forward and remove battery toward the top 3 14 Installing the battery H00386 10 Main work Insert the battery into the battery compartment with the termi nals facing forward and secure with holding bracket 1...

Page 31: ...contain environmentally hazardous materials Do not dispose of batteries as household waste Dispose of batteries at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Even when there is no load on the bat...

Page 32: ...se 3 months Finishing work Mount the seat p 26 3 16 Recharging the battery EXC F BR Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the battery Only charge batteries in well ventila...

Page 33: ...t in a discharged state for an extended period over discharge and sulfating occurs destroying the battery The battery is maintenance free i e the acid level does not have to be checked Preparatory work Remove the seat p 26 311910 10 Main work Connect the battery charger to the battery Set the battery charger Alternative 1 Battery charger XCharge professional EU 00029095050 Alternative 2 Battery ch...

Page 34: ...apors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work Remove the seat p 26 K00555 10 Main work Unplug connector 1 of the fuel pump Remove...

Page 35: ...he injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel line Mount wash cap set 2 Wash cap set 81212016100 K00558 10 Remove screws 3 with the collar bushings Hang the horn and horn bracket to one side K00556 11 Remove screw 4 with the rubber bushing K00559 10 Pull both spoilers off the sides of the radiator bracket and lift off the fuel ta...

Page 36: ... if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Check throttle cable routing p 35 Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracke...

Page 37: ... line at a safe distance from the exhaust system E00509 10 EXC F US Plug in connector 3 for the fuel pump Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 4 for the fuel line Info Ro...

Page 38: ...bber band If the throttle cable routing is not as specified Correct throttle cable routing S01404 01 EXC F US Check throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars and above the fuel tank bracket to the throttle valve body Both throttle cables must be secured behind the fuel tank contact area rubber band If the throttle cable routing is not as ...

Page 39: ...t off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact wit...

Page 40: ...h hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes t...

Page 41: ...ngly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds The Setup menu is displayed and the active functions are shown Repeatedly press the button briefly until Km h Mph flashes Setting the Km h Press t...

Page 42: ...the setup menu is closed Repeatedly press the button briefly until the desired func tion flashes The selected function flashes Activating the function Press the button The symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappears in the display and the next function appears 3 26 Setting the clock Condition The motorcycle ...

Page 43: ...RK 41 Info The seconds can only be set to zero If no button is pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed ...

Page 44: ...s chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw chain sliding guard M6 14 Nm 10 3 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw throttle grip M6 5 Nm 3 7 lbf ft Fuel connection on fuel pump M8 ...

Page 45: ...e clamp EXC F EU AU BR US M8 20 Nm 14 8 lbf ft Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Screw top shock absorber M12 80 Nm 59 lbf ft Loctite ...

Page 46: ...M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded type C ROZ 95 RON 95 PON 91 Standard classification ANP Agência Nacional do Petróleo 57 ROZ 95 RON 95 PON 91 Guideline Only use super unleaded fuel that matches or is equivalent to the following specifications Super unleaded fuel with an ethanol content of 19 to 27 is permissible Info Do not use fuel made of methanol e g M15 ...

Page 47: ...6 AUXILIARY SUBSTANCES 45 Long life grease Recommended supplier Motorex Bike Grease 2000 ...

Page 48: ... 3213717en 3213717en 04 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 250 EXC-F 2018, Setup Instructions

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