KTM 250 SX-F 2013 Owner's manual
OWNER'S MANUAL 2013
250 SX‑F EU
250 SX‑F USA
250 XC‑F USA
Art. no. 3211858en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.
Chassis number ( p. 10) Dealer's stamp
Engine number ( p. 10)
The Owner's Manual contained the latest information for this model at the time of going to print. Slight deviations resulting from continuing development and design can, however, not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2012 KTM-Sportmotorcycle AG, 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 AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 4
1.1 Symbols used ................................................... 4
1.2 Formats used.................................................... 4
2 SAFETY ADVICE........................................................... 5
2.1 Use definition - intended use ............................. 5
2.2 Safety advice.................................................... 5
2.3 Degrees of risk and symbols ............................... 5
2.4 Tampering warning............................................ 5
2.5 Safe operation .................................................. 6
2.6 Protective clothing ............................................ 6
2.7 Work rules........................................................ 6
2.8 Environment..................................................... 6
2.9 Owner's Manual ................................................ 6
3 IMPORTANT NOTES..................................................... 7
3.1 Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Service ............................................................ 7
3.5 Figures ............................................................ 7
3.6 Customer service............................................... 7
4 VIEW OF VEHICLE ....................................................... 8
4.1 View of vehicle, front left side (example) ............. 8
4.2 View of vehicle, rear right (example) ................... 9
5 SERIAL NUMBERS .................................................... 10
5.1 Chassis number .............................................. 10
5.2 Type label ...................................................... 10
5.3 Engine number ............................................... 10
5.4 Fork part number ............................................ 10
5.5 Shock absorber part number ............................ 10
6 CONTROLS................................................................ 11
6.1 Clutch lever.................................................... 11
6.2 Hand brake lever............................................. 11
6.3 Throttle grip ................................................... 11
6.4 Kill switch...................................................... 11
6.5 Electric starter button...................................... 11
6.6 Overview of indicator lamps ............................. 12
6.7 Opening the filler cap...................................... 12
6.8 Closing the filler cap ....................................... 13
6.9 Cold start button............................................. 13
6.10 Idle speed adjusting screw............................... 14
6.11 Shift lever ...................................................... 14
6.12 Foot brake lever .............................................. 14
6.13 Plug-in stand (All SX‑F models)........................ 15
6.14 Side stand (XC‑F)............................................ 15
7 PREPARING FOR USE................................................ 16
7.1 Advice on first use .......................................... 16
7.2 Running in the engine ..................................... 17
7.3 Preparing the vehicle for difficult operating
conditions ...................................................... 17
7.4 Preparing for rides on dry sand......................... 18
7.5 Preparing for rides on wet sand ........................ 18
7.6 Preparing for rides on wet and muddy
surfaces ......................................................... 19
7.7 Preparing for rides at high temperatures and
low speeds ..................................................... 19
7.8 Preparing for rides at low temperatures or in
snow.............................................................. 19
8 RIDING INSTRUCTIONS............................................. 20
8.1 Checks and maintenance before putting into
operation........................................................ 20
8.2 Starting.......................................................... 20
8.3 Starting off..................................................... 21
8.4 Shifting, riding ............................................... 21
8.5 Applying the brakes......................................... 21
8.6 Stopping, parking............................................ 21
8.7 Transport ....................................................... 22
8.8 Refueling ....................................................... 22
9 SERVICE SCHEDULE ................................................. 24
9.1 Service schedule............................................. 24
9.2 Service work (as additional order) ..................... 25
10 TUNING THE CHASSIS .............................................. 26
10.1 Checking the basic chassis setting with the
rider's weight.................................................. 26
10.2 Compression damping of the shock absorber...... 26
10.3 Adjusting the low-speed compression damping
of the shock absorber ...................................... 26
10.4 Adjusting the high-speed compression
damping of the shock absorber ......................... 27
10.5 Adjusting the rebound damping of the shock
absorber......................................................... 28
10.6 Measuring rear wheel sag unloaded................... 28
10.7 Checking the static sag of the shock absorber.... 29
10.8 Checking the riding sag of the shock absorber.... 29
10.9 Adjusting the spring preload of the shock
absorber x.................................................... 29
10.10 Adjusting the riding sag x .............................. 30
10.11 Checking the basic setting of the fork ............... 31
10.12 Adjusting the compression damping of the
fork ............................................................... 31
10.13 Adjusting the rebound damping of the fork ........ 32
10.14 Handlebar position.......................................... 32
10.15 Adjusting the handlebar position x ................. 32
11 SERVICE WORK ON THE CHASSIS.............................. 34
11.1 Raising the motorcycle with the lift stand .......... 34
11.2 Removing the motorcycle from the lift stand ...... 34
11.3 Bleeding the fork legs...................................... 34
11.4 Cleaning the dust boots of the fork legs............. 35
11.5 Loosening the fork protection ........................... 35
11.6 Positioning the fork protection.......................... 35
11.7 Removing the fork legs x ............................... 36
11.8 Installing the fork legs x ................................ 36
11.9 Removing the fork protector x ........................ 37
11.10 Installing the fork protector x......................... 37
11.11 Removing the lower triple clamp x.................. 37
11.12 Installing the lower triple clamp x .................. 38
11.13 Checking the steering head bearing play............ 39
11.14 Adjusting the play of the steering head
bearing x ..................................................... 40
11.15 Greasing the steering head bearing x .............. 40
11.16 Removing the start number plate ...................... 41
11.17 Installing the start number plate....................... 41
11.18 Removing the front fender ............................... 41
11.19 Installing the front fender ................................ 42
11.20 Removing the shock absorber x ...................... 42
11.21 Installing the shock absorber x....................... 43
11.22 Removing the seat .......................................... 44
11.23 Mounting the seat ........................................... 44
11.24 Removing the air filter box lid .......................... 44
11.25 Installing the air filter box lid ........................... 45
11.26 Removing the air filter x ................................ 45
11.27 Installing the air filter x................................. 45
11.28 Cleaning the air filter and air filter box x ......... 46
11.29 Securing the air filter box lid x....................... 46
11.30 Sealing the air filter box x.............................. 47
TABLE OF CONTENTS 3
11.31 Removing the main silencer ............................. 47
11.32 Installing the main silencer.............................. 47
11.33 Changing the glass fiber yarn filling of the
main silencer x............................................. 47
11.34 Removing the fuel tank x............................... 48
11.35 Installing the fuel tank x................................ 49
11.36 Checking for chain dirt accumulation ................ 50
11.37 Cleaning the chain .......................................... 50
11.38 Checking the chain tension .............................. 51
11.39 Adjusting the chain tension.............................. 51
11.40 Checking the chain, rear sprocket, engine
sprocket and chain guide ................................. 52
11.41 Adjusting the chain guide x ........................... 54
11.42 Checking the frame x .................................... 54
11.43 Checking the swingarm x............................... 54
11.44 Checking the throttle cable routing ................... 54
11.45 Checking the rubber grip ................................. 55
11.46 Additionally securing the rubber grip................. 55
11.47 Adjusting the basic position of the clutch
lever .............................................................. 55
11.48 Checking/rectifying the fluid level of the
hydraulic clutch.............................................. 56
11.49 Changing the hydraulic clutch fluid x.............. 56
12 BRAKE SYSTEM ........................................................ 57
12.1 Checking the free travel of the hand brake
lever .............................................................. 57
12.2 Adjusting the basic position of the hand brake
lever .............................................................. 57
12.3 Checking the brake discs ................................. 57
12.4 Checking the front brake fluid level .................. 58
12.5 Adding front brake fluid x.............................. 58
12.6 Checking the front brake linings ....................... 59
12.7 Changing the front brake linings x .................. 59
12.8 Checking the free travel of foot brake lever ........ 61
12.9 Adjusting the basic position of the foot brake
lever x ......................................................... 61
12.10 Checking the rear brake fluid level.................... 62
12.11 Adding rear brake fluid x ............................... 62
12.12 Checking the rear brake linings ........................ 63
12.13 Changing the rear brake linings x ................... 63
13 WHEELS, TIRES ........................................................ 65
13.1 Removing the front wheel x ........................... 65
13.2 Installing the front wheel x ............................ 65
13.3 Removing the rear wheel x............................. 66
13.4 Installing the rear wheel x.............................. 66
13.5 Checking the tire condition .............................. 67
13.6 Checking the tire air pressure........................... 68
13.7 Checking the spoke tension.............................. 68
14 ELECTRICAL SYSTEM ................................................ 69
14.1 Removing the battery x.................................. 69
14.2 Installing the battery x .................................. 69
14.3 Recharging the battery x................................ 70
14.4 Changing the main fuse................................... 71
15 COOLING SYSTEM ..................................................... 72
15.1 Cooling system ............................................... 72
15.2 Checking the antifreeze and coolant level .......... 72
15.3 Checking the coolant level ............................... 73
15.4 Draining the coolant x................................... 73
15.5 Refilling coolant x......................................... 74
16 TUNING THE ENGINE................................................ 75
16.1 Checking the play in the throttle cable .............. 75
16.2 Adjusting the play in the throttle cable x......... 75
16.3 Adjusting the idle speed x ............................. 76
16.4 Checking the basic position of the shift lever ..... 76
16.5 Adjusting the basic position of the shift
lever x ......................................................... 76
17 SERVICE WORK ON THE ENGINE ............................... 77
17.1 Changing the fuel screen x ............................ 77
17.2 Checking the engine oil level............................ 77
17.3 Changing the engine oil and oil filter, cleaning
the oil screen x............................................. 78
17.4 Adding engine oil............................................ 80
18 CLEANING, CARE ...................................................... 81
18.1 Cleaning the motorcycle .................................. 81
19 STORAGE.................................................................. 82
19.1 Storage.......................................................... 82
19.2 Putting into operation after storage ................... 82
20 TROUBLESHOOTING ................................................. 83
21 BLINK CODE ............................................................. 85
22 TECHNICAL DATA...................................................... 86
22.1 Engine........................................................... 86
22.2 Engine tightening torques ................................ 87
22.3 Capacities...................................................... 88
22.3.1 engine oil................................................... 88
22.3.2 coolant ...................................................... 88
22.3.3 fuel ........................................................... 88
22.4 Chassis.......................................................... 88
22.5 Electrical system............................................. 89
22.6 Tires.............................................................. 89
22.7 Fork............................................................... 89
22.7.1 250 SX‑F EU.............................................. 89
22.7.2 SX‑F USA................................................... 90
22.7.3 XC‑F.......................................................... 90
22.8 Shock absorber ............................................... 91
22.8.1 250 SX‑F EU.............................................. 91
22.8.2 SX‑F USA................................................... 91
22.8.3 XC‑F.......................................................... 92
22.9 Chassis tightening torques ............................... 92
23 SUBSTANCES ........................................................... 94
24 AUXILIARY SUBSTANCES .......................................... 96
25 STANDARDS ............................................................. 98
INDEX .............................................................................. 99
1 MEANS OF REPRESENTATION 4
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
2 SAFETY ADVICE 5
2.1 Use definition - intended use
(All SX‑F models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
(XC‑F)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 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, 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 exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
2 SAFETY ADVICE 6
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own 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 should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 7
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your 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 tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 8
4.1 View of vehicle, front left side (example)
1 Hand brake lever ( p. 11)
2 Clutch lever ( p. 11)
3 Filler cap
4 Fork rebound setting
5 Cold start button ( p. 13)
6 Shift lever ( p. 14)
7 Air filter box lid
8 Plug-in stand ( p. 15)
101753-10
4 VIEW OF VEHICLE 9
4.2 View of vehicle, rear right (example)
1 Kill switch ( p. 11)
2 Electric starter button ( p. 11)
3 Throttle grip ( p. 11)
4 Fork compression adjustment
5 Level viewer for brake fluid, rear
6 Shock absorber rebound adjustment
7 Shock absorber compression adjustment
8 Level viewer, engine oil
9 Foot brake lever ( p. 14)
101754-10
5 SERIAL NUMBERS 10
5.1 Chassis number
The chassis number 1 is stamped on the right side of the steering head.
101755-10
5.2 Type label
The type label 1 is fixed to the front of the steering head.
5.3 Engine number
5.4 Fork part number
101756-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
101757-10
The fork part number 1 is stamped on the inner side of the axle clamp.
101654-10
5.5 Shock absorber part number
101758-10
The shock absorber part number 1 is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
6 CONTROLS 11
6.1 Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
101656-10
6.2 Hand brake lever
Hand brake lever 1 is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
6.3 Throttle grip
6.4 Kill switch
101759-10
The throttle grip 1 is fitted on the right side of the handlebar.
101760-10
Kill switch 1 is fitted on the left side of the handlebar.
Possible states
• Kill switch in the 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 is interrupted, a running engine stops, and a non-running engine will not start.
101761-10
6.5 Electric starter button
101762-10
The electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
6 CONTROLS 12
6.6 Overview of indicator lamps
Possible states
FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard
diagnosis) has identified an emissions- or safety-critical fault.
(XC‑F)
Fuel level warning lamp lights up orange – Fuel level has reached
the reserve mark.
C00218-01
6.7 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
(All SX‑F models)
– Turn filler cap 1 counterclockwise and lift it off.
101763-10
(XC‑F)
– Press release button 1, turn the filler cap counterclockwise, and lift it off.
101764-10
6 CONTROLS 13
6.8 Closing the filler cap
(All SX‑F 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.
101765-10
(XC‑F)
– Replace the filler cap and turn clockwise until the release button 1 locks in
place.
Info
Run the fuel tank breather hose 2 without kinks.
101766-10
6.9 Cold start button
The cold start button 1 is fitted on the left on the throttle valve body.
The injection system extends the injection time if the engine is cold and the outside
temperature is low. The engine can only burn the increased fuel quantity if it receives
more air. It obtains more air by pulling the cold start button.
Possible states
• The cold start button is activated – The cold start button is pulled out all the way.
• The cold start button is deactivated – The cold start button is pushed in all the
way.
101767-10
6 CONTROLS 14
6.10 Idle speed adjusting screw
The idle setting of the throttle valve body has a big influence on the starting behavior,
stable idling and the response to throttle opening. This means that an engine with a
correctly set idle speed is easier to start than if the idle is set wrongly.
The idle speed is adjusted with the idle speed adjusting screw 1.
Turning the adjusting screw clockwise increases the idle speed.
Turning the adjusting screw counterclockwise lowers the idle speed.
101768-10
6.11 Shift lever
6.12 Foot brake lever
Shift lever 1 is mounted on the left side of the engine.
101769-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
101770-10
Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
101771-10
6 CONTROLS 15
6.13 Plug-in stand (All SX‑F models)
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.
Info
Remove the plug-in stand before starting on a trip.
101668-10
6.14 Side stand (XC‑F)
The side stand 1 is on the left side of the vehicle.
101772-10
101773-10
The side stand is used to park the motorcycle.
Info
When you are riding, side stand 1 must be folded up and secured with rubber
band 2.
7 PREPARING FOR USE 16
7.1 Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take
your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Familiarize yourself with the controls.
– Adjust the basic position of the clutch lever. ( p. 55)
– Adjust the basic position of the hand brake lever. ( p. 57)
–
Adjust the basic position of the foot brake lever. x ( p. 61)
–
Adjust the basic position of the shift lever. x ( p. 76)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Your motorcycle is not authorized for riding on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
7 PREPARING FOR USE 17
(All SX‑F models)
– Do not transport luggage.
(XC‑F)
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight
distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Run in the engine. ( p. 17)
7.2 Running in the engine
– During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first operating hour 7,000 rpm
Maximum engine performance
During the first 3 service hours ≤ 75 %
– Avoid fully opening the throttle!
7.3 Preparing the vehicle for difficult operating conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more
rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
–
Seal the air filter box. x ( p. 47)
–
Secure the air filter box lid. x ( p. 46)
–
Clean the air filter and air filter box. x ( p. 46)
Info
Check the air filter approx. every 30 minutes.
– Additionally secure the rubber grip. ( p. 55)
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult operating conditions are:
– Rides on dry sand. ( p. 18)
– Rides on wet sand. ( p. 18)
– Rides on wet and muddy surfaces. ( p. 19)
– Rides at high temperatures and low speeds. ( p. 19)
– Rides at low temperatures or in snow. ( p. 19)
7 PREPARING FOR USE 18
7.4 Preparing for rides on dry sand
– Fit a dust protection device on the air filter.
Dust protection device for air filter (77206920000)
Info
See the KTM PowerParts fitting instructions.
B00435-01
– Fit a sand protection device on the air filter.
Sand protection device for air filter (77206922000)
Info
See the KTM PowerParts fitting instructions.
B00436-01
– Clean the chain.
600868-01
7.5 Preparing for rides on wet sand
B00437-01
Chain cleaner ( p. 96)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– If used in sand regularly, replace the piston every 20 operating hours.
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (77206921000)
Info
See the KTM PowerParts fitting instructions.
– Clean the chain.
Chain cleaner ( p. 96)
600868-01
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– If used in sand regularly, replace the piston every 20 operating hours.
7 PREPARING FOR USE 19
7.6 Preparing for rides on wet and muddy surfaces
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (77206921000)
Info
See the KTM PowerParts fitting instructions.
B00437-01
– Fit the steel sprocket.
– Clean the motorcycle. ( p. 81)
– Straighten bent radiator fins carefully.
600868-01
7.7 Preparing for rides at high temperatures and low speeds
– Adjust the secondary drive to the road conditions.
Info
The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.
– Clean the chain.
Chain cleaner ( p. 96)
600868-01
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 73)
7.8 Preparing for rides at low temperatures or in snow
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (77206921000)
Info
See the KTM PowerParts fitting instructions.
B00437-01
8 RIDING INSTRUCTIONS 20
8.1 Checks and maintenance before putting into operation
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when used.
– Check the engine oil level. ( p. 77)
– Check the front brake fluid level. ( p. 58)
– Check the rear brake fluid level. ( p. 62)
– Check the front brake linings. ( p. 59)
– Check the rear brake linings. ( p. 63)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 73)
– Check for chain dirt accumulation. ( p. 50)
– Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 52)
– Check the chain tension. ( p. 51)
– Check the tire condition. ( p. 67)
– Check the tire air pressure. ( p. 68)
– Check the spoke tension. ( p. 68)
– Clean the dust boots of the fork legs. ( p. 35)
– Bleed the fork legs. ( p. 34)
– 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 regularly for tightness.
– Check the fuel reserves.
8.2 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
(All SX‑F models)
– Remove the plug-in stand.
(XC‑F)
– Raise the motorcycle off of the stand and secure the stand with the rubber
band 1.
– Shift gear to neutral.
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Pull the cold start button out all the way.
– Press the electric starter button.
101774-10
Info
Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
FI warning lamp lights up briefly as a functional control when starting.
8 RIDING INSTRUCTIONS 21
8.3 Starting off
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
8.4 Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the cold start button was pulled out during starting, push the cold start button all the way in after the engine warms up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the
speed but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – opening the throttle abruptly increases fuel consumption.
– To shift down, brake and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.
Guideline
≥ 1 min
– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
8.5 Applying the brakes
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.
– Clean or dry a dirty or wet brake system by riding and braking gently.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to apply the brakes far less frequently and the brake system does not overheat.
8.6 Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
8 RIDING INSTRUCTIONS 22
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Brake the motorcycle.
– Shift gear to neutral.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Park the motorcycle on firm ground.
8.7 Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.
401475-01
8.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Note
Material damage Premature clogging of the fuel filter.
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system. (Your authorized KTM workshop will be glad to help.)
– Only refuel with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
8 RIDING INSTRUCTIONS 23
– Switch off the engine.
– Open the filler cap. ( p. 12)
– Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A 35 mm (1.38 in)
401226-10
Total fuel tank
capacity, approx.
(All SX‑F models)
Total fuel tank
capacity, approx.
(XC‑F)
– Close the filler cap. ( p. 13)
7.5 l
(1.98 US gal)
9 l (2.4 US gal) Super unleaded (ROZ 95/RON 95/PON
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 95)
91) ( p. 95)
9 SERVICE SCHEDULE 24
9.1 Service schedule
S1N S10A S20A S30A
Read out the fault memory using the KTM diagnostics tool. x
Check and charge the battery. x
Check the front brake linings. ( p. 59) • • •
Check the rear brake linings. ( p. 63) • • •
Check the brake discs. ( p. 57) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. ( p. 62) • • •
Check the free travel of the foot brake lever. ( p. 61) • • •
Check the frame and swingarm. x
Check the swingarm bearing. x
Check the shock absorber linkage. x
Conduct a minor fork service. x
Conduct a major fork service. x
Check the tire condition. ( p. 67) • • • •
Check the tire air pressure. ( p. 68) • • • •
Check the wheel bearing for play. x
Check the wheel hubs. x
Check the rim run-out. x
Check the spoke tension. ( p. 68) • • • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 52) • • •
Check the chain tension. ( p. 51) • • • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x
Check/rectify the fluid level of the hydraulic clutch. ( p. 56) • • •
Check the front brake fluid level. ( p. 58) • • •
Check the free travel of the hand brake lever. ( p. 57) • • •
Check the steering head bearing play. ( p. 39) • • • •
Check the valve clearance. x
Check the clutch. x
Change the shaft seal rings of the water pump. x
Change the engine oil and oil filter, clean the oil screen. x ( p. 78)
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, leaks and
incorrect routing. x
Check the antifreeze and coolant level. ( p. 72) • • • •
Check the cables for damage and routing without sharp bends. x
Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • • • •
Clean the air filter and air filter box. x ( p. 46)
Change the glass fiber yarn filling of the main silencer. x ( p. 47)
Check the screws and nuts for tightness. x
Change the fuel screen. x ( p. 77)
Check the fuel pressure. x
Check the idle. x
Final check: Check the vehicle for roadworthiness and take a test ride. • • • •
Read out the fault memory using the KTM diagnostics tool after a test ride. x
Make the service entry in KTM DEALER.NET and in the service record. x
• • • •
• • •
• • •
•
• • •
• • •
•
• • •
• • •
• • • •
• • •
• •
•
•
• • • •
• • • •
• • •
• • •
•
• • • •
• • • •
• • •
• • • •
• • • •
• • • •
S1N: Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal)
S10A: Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S30A: Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal)
9 SERVICE SCHEDULE 25
9.2 Service work (as additional order)
S20N S40A S50A S100A J1A
Change the front brake fluid. x
Change the rear brake fluid. x
Change the hydraulic clutch fluid. x ( p. 56)
Grease the steering head bearing. x ( p. 40)
Service the shock absorber. x
Change the spark plug and spark plug connector. x
Change the piston. x
Check/measure the cylinder. x
Check the cylinder head. x
Change the valves, valve springs and valve spring seats. x
Check the camshaft and cam lever. x
Change the connecting rod, conrod bearing, and crank pin. x
Check the transmission and shift mechanism. x
Check the oil pressure regulator valve. x
Change the suction pump. x
Check the force pump and lubrication system. x
Change the timing chain. x
Check the timing assembly. x
Change all engine bearings. x
• •
•
• •
• •
• •
•
• •
•
•
• •
•
•
•
• •
•
•
•
•
•
S20N: Once after 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal)
S50A: Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal)
S100A: Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal)
J1A: Annually
10 TUNING THE CHASSIS 26
10.1 Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for an average rider's weight
(with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
– If the rider's weight is above or below this range, the basic setting of the suspen-
sion components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.
401030-01
10.2 Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more
slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
10.3 Adjusting the low-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible
click.
101727-10
Info
Do not loosen fitting 2.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
10 TUNING THE CHASSIS 27
Guideline
Compression damping, low-speed (250 SX‑F EU)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (SX‑F USA)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (XC‑F)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.4 Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw 1 all the way clockwise with a socket wrench.
Info
Do not loosen fitting 2.
– Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed (250 SX‑F EU)
101728-10
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Compression damping, high-speed (SX‑F USA)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Compression damping, high-speed (XC‑F)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10 TUNING THE CHASSIS 28
10.5 Adjusting the rebound damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
– Turn adjusting screw 1 clockwise up to the last perceptible click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping (250 SX‑F EU)
Comfort 17 clicks
Standard 15 clicks
101669-10
Sport 13 clicks
Rebound damping (SX‑F USA)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Rebound damping (XC‑F)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
10.6 Measuring rear wheel sag unloaded
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 34)
Main work
– Measure the distance – as vertical as possible – between the rear axle and a fixed
point, for example, a mark on the side cover.
– Note down the value as dimension A.
400988-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 34)
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
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