KTM 250 SX-F 2013 Owner's manual

5 (2)

OWNER'S MANUAL 2013

250 SX F EU

250 SX F USA

250 XC F USA

Art. no. 3211858en

DEAR KTM 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.

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

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

7.3Preparing 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

7.6Preparing for rides on wet and muddy

surfaces .........................................................

7.7Preparing for rides at high temperatures and

low speeds .....................................................

7.8Preparing for rides at low temperatures or in

snow..............................................................	19
8 RIDING INSTRUCTIONS.............................................	20

8.1Checks 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

10.1Checking the basic chassis setting with the

rider's weight..................................................	26
10.2 Compression damping of the shock absorber......	26

10.3Adjusting the low-speed compression damping

of the shock absorber ......................................

10.4Adjusting the high-speed compression

damping of the shock absorber.........................

10.5Adjusting 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
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

12.1Checking the free travel of the hand brake

lever ..............................................................

12.2Adjusting 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

			3
	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

MEANS OF REPRESENTATION

1.1Symbols 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).

1.2Formats used

The typographical formats used in this document are explained below.

Specific name	Identifies a proprietary name.
Name®	Identifies a protected name.
Brand™	Identifies a brand available on the open market.

SAFETY ADVICE

2.1Use 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)

Info

This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.

2.2Safety 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.

2.3Degrees 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.

2.4Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1The 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

2the 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:

1Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.

2Removal or puncturing of any part of the intake system.

3Lack of proper maintenance.

4Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

SAFETY ADVICE

2.5Safe 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.

2.6Protective 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.

2.7Work 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.

2.8Environment

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.

2.9Owner'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.

IMPORTANT NOTES

3.1Guarantee, 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.

3.2Operating 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.

3.3Spare 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

3.4Service

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.

3.5Figures

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.

3.6Customer 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

VIEW OF VEHICLE

4.1View of vehicle, front left side (example)

101753-10

1Hand brake lever ( p. 11)

2Clutch lever ( p. 11)

3Filler cap

4Fork rebound setting

5Cold start button ( p. 13)

6Shift lever ( p. 14)

7Air filter box lid

8Plug-in stand ( p. 15)

VIEW OF VEHICLE

4.2View of vehicle, rear right (example)

101754-10

1Kill switch ( p. 11)

2Electric starter button ( p. 11)

3Throttle grip ( p. 11)

4Fork compression adjustment

5Level viewer for brake fluid, rear

6Shock absorber rebound adjustment

7Shock absorber compression adjustment

8Level viewer, engine oil

9Foot brake lever ( p. 14)

SERIAL NUMBERS

5.1Chassis number

The chassis number 1 is stamped on the right side of the steering head.

101755-10

5.2Type label

The type label 1 is fixed to the front of the steering head.

101756-10

5.3Engine number

The engine number 1 is stamped on the left side of the engine under the engine sprocket.

101757-10

5.4Fork part number

The fork part number 1 is stamped on the inner side of the axle clamp.

101654-10

5.5Shock absorber part number

The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side.

101758-10

CONTROLS

6.1Clutch lever

The clutch lever 1 is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

101656-10

6.2Hand 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.

101759-10

6.3Throttle grip

The throttle grip 1 is fitted on the right side of the handlebar.

101760-10

6.4Kill switch

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

6.5Electric starter button

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.

101762-10

CONTROLS

6.6Overview of indicator lamps

Possible states

FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagnosis) has identified an emissionsor safety-critical fault.

(XC F)

Fuel level warning lamp lights up orange – Fuel level has reached the reserve mark.

C00218-01

6.7Opening 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 immediately 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

CONTROLS

6.8Closing 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

6.9Cold 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

CONTROLS

6.10Idle 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

6.11Shift 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

6.12Foot brake lever

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

CONTROLS

6.13Plug-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

6.14Side stand (XC F)

The side stand 1 is on the left side of the vehicle.

101772-10

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.

101773-10

PREPARING FOR USE

7.1Advice 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.

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.

PREPARING FOR USE

(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!

7.3Preparing the vehicle for difficult operating conditions

Info

–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)

PREPARING FOR USE

7.4Preparing 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.

Chain cleaner ( p. 96)

– Fit the steel sprocket.

			Tip
			Tip
			Do not grease the chain.
	–
	–	Clean the radiator fins.
	–	Straighten bent radiator fins carefully.
600868-01	–	Straighten bent radiator fins carefully.

–If used in sand regularly, replace the piston every 20 operating hours.

7.5Preparing for rides on wet sand

–Fit a waterproofing device on the air filter.

Waterproofing device for air filter (77206921000)

Info

See the KTM PowerParts fitting instructions.

B00437-01

– Clean the chain.

Chain cleaner ( p. 96)

– Fit the steel sprocket.

			Tip
			Tip
			Do not grease the chain.

	– Clean the radiator fins.
	–	Straighten bent radiator fins carefully.
600868-01	–	Straighten bent radiator fins carefully.
	–	If used in sand regularly, replace the piston every 20 operating hours.

PREPARING FOR USE

7.6Preparing 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

7.7Preparing 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)

	– Clean the radiator fins.
600868-01	– Clean the radiator fins.
600868-01	– 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

RIDING INSTRUCTIONS

8.1Checks 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.

8.2Starting

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.

RIDING INSTRUCTIONS

8.3Starting off

–Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

8.4Shifting, 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 simultaneously 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.

8.5Applying 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.

8.6Stopping, 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.

RIDING INSTRUCTIONS

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.

8.7Transport

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

8.8Refueling

Danger

Fire hazard Fuel is highly flammable.

–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 immediately 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.

RIDING INSTRUCTIONS

–Switch off the engine.

–Open the filler cap. ( p. 12)

401226-10

–Fill the fuel tank with fuel up to measurement A. Guideline

Measurement of A		35 mm (1.38 in)


Total fuel tank	7.5 l	Super unleaded (ROZ 95/RON 95/PON
capacity, approx.	(1.98 US gal)	91) (	p. 95)
(All SX F models)

Total fuel tank	9 l (2.4 US gal)	Super unleaded (ROZ 95/RON 95/PON
capacity, approx.		91) (	p. 95)
(XC F)

–Close the filler cap. ( p. 13)

SERVICE SCHEDULE

9.1Service 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							•	•	•	•
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)

SERVICE SCHEDULE

9.2Service 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

10.1Checking 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.

401030-01

–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 suspension 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.

10.2Compression 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.

10.3Adjusting 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.

Info

Do not loosen fitting 2.

–Turn back counterclockwise by the number of clicks corresponding to the shock absorber type.

101727-10

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.

10.4Adjusting 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
				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
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

10.5Adjusting 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

	Sport	13 clicks
101669-10
101669-10	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

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

10.6Measuring rear wheel sag unloaded

Preparatory work

–Raise the motorcycle with the lift stand. ( p. 34)

400988-10

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.

Finishing work

–Remove the motorcycle from the lift stand. ( p. 34)

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