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INTRODUCTION

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*3213443en*

3213443en

11/2015

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest
of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It
is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.

© 2015 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria

This document is valid for the following models:

250 SX

F EU (F8101P5)

250 SX

F US (F8175P5)

250 XC

F US (F8175P0)

Summary of Contents for 250 SX-F

Page 1: ...SETUP INSTRUCTIONS 2016 250 SX F 250 XC F Art no 3213443en ...

Page 2: ......

Page 3: ...ms 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 devi ations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong ...

Page 4: ...page Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Identifies a proprietary name Name Identifies a protected name Brand Identifies a trademark Underlined terms Refe...

Page 5: ... transport damage M00075 11 Package 12 Remove the box and the plastic packaging Info An assistant prevents the motorcycle from falling over To avoid damaging the motorcycle during the setup leave the protective film on the vehicle until you have finished Remove the separate enclosure and unpack it Check that the scope of supply is complete on the basis of the enclosed packing list 402051 01 Have a...

Page 6: ...per 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 air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg Tighten the screws of the triple clamp Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 402556 13 SX F US XC F ...

Page 7: ...les can be seen in the figure M01068 01 Position the controls on the left half of the handlebar Info The figure shows how to route the clutch line and wiring harness Install the front fender p 7 Install the front wheel p 6 Mount the fuel tank breather correctly M01069 01 Mount the handlebar cushion Install the start number plate p 7 Install the footrests p 8 Recharge the battery p 10 Install the b...

Page 8: ...spindle Info Remove the plug in stand before starting on a trip 401943 10 XC F US Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 3 3 Installing the front wheel Warning Danger of accidents Reduc...

Page 9: ... legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 3 4 Installing the front fender 102162 10 Main work Position the front fender Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 7 3 5 Installing the start number plate 102161 10 Attach the start number plate to the brake line Position the ...

Page 10: ...rear and simultaneously push it forward The seat is correctly engaged 102173 10 Mount and tighten the seat fixing screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 3 8 Installing the footrests Info The procedures are the same on both footrests Condition The frame protectors have been removed on the left and right D00674 10 Position the new footrest and pin Info Only insert the pin to t...

Page 11: ...ry Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Contact disks must be mounted under screws and cable sockets with the claws toward the battery terminal Slide positive terminal cover over the positive terminal H00386 10 XC F US Insert the battery into the battery compartment with the terminals facing for ward and secure with the holding bracket Battery HJTZ5S FP Mount and tighten screw Gu...

Page 12: ...the battery it discharges steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current charging voltage or charging time are exceeded the battery will be destroyed If the battery is depleted by repeated starting the battery must be charged ...

Page 13: ...o test the alternator With this device you cannot overcharge the battery The charging time may be longer at low temperatures Switch off the battery charger after charging and disconnect from the battery Finishing work Install the battery p 9 Mount the seat p 8 3 11 Opening the filler cap Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and...

Page 14: ...ff the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If co...

Page 15: ...he ground or the sewage system Switch off the engine Open the filler cap p 11 A A 401522 10 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx All SX F models 7 5 l 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 15 Total fuel tank capacity approx XC F US 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 15 Close the filler...

Page 16: ...ining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw side stand attachment XC F US M8 35 Nm 25 8 lbf ft Loctite 2701 Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 25 Nm 18 4 lbf ft Loctite 2701 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Sc...

Page 17: ...8 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 E85 E100 ...

Page 18: ...6 AUXILIARY SUBSTANCES 16 Long life grease Recommended supplier Motorex Bike Grease 2000 ...

Page 19: ... 3213443en 3213443en 11 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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