KTM 250 SX 2019 Owner'S Manual Download

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12 BRAKE SYSTEM

12.12

Checking the brake linings of the rear brake

Warning

Danger of accidents

Worn-out brake linings reduce the braking effect.

–

Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)

M01180-10

–

Check the brake linings for minimum thickness

Minimum thickness

≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings.

(

p. 92)

–

Check the brake linings for damage and cracking.
» If damage or wear is encountered:

–

Change the rear brake linings.

(

p. 92)

12.13

Changing the rear brake linings

Warning

Danger of accidents

Incorrect maintenance will cause the brake system to fail.

–

Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)

Warning

Skin irritation

Brake fluid causes skin irritation.

–

Keep brake fluid out of the reach of children.

–

Wear suitable protective clothing and safety glasses.

–

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

–

Consult a doctor immediately if brake fluid has been swallowed.

–

Rinse the affected area with plenty of water in the event of contact with the skin.

–

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.

–

If brake fluid spills on to your clothing, change the clothing.

Warning

Danger of accidents

Old brake fluid reduces the braking effect.

–

Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

Note

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.

Summary of Contents for 250 SX 2019

Page 1: ...OWNER S MANUAL 2019 250 SX 250 XC 300 XC Art no 3213848en ...

Page 2: ......

Page 3: ...nt 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 2018 KTM Spor...

Page 4: ... Service hour counter 22 7 PREPARING FOR USE 23 7 1 Advice on first use 23 7 2 Running in the engine 24 7 3 Preparing the vehicle for difficult operating conditions 24 7 4 Preparing vehicle for rides on dry sand 25 7 5 Preparing vehicle for rides on wet sand 26 7 6 Preparing vehicle for rides on wet and muddy circuits 27 7 7 Preparing vehicle for high temperatures or slow riding 28 7 8 Preparing v...

Page 5: ...in the main silencer 69 11 31 Removing the fuel tank 70 11 32 Installing the fuel tank 71 11 33 Checking the chain for dirt 73 11 34 Cleaning the chain 73 11 35 Checking the chain tension 74 11 36 Adjusting the chain tension 74 11 37 Checking the chain rear sprocket engine sprocket and chain guide 75 11 38 Checking the frame 78 11 39 Checking the swingarm 78 11 40 Checking the throttle cable routi...

Page 6: ...ing gear oil 122 18 CLEANING CARE 124 18 1 Cleaning the motorcycle 124 19 STORAGE 126 19 1 Storage 126 19 2 Preparing for use after storage 127 20 TROUBLESHOOTING 128 21 TECHNICAL DATA 130 21 1 Engine 130 21 1 1 All SX models 130 21 1 2 250 XC US 130 21 1 3 300 XC US 131 21 2 Engine tightening torques 132 21 2 1 All SX models 132 21 2 2 All XC models 133 21 3 Carburetor 135 21 3 1 All SX models 13...

Page 7: ...ined experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this documen...

Page 8: ...s vehicle in closed off areas remote from public road traffic 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respe...

Page 9: ...of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exh...

Page 10: ...2 8 Work rules Special tools are necessary for certain tasks The tools are not a component of the vehicle but can be ordered using the number in parentheses Example bearing puller 15112017000 During assembly use new parts to replace parts which cannot be reused e g self locking screws and nuts seals sealing rings O rings pins and lock washers In the case of certain screws a thread locker e g Locti...

Page 11: ...use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold The Owner...

Page 12: ...uthorized KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and ...

Page 13: ...IMPORTANT NOTES 3 11 A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com ...

Page 14: ... OF VEHICLE 12 4 1 View of vehicle front left example K01222 10 1 Hand brake lever p 16 2 Kill switch p 16 3 Clutch lever p 16 4 Air filter box cover 5 Plug in stand 6 Shift lever p 20 7 Choke p 20 8 Fuel tap ...

Page 15: ... vehicle rear right example K01223 10 1 Seat 2 Filler cap 3 Throttle grip p 16 4 Kick starter p 21 5 Foot brake lever p 21 6 Shock absorber compression adjustment 7 Level viewer for brake fluid rear 8 Shock absorber rebound adjustment ...

Page 16: ...eer ing head 5 2 Type label 401946 10 The type label 1 is fixed to the front of the steering head 5 3 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part number 1 is stamped on the inside of the axle clamp ...

Page 17: ...SERIAL NUMBERS 5 15 5 5 Shock absorber article number 0 0 1 1 401948 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 18: ...ke is engaged using the hand brake lever 6 3 Throttle grip F00001 11 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch F00002 10 The kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit ...

Page 19: ... vehicle If any fuel is spilled wipe it 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 consul...

Page 20: ...ing the filler cap K01132 10 All SX models Mount filler cap 1 and turn it clockwise until the fuel tank is tightly closed Info Run the fuel tank breather hose 2 without kinks K01200 10 All XC models Mount filler cap 1 and turn it clockwise until the release button engages Info Run the fuel tank breather hose 2 without kinks ...

Page 21: ...carburetor The fuel tank empties completely 6 9 Fuel tap All XC models K01202 10 The fuel tap is on the left side of the fuel tank Open or close the fuel supply to the carburetor using tap han dle 1 on the fuel tap Possible states Fuel supply closed OFF Fuel cannot flow from the fuel tank to the carburetor Open fuel supply ON Fuel can flow from the fuel tank to the carburetor The fuel tank empties...

Page 22: ...lts in a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deacti vated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed in to the stop 6 11 Shift lever 401950 10 Shift lever 1 is mounted on the left of the engine 401950 11 All XC models The gear posit...

Page 23: ...ding swing the top part of the kick starter inward toward the engine 6 13 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 14 Plug in stand All SX models H02629 10 The holder for the plug in stand 1 is the left side of the wheel spindle The plug in stand is used to park the motorcycle The plug in stand...

Page 24: ...tand 1 must be folded up and secured with rubber band 2 6 16 Service hour counter K01135 10 The service hour counter 1 is fitted in front of the handlebar It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off Info It is not possible to delete or adjust anything on the service hour count...

Page 25: ... speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of acc...

Page 26: ...ssible rear axle load 190 kg 419 lb Check the spoke tension p 100 Info The spoke tension must be checked after half an hour of operation Run in the engine p 24 7 2 Running in the engine During the running in phase do not exceed the specified engine performance Guideline Maximum engine performance During the first 3 operating hours 70 During the first 5 operating hours 100 Avoid fully opening the t...

Page 27: ...hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operat ing temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Chang...

Page 28: ... sand M01129 01 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the indicated value does not correspond to the setpoint value Warning Danger of scalding During motorcycle oper ation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operat ing temperature Allow ...

Page 29: ...ght carburetor tuning 600868 01 Clean the chain Chain cleaner p 149 Mount the steel sprocket Grease the chain Universal oil spray p 150 Clean the radiator fins Straighten bent radiator fins carefully Condition Regular use in sand Change the piston every 10 operating hours 7 6 Preparing vehicle for rides on wet and muddy circuits M01106 01 Fit a rain cover on the air filter Waterproofing device for...

Page 30: ...8 bar 26 psi If the indicated value does not correspond to the setpoint value Warning Danger of scalding During motorcycle oper ation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operat ing temperature Allow the cooling system and the engine to cool down before you open the ...

Page 31: ...aner p 149 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 106 7 8 Preparing vehicle for low temperatures or snow M01106 01 Fit a rain cover on the air filter Waterproofing device for air filter 79006921000 Info Observe fitting instructions for KTM PowerParts M01107 01 Adjust the carburetor jetting and setting Info Your authorized KTM workshop can recommen...

Page 32: ...ondition p 99 Check the tire air pressure p 99 Check the spoke tension p 100 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 53 Bleed the fork legs p 53 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps reg...

Page 33: ...e choke lever out as far as possible Press the kick starter robustly through its full range Info Do not open the throttle All XC models Turn tap handle of the fuel tap to the ON position Fuel can flow from the fuel tank to the carburetor Remove the motorcycle from the side stand Shift the transmission to idle Condition The engine is cold Pull the choke lever out as far as possible Press the electr...

Page 34: ... the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if running at idle or stationary for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch As a result the gear oil engine and cooling system heat up Ride at a low engine speed instead of at a high ...

Page 35: ...re highly flammable or explosive Allow the vehicle to cool down before covering it Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on t...

Page 36: ... fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a ...

Page 37: ...1 38 in Total fuel tank capacity approx All SX models 7 5 l 1 98 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 148 Total fuel tank capacity approx All XC models 10 l 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 148 Engine oil 2 stroke p 147 Close the filler cap p 18 ...

Page 38: ...brake discs p 83 Check the brake lines for damage and leakage Check the rear brake fluid level p 90 Check the free travel of the foot brake lever p 89 Check the frame p 78 Check the swingarm p 78 Check the swingarm bearing for play Check the heim joint for play Check the shock absorber linkage Check the tire condition p 99 Check the tire air pressure p 99 Check the wheel bearing for play Check the...

Page 39: ...ting hours Once after 20 operating hours Every 20 operating hours Once after 10 operating hours Every 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 81 Lubricate the steering head bearing p 59 Service the fork Perform the shock absorber service Check adjust the carburetor components Check the electric starter drive Check the reed val...

Page 40: ...perating hours Perform minor engine service Check the exhaust control for functioning and smooth operation Check the clutch All XC models Perform major engine service including removing and installing the engine Change the piston and check the cylinder Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Change all engine bear ings All XC models One tim...

Page 41: ... left fork leg and damp ing in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is frequen...

Page 42: ...ing in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info The effect of the ...

Page 43: ... The effect of the high speed setting can be seen in fast compression of the shock absorber K01195 10 Turn adjusting screw 1 all the way clockwise with a socket wrench Info Do not loosen fitting 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed 250 SX EU Comfort 2 turns Standard 1 5 turns Sport 1 turn Compression dampin...

Page 44: ...ew 1 clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping 250 SX EU Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping 250 SX US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping All XC models Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn cloc...

Page 45: ... Measure dimension A of rear wheel unloaded p 42 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and mark ing SAG on the rear fender using the sag gauge Note down the value as dimension B Info The static sag is the difference between measurements A and B Check the static sag Static sag 250 SX EU 35 mm 1 38 in Static sag 250 SX US 35 mm 1 38...

Page 46: ...iding sag Guideline Riding sag 250 SX EU 105 mm 4 13 in Riding sag 250 SX US 105 mm 4 13 in Riding sag All XC models 105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag p 45 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock abs...

Page 47: ...28 in Spring preload All XC mod els 6 mm 0 24 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 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 62 Remove the motorcycle from the lift stand p 52 10 11 Adjusting the riding sag Preparatory work Raise the ...

Page 48: ... The spring rate is shown on the outside of the spring Finishing work Install the shock absorber p 62 Remove the motorcycle from the lift stand p 52 Check the static sag of the shock absorber p 43 Check the riding sag of the shock absorber p 44 Adjust the rebound damping of the shock absorber p 42 10 12 Checking the basic setting of the fork Info For various reasons no exact riding sag can be dete...

Page 49: ... leg Preparatory work Raise the motorcycle with a lift stand p 52 K01141 10 Main work Remove protection cap 1 Push fork pump 2 together fully Fork airpump 79412966000 Info The fork pump is included as part of the motorcycle s separate enclosure Connect the fork pump to the left fork leg The fork pump indicator switches on automatically A little air escapes from the fork leg when connecting Info Th...

Page 50: ...pression damping determines the fork suspension behavior K01142 10 Turn adjusting screw 1 clockwise all the way Info Adjusting screw 1 is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping 250 SX EU Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping 250 SX US Comfort 17 click...

Page 51: ... EU Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping 250 SX US Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping All XC models Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping Mount protection cap 1 10 16 Handlebar position H01188 10 The holes on the handlebar supports are place...

Page 52: ...e off handlebar supports 3 Position rubber bushings 4 and push through nuts 5 from below Place the handlebar supports in the required position Info The handlebar supports are longer and higher on one side Position the left and right handlebar supports evenly Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cab...

Page 53: ...TUNING THE CHASSIS 10 51 Finishing work Mount the handlebar cushion ...

Page 54: ...t stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand H02629 10 All SX models Re...

Page 55: ... 1 of both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with...

Page 56: ...ew screws 4 Take out the right fork leg 11 6 Installing the fork legs H01182 10 Main work Position the fork legs Air release screw 1 of the right fork leg is positioned to the front Valve A of the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp The a...

Page 57: ...ght fork protector 11 8 Installing the fork protector F00024 11 Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 9 Removi...

Page 58: ...iple clamp with the steering stem Remove the upper steering head bearing 11 10 Installing the lower triple clamp 102146 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 149 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether upper steering head seal 1 is correctly posi tioned Slide on protec...

Page 59: ...of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp K01175 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft K01151 10 Tighten screw 4 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft K01152 10 Mount and tighten screw 7 Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243...

Page 60: ...am ages components Correct incorrect steering head bearing play immediately Your authorized KTM workshop will be glad to help Info If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 52 H01167 01 Main work Move the handlebar to th...

Page 61: ...hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Finishing work Check the play of the steering head bearing p 58 Remove the motorcycle from the lift stand p 52 Mount the handlebar cushion 11 13 Lubricating the steering hea...

Page 62: ...art number plate Position the start number plate The holding lugs engage in the fender Mount and tighten screw 1 11 16 Removing front fender Preparatory work Remove the start number plate p 60 M01144 10 Main work Remove screws 1 and 2 Remove front fender 11 17 Installing front fender M01144 10 Main work Position front fender Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10...

Page 63: ...the left frame protector Push the right frame protector to the front and take off at the bottom K01134 10 Remove screw 3 Remove fitting 4 Info Raise the wheel slightly to be able to remove the screws more easily K01136 10 Press angle lever 5 toward the rear Press linkage lever 6 downward K01137 10 Remove screws 7 and pull foot brake cylinder off the push rod M01149 01 Remove the connecting link of...

Page 64: ...r K01139 10 Hold the shock absorber and remove screw 9 K01140 10 Remove the shock absorber carefully at the bottom 11 19 Installing the shock absorber K01140 11 Main work Carefully position the shock absorber into the vehicle from the bottom K01139 11 Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 ...

Page 65: ... K01148 10 Position the foot brake cylinder The push rod 3 engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws 4 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00864 10 Position the angle lever and linkage lever Mount and tighten fitting 5 Guideline Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Info Pay attention to flat area B Moun...

Page 66: ...uideline Screw frame protec tor M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Remove the motorcycle from the lift stand p 52 11 20 Removing the seat K01133 10 Remove screw 1 H02218 10 Raise the rear of the seat pull the seat back and lift it off 11 21 Mounting the seat H02218 11 Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear and push the ...

Page 67: ...ir filter box cover Condition The air filter box cover is secured Remove the seat p 64 K01226 10 Remove screw 1 K01227 10 Pull off the air filter box cover in area A sideways and take off toward the front K01225 10 Condition The air filter box cover is not secured Pull off the air filter box cover in area A sideways and take off toward the front ...

Page 68: ... not secured Insert the air filter box cover in area A and clip it into area B 11 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose o...

Page 69: ...fo Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 65 Remove the air filter p 66 K00518 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 149 Info Only squeeze the air filter to dry it never wring it out Oil the dry air filter with a hi...

Page 70: ...e air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 66 11 27 Preparing air filter box cover for securing Preparatory work Remove the air filter box cover p 65 S02308 10 Main work Drill a hole at marking A Guideline Diameter 6 mm 0 24 in Finishing work Install the air filter box cover p 66 11 28 Removing the...

Page 71: ...deline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 30 Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher th...

Page 72: ...en flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it 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 i...

Page 73: ...her hose off the tank lid K01191 01 Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank 11 32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fue...

Page 74: ...work Check the throttle cable routing p 78 K01191 02 Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables or throttle cables are trapped or dam aged K01190 11 All SX models Mount the fuel tank breather hose Mount and tighten screw 1 with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K01221 11 All XC models Mount t...

Page 75: ...ake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note 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 The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle w...

Page 76: ... The lower chain section 1 must be taut Info Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet the specification Adjust the chain tension p 74 Finishing work Remove the motorcycle from the lift stand p 52 11 36 Adjusting the chain tension Warning Danger of accidents Incorrect chain...

Page 77: ...ghten nut 1 Guideline Nut rear wheel spin dle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm enables different secondary ratios with the same chain length Chain adjusters 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 52 11 37 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycl...

Page 78: ...72 mm 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprock ets K01198 10 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding ...

Page 79: ... Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 402421 10 Check the chain guide with a slide gauge for dimension C Minimum thickness C of the chain guide 6 mm 0 24 in If the measured value is less than the specification Change the chain guide 102192 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws...

Page 80: ...acking or defor mation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by KTM 11 40 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly The throttle slide will then no longer be closed and the speed can no longer be controlled Make sure that the throttle cable routing a...

Page 81: ...ork Install the fuel tank p 71 Mount the seat p 64 11 41 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle t...

Page 82: ...lt a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Info The fluid level rises with increasing wear of the clutch facing discs Never us...

Page 83: ... spills on to your clothing change the clothing Note 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 Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid cont...

Page 84: ...extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 85: ...sic position of the hand brake lever K00453 10 Check the free travel of the hand brake lever p 83 Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han dlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake le...

Page 86: ...ts An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduce...

Page 87: ...ater in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule You...

Page 88: ...nts Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help H01333 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings p 86 Check the brake linings for damage and cracking If damage or w...

Page 89: ...iciency Not all brake linings are tested and approved for KTM motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homologa tion is not guaranteed In this case the vehicle no longer corresponds to its condi...

Page 90: ...are seated correctly 101738 01 Insert the new brake linings insert the pin and mount the cot ter pins Info Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point K00521 10 Correct the brake fluid quantity to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in ...

Page 91: ...djusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification K00523 10 Detach spring 1 Loosen nut 2 and with push rod 3 turn it back until yo...

Page 92: ...ure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Preparatory work Check the brake linings of the rear brake p 92 K01216 10 Main work Stand the vehicle upright Check the brake fluid level in level viewer 1 If the brake fluid has dropped below marking A Add rear brake fluid p 90 12 11 Adding rear br...

Page 93: ... changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Note 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 Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines...

Page 94: ...arning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoro...

Page 95: ...does Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove cotter pins 3 pull out pin 4 and remove the brake linings Clean the brake caliper and brake caliper support 101741 10 Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly Info The arrow on the leaf spring points in t...

Page 96: ...SYSTEM 94 K01185 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 147 Mount and tighten screw cap 1 with membrane 2 and the O ring Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 97: ... back the brake pistons K00454 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 H01340 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out...

Page 98: ...rs Clean and grease the wheel spindle Long life grease p 149 K00454 11 Lift the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake lin ings are seated correctly against the brake disc Remove the...

Page 99: ...ear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed H03002 10 Remove sp...

Page 100: ...d Mount the chain H00007 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 74 Tighten nut 4 Guideline Nut rear wheel spin dle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length C...

Page 101: ...The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 years old Change the tires 13 6 C...

Page 102: ...ularly and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tensions You should hear a high not...

Page 103: ... and hold the kill switch while the engine is idling until the engine stops Remove the seat p 64 F00138 10 Main work Disconnect negative cable 1 from the battery Pull back positive terminal cover 2 and disconnect the posi tive cable from the battery Remove screw 3 Pull holding bracket 4 forward and remove battery toward the top 14 2 Installing the battery All XC models H00386 10 Main work Position...

Page 104: ...Do not dispose of batteries as household waste Dispose of batteries at a collection point for used batteries Note 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 battery it discharges steadily The charging level ...

Page 105: ...harge the battery regu larly when the motorcy cle is not in use 6 months US battery charger 79629974500 Alternative 1 EU battery charger 79629974000 These battery chargers test whether the battery retains its voltage It is also impossible to overcharge the bat tery with these battery chargers The charging time may be longer at low temperatures These battery chargers are only suitable for lithium i...

Page 106: ...witch while the engine is idling until the engine stops Remove the seat p 64 K01230 10 Main work Pull starter relay 1 from the holder K01231 10 Take off protection caps 2 Remove faulty main fuse 3 Info A faulty fuse has a burned out fuse wire A A spare fuse 4 is located in the starter relay Install a new main fuse Fuse 58011109110 p 141 Check that the electrical system is functioning properly Tip ...

Page 107: ...ring motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area...

Page 108: ...cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if co...

Page 109: ... come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Position the motorc...

Page 110: ...05 10 All SX models Make sure that screw 1 is tightened Position the motorcycle upright Completely fill the radiator with coolant Coolant p 147 K01208 10 Loosen screw 2 until coolant escapes without bubbles Mount and tighten screw 2 Guideline Bleeder screw cylinder head M6 10 Nm 7 4 lbf ft Completely fill the radiator with coolant Coolant p 147 K01179 10 Mount radiator cap 3 Danger Danger of poiso...

Page 111: ...w cylinder head M6 10 Nm 7 4 lbf ft Completely fill the radiator with coolant Coolant p 147 K01210 10 Mount radiator cap 3 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed s...

Page 112: ...hen starting or running the engine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 110 16 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cable has already been secured the fuel tank does not n...

Page 113: ...t MJ has the greatest influence with the throttle slide open full throttle If the insulator of a new spark plug is very light or white after a brief ride at full throttle or if the engine knocks a larger main jet needs to be used If the insulator is dark brown or sooty a smaller main jet needs to be used Needle position POS The needle position has the greatest influence in the mid throttle slide r...

Page 114: ...e is 1 8 open the first cylindrical part of the needle the idling jet and the clip position have the greatest influence 1 4 1 8 1 2 3 4 0 1 1 4 1 8 1 2 3 4 0 1 K00496 01 When the throttle slide is 1 4 open the idling jet and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle ...

Page 115: ...he optimal carburetor tuning is shown under the respective model 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and operat ing conditions 16 4 Carburetor idle 402799 10 The idle setting of the carburetor has a big influence on the start ing behavior sta...

Page 116: ... shown under the respective model Run the engine until warm Guideline Warm up time 5 min Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Adjust the idle speed with a...

Page 117: ...iming map adjustment K01214 10 All SX models Plug in connector 1 of the ignition timing map adjustment is located on the frame under the fuel tank K01217 10 All XC models Plug in connector 1 of the ignition timing map adjustment is located on the frame under the fuel tank Possible states All SX models Soft The plug in connector of the ignition timing map adjustment is disconnected to achieve bette...

Page 118: ...ls Join plug in connector 1 of the ignition timing map adjustment Figure K01217 10 p 115 Performance better performance 16 8 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400692 10 Sit on the vehicle in the ...

Page 119: ...iary spring with yellow marking Auxiliary spring mounted at the factory with medium tuning standard for good rideability Auxiliary spring with green marking Auxiliary spring for even softer performance Auxiliary spring with red marking Auxiliary spring for aggres sive performance The engine characteristic can be influenced by different spring strengths of auxiliary spring 1 16 11 Engine characteri...

Page 120: ...nd position them together in the clutch cover Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring insert 5 engages in the angle lever Info Screw 6 must not be turned as this would worsen the engine characteristic Check the O ring in the cap Position the cap Mount and tighten screws Guide...

Page 121: ...sition them together in the clutch cover Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring insert 5 engages in the angle lever Info Screw 6 must not be turned as this would worsen the engine characteristic Check the O ring in the cap Position the cap Mount and tighten screws Guideline ...

Page 122: ...enty 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 Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Info ...

Page 123: ...10 Nm 7 4 lbf ft Screw gear oil level check All XC mod els M6 10 Nm 7 4 lbf ft Attach the foot brake lever spring 17 3 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous ...

Page 124: ...ear oil Gear oil 0 80 l 0 85 qt Engine oil 15W 50 p 147 Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space St...

Page 125: ...rew gear oil level check All SX mod els M6 10 Nm 7 4 lbf ft Screw gear oil level check All XC mod els M6 10 Nm 7 4 lbf ft Install and tighten the filler plug with O ring 2 Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extra...

Page 126: ...d direct sunlight on the motorcycle during cleaning 401061 01 Close off the exhaust system to prevent water from entering Remove coarse dirt particles by spraying gently with water Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft brush Motorcycle cleaner p 149 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner...

Page 127: ... exhaust sys tem with anti corrosion materials Preserving materials for paints metal and rubber p 150 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 150 ...

Page 128: ...s or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 149 Refuel p 34 Clean the motorcycle p 124 Change the gear oil p 121 Check the antifreeze and ...

Page 129: ...e the engine will not warm up sufficiently the water vapor produced during combustion will condense caus ing engine parts and the exhaust system to rust 19 2 Preparing for use after storage 401059 01 All XC models Install the battery p 101 Remove the motorcycle from the lift stand p 52 Perform checks and maintenance measures when preparing for use p 30 Make a test ride ...

Page 130: ...rode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap All SX mod els 0 60 mm 0 0236 in Spark plug electrode gap All XC mod els 0 60 mm 0 0236 in Fault in ignition system Check the ignition system Kill switch cable in wiring har ness frayed kill switch defec tive Check the kill switch The connector or ignition coil is loose or oxidized Clean the connec...

Page 131: ...uel tap to the RES position Refuel p 34 Engine takes in bad air Check the intake flange and carburetor for tightness The connector or ignition coil is loose or oxidized Clean the connector and treat it with contact spray Engine overheats Too little coolant in cooling sys tem Check the cooling system for leakage Check the coolant level p 106 Too little air stream Switch off engine when stationary R...

Page 132: ...lically activated Transmission 5 gear claw shifted Transmission ratio First gear 14 28 Second gear 16 26 Third gear 18 24 Fourth gear 21 24 Fifth gear 22 21 Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment type Kokusan Spark plug NGK BR 8 ECM Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter 21 1 2 250 XC US Design 1 cylinder 2 st...

Page 133: ...lacement 293 2 cm 17 892 cu in Stroke 72 mm 2 83 in Hole 72 mm 2 83 in Exhaust valve beginning of adjustment 5 500 rpm Crankshaft bearing 1 grooved ball bearing 1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings X distance upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z distance height of con...

Page 134: ...octite 243 Screw retaining bracket of exhaust control M5 7 Nm 5 2 lbf ft Loctite 2701 Screw stator M5 6 Nm 4 4 lbf ft Loctite 243 Bleeder screw cylinder head M6 10 Nm 7 4 lbf ft Nut water pump impeller M6 6 Nm 4 4 lbf ft Loctite 243 Screw alternator cover M6 8 Nm 5 9 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw control flap exhaust con trol M6 8 Nm 5 9 lbf ft Loctite 243 Screw engi...

Page 135: ...er exhaust control M5 6 Nm 4 4 lbf ft Loctite 243 Screw bearing retainer M5 7 Nm 5 2 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf ft Screw crankshaft position sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw exhaust control bearing support M5 6 Nm 4 4 lbf ft Loctite 243 Screw exhaust control cap M5 5 Nm 3 7 lbf ft Screw exhaust control cover M5 4 Nm 3 lbf ft Loctite 222 Screw locking...

Page 136: ...ctite 243 Screw starter motor protection cap M6 8 Nm 5 9 lbf ft Screw stator M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Screw balancer shaft M8 30 Nm 22 1 lbf ft Loctite 243 Screw cylinder head M8 27 Nm 19 9 lbf ft Screw kick starter M8 25 Nm 18 4 lbf ft Loctite 2701 Nut cylinder base M10 35 Nm 25 8 lbf ft Screw drive chain engine sprocket M10 60 Nm 44 3 lbf ft Loct...

Page 137: ...r identification number TMX 38 87 Needle position 3rd position from top Jet needle 6BFY42 71 6BFY43 71 Main jet 450 430 440 460 470 Idling jet 35 30 32 5 37 5 40 Starting jet 80 Needle jet S 1 Idle air adjusting screw Open 1 5 turns 21 3 2 Carburetor tuning All SX models 403172 01 M FT ASL Sea level ...

Page 138: ...ion from top MJ Main jet Info Do not use on sandy terrain 21 3 3 Carburetor basic setting for sandy surfaces All SX models Idle air adjusting screw Open 1 5 turns Idling jet 37 5 Jet needle 6BFY43 71 Needle position 3rd position from top Main jet 470 Info If the engine is not running smoothly use a smaller main jet ...

Page 139: ... 38 85 Needle position 2nd position from top Jet needle 6BFY43 75 6BFY42 75 Main jet 470 450 460 480 Idling jet 35 30 32 5 Starting jet 80 Needle jet S 4 Idle air adjusting screw Open 2 turns 21 3 5 Carburetor tuning 250 XC US 403173 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open ...

Page 140: ...21 TECHNICAL DATA 138 IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain ...

Page 141: ...8 80 Needle position 2nd position from top Jet needle 6BFY43 75 6BFY42 75 Main jet 450 430 440 460 Idling jet 25 22 5 27 5 Starting jet 80 Needle jet S 4 Idle air adjusting screw Open 1 5 turns 21 3 7 Carburetor tuning 300 XC US 402896 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open ...

Page 142: ...l XC models 10 l 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 148 Fuel reserve approx All XC models 1 5 l 1 6 qt 21 5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Upside down AER 48 Suspension travel front 310 mm 12 2 in rear 300 mm 11 81 in Fork offset 22 mm 0 87 in Shock absorber WP Suspension 5018 DCC Link Brake system D...

Page 143: ...lb 21 6 Electrical system Battery All XC models HJTZ5S FP Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Fuse All XC models 58011109110 10 A 21 7 Tires Validity Front tire Rear tire All SX models 80 100 21 51M TT Dunlop GEOMAX MX3S 110 90 19 62M TT Dunlop GEOMAX MX3S All XC models 90 90 21 54M TT Dunlop GEOMAX AT81F 110 100 18 64M TT Dunlop GEOMAX AT81 The tires ...

Page 144: ...ebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 10 4 bar 151 psi Fork length 950 mm 37 4 in Oil capacity external mechanism left 200 40 20 ml 6 76 1 35 0 68 fl oz Fork oil SAE 4 48601166S1 p 148 Oil capacity external mechanism right 200 40 20 ml 6 76 1 35 0 68 fl oz Fork oil SAE 4 48601166S1 p 148 Grease capacity left cartridge 5 g 0 18 oz Multi purpose grease 00062...

Page 145: ...rd 12 clicks Sport 10 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring preload 7 mm 0 28 in Spring rate Weight of rider 65 75 kg 143 165 lb 39 N mm 223 lb in Weight of rider 75 85 kg 165 187 lb 42 N mm 240 lb in Weight of rider 85 95 kg 187 209 lb 45 N mm 257 lb in Spring length 260 mm ...

Page 146: ... 21 9 3 All XC models Shock absorber article number 18 18 7S 73 Shock absorber WP Suspension 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 6 mm 0 24 in Spring rate Weight of rider 65 ...

Page 147: ...4 lbf ft Screw absorbing element on mani fold M6 6 Nm 4 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 6 Nm 4 4 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 Nut foot brake lever stop M8 20 Nm 14 8 lbf ...

Page 148: ... Loctite 2701 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut frame on linkage lever M14x1 5 80 Nm 59 lbf ft Nut linkage lever on swingarm M14x1 5 80 Nm 59 lbf ft Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw to...

Page 149: ... stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility comp...

Page 150: ...ainer and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 ...

Page 151: ...zer High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Multi purpose grease 00062010051 Recommended supplier Klüber Lubrication CENTOPLEX 2 EP Off road chain spray Recommended supplier Motorex Chainlube Offroad Oil for foam air filter Recommended supplier Motorex Racing Bio ...

Page 152: ...aints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 153: ...t motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classificati...

Page 154: ...25 LIST OF ABBREVIATIONS 152 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 155: ... 140 Carburetor float chamber emptying 120 idle 113 idle speed adjusting 114 Carburetor setting 111 Chain checking 75 cleaning 73 Chain guide checking 75 Chain tension adjusting 74 checking 74 Chassis number 14 Choke 20 Clutch fluid level checking correcting 80 fluid changing 81 Clutch lever 16 basic position adjusting 80 Compression damping fork adjusting 48 Coolant draining 107 refilling 108 Coo...

Page 156: ... High speed compression damping shock absorber adjusting 41 I Ignition timing map changing 116 plug in connector 115 Implied warranty 10 Intended use 6 K Kick starter 21 Kill switch 16 L Lower triple clamp installing 56 removing 55 Low speed compression damping shock absorber adjusting 40 M Main fuse changing 104 Main silencer glass fiber yarn filling changing 69 installing 69 removing 68 Misuse 6...

Page 157: ...60 removing 60 Starting 30 Steering head bearing lubricating 59 Steering head bearing play adjusting 59 checking 58 Storage 126 Swingarm checking 78 T Technical data capacities 140 carburetor 135 chassis 140 chassis tightening torques 145 electrical system 141 engine 130 engine tightening torques 132 fork 141 shock absorber 143 tires 141 Throttle cable play adjusting 110 checking 110 Throttle cabl...

Page 158: ... 3213848en 3213848en 03 2018 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 250 SX 2019, Owner'S Manual

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