KTM 250 SX-F, XCF-W 250 EXC-F, EXC-F SIX DAYS, 250 XC-F, XCF-W User Manual

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KTM 250 SX-F, XCF-W 250 EXC-F, EXC-F SIX DAYS, 250 XC-F, XCF-W User Manual

OWNER’S MANUAL 2008

250 SX-F

250 XC-F, XCF-W

250 EXC-F, EXC-F SIX DAYS

3211228en

INTRODUCTION »

We would like to congratulate you on your purchase of a KTM motorcycle.

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.

Please insert the serial numbers of your motorcycle in the boxes below

Frame number

Engine number

Key number

Stamp of dealer

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

© 2006 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

Tampering with noise control system prohibited

Owners are warned that the law may prohibit:

(a)The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

(b)the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

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In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

IMPORTANT INFORMATION »

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2

INTENDED PURPOSE

KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions.

The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.

The SX-F and XC-F models are prohibited on public roads.

„On the road“ approved models are only allowed on public roads in the original homologated (throttled) version. Without this performance restriction (i.e. de-throttled), these models are only allowed to be driven off-road and not on public roads.

The EXC-F models are designed for off-road sports endurance competitions(enduro) and not suitable for predominant motocross use.

OWNER’S MANUAL

Please read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance.

In your own interest, please pay particular attention to notices that are marked as follows:

Ignoring these instructions can be dangerous to life and limb!

Ignoring these instructions may damage parts of the motorcycle or impair the motorcycle's traffic safety!

At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it.

SERVICE

Observance of the service, maintenance and tuning instructions for the engine and chassis specified in the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on checking the basic chassis setting).

The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached.

IMPORTANT INFORMATION »

The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle.

WARRANTY

The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle.

AUTOMOTIVE FLUIDS

The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule.

SPARE PARTS, ACCESSORIES

For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products.

TRANSPORT

When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position. Be sure that the fuel tap is closed. If the motorcycle topples over, fuel can flow out of the carburetor or fuel tank

ENVIRONMENT

Offroad-Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others.

Enjoy driving your motorcycle !

KTM-SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

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TABLE OF CONTENTS »

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4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . .

. . . . . .2

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . .

. . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . .

. . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . .

. . . . .5

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .5

Hot start lever . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .5

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .6

Short circuit button . . . . . . . . . . . . . . . . . . . . . . .

. . . . .6

Combination switch . . . . . . . . . . . . . . . . . . . . . . .

. . . . .6

Headlamp switch . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .6

Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .6

Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .7

Emergency OFF switch . . . . . . . . . . . . . . . . . . . . .

. . . . .7

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .7

Electronic speedometer . . . . . . . . . . . . . . . . . . . . .

. . . . .7

Activating and deactivating display modes . . . . . . .

. . . . .8

Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .11

Overview of the electronic speedometer functions . .

. . . .11

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .12

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .12

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .12

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .13

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .13

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .13

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .13

Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .13

Compression damping of fork . . . . . . . . . . . . . . . .

. . . .14

Rebound damping of fork . . . . . . . . . . . . . . . . . . .

. . . .14

Compression damping of shock absorber . . . . . . . . .

. . . .15

Rebound damping of shock absorber . . . . . . . . . . .

. . . .15

Engine characteristic . . . . . . . . . . . . . . . . . . . . . .

. . . .16

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE .16

Instructions for initial operation . . . . . . . . . . . . . . .

. . . .16

Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .16

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .

. . . .17

Check the following before each start . . . . . . . . . . .

. . . .17

Starting when the engine is cold . . . . . . . . . . . . . .

. . . .18

Starting when the engine is warm . . . . . . . . . . . . .

. . . .18

What to do when the engine is „flooded“ . . . . . . . .

. . . .18

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .18

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .18

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .19

Stopping and parking . . . . . . . . . . . . . . . . . . . . . .

. . . .19

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .19

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . .

. . . .20

MAINTENANCE WORK ON CHASSIS AND ENGINE . . .

. . . .24

Changing the spring preloading of the shock absorber . . .24

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .24

Basic suspension setup for the weight of the driver

. . . . .25

Checking the shock absorber and spring . . . . . . . . .

. . . .25

Determining the static sag of the shock absorber . . .

. . . .25

Determining the riding sag of the shock absorber . . .

. . . .25

Checking the basic setup of the telescopic fork . . . .

. . . .26

Changing the spring preload on the telescopic fork

. . . . .26

Replacing fork springs . . . . . . . . . . . . . . . . . . . . .

. . . .26

Breather plug front fork . . . . . . . . . . . . . . . . . . . . .

. . . .27

Cleaning the dust sleeves of the telescopic fork . . .

. . . . .27

Checking and adjusting the steering head bearing

. . . . .27

Changing the fork offset (caster) . . . . . . . . . . . . .

. . . . .28

How to change the handlebar position . . . . . . . . .

. . . . .29

Check chain tension . . . . . . . . . . . . . . . . . . . . . .

. . . . .30

Correct chain tension . . . . . . . . . . . . . . . . . . . . . .

. . . .30

Adapting the chain guide to the number of rear sprocket teeth .31

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . .

. . . .32

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .32

General information about KTM disc brakes . . . . . .

. . . .33

Adjusting the free travel at the hand brake lever . . .

. . . .34

Checking the brake fluid level - front brake . . . . . . .

. . . .34

Refilling the front brake fluid reservoir . . . . . . . . . .

. . . .34

Checking the front brake pads . . . . . . . . . . . . . . . .

. . . .35

Replacing the front brake pads . . . . . . . . . . . . . . .

. . . .35

Changing the basic position of the foot brake pedal .

. . . .35

Checking the rear brake fluid level . . . . . . . . . . . . .

. . . .36

Refilling the rear brake fluid reservoir . . . . . . . . . . .

. . . .36

Checking the rear brake pads . . . . . . . . . . . . . . . . .

. . . .36

Replacing the rear brake pads . . . . . . . . . . . . . . . .

. . . .37

Dismounting and mounting the front wheel . . . . . . .

. . . .37

Dismounting and mounting the rear wheel . . . . . . .

. . . .38

Checking spoke tension . . . . . . . . . . . . . . . . . . . . .

. . . .38

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .39

Check/set distance of the magnetic sensor . . . . . . .

. . . .39

Replacing the battery of the digital speedometer . . .

. . . .39

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .40

Charging the battery . . . . . . . . . . . . . . . . . . . . . . .

. . . .40

Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .41

Replacing headlight lamp/parking light lamp . . . . . .

. . . .41

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .42

Checking the coolant level . . . . . . . . . . . . . . . . . . .

. . . .42

Bleeding the cooling system . . . . . . . . . . . . . . . . .

. . . .42

Replacing the glassfiber yarn packing of the silencer . . . .43

Cleaning the spark arrester . . . . . . . . . . . . . . . . . .

. . . .43

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . .

. . . .44

Adjusting the throttle cables . . . . . . . . . . . . . . . . .

. . . .44

Changing the original position of the clutch lever . . .

. . . .45

Checking the oil level of the hydraulic clutch . . . . .

. . . .45

Bleeding of the hydraulic clutch . . . . . . . . . . . . . .

. . . .45

Carburetor – Adjust idling . . . . . . . . . . . . . . . . . . .

. . . .46

Basic information on carburetor wear . . . . . . . . . . .

. . . .46

Checking the float level (float height) . . . . . . . . . . .

. . . .46

Draining the float chamber of the carburetor . . . . . .

. . . .46

Checking the engine oil level . . . . . . . . . . . . . . . . .

. . . .47

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .47

Changing the engine oil . . . . . . . . . . . . . . . . . . . .

. . . .48

Changing the oil filters . . . . . . . . . . . . . . . . . . . . .

. . . .49

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . .

. . . .50

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .52

CONSERVATION FOR WINTER OPERATION . . . . . . . .

. . . .52

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .52

USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . .

. . . .52

TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . .

. . . .53

TECHNICAL DATA – CHASSIS . . . . . . . . . . . . . . . . . .

. . . .55

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .57

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .61

SERIAL NUMBER LOCATIONS »

Chassis number

The chassis number is stamped on the right side of the steering head tube.

Enter this number in the field on page no 1.

Engine number, engine type

The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1.

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OPERATION INSTRUMENTS »

 

 

 

Clutch lever

 

 

 

 

2

 

The clutch lever [1] is located on the left side of the handlebar. The adjus-

 

 

 

ting screw [A] is used to change the original position of the clutch lever (see

 

 

 

maintenance work on chassis and engine).

 

 

 

The clutch is hydraulically actuated and adjusts itself automatically.

1

A

Hot start lever (SX-F)

If you pull the red hot start lever [2] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a “lean“ fuel-air mixture of the type needed for hot starts.

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OPERATION INSTRUMENTS »

Hand brake lever

The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see "Maintenance").

 

1

A

Short circuit button

The short circuit button [2] turns off the engine. When pressing this button,

the ignition circuit is short-circuited.

2

4

 

 

 

3

 

 

 

 

A

B

C

5

Combination switch

The light switch has 2, respectively 3 switch positions.

[A]= Light off (this function is not available in all models)

[B]= Low beam on

[C]= High beam on

You may use button [3] to actuate the horn.

The red short circuit button [4] serves to switch off the engine. Leave the switch pressed until the engine stops.

Headlamp switch (XCF-W)

In this model the headlamp is switched on with the pull switch [5].

Flasher switch

The flasher switch is a separate unit and is mounted on the left portion of the handlebar.

The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system.

Flasher left

Flasher right

OPERATION INSTRUMENTS »

Starter button

Pushing the red starter button [1] will actuate the E-starter.

1

 

 

 

 

Emergency OFF switch (EXC-F Australia)

 

 

 

 

 

 

 

 

The red emergency-OFF switch [2] is arranged adjacent to the throttle grip.

 

 

 

 

 

 

 

 

In this position, the E-starter is operational and the engine can

 

2

 

 

 

 

 

 

be started.

 

 

 

 

 

 

 

 

 

 

In this position, the E-starter and ignition circuits are

 

 

 

 

 

 

 

 

interrupted.The E-starter cannot be actuated, and the engine will

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

not start, not even if you attempt to start it with the kickstarter.

 

 

 

 

 

 

 

 

 

 

3

 

 

Pushing the black starter button [3] will actuate the E-starter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Indicator lamps

 

 

 

 

 

 

 

 

 

 

 

The green control lamp [4] flashes in the same rhythm as the flash-

 

 

 

 

 

 

ing indicator when the indicator is working.

 

5

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The blue control lamp [5] lights up when the high beam is on.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Electronic speedometer

The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running.

The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor.

The | button is used to change between display modes. The + and buttons are used to control various functions.

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TEST

All of the display segments briefly light up for the display function test.

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OPERATION INSTRUMENTS »

WS (wheel size)

The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires).

Afterwards the display will return to the previous display mode.

SPEED display mode / H (service hours)

Only the SPEED / H and SPEED / ODO display modes are activated in the condition at delivery. SPEED/H is displayed whenever the display is activated and the front wheel is not turning. It automatically changes to the SPEED/ODO display mode as soon as the front wheel starts turning.

SPEED displays the speed.

H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motorcycles, making the service hour counter a very practical function.

SPEED / ODO display mode (odometer)

The SPEED/ODO mode displays the speed and the total distance traveled. The display automatically changes to the SPEED/H display mode when the front wheel stops turning.

+ button

no function

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

changes to the next display mode

The electronic speedometer has a number of display modes (functions) that you can also activate (reveal) (see: Activating and deactivating display modes).

Activating and deactivating display modes

In the display mode SPEED/H, press and hold the | button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blinking function can be activated by pressing the + button and deactivated by pressing the button.

Press and hold the | button 3 seconds to store the settings.

If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode.

+ button

 

activates the blinking display

button

 

deactivates the blinking display

briefly press | button

changes to the next display without changing any

 

 

settings

hold | button 3 secs.

starts the SETUP

 

 

stores the settings and changes to the SPEED/H

 

 

mode

The following display modes can be activated:

TR1

tripmaster 1

TR2

tripmaster 2

A1

average speed 1

A2

average speed 2

S1

stop watch 1

S2

stop watch 2

CLK

clock

 

LAP

lap time

KMH/MPH

display in kilometers or miles (see: Kilometers or miles)

If you have activated all of the display modes, they will be displayed in the following order:

SPEED/H, SPEED/CLK, SPEED/LAP, LAP/LAP, SPEED/ODO, SPEED/TR1, SPEED/TR2, SPEED/A1, SPEED/A2, SPEED/S1, SPEED/S2

OPERATION INSTRUMENTS »

SPEED / CLK (time) display mode

CLK displays the time in hours, minutes and seconds.

+ button

no function

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

set the clock menu

To set the clock, see „Setting the clock“.

SPEED / LAP (lap time) display mode

You can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below).

LAP displays the lap times in hours, minutes and seconds.

+ button

Starts and stops the stop watch, lap time is not

button

reset to 0

Stops the stop watch, stores the lap time and restarts

 

the stop watch again. The time is reset to 0. A total

 

of 10 lap times can be stored. If the lap time con-

 

tinues to run after you press the - button, all 10 mem-

 

ory locations are occupied.To clear all of the stored

 

lap times, hold the | button for 3 seconds in the

 

SPEED/LAP mode.Up to 10 lap times can be stored

 

in this way.

briefly press | button

Changes to the next display mode.If no lap time is

 

stored or the motorcycle is driving, the LAP/LAP

 

mode will be skipped.

hold | button 3 secs.

Clears all LAP figures

LAP / LAP display mode (to view lap times)

The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds. Press the + button to access the next lap time.

To clear all of the stored lap times, hold the | button for 3 seconds in the SPEED/LAP mode.

+ button

changes to the next lap time

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

changes to the next display mode

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9

SPEED / TR1 display mode (tripmaster 1)

The TR1 tripmaster is always active and counts to 999.9. It is used to measure the length of a trip or the distance between 2 refueling stops.

TR1 is linked to A1 (average speed 1). The calculation of these figures is activated by the first impulse received from the wheel sensor (when the front wheel starts to turn) and stops 3 seconds after the last impulse is received (when the front wheel has stopped).

The TR1, A1 and S1 figures are automatically cleared after passing 999.9.

+ button

no function

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

clears the TR1, S1, A1 figures

OPERATION INSTRUMENTS »

SPEED / TR2 display mode (tripmaster 2)

The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the displayed figure can be changed using the + and buttons. This is a very useful function for trips taken according to a roadbook.

+ button

increases the TR2 figure

button

decreases the TR2 figure

briefly press | button

changes to the next display mode

hold | button 3 secs.

clears the TR2 figure

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10

SPEED / A1 display mode (average speed 1)

A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (stop watch 1) figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

+ button

no function

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

clears the TR1, S1, A1 figures

SPEED / A2 display mode (average speed 2)

A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures.

The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.

+ button

no function

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

changes to the next display mode

SPEED / S1 display mode (stop watch 1)

S1 shows the traveling time based on TR1 and continues to run whenever it receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

+ button

no function

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

clears the TR1, S1, A1 figures

SPEED / S2 display mode (stop watch 2)

S2 is a manual stop watch. Start the stop watch by pressing the + button, press again to hold. Press again to continue timing.

Press the | button to change to the next mode. The S2 display will blink in the other modes if S2 continues to run in the background. To stop S2, return to the SPEED/S2 mode and press the + button.

+ button

starts and stops the stop watch

button

no function

briefly press | button

changes to the next display mode

hold | button 3 secs.

clears the S2 figure

OPERATION INSTRUMENTS »

Kilometers or miles

The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly. The TR1, A1, S1, TR2 and A2 figures will be cleared.

To select the unit, select the SPEED/H mode and hold the | button for 3 seconds to access the SETUP menu. Press the | button until the KMH/MPH function blinks. Press the + button briefly to move to the options. Press the + button for KMH or the button for MPH.

To set, briefly press the | button 1 x and hold for 3 seconds until the display returns to the SPEED/H mode.

If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode.

+ button

to access the menu

button

to activate the KMH display

to activate the MPH display

briefly press | button

changes to the next mode

 

changes from the menu to the SETUP menu

hold | button 3 secs.

stores and closes the SETUP menu

Setting the clock

To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the | button for 3 seconds. The blinking digits can be changed using the + and - buttons. Press the | button to move to the next digit. 0- 12 will show the time in the 12-hour mode, 0-24 in the 24-hour mode.

Press and hold the | button for 3 seconds to store the settings.

If no button is pressed for 20 seconds, the settings will be stored automatically and the display will return to the SPEED/CLK mode.

+ button

time +

button

time -

briefly press | button

changes to the next digit

hold | button 3 secs.

starts the SETUP menu

 

stores the time and changes to the SPEED/CLK dis-

 

play mode

ENGLISH

11

Motorcycle is standing

Motorcycle is driving

 

OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS

 

 

 

 

 

 

display

briefly press + button

briefly press button

briefly press | button

hold | button 3 secs.

 

 

 

 

 

 

 

X

 

SPEED / H

no function

no function

next display mode

displays the SETUP menu

 

 

 

 

 

 

 

X

X

SPEED / CLK

no function

no function

next display mode

Setting the clock menu

 

 

 

 

 

 

 

X

X

SPEED / LAP

starts/stops LAP without

stops LAP, stores LAP

next display mode

clears all LAP figures

clearing LAP figure

figure, resets LAP to 0

 

 

 

 

 

 

 

 

 

 

 

 

X

 

LAP / LAP

next figure

no function

next display mode

next display mode

 

 

 

 

 

 

 

 

X

SPEED / ODO

no function

no function

next display mode

next display mode

 

 

 

 

 

 

 

X

X

SPEED / TR1

no function

no function

next display mode

clears TR1, S1, A1

 

 

 

 

 

 

 

X

X

SPEED / TR2

increases the TR2 figure

reduces the TR2 figure

next display mode

clears TR2

 

 

 

 

 

 

 

X

X

SPEED / A1

no function

no function

next display mode

clears TR1, S1, A1

 

 

 

 

 

 

 

X

X

SPEED / A2

no function

no function

next display mode

next display mode

 

 

 

 

 

 

 

X

X

SPEED / S1

no function

no function

next display mode

clears TR1, S1, A1

 

 

 

 

 

 

 

X

X

SPEED / S2

starts - stops S2

no function

next display mode

clears S2

 

 

 

 

 

 

 

If the CLK, LAP, TR1, TR2 A1, A2, S1 and S2 figures are suddenly cleared, the battery in the electronic speedometer is empty and must be replaced (see: Replacing the battery in the electronic speedometer).

A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar.

OPERATION INSTRUMENTS »

 

 

Filler cap

2

To open the filler cap: Press the release button [1] and turn the tank cap in a

counterclockwise direction.

1

To close the filler cap: Put the tank cap back on and turn in a clockwise direc-

tion until the release button snaps into place.

 

Install the tank breather hose [2] without kinks.

ENGLISH

12

Fuel tap (SX-F)

OFF In this position the fuel tap is closed. No fuel can flow to the carburetor.

ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor.

OFF ON

Fuel tap (XC-F, XCF-W, EXC-F)

OFF In this position the fuel tap is closed. No fuel can flow to the carburetor.

ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. With the twist grip in this position the tank will be emptied until only the reserve is left.

RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position. Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time, too.

Reserve . . . . . . . . . .2.0 l (0.6 US gallons)

3

4

Choke (SX-F, XC-F, XCF-W)

If you pull the choke button [3] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a “fat“ fuel-air mixture of the type needed for cold starts.

To deactivate the choke, push the choke button back into its basic position.

Choke (EXC-F)

If you press the choke lever towards the handlebar [4], a bore in the carburetor is opened through which the engine can take in additional fuel. The result is a "rich" fuel-air mixture of the type needed for cold starts. The amount of fuel and thus the engine speed is determined by the position of the choke lever.

To close the bore, press the choke lever away from the handlebar.

OPERATION INSTRUMENTS »

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

2,3,4 (5,6)

N

1

Kickstarter

The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled.

ENGLISH

13

Foot brake pedal

The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

 

 

 

 

Side stand

 

 

 

 

 

 

 

 

Push the side stand to the ground with your foot and load it with the motor-

 

1

 

 

 

 

 

cycle. Make sure that you put your bike on solid ground and in a secure posi-

 

 

 

 

 

 

 

 

 

 

tion. For off-road riding, you can use the rubber band [1] to additionally secure

 

 

 

 

the center stand in its folded-up position

 

 

 

 

 

Steering lock

The handlebar can be locked by means of the lock located on the steering head. To lock it, turn handlebar all the way to the right, insert key, turn it to left, press it in, turn it to right, and remove it.

Never leave the key inserted in the steering lock. If you turn the handlebar to the left the key could get damaged.

OPERATION INSTRUMENTS »

1

ENGLISH

3

14

2

5

4

6

Compression damping of fork (SX-F, XC-F)

Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the top of the fork legs.

Turn the adjusting screws [1] clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

STANDARD ADJUSTMENT

turn adjusting screw clockwise as far as it will go

turn it back by as many clicks as are specified for the relevant type of fork

WP 14.18.7D.03 . . . . . .

14 clicks WP 14.18.7D.28 . . . . . .

20 clicks

Rebound damping of fork (SX-F, XC-F)

Hydraulic rebound damping determines the reaction when the fork is rebound. Remove the protecting cap [2].

By turning the adjusting screw [3], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT

turn adjusting screw clockwise as far as it will go

turn it back by as many clicks as are specified for the relevant type of fork

WP 14.18.7D.03 . . . . . .

21 clicks WP 14.18.7D.28 . . . . . .

21 clicks

Compression damping of fork (XCF-W, EXC-F, EXC-F Six Days)

Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap [4].

Turn the adjusting screws [5] clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

STANDARD ADJUSTMENT

turn adjusting screw clockwise as far as it will go

turn it back by as many clicks as are specified for the relevant type of fork

WP 14.18.7D.04 . . . . . .

22 clicks WP 14.18.7D.34 . . . . . .

24 clicks

Rebound damping of fork (XCF-W, EXC-F, EXC-F Six Days)

Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw [6], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT

turn adjusting screw clockwise as far as it will go

turn it back by as many clicks as are specified for the relevant type of fork

WP 14.18.7D.04 . . . . . .

20 clicks WP 14.18.7D.34 . . . . . .

22 clicks

OPERATION INSTRUMENTS »

Compression damping of shock absorber

The shock absorber on these models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle.

The low and high-speed technology overlaps.

The low-speed setting is primarily for slow to normal shock absorber compression rates.

The high-speed setting is effective at fast compression rates.

Turning in a clockwise direction will increase the damping, turning counterclockwise will decrease the damping.

STANDARD LOW-SPEED SETTING:

3– turn the adjusting screw [1] to the limit in a clockwise direction using a screwdriver .

unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction.

WP 12.18.7D.03 . . . . . .

14 clicks

WP 12.18.7D.04 . . . . . .

15 clicks

WP 12.18.7D.28 . . . . . .

15 clicks

WP 12.18.7D.34 . . . . . .

15 clicks

1

2

4

5

STANDARD HIGH-SPEED SETTING:

turn the adjusting screw [2] to the limit in a clockwise direction using a box wrench.

unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction.

WP 12.18.7D.03 . . . . . . .

1 clicks

WP 12.18.7D.04

. . . . . 1.5 clicks

WP 12.18.7D.28 . . . . . . .

1 clicks

WP 12.18.7D.34

. . . . . 1.5 clicks

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The damping unit of the shock absorber is filled with high-compression nitrogen. Never try to take the shock absorber apart or to do any maintenance work yourself. Severe injuries could be the result.

Never unscrew the black screw connection [3] (24mm).

Rebound damping of shock absorber

By using the adjusting screw [4], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT:

turn the adjusting screw clockwise to the stop.

then turn the adjusting screw counterclockwise, counting the number of clicks that corresponds to the respective type of shock absorber.

WP 12.18.7D.03 . . . . . .

23 clicks

WP 12.18.7D.04 . . . . .

.24 clicks

WP 12.18.7D.28 . . . . . .

23 clicks

WP 12.18.7D.34 . . . . . .

22 clicks

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The damping unit of the shock absorber is filled with high-compression nitrogen. Never try to take the shock absorber apart or to do any maintenance work yourself. Severe injuries could be the result.

Never unscrew the black screw connection [5] (15mm).

ENGLISH

15

OPERATION INSTRUMENTS »

 

 

 

Engine characteristic (EXC-F)

 

 

 

 

 

 

The CDI unit is pre-programmed with 2 ignition curves (Performance and Soft).

 

1

 

 

 

 

The Performance ignition curve (higher engine performance) is activated when

 

 

 

 

 

 

the socket connector [1] is connected, the Soft ignition curve (improved dri-

 

 

 

veability) when it is disconnected.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Homologated models driven on public roads must be operated with a discon-

 

 

 

nected socket connector, otherwise the type approval will be cancelled.

 

 

 

 

 

 

 

ENGLISH

16

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

Instructions for initial operation

Make sure the work for the „pre-delivery inspection“ was performed by your authorized KTM workshop. The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.

Read these operating instructions carefully before your first ride.

Familiarize yourself with the operating elements.

Set the clutch lever, the handbrake lever, and the footbrake pedal to the positions that are most convenient for you.

Get used to handling the motorcycle on an empty parking lot or open space, before starting on a longer drive. Also try to drive as slowly as possible and in a standing position, to improve your feeling for the vehicle.

Do not drive along off-road tracks which go beyond your abitily and experience.

Hold the handlebars with both hands and leave your feet on the foot rests while driving.

Remove your foot from the foot brake lever when you are not braking. If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated.

Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle.

Motorcycles are sensitive to alterations in the distribution of weight. If you are taking luggage with you, this should be secured as close as possible to the middle of the vehicle; distribute the weight evenly between the front and rear wheel. Never exceed the maximum permissible laden weight and the axle weights. The maximum permissible laden weight is comprised of the following components:

Motorcycle ready for operation and tank full

Luggage

Driver with protective clothing and helmet.

Pay attention to the running-in procedure.

Running in

Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time. Therefore, every engine needs to be broken in.

For this reason, do not load the engine more than 50% of its capacity during the first 3 operating hours. Besides, the engine speed must not exceed 7000 rpm. Avoid going full-throttle!

In the following 12 operating hours, you may load the engine up to 75% of its capacity. Use the motorcycle on various types of terrain (road, easy off-road trails).

Wear suitable clothing when driving a motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regardless of whether driving all day or just for a short trip. The protective clothing should be brightly colored so that other vehicles can see you as early as possible.

Do not drive after having consumed alcohol.

Only use accessories recommended by KTM. For example, front panelling can impair the driving properties of the motorcycle. Cases, extra tanks, etc. can alter the weight distribution and thus also impair the vehicles driving properties.

The front and rear wheel may only be fitted with tires that have the same profile type.

Be sure to check the spoke tension after driving for 30 minutes. The spoke tension on new tires decreases rapidly. If you continue to drive with loose spokes, the spokes may tear and lead to unstable handling (see "Checking the spoke tension").

The above mentioned models are designed are designed and dimensioned for 1 person only. Never take another rider along.

Observe the traffic regulations, drive defensively and try to look ahead as far as possible so that any hazards can be recognized as early as possible.

Adjust your driving speed according to the conditions and your driving skills.

Drive carefully on unknown roads or on unfamiliar trials.

When driving off-road, always have a friend on a second motorcycle to keep you company, so that you can help each other should difficulties arise.

Replace the helmet visor or goggle lens when scratched or damaged. if bright light shines through a scratched visor or lens, the operator will be blinded.

Never leave your motorcycle without supervision if the engine is running.

Only 250 EXC-F models are approved for use on public roads and motorways.

When riding your motorcycle, please bear in mind that other people may feel molested by excessive noise.

DRIVING INSTRUCTIONS »

 

Check the following before each start

When you start off, the motorcycle must be in perfect technical condition.

For safety reasons, you should make a habit of performing an overall check

of your motorcycle before each start.

The following checks should be performed:

1 CHECK THE OIL LEVEL

 

Insufficient oil results in premature wear and consequently to engine

B

damage.

 

2

FUEL

A

Check that there is sufficient fuel in the tank; when closing the filler cap,

 

check that the tank venting hose is free of kinks.

3CHAIN

A loose chain can fall from the chain wheels; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear to the chain and chain wheels. Excessive tensioning of the chain will put additional load on the components of the secondary drivetrain (chain, bearings of transmission and rear wheel). Aside from resulting in premature wear, if worst comes to worst the chain may rupture or the countershaft of the transmission may break.

4TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance.

5BRAKES

Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn. If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided.

Also check the state of the brake hose and the thickness of the brake linings.

Check free travel at the hand brake lever and foot brake lever.

If the resistance on the hand brake lever or foot brake lever feels unresponsive, something is wrong with the brake system. Have the brake system inspected at an authorized KTM workshop before you drive the motorcycle.

2

6 CABLES

 

Check correct setting and easy running of all control cables.

 

7COOLING FLUID

Check the level of the cooling fluid when the engine is cold.

8ELECTRICAL SYSTEM

Check correct functioning of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running.

9LUGGAGE

If you are taking luggage with you, check that this is securely fastened.

ENGLISH

17

ENGLISH

18

DRIVING INSTRUCTIONS »

1

2

2

Starting when the engine is cold

1Open the fuel tap [1].

2Swing up the side stand or center stand.

3Put the gear in neutral.

4Operate the choke [2].

5Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter.

If you want to start the engine, make sure that you always put on sturdy motorcycle boots in order to avoid injuries. You might slip off the kickstarter, or the engine may kick back and propel your foot upward with great force.

Always kick the kickstarter briskly all the way without opening the throttle. If you do not Kick hard enought, with an open throttle grip, the kickback hazard will be higher.

Do not start the engine and allow it to idle in a closed area. Exhaust fumes are poisonous and can cause loss of consciousness and death. Always provide adequate ventilation while the engine is running.

Always verify that the transmission has been set to idle (neutral) before actuating the starter button. If you start the motorcycle with a gear engaged, the motorcycle will move forward.

Maximal period for continuous starting: 5 seconds. Wait at least 5 seconds before trying again.

Don’t ride your motorcycle with full load and don’t rev up the engine when cold because the piston is warming up faster than the water cooled cylinder and can cause engine damage.

NOTE: If you have trouble starting the motorcycle, this could be due to old fuel in the float chamber. The easily inflammable components of the new fuels evaporate during longer periods of standstill.When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel.

Starting when the engine is warm

1Open the fuel tap [1].

2Swing up the side stand.

3Put the gear in neutral.

4Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter.

What to do when the engine is „flooded“

Unscrew the spark plug and dry it.

NOTE:

The carburetor has an accelerator pump. Every time you open the throttle, fuel will be injected into the intake passage. When starting, be sure that you open the throttle completely only once.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open the throttle at the same time.

Before you start off, check that the side stand has been swung up fully. If the stand drags on the ground, the motorcycle can go out of control.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever in and shift to the next higher gear. Let clutch lever go again and accelerate. If you turned on the choke, make sure you turn it off again as soon as engine is warm.

When you reach full speed through opening the throttle all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Only give as much gas as the engine can handle. Through quick and high revving of the throttle, the fuel usage increases.

By shifting down, use the brakes if necessary and close the throttle at the same time. Pull the clutch lever and shift down to the next gear. Let clutch lever go slowly and open the throttle or shift down again.

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