KTM 250 EXC-F AUS Owner'S Manual Download

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SERVICE WORK ON THE CHASSIS

10.28

Installing the air filter

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. 109)

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. 52)

10.29

Cleaning the air filter and air filter box

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

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

–

Remove the air filter.

(

p. 52)

B00325-01

–

Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner (

p. 109)

Info

Only press the air filter to dry it, never wring it out.

–

Oil the dry air filter with a high quality filter oil.

Oil for foam air filter (

p. 109)

–

Clean the air filter box.

–

Check the carburetor connection boot for damage and firm seating.

–

Install the air filter.

(

p. 53)

10.30

Removing main silencer

Warning

Danger of burns

The exhaust system gets very hot when the vehicle is driven.

–

Allow the exhaust system to cool down. Do not touch hot components.

Summary of Contents for 250 EXC-F AUS

Page 1: ...OWNER S MANUAL 2011 250 EXC F EU 250 EXC F Factory Edition EU 250 EXC F AUS 250 EXC F SIX DAYS EU 250 XCF W SIX DAYS USA Art no 3211689en ...

Page 2: ......

Page 3: ...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 models portrayed p...

Page 4: ...arations for riding on wet sand 26 Preparing for rides on wet and muddy surfaces 27 Preparing for rides at high temperature and slow speed 28 Preparing for rides at low temperatures or in snow 28 RIDING INSTRUCTIONS 29 Checks and maintenance before putting into operation 29 Starting 29 Starting up 30 Shifting riding 30 Braking 30 Stopping parking 31 Refueling 31 SERVICE SCHEDULE 33 Service schedul...

Page 5: ...x 72 Checking the tire condition 73 Checking tire air pressure 74 Checking spoke tension 74 ELECTRICAL SYSTEM 76 Removing the battery x 76 Installing the battery x 76 Recharging the battery x 76 Removing the main fuse 77 Installing the main fuse 77 Changing the fuse of the radiator fan EXC F SIX DAYS XCF W SIX DAYS 78 Removing headlight mask with headlight 78 Refitting the headlight mask with the ...

Page 6: ...l 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 below Proprietary name Denotes a prop...

Page 7: ...the prescribed running in period and service 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 by an authorized KTM workshop only and confirmed in the customer s service record and in the KTM dealer net otherwise all warranty claims will be void No warranty claim can be hono...

Page 8: ...formation 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 permanent injury if the appropriate measures are not taken Warning Identifies a danger that is lik...

Page 9: ...E 7 3 1 View of the vehicle from the left front example 100882 10 1 Hand brake lever 2 Clutch lever 3 Filler cap 4 Air filter box lid 5 Fork compression adjustment 6 Fuel tap 7 Shift lever 8 Side stand 9 Chain guide ...

Page 10: ...right rear example 100883 10 1 Shock absorber compression adjustment 2 Light switch 3 Throttle grip 4 Fork rebound adjustment 5 Shock absorber rebound adjustment 6 Level viewer rear brake fluid 7 Level viewer engine oil 8 Foot brake lever 9 Kick starter ...

Page 11: ...label is fixed to the front of the steering head 4 3 Key number All EXC F models 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 12: ...SERIAL NUMBERS 10 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 13: ...ed The choke lever is pulled to the stop Choke function deactivated The choke lever is pushed back to the stop 5 3 Hand brake lever 400196 10 Hand brake lever is located on the right side of the handlebar The hand brake lever is used to activate the front brake 5 4 Throttle grip 100858 10 The throttle grip is fitted on the right side of the handlebar 5 5 Short circuit button XCF W SIX DAYS 500132 ...

Page 14: ...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 Turn signal switch All EXC F models 500145 10 Turn signal switch is fitted on the left side of the handleb...

Page 15: ...tch XCF W SIX DAYS 100885 10 The light switch is on the right of the speedometer Possible states Light off Light switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on 5 14 Overview of indicator lamps All EXC F models 500147 01 Possible states High beam indicator lam...

Page 16: ...handlebar Info The trip master is an optional accessory 5 18 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Press the button briefly and repeatedly until H appears at the bottom right of the display ...

Page 17: ...er functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is stationary 400318 01 Press the button briefly and repeatedly until H appears at the bottom right of the display Press the button for 3 5 seconds The Setup menu is displayed and the activated functions are shown Change to the desired function by pressing the button ...

Page 18: ...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 5 23 Display mode SPEED H service hours 400316 01 Condition The motorcycle is stationary Press the button briefly and repeatedly until H appears at the bottom right of the display In display mode H the...

Page 19: ... 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 5 26 Display mode SPEED ODO odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display The total distance traveled is displayed in the ODO display mode Press the button No function Press the button...

Page 20: ...e button briefly and repeatedly 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...

Page 21: ...y 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 starts the next lap The...

Page 22: ...ed See the notes on refueling Warning Danger of poisoning Fuel is poisonous and 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 co...

Page 23: ... 5 36 Choke EXC F AUS XCF W SIX DAYS 100884 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 be deactivated Possible states Choke function activated The choke lever is pulled out to ...

Page 24: ... Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 5 40 Side stand 100886 10 The side stand is on the left side of the vehicle 600665 10 The side stand is used to park the motorcycle Info When you are riding the side stand must be folded up and secured with the rubber band 5 41 Steering lock All EXC F models 500126 10 Steering lock i...

Page 25: ... 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 5 43 Unlocking the steering All EXC F models 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info ...

Page 26: ... brake may fail due to overheating Take your foot off the foot brake lever when you are not braking 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 y...

Page 27: ...sing 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 Arduous riding conditions are Riding on dry sand p 25 Riding on wet sand p 26 Rides on wet and muddy surfaces p 27 Rides at high temperature and slow spee...

Page 28: ... the chain Clean the radiator fins Carefully align bent radiator fins 6 5 Preparations for riding on wet sand 600872 10 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other c...

Page 29: ...y align bent radiator fins 6 6 Preparing for rides 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 and air filter box x p 53 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 Info See the KTM Power...

Page 30: ...x x p 53 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 109 Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 82 6 8 Preparing for rides at low t...

Page 31: ...gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine 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 lo...

Page 32: ...pen the throttle If the choke function was activated deactivate it after the engine has warmed up When you reach maximum speed after fully opening the throttle turn back the throttle to about of its range This barely reduces vehicle 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 shi...

Page 33: ...he 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 Brake the motorcycle Shift transmission to neutral XCF W SIX DAYS Press and hold the short circuit button while the engine is idling until the engine stops All EXC F models Press and hold the short circuit butt...

Page 34: ... 32 A A 400382 10 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx 9 2 l 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 108 Close the filler cap p 20 ...

Page 35: ...smooth operation x Check the fluid level of the hydraulic clutch p 61 Check the brake fluid level of the front brake p 64 Check the free travel of the hand brake lever p 63 Check the steering head bearing play p 49 Check the valve clearance x Check the clutch x Check all hoses e g fuel cooling bleeding drainage and sleeves for tearing tightness and correct routing x Check the anti freeze and coola...

Page 36: ... the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the oil pressure regulator valve x Check the oil pumps and lubrication system x Ch...

Page 37: ...on speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition betwe...

Page 38: ...onding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 9 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen ...

Page 39: ...ference between measurements and Check the static sag Static sag 35 mm 1 38 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 38 9 8 Checking the riding sag of the shock absorber C C 0 0 A A 400222 10 Measure distance of rear wheel unloaded p 37 With another person holding the motorcycle the rider wearing full protective cloth ing sit...

Page 40: ...g to measurement Guideline Spring preload 8 mm 0 31 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Guideline Screw shock absorber adjusting ring M6 5 Nm 3 7 lbf ft Install the shock absorber x p 51 9 10 Adjusting the riding sag x Remove shock absorber x p 50 After removing the shock absorber clean it thoroughly...

Page 41: ...g 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 18 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection covers 9 13 Adjusting the rebound damp...

Page 42: ...0223 11 On the upper triple clamp there are 2 holes at a distance of to each other Distance between holes 15 mm 0 59 in The 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 9 16 Adjusting handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar...

Page 43: ...ebar supports evenly Position the handlebars Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Fit 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 ...

Page 44: ...ust be folded up and secured with the rubber band 10 3 Bleeding fork legs Raise the motorcycle with the lift stand p 42 100888 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the lift stand p 42 10 4 Cleaning the dust boots of the fork legs Raise the motorcycle with the lift stand p 42 Loosen the...

Page 45: ... ft Position the wiring harness Position the brake line Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 7 Removing the fork legs Remove the headlight mask with the headlight p 78 Remove front wheel x p 71 100802 10 Remove screws and take off the clamp Remove cable cli...

Page 46: ...AYS Fully tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Fully tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 100802 11 Position the brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable clip Refit the headlight mask with the headlight p 79 Position the brake line wiring harness and ...

Page 47: ...o Do not unplug the CDI control unit Remove screw Remove screw take off the top triple clamp with the handle bar and set it aside Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines 500100 10 Remove O ring Remove protector ring Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 10 12 Installing the l...

Page 48: ... Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp Position bleeder screws toward the front 100892 10 Fully tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 100894 10 Tighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 lbf ft 100893 10 Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf...

Page 49: ...fender p 51 500149 10 Remove screws and hang the CDI control unit to the side Info Do not unplug the CDI control unit Remove screw Loosen screw Take off the top triple clamp with the handle bar and place it on one side Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines 500150 10 Remove protector ring Remove the lower triple clamp with the ...

Page 50: ...e fork legs Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp Position bleeder screws toward the front 100887 12 Fully tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 100889 10 Tighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 lbf ft 100890 10 Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 l...

Page 51: ...fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present EXC F Factory Edition EXC F SIX DAYS XCF W SIX DAYS Adjust the play of the steering head bearing x p 49 EXC F EU AUS Adjust play of the steering head bearing x p 50 Move the handlebar to and fro over the entire steering range The handlebar must be able to mo...

Page 52: ...mp M8 20 Nm 14 8 lbf ft Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Check the steering head bearing play p 49 10 18 Greasing the steering head bearing x 800010 10 EXC F Factory Edition EXC F SIX DAYS XCF W SIX DAYS Remove the lower triple clamp x p 45 Install the lower triple clamp x p 45 EXC F EU AUS Remove the lower triple clamp x p 47 Install the lower triple clamp x p ...

Page 53: ...bricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Remove the motorcycle from the lift stand p 42 10 21 Removing the front fender 600692 10 Remove screws Remove the front fender Make sure the spacers remain in place 10 22 Installing the front fender 600692 10 Ensure that the spacers are mounted in the fender Position the front fender Mount and tighten sc...

Page 54: ... the air filter box lid into the rear area and clip it into the front area 10 27 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage ...

Page 55: ...s fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 52 B00325 01 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 109 Info Only press the air filter to dry it never wring it out ...

Page 56: ...not touch hot components Remove the main silencer p 53 100444 10 All EXC F models Remove screws of connecting cap Remove the connecting cap perforated pipe and glass fiber yarn filling Remove screws and take off silencer cap with stuffing yarn Mount the new stuffing yarn on silencer cap and fix it with adhesive tape Position the end cap Mount and tighten the screws Insert the perforated piping and...

Page 57: ...ehicle 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 escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eye...

Page 58: ...kin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Check the throttle cable routing p 60 600676 01 Position the fuel tank and fit the two spoilers to the sides of t...

Page 59: ...the chain regularly and then treat with chain spray Chain cleaner p 109 Off road chain spray p 109 10 37 Checking the 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 prematur...

Page 60: ...t the chain tension by turning the adjusting screws left and right Guideline Chain tension 8 10 mm 0 31 0 39 in Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned Tighten nuts Make sure that the chain adjusters are fitted correctly on the adjusting screw...

Page 61: ...t should also be changed New chains wear out faster on old worn sprockets 400983 01 Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M6...

Page 62: ... chain guide x 100857 10 Remove the nut of screw 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 Mount the nut on screw and tighten Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft Condition Number of teeth 45 teeth Insert nut in hole Po...

Page 63: ...justments while riding 10 43 Checking the fluid level of hydraulic clutch Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Info The fluid ...

Page 64: ...ake 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 600683 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 107 On the slave cylinder remove bleeder...

Page 65: ...he free travel of the hand brake lever p 63 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing screw Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited ...

Page 66: ...or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 400231 10 Move the brake fluid reservoir mounted on the handle...

Page 67: ...osition the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 11 7 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 100394 10 Check the brake linings for minimum thickness ...

Page 68: ...valid 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 use DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brak...

Page 69: ...ver 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 foot brake lever x p 67 Reconnect spring 11 10 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system fa...

Page 70: ...e system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective c...

Page 71: ...ble protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Red...

Page 72: ... back the brake piston that you do not press the brake caliper against the spokes 100808 10 Remove locking split pins withdraw bolt and take out the brake linings Clean the brake caliper and brake caliper support 100407 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly 100408 01 Fit the brake linings insert the bolt and mount the loc...

Page 73: ...rk Info Do not operate 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 spacers 12 2 Installing the front wheel x 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 nece...

Page 74: ...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 nut Remove chain adjuster Withdraw 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 spin...

Page 75: ...80 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Remove the motorcycle from the lift stand p 42 12 5 Checking the tire condition Info Only mount tires approved and 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 ...

Page 76: ...ls Front 1 5 bar 22 psi Rear 2 0 bar 29 psi If the tire pressure does not meet specifications Correct the tire air pressure Fit the dust cap 12 7 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect 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 mor...

Page 77: ...WHEELS TIRES 75 Torque wrench with various accessories in set 58429094000 ...

Page 78: ...2 Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat p 52 13 3 Recharging the battery x 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 battery acid and battery gases Keep the battery away f...

Page 79: ...e motor 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 o...

Page 80: ...e only fuses with the prescribed amperage Never by pass or repair fuses 100863 10 Take off the protection cap Info The radiator fan fuse is in the area of the right hand radiator Remove the faulty fuse Insert a new fuse Fuse 58011109105 p 102 Info Replace a faulty fuse by an equivalent fuse only Mount the protection cap 13 7 Removing headlight mask with headlight 600703 10 Switch off all electrica...

Page 81: ...flector Clean the lamp and keep it free of grease before mounting Remove the headlight mask with the headlight p 78 100861 10 Turn rubber cap together with the underlying lamp socket counterclockwise all the way and remove it Pull lamp socket of the parking light out of the reflector 100862 10 Press headlight bulb into the lamp socket lightly turn it counterclockwise all the way and pull it out In...

Page 82: ...cifications Adjust the headlight range p 80 13 11 Adjusting the headlight range Check the headlight adjustment p 80 301251 10 Loosen screw Adjust the headlight range of the headlight by moving it up or down Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider mark is applied under Checking the headlight setting Info A change in weight on the...

Page 83: ...l the way Press any button on the speedometer The speedometer is activated Position the speedometer in the bracket Mount and tighten the screws with washers Refit the headlight mask with the headlight p 79 Set kilometers or miles p 14 Adjust the speedometer functions p 15 Set the clock p 15 ...

Page 84: ...contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition Engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove radiator cap Check the anti freeze of the coolant 25 45 C 13 49 F If the anti freeze of the coolant does not meet specifications Correct the anti freeze of the coolant Check th...

Page 85: ...h affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out 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 ...

Page 86: ...COOLING SYSTEM 84 Refit the radiator cap Make a short test ride Check the coolant level p 82 ...

Page 87: ... p 55 Check the throttle cable routing p 60 600673 10 Move the handlebar to the straight ahead position Push back sleeves Loosen nut Turn adjusting screw in as far as possible Loosen nut Turn adjusting screw so that there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut Press and hold the throttle grip in the closed setting Turn adj...

Page 88: ...on and turn the idle adjusting screw slowly counterclockwise until the idle speed falls Adjust to the point between these two positions with the highest idle speed Info If there is a large engine speed rise reduce the idle speed to a normal level and repeat the above steps The extreme sport motorcyclist will set the mixture about of a turn back from this ideal value leaner in a clockwise direction...

Page 89: ...g to regulations and keep it out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Info Carry out this work with a cold engine Turn handle of the fuel tap to the OFF position Figure 500137 10 p 21 600684 11 Guide the hose coming down behind the engine into a s...

Page 90: ...ever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Mount and tighten screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 91: ... x p 91 Fill up with engine oil x p 92 16 3 Draining the engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc ...

Page 92: ...e 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 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 M2...

Page 93: ...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 16 6 Installing the oil filter x 600689 10 Lay the motorcycle on its side and fill the oil filter housing to about full wi...

Page 94: ...sed space without an effective exhaust extraction system Start the engine and check that it is oil tight Check the engine oil level p 89 16 8 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 107 Mount and tighten screw cap Danger Danger...

Page 95: ... 109 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 87 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 ride a short distance until the engin...

Page 96: ...alted roads clean it with cold water Warm water intensifies the effects of salt 401060 01 Clean the motorcycle p 93 Treat the engine swingarm and all other bare or galvanized parts except the brake discs with a wax based anticorrosive Info Avoid getting anticorrosive on the brake discs this would badly affect the braking After use on salted roads clean the motorcycle thoroughly with cold water and...

Page 97: ...e engine oil and oil filter clean the oil screen x p 89 Check the anti freeze and coolant level p 82 Drain the fuel from the tank into a suitable container Empty the carburetor float chamber x p 87 Check the tire air pressure p 74 Remove the battery x p 76 Recharge the battery x p 76 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location...

Page 98: ...sual 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 carburetor components x Engine has no idle Idling jet blocked Check adjust the carburetor components x Adjusting screws on carburetor dis torted Carburetor adjust the idl...

Page 99: ... C 158 F Defect in radiator fan system EXC F SIX DAYS XCF W SIX DAYS Check the radiator fan fuse Check the radiator fan x Check the thermostat x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 89 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x...

Page 100: ... rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two rotary pumps Primary transmission 22 68 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 13 33 2nd gear 17 33 3rd gear 19 29 4th gear 23 28 5th gear 23 23 6th gear 26 22 Alternator Light coil and charging coil 12 V 80 W Ignition Contactless controlled ful...

Page 101: ...ming chain securing guide M6 8 Nm 5 9 lbf ft Loctite 243 Screw timing chain tensioning rail 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 Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Nut camshaft bearing bridge M7 15 Nm 11 1 lbf ft Lubricated with engine oil Screw camshaft bearing bridge M7 15 Nm 11 1 lbf ft Lubricated w...

Page 102: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 100 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 103: ...846 in Main jet 168 Jet needle OBDYS OBETP Idling jet 42 Idle air jet 100 Cold start jet 65 85 Leakage nozzle 70 Slide stop present 22 2 XCF W SIX DAYS Carburetor type KEIHIN FCR MX 39 Carburetor identification number 3900K Needle position 3rd position from top Idle mixture adjusting screw Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 168 Jet needle OBEKT Idling jet 42 Idle air jet ...

Page 104: ... 50 Final drive XCF W SIX DAYS 13 50 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 All EXC F models 105 7 kg 233 lb Weight without fuel approx XCF W SIX DAYS 103 6 kg 228 4 lb Maximum permissible front axle load...

Page 105: ...AYS EXTREME 120 90 18 M C 65M M S TT Metzeler MEC 6 DAYS EXTREME XCF W SIX DAYS 80 100 21 51M TT Bridgestone Bridgestone M59 100 100 18 64M TT Bridgestone Bridgestone M402 Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel tank capacity approx 9 2 l 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 108 Fuel reserve approx 2 l 2 qt ...

Page 106: ...turns Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 510 mm 20 08 in Weight of rider 75 85 kg 165 187 lb 513 mm 20 2 in Weight of rider 85 95 kg 187 209 lb 510 mm 20 08 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 0 N mm 22 8 lb in Weight of rider 75 85 kg 165 187 lb 4 2 N mm 24 lb in Weight of rider 85 95 kg 187 209 lb 4 4 N mm 25 1 lb in Fork length 940 mm 37 01 ...

Page 107: ... 25 turns Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Spring preload 8 mm 0 31 in 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 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 leng...

Page 108: ...lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand fixing M8 40 Nm 29 5 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem EXC F Factory Edition EXC F SIX DAYS XCF W SIX DAYS M8 17 Nm 12 5 lbf ft Loctite 24...

Page 109: ...y to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 111 SAE p 111 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 engine oil Supplier Motorex Cross Power 4T Fork oil SAE 5 According t...

Page 110: ...SUBSTANCES 108 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 111: ...products Supplier Motorex Protect Shine High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offr...

Page 112: ... polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 113: ...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 114: ...g 58 Chain tension adjusting 58 checking 57 Chassis number 9 Choke 11 21 Clutch fluid level checking 61 fluid changing 62 Clutch lever 11 basic position adjusting 61 Compression damping fork adjusting 39 Compression damping high speed shock absorber adjusting 36 Compression damping low speed shock absorber adjusting 35 Coolant draining 83 refilling 83 Coolant level checking 82 Cooling system 82 D ...

Page 115: ...removing 53 Motorcycle cleaning 93 raising with lift stand 42 removing from lift stand 42 O Oil filter changing 89 installing 91 removing 91 Oil screen cleaning 89 Oil screens cleaning 90 Overview of indicator lamps 13 Owner s manual 6 P Play in throttle cable adjusting 85 checking 85 Protection for winter operation 94 Putting into operation advice on first use 24 after storage 95 checks and maint...

Page 116: ...g 49 Storage 95 T Technical data carburetor 101 chassis 102 103 chassis tightening torques 106 engine 98 engine tightening torques 99 100 fork 104 shock absorber 105 Throttle cable routing checking 60 Throttle grip 11 Tire condition checking 73 Tire pressure checking 74 Transport 6 Troubleshooting 96 97 Turn signal switch 12 Type label 9 U Use definition 5 V View of vehicle left front 7 right rear...

Page 117: ... 3211689en 3211689en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 09 2010 Photo Mitterbauer ...

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