KTM 250 XC-F USA, 250 EXC-F, 250 SX-F USA, 250 EXC-F AUS, 250 EXC-F EU User Manual

OWNER'S MANUAL 2009

250 EXC-F EU

250 EXC-F AUS

250 EXC-F SIX DAYS EU

250 XCF-W USA

250 XCF-W ZA

250 XC-F USA

250 SX-F EU

250 SX-F USA

ART. NO. 3211348en

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 great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 10) Dealer's stamp

Engine number ( p. 10)

Key number (EXC-F, EXC‑F SIX DAYS) ( p. 10)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles 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 printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
Within the meaning of 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

CONTENTS 2

CONTENTS

MEANS OF REPRESENTATION ............................................ 5

IMPORTANT NOTES............................................................ 6

VIEW OF VEHICLE............................................................... 8

View of the vehicle from the left front (example) ................. 8

View of the vehicle from the right rear (example) ................ 9

LOCATION OF SERIAL NUMBERS ...................................... 10

Chassis number............................................................. 10

Type label..................................................................... 10

Key number (EXC-F, EXC‑F SIX DAYS)............................. 10

Engine number.............................................................. 10

Fork part number........................................................... 10

Shock absorber part number ........................................... 11

CONTROLS....................................................................... 12

Clutch lever .................................................................. 12

Hand brake lever ........................................................... 12

Short circuit button (XCF‑W, XC‑F, SX‑F) ......................... 12

Short circuit button (EXC-F, EXC‑F SIX DAYS).................. 12

Emergency OFF switch (250 EXC-F AUS) ........................ 12

Electric starter button (EXC‑F EU, EXC‑F SIX DAYS,

XCF‑W, XC‑F) ................................................................ 13

Electric starter button (250 EXC-F AUS).......................... 13

Light switch (EXC-F, EXC‑F SIX DAYS) ............................ 13

Light switch (XCF‑W) ..................................................... 13

Horn button (EXC-F, EXC‑F SIX DAYS)............................. 13

Flasher switch (EXC-F, EXC‑F SIX DAYS) ......................... 14

Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) ...... 14

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) ...................... 15

Speedometer................................................................. 15

Speedometer activation and test ..................................... 15

Tripmaster switch .......................................................... 15

Setting kilometers or miles ............................................. 15

Setting the clock ........................................................... 16

Adjusting the speedometer functions............................... 16

Querying the lap time .................................................... 17

SPEED display mode (speed).......................................... 17

SPEED/H display mode (service hours) ............................ 17

SPEED/CLK display mode (time)..................................... 18

SPEED/LAP display mode (lap time)................................ 18

SPEED/ODO display mode (odometer) ............................. 18

SPEED/TR1 display mode (trip master 1)......................... 18

SPEED/TR2 display mode (trip master 2)......................... 19

SPEED/A1 display mode (average speed 1) ...................... 19

SPEED/A2 display mode (average speed 2) ...................... 19

SPEED/S1 display mode (stop watch 1) ........................... 20

SPEED/S2 display mode (stop watch 2) ........................... 20

CONTROLS....................................................................... 22

Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F).............. 22

Fuel tap (SX‑F).............................................................. 22

Opening filler cap.......................................................... 22

Closing filler cap ........................................................... 23

Choke (EXC-F EU, EXC‑F SIX DAYS)................................ 23

Choke (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) .......................... 23

Shift lever..................................................................... 23

Foot brake pedal ........................................................... 24

Kickstarter.................................................................... 24

Side stand (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) .......... 24

Plug-in stand (SX‑F) ...................................................... 24

Steering lock (EXC-F, EXC‑F SIX DAYS) ........................... 25

Locking the steering (EXC-F, EXC‑F SIX DAYS)................. 25

Unlocking the steering (EXC-F, EXC‑F SIX DAYS).............. 25

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION...................................................................... 26

Advice on first use ......................................................... 26

Running in the engine.................................................... 27

RIDING INSTRUCTIONS .................................................... 28

Checks before putting into operation ............................... 28

Starting ........................................................................ 28

Starting up ................................................................... 29

Shifting, riding.............................................................. 29

Braking ........................................................................ 29

Stopping, parking .......................................................... 30

Refueling...................................................................... 30

SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)........ 32

Important maintenance work to be carried out by an

authorized KTM workshop. ............................................. 32

Important maintenance work to be carried out by an

authorized KTM workshop (as additional order)................. 33

SERVICE SCHEDULE (XC‑F, SX‑F) ...................................... 34

Important maintenance work to be carried out by an

authorized KTM workshop. ............................................. 34

Important maintenance work to be carried out by an

authorized KTM workshop (as additional order)................. 35

SERVICE SCHEDULE FOR RIDER....................................... 36

Important checks and maintenance work to be carried

out by the rider. ............................................................ 36

MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 37

Jacking up the motorcycle .............................................. 37

Removing the motorcycle from the work stand.................. 37

Checking the basic chassis setting with the rider's

weight .......................................................................... 37

Compression damping of shock absorber.......................... 37

Adjusting high-speed compression damping of the shock

absorber ....................................................................... 37

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 38

Adjusting the rebound damping of the shock absorber....... 39

Measuring rear wheel sag unloaded ................................. 40

Checking the static sag of the shock absorber .................. 40

Checking the riding sag of the shock absorber .................. 41

Adjusting the spring preload of the shock absorber x ...... 41

Adjusting the riding sag x............................................. 42

Removing the shock absorber x..................................... 42

Installing the shock absorber x ..................................... 42

Checking basic setting of fork ......................................... 43

Adjusting the compression damping of the fork ................ 43

Adjusting the rebound damping of fork ............................ 44

Adjusting the spring preload of the fork (EXC‑F,

EXC‑F SIX DAYS, XCF-W) ............................................... 45

Bleeding fork legs.......................................................... 45

Cleaning dust boots of fork legs ...................................... 46

Loosening the fork protection.......................................... 46

Positioning the fork protection ........................................ 46

Checking play of steering head bearing............................ 46

Adjusting play of steering head bearing x (EXC‑F EU,

EXC‑F AUS, XCF‑W ZA) .................................................. 47

Adjusting play of steering head bearing x

(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ..................... 47

Fork offset (XCF‑W USA, XC‑F, SX‑F)............................... 48

Setting the fork offset x (XCF‑W USA, XC‑F, SX‑F).......... 48

Removing the fork legs................................................... 48

Installing the fork legs x............................................... 49

Removing the fork protector x....................................... 50

Installing the fork protector x ....................................... 50

CONTENTS 3

Removing the lower triple clamp x (EXC‑F SIX DAYS,

XCF‑W USA, XC‑F, SX‑F) ................................................ 50

Removing the lower triple clamp x (EXC‑F EU,

EXC‑F AUS, XCF‑W ZA) .................................................. 51

Installing the lower triple clamp x (EXC‑F SIX DAYS,

XCF‑W USA, XC‑F, SX‑F) ................................................ 51

Installing the lower triple clamp x (EXC‑F EU,

EXC‑F AUS, XCF‑W ZA) .................................................. 52

Greasing the steering head bearing x............................. 53

Dismounting the front fender .......................................... 53

Installing the front fender............................................... 53

Removing headlight mask with headlight (EXC‑F,

EXC‑F SIX DAYS, XCF-W ZA) .......................................... 53

Refitting the headlight mask with the headlight (EXC‑F,

EXC‑F SIX DAYS, XCF-W ZA) .......................................... 54

Dismount the start number plate (XCF‑W USA, XC‑F,

SX‑F)............................................................................ 54

Installing the start number plate (XCF‑W USA, XC‑F,

SX‑F)............................................................................ 54

Handlebar position ........................................................ 54

Adjusting the handlebar position x................................ 55

Checking gas Bowden cable route ................................... 56

Checking play in the gas Bowden cable ........................... 56

Adjusting the gas Bowden cable play x.......................... 57

Checking for chain dirt accumulation .............................. 57

Cleaning the chain......................................................... 57

Checking the chain tension ............................................ 58

Checking the chain tension when fitting rear wheel........... 58

Checking the rear sprocket / engine sprocket for wear ....... 59

Checking chain wear...................................................... 59

Adjusting the chain tension ............................................ 59

Adjusting chain tension - after checking .......................... 60

Adjusting chain tension - fitting rear wheel ...................... 61

Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS,

XCF‑W, XC‑F) ................................................................ 61

Adjusting the chain guide x (SX‑F)................................ 62

Adjusting basic position of clutch lever............................ 62

Checking the fluid level of hydraulic clutch...................... 62

Changing the hydraulic clutch fluid x ............................ 63

Checking the brake discs................................................ 64

Checking free travel of hand brake lever........................... 64

Adjusting basic position of handbrake lever

(XCF‑W, XC‑F, SX‑F) ...................................................... 64

Adjusting free travel of handbrake lever

(EXC-F, EXC‑F SIX DAYS)............................................... 65

Checking the front brake fluid level ................................. 65

Adding front brake fluid x ............................................ 65

Checking the front brake linings...................................... 66

Removing the front brake linings x................................ 66

Installing the front brake linings x................................. 67

Changing the front brake linings x................................. 67

Checking free travel of foot brake lever ............................ 68

Adjusting basic position of footbrake lever x................... 68

Checking the rear brake fluid level .................................. 69

Adding brake fluid for the rear brake x .......................... 69

Checking the rear brake linings ....................................... 70

Removing rear brake linings x....................................... 70

Installing the rear brake linings x.................................. 70

Changing the rear brake linings x.................................. 71

Removing the front wheel x .......................................... 72

Installing the front wheel x........................................... 72

Removing rear wheel x................................................. 73

Installing the rear wheel x ............................................ 73

Tire condition checking.................................................. 74

Checking tire air pressure ............................................... 75

Checking spoke tension.................................................. 75

Removing the battery x (EXC‑F, EXC‑F SIX DAYS,

XCF‑W, XC‑F) ................................................................ 75

Installing the battery x (EXC‑F, EXC‑F SIX DAYS,

XCF‑W, XC‑F) ................................................................ 76

Recharging the battery x (EXC‑F, EXC‑F SIX DAYS,

XCF‑W, XC‑F) ................................................................ 76

Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W,

XC‑F)............................................................................ 77

Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W,

XC‑F)............................................................................ 77

Removing the seat ......................................................... 77

Mounting the seat ......................................................... 78

Dismounting the fuel tank x ......................................... 78

Installing the fuel tank x .............................................. 79

Cooling system .............................................................. 79

Checking antifreeze and coolant level .............................. 80

Checking the coolant level.............................................. 80

Draining the coolant x.................................................. 81

Refilling coolant x ....................................................... 81

Glass fiber yarn filling of main silencer ............................ 81

Removing main silencer ................................................. 82

Installing the main silencer ............................................ 82

Dismounting the air filter box lid..................................... 82

Installing the air filter box lid.......................................... 82

Removing the air filter x............................................... 83

Installing the air filter x ............................................... 83

Cleaning air filter x...................................................... 83

Carburetor - idle ............................................................ 84

Carburetor - adjusting idle x ......................................... 84

Emptying the carburetor float chamber x ....................... 85

Checking the engine oil level .......................................... 86

Changing the engine oil and oil filter, cleaning the oil

screen x ..................................................................... 86

Draining the engine oil x .............................................. 86

Cleaning the oil screens x ............................................ 87

Removing the oil filter x............................................... 88

Installing the oil filter x ............................................... 88

Filling up with engine oil x........................................... 89

Adding engine oil .......................................................... 89

TROUBLESHOOTING......................................................... 90

CLEANING........................................................................ 92

Cleaning motorcycle ...................................................... 92

STORAGE ......................................................................... 93

Storage......................................................................... 93

Putting into operation after storage ................................. 93

TECHNICAL DATA - ENGINE .............................................. 94

Capacity- engine oil ....................................................... 95

Capacity - coolant.......................................................... 95

TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 96

TECHNICAL DATA - CARBURETOR..................................... 98

EXC-F, EXC‑F SIX DAYS ................................................. 98

XCF‑W, 250 XC-F USA................................................... 98

SX‑F............................................................................. 98

TECHNICAL DATA - CHASSIS ............................................ 99

Lighting equipment ..................................................... 100

Tires .......................................................................... 100

Capacity - fuel............................................................. 100

CONTENTS 4

TECHNICAL DATA - FORK................................................ 101

EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 101

250 XC-F USA ............................................................ 101

250 SX-F EU .............................................................. 102

250 SX-F USA ............................................................ 102

TECHNICAL DATA - SHOCK ABSORBER ........................... 103

EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 103

250 XC-F USA ............................................................ 103

250 SX-F EU .............................................................. 104

250 SX-F USA ............................................................ 104

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 105

WIRING DIAGRAM .......................................................... 106

Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)................. 106

Wiring diagram (250 EXC-F AUS) ................................. 110

Wiring diagram (XCF‑W, 250 XC-F USA) ........................ 112

Wiring diagram (SX‑F).................................................. 114

SUBSTANCES................................................................. 116

AUXILIARY SUBSTANCES................................................ 117

STANDARDS................................................................... 119

INDEX ............................................................................ 120

MEANS OF REPRESENTATION 5

1MEANSOFREPRESENTATION

Symbols used

The symbols used are explained in the following.

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 done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained in the following.

Specific name Identifies a specific name.

®

Name

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT NOTES 6

2IMPORTANTNOTES

Use definition (EXC-F, EXC‑F SIX DAYS)

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 is authorized for public road traffic in the homologous (reduced) version only.
In the derestricted version, the motorcycle must be used only on secluded property remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Use definition (XCF‑W, XC‑F, SX‑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

The motorcycle must be used only on secluded property remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break­age of components.
Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as
the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's ser­vice record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from
manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

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.

The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com

Work rules

When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash­ers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

Transport

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

– Do not place the vehicle where there are flammable or explosive substances.

– Switch off the engine.

IMPORTANT NOTES 7

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten­tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can
ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your
motorcycle legally, display environmental consciousness, and respect the rights of others.

Notes/warnings

Be sure to pay attention to the notes and warnings given here.

Info

Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are miss­ing, you or others may not recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-

mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motor­cycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on
servicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is

sold.

VIEW OF VEHICLE 8

3VIEWOFVEHICLE

3.1View of the vehicle from the left front (example)

1 Hand brake lever
2 Filler cap
3 Clutch lever
4 Fuel tap
5 Shift lever
6 Air filter box lid
7 Chain guide

600657-10

VIEW OF VEHICLE 9

3.2View of the vehicle from the right rear (example)

1 Rubber band for the side stand
2 Shock absorber, compression adjustment
3 Chassis number
4 Fork protector
5 Shock absorber, rebound adjustment
6 Level viewer, rear brake fluid
7 Level viewer, engine oil
8 Kickstarter

600656-10

LOCATION OF SERIAL NUMBERS 10

4LOCATIONOFSERIALNUMBERS

4.1Chassis number

The chassis number  is stamped on the steering head on the right.

500127-10

4.2Type label

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

500128-10

4.3Key number (EXC-F, EXC‑F SIX DAYS)

500125-10

4.4Engine number

The key number  is stamped on the key strap.

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

4.5Fork part number

600661-12

The fork part number  is stamped on the inner side of the fork stub.

500082-10

LOCATION OF SERIAL NUMBERS 11

4.6Shock absorber part number

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

500129-10

CONTROLS 12

5CONTROLS

5.1Clutch lever

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

600659-10

5.2Hand brake lever

Hand brake lever  is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.

400196-10

5.3Short circuit button (XCF‑W, XC‑F, SX‑F)

The short circuit button  is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is

• Short circuit button pressed – In this position, the ignition circuit is interrupted,

500132-10

5.4Short circuit button (EXC-F, EXC‑F SIX DAYS)

The short circuit button  is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is

• Short circuit button pressed – In this position, the ignition circuit is interrupted,

closed, and the engine can be started.

a running engine stops, and a non-running engine will not start.

closed, and the engine can be started.

a running engine stops, and a non-running engine will not start.

500134-10

5.5Emergency OFF switch (250 EXC-F AUS)

500131-10

The emergency OFF switch  is fitted on the left side of the handlebar.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a run­ning engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.

CONTROLS 13

5.6Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W, XC‑F)

The electric starter button  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.

400198-10

5.7Electric starter button (250 EXC-F AUS)

The electric starter button  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.

500131-11

5.8Light switch (EXC-F, EXC‑F SIX DAYS)

500134-12

5.9Light switch (XCF‑W)

500146-10

The light switch  is fitted on the left side of the handlebar.

Possible states

Light off – Light switch is turned to the right. In this position, the light is
switched off.

Low beam on – Light switch is in the central position. In this position,
the low beam and tail light are switched on.

High beam on – Light switch is turned to the left. In this position, the
high beam and the tail light are switched on.

The light switch  is on the right of the speedometer.

Possible states

(250 XCF-W ZA)

• Light off – Light switch is pressed in up to the stop. In this position, the light
is switched off.

• Light on – Light switch is pulled out to the stop. In this position, the low beam
and the tail light are switched on.

(250 XCF-W USA)

• The light switch has no function when delivered. – It can be used if lighting is
fitted later.

5.10Horn button (EXC-F, EXC‑F SIX DAYS)

500134-11

The horn button  is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position

• Horn button pressed – The horn is operated in this position.

CONTROLS 14

5.11Flasher switch (EXC-F, EXC‑F SIX DAYS)

Flasher switch  is fitted on the left side of the handlebar.

Possible states

Flasher light off – Flasher switch is in the central position.
Flasher light, left, on – Flasher switch turned to the left.

Flasher light, right, on – Flasher switch turned to the right.

500145-10

5.12Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS)

Possible states

High beam indicator lamp lights up blue – High beam is switched on.

Flasher indicator lamp flashes green – Flasher light is switched on.

500147-01

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 15

6CONTROLS(EXC‑F,EXC‑FSIX DAYS, XCF-W)

6.1Speedometer

– Press the key to change the display mode or change to one of the setup menus.
– Press the button to control different functions.
– Press the button to control different functions.

Info

In its condition at delivery, the display mode SPEED/H and SPEED/ODO is acti­vated.

400312-01

6.2Speedometer activation and test

Activating the speedometer:
The speedometer is activated when one of the keys is pressed or an impulse comes
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.

400313-01

WS (wheel size)
After the display function test, the wheel size WS is displayed briefly.

Info

2205 mm corresponds to the size of the 21" front wheel with a series produc­tion tire.

The display then changes to the last selected mode.

400314-01

6.3Tripmaster switch

(Option: Tripmaster switch)

You can use the trip master switch to control the functions of the speedometer from the handlebar.

Info

The trip master is an optional accessory.

6.4Setting kilometers or miles

Info

If you change the unit of measure, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

400329-01

Condition

The motorcycle is standing.
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

– Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

– Press the button repeatedly until the Km/h/Mph display flashes.
Adjusting Km/h

– Press the button .

Adjusting Mph

– Press the button .

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 16

– Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.

6.5Setting the clock

Condition

The motorcycle is standing.
– Press the button briefly and repeatedly until CLK appears at the bottom right of

the display.

– Press the button for 3 - 5 seconds.

The hour display flashes.

– Set the hour display with the button and/or button .
– Press the button briefly.

The next segment of the display flashes and can be set.

400330-01

– You can set the following segments in the same way as the hours by pressing the

button and the button .

Info

The seconds can only be set to zero.

– Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.

6.6Adjusting the speedometer functions

Info

Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated.

Condition

The motorcycle is standing.
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

– Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

– Switch to the function you require by briefly pressing the button .

The selected function flashes.

Activating a function

– Press the button .

400318-01

Deactivating a function

– Press the button .

– Activate or deactivate all functions accordingly.

The icon remains in the display and the display changes to the next func­tion.

The icon disappears from the display and the display changes to the next
function.

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 17

– Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.

6.7Querying the lap time

Info

This function can be called only if lap times are measured.

Condition

The motorcycle is standing.
– Press the button briefly and repeatedly until LAP appears at the bottom right of

the display.

– Press the button briefly.

LAP 1 appears on the left side of the display.

– Laps 1-10 can be displayed by pressing the button .
– The button has no function
– Press the button briefly.

400321-01

Next display mode

Info

If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.

6.8SPEED display mode (speed)

400317-02

6.9SPEED/H display mode (service hours)

400316-01

– Press the button briefly and repeatedly until SPEED appears on the left side of

the display.

The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.

Info

Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.

Condition

• Vehicle at a standstill
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

The number of service hours of the engine is shown in the H display mode.
The service hour counter stores the total traveling time.

Info

The service hour counter is necessary for ensuring that maintenance work is car­ried out at the right intervals.
If the speedometer is in the H display mode at the start of the trip, it automati­cally changes to the ODO display mode.
The H display mode is suppressed during travel.

Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.

The display changes to the Setup menu of the speedometer
functions.

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 18

6.10SPEED/CLK display mode (time)

400319-01

6.11SPEED/LAP display mode (lap time)

Press the button

next display mode

briefly.

– Press the button briefly and repeatedly until CLK appears at the bottom right of

the display.

The time is displayed in the CLK display mode.

Press the button . No function
Press the button . No function
Press the button

The display changes to the Setup menu of the clock.
for 3 - 5 seconds.
Press the button

next display mode
briefly.

– Press the button briefly and repeatedly until LAP appears at the bottom right of

the display.

In the LAP display mode, up to ten laps can be timed with the stop watch.

Info

If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .

400320-01

6.12SPEED/ODO display mode (odometer)

400317-01

6.13SPEED/TR1 display mode (trip master 1)

Press the button . Starts or stops the clock.
Press the button . Stops the current lap time and saves it, and the stop watch

starts the next lap.
Press the button

The stop watch and the lap time are reset.
for 3 - 5 seconds.
Press the button

next display mode
briefly.

– Press the button briefly and repeatedly until ODO appears at the bottom right of

the display.

The total number of kilometers ridden is shown in the ODO display mode.

Press the button . No function
Press the button . No function
Press the button

–

for 3 - 5 seconds.
Press the button

next display mode
briefly.

– Press the button briefly and repeatedly until TR1 appears at the top right of the

display.

TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

400323-01

Info

If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to

0.0.

Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
briefly.

The TR1, A1 and S1 displays are reset to 0.0.

next display mode

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 19

6.14SPEED/TR2 display mode (trip master 2)

– Press the button briefly and repeatedly until TR2 appears at the top right of the

display.

TR2 (trip master 2) runs constantly and counts to 999.9.
The displayed value can be set manually with the button and the button . A very
practical function for rides by the road book.

Info

The TR2 value can also be corrected manually during the trip using the but-

400324-01

6.15SPEED/A1 display mode (average speed 1)

ton and the button .
If 999.9 is exceeded, TR2 is automatically reset to 0.0.

Press the button . Increases value TR2.
Press the button . Decreases value TR2.
Press the button

Clears value TR2.
for 3 - 5 seconds.
Press the button

next display mode
briefly.

– Press the button briefly and repeatedly until A1 appears at the top right of the

display.

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas­ter 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.

Press the button . No function
Press the button . No function

400325-01

Press the button
for 3 - 5 seconds.
Press the button
briefly.

6.16SPEED/A2 display mode (average speed 2)

– Press the button briefly and repeatedly until A2 appears at the top right of the

A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.

400326-01

Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
briefly.

The TR1, A1 and S1 displays are reset to 0.0.

next display mode

display.

Info

The displayed value can differ from the actual average speed if S2 is not
stopped after the ride.

–

next display mode

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 20

6.17SPEED/S1 display mode (stop watch 1)

– Press the button briefly and repeatedly until S1 appears at the top right of the

display.

S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running when
an impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends three seconds after the last impulse.

Press the button . No function
Press the button . No function

400327-01

6.18SPEED/S2 display mode (stop watch 2)

400328-01

Press the button
for 3 - 5 seconds.
Press the button
briefly.

– Press the button briefly and repeatedly until S2 appears at the top right of the

display.

S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button . Starts or stops S2.
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
briefly.

The TR1, A1 and S1 displays are reset to 0.0.

next display mode

The S2 and A2 displays are reset to 0.0.

next display mode

Table of functions
Display Press the button . Press the button . Press the button for 3 -

5 seconds.

SPEED/H display mode

(service hours)

No function No function The display changes to

the Setup menu of the
speedometer functions.

SPEED/CLK display mode
(time)

No function No function The display changes to

the Setup menu of the
clock.

SPEED/LAP display mode
(lap time)

Starts or stops the
clock.

Stops the current lap
time and saves it, and

The stop watch and the

lap time are reset.
the stop watch starts
the next lap.

SPEED/ODO display mode

No function No function – next display mode

(odometer)
SPEED/TR1 display mode

(trip master 1)
SPEED/TR2 display mode

No function No function The TR1, A1 and S1 dis-

plays are reset to 0.0.

Increases value TR2. Decreases value TR2. Clears value TR2. next display mode

(trip master 2)
SPEED/A1 display mode

(average speed 1)
SPEED/A2 display mode

No function No function The TR1, A1 and S1 dis-

plays are reset to 0.0.

No function No function – next display mode

(average speed 2)
SPEED/S1 display mode

(stop watch 1)
SPEED/S2 display mode

(stop watch 2)

No function No function The TR1, A1 and S1 dis-

plays are reset to 0.0.

Starts or stops S2. No function The S2 and A2 displays

are reset to 0.0.

Press the button
briefly.

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

Table of conditions and activability
Display Vehicle at a stand-

still

Menu can be acti­vated

SPEED/H display mode (service hours) •
SPEED/CLK display mode (time) •
SPEED/LAP display mode (lap time) •

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 21

Table of conditions and activability
Display Vehicle at a stand-

still

SPEED/TR1 display mode (trip master 1) •
SPEED/TR2 display mode (trip master 2) •
SPEED/A1 display mode (average speed 1) •
SPEED/A2 display mode (average speed 2) •
SPEED/S1 display mode (stop watch 1) •
SPEED/S2 display mode (stop watch 2) •

Menu can be acti­vated

CONTROLS 22

7CONTROLS

7.1Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

The fuel tap is on the left side of the fuel tank.
Using tap handle  on the fuel tap, you can open or close the supply of fuel to the
carburetor.

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.

• Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The
fuel tank empties completely.

500137-10

7.2Fuel tap (SX‑F)

7.3Opening filler cap

The fuel tap is on the left side of the fuel tank.
Using tap handle  on the fuel tap, you can open or close the supply of fuel to the
carburetor.

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank
empties completely.

500178-10

– Press release button , turn filler cap counterclockwise and lift it free.

400199-10

CONTROLS 23

7.4Closing filler cap

– Replace the filler cap and turn clockwise until the release button  locks in place.

Info

Run the fuel tank breather hose  without kinks.

400199-11

7.5Choke (EXC-F EU, EXC‑F SIX DAYS)

The flasher switch  is fitted on the left side of the handlebar.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

500136-10

• Choke function activated – The choke lever is pulled to the stop.

• Choke function deactivated – The choke lever is pushed back to the stop.

7.6Choke (EXC‑F AUS, XCF‑W, XC‑F, SX‑F)

600660-10

7.7Shift lever

600661-13

Choke  is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

• Choke function activated – The choke lever is pulled out to the stop.

• Choke function deactivated – The choke lever is pushed in to the stop.

Shift lever  is mounted on the left side of the engine.

The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

600661-10

CONTROLS 24

7.8Foot brake pedal

Foot brake pedal  is located in front of the right footrest.
The foot brake pedal is used to activate the rear brake.

600664-10

7.9Kickstarter

Kickstarter  is fitted on the right of the engine.
The engine can be started with either the kickstarter or the electric starter.
The upper part of the kickstarter can be swung out.

Info

Before riding, swing the upper part of the kickstarter inward toward the engine.

600664-11

7.10Side stand (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

Note

Material damage Damage and destruction of components by excessive load.

– The side stand is designed for the weight of the motorcycle only. Do not sit on the

500140-10

motorcycle when it is supported by the side stand only. The side stand and/or the
frame could be damaged and the motorcycle could fall over.

To park the motorcycle, press the side stand  to the ground with your foot and lean
the motorcycle on it.

When you are riding, the side stand  must be folded up and secured with the rubber
band .

7.11Plug-in stand (SX‑F)

600665-10

400203-10

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

To park the motorcycle, insert plug-in stand  into the left side of the wheel spindle.

Info

Remove the plug-in stand before starting on a trip.

CONTROLS 25

7.12Steering lock (EXC-F, EXC‑F SIX DAYS)

Steering lock  is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.

500126-10

7.13Locking the steering (EXC-F, EXC‑F SIX DAYS)

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

– Park the motorcycle.
– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.

Steering is no longer possible.

Info

Never leave the key in the steering lock.

7.14Unlocking the steering (EXC-F, EXC‑F SIX DAYS)

– Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key.

You can now steer the bike again.

Info

Never leave the key in the steering lock.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 26

8GENERALTIPSANDHINTS ONP UTTINGINTO OPERATION

8.1Advice on first use

Danger

Danger of accidents Danger from insufficient traffic competence.

– Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.

Warning

Risk of injury Risk of injury by missing/inadequate protective clothing.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always

wear protective clothing, which must be in perfect condition and meet legal requirements.

Warning

Danger of crashing Impairment of riding behavior 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 Brake system failure.

– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take

your foot off the foot brake pedal if you do not want to brake.

Warning

Danger of accidents Unstable riding behavior.

– Do not exceed the maximum permitted 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.
– Get to know the controls.
– Adjust the basic position of clutch lever. ( p. 62)
(XCF‑W, XC‑F, SX‑F)

– Adjust the basic position of handbrake lever. ( p. 64)

(EXC-F, EXC‑F SIX DAYS)

– Adjust the free travel of the handbrake lever. ( p. 65)

–

Adjust the basic position of the footbrake lever. x ( p. 68)

– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info

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.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 27

– 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 dis-

tribution 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 the engine in.

8.2Running 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 3 service hours 7,000 rpm

Maximum engine performance during the running-in period

During the first 3 service hours ≤ 50 %
During the next 12 service hours ≤ 75 %

– Avoid fully opening the throttle!

RIDING INSTRUCTIONS 28

9RIDINGINSTRUCTIONS

9.1Checks before putting into operation

Info

Make sure that the motorcycle is in a perfect technical condition before use.

Info

In the interests of riding safety, make a habit of making a general check before you ride.

– Check the engine oil level. ( p. 86)
– Check the chain tension. ( p. 58)
– Check for chain dirt accumulation. ( p. 57)
– Check the tire condition. ( p. 74)
– Check the tire air pressure. ( p. 75)
– Check the front brake fluid level. ( p. 65)
– Check the rear brake fluid level. ( p. 69)
– Check the front brake linings. ( p. 66)
– Check the rear brake linings. ( p. 70)
– Check brake system function.
– Check the coolant level. ( p. 80)
– Check that all operating elements are correctly adjusted and free to move.
– Check the functioning of the electrical equipment.

9.2Starting

Danger

Danger of poisoning Exhaust gases are poisonous and can 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 a closed

space.

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.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

Engine has been out of use for more than 1 week

–

Empty the carburetor float chamber. x ( p. 85)

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Turn handle  of the fuel tap to the ON position. (Figure 500137-10 p. 22)

Fuel can flow from the fuel tank to the carburetor.

(SX‑F)

– Turn handle  of the fuel tap to the ON position. (Figure 500178-10 p. 22)

Fuel can flow from the fuel tank to the carburetor.

– Remove the motorcycle from the stand.
– Shift gear to neutral.

(250 EXC-F AUS)

– Turn the emergency OFF switch to the position .

The engine is cold

‑F AUS, XCF‑W, XC‑F, SX‑F)

(EXC

– Pull the choke lever out as far as possible.

(EXC-F EU, EXC‑F SIX DAYS)

– Pull the choke lever to the stop.

RIDING INSTRUCTIONS 29

– Press the electric starter button or press the kickstarter robustly through its full range.

Info

Don't open the throttle.

9.3Starting up

Info

If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists.
When you are riding, the side stand must be folded up and secured with the rubber band.

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

9.4Shifting, 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 block.

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 and open the throttle.

– If the choke function was activated, deactivate it after the engine has warmed up.
– When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range; the speed hardly

drops, but the fuel consumption falls considerably.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening 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

≥ 2 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.

9.5Braking

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 caused by spongy pressure point of front or rear brake.

– Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes 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 brake far less and the brakes do not overheat.

RIDING INSTRUCTIONS 30

9.6Stopping, 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 get very hot when the machine is driven.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-

nents to cool down before starting work on them.

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

– Do not place the vehicle where there are flammable or explosive substances.

Note

Material damage Damage and destruction of components by excessive load.

– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side

stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle.
– Shift gear to neutral.
(XCF‑W, XC‑F, SX‑F)

– Press and hold the short circuit button while the engine is idling until the engine stops.

(EXC-F, EXC‑F SIX DAYS)

– Press and hold the short circuit button while the engine is idling until the engine stops.

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

– Park the motorcycle on firm ground.

9.7Refueling

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up 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 specifications on filling up with fuel.

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 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.

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.

– Switch off the engine.
– Open the filler cap. ( p. 22)

AA

RIDING INSTRUCTIONS 31

– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

400382-10

Total fuel tank
capacity,
approx. (EXC‑F,
EXC‑F SIX DAYS,
XCF‑W, XC‑F)

Total fuel tank
capacity, approx.
(SX‑F)

– Close the filler cap. ( p. 23)

9.2 l
(2.43 US gal)

8.0 l
(2.11 US gal)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 116)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 116)

SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) 32

10SERVICESC HEDULE(EXC‑F, EXC‑F SIXDAYS, XCF-W)

10.1Important maintenance work to be carried out by an authorized KTM workshop.

S3N S20A S30A

Engine

Change the engine oil and oil filter, clean the oil screen. x ( p. 86)

Replace the spark plug. •

Check the valve clearance. x

Check the engine mounting screws for tightness. • •
Clean the spark plug connectors and check for tightness. • •
Check that the screws in the shift lever and the kickstarter are tight. • •

Carburetor Check the carburetor connection boots for cracks and leakage. •

Check the vent hoses for damage and routing without sharp bends. • •
Check the idle. • •

Attachments Check the cooling system for leakage. • •

Check the antifreeze and coolant level. ( p. 80) • •
Check the exhaust system for leakage and looseness. •
Check the Bowden cables for damage, smooth operation and routing without sharp

bends.
Check the fluid level of the hydraulic clutch. ( p. 62) • •

Clean the air filter. x ( p. 83)

Check the cables for damage and routing without sharp bends. •
Check the functioning of the electrical equipment. • •
Check the headlamp setting. •

Brakes Check the front brake linings. ( p. 66) • •

Check the rear brake linings. ( p. 70) • •
Check the brake discs. ( p. 64) • •
Check the front brake fluid level. ( p. 65) • •
Check the rear brake fluid level. ( p. 69) • •
Check the brake lines for damage and leakage. • •
Check the free travel of the hand brake lever. ( p. 64) • •
Check the free travel of the foot brake lever. ( p. 68) • •
Check the brake system function. • •
Check the screws and guide bolts of the rake system for tightness. • •

Chassis

Check the shock absorber and fork for leakage and functioning. x

Clean dust boots of fork legs. ( p. 46) •
Bleed fork legs. ( p. 45) •
Check the swingarm bearing. •
Check play of steering head bearing. ( p. 46) • •
Check all screws to see if they are tight. • •

Wheels Check the spoke tension. ( p. 75) • •

Check the rim run-out. • •
Check the tire condition. ( p. 74) • •
Check the tire air pressure. ( p. 75) • •
Check the chain wear. ( p. 59) • •
Check the chain tension. ( p. 58) • •
Clean the chain. ( p. 57) • •
Check the wheel bearing for play. • •
Clean and grease the adjusting screws of the chain adjuster. • •

• •

• •

• •

• •

• •

S3N: After 3 service hours
S20A: Every 20 service hours
S30A: Every 30 service hours

SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) 33

10.2Important maintenance work to be carried out by an authorized KTM workshop (as additional order).

Competition use Hobby use J1A J2A

S10A S20A S40A S80A S20A S40A S80A

Carry out a complete fork service. x
Carry out a complete shock absorber service. x
Grease the steering head bearing. x ( p. 53)

Treat electric contacts with contact spray. • •

Change the hydraulic clutch fluid. x ( p. 63)
Change the front brake fluid. x
Change the rear brake fluid. x
Clean the spark arrestor. x (250 XCF-W USA)
Check the clutch discs for wear. x
Check the clutch. x
Check the cylinder and piston for wear. x
Check the camshafts. x
Check the valve spring seat. x
Check the valves. x
Change the valves. x
Check wear of valve guides. x
Change the valve springs. x
Check the timing-chain tensioner function. x

Check the crankshaft run-out at the bearing

pin. x
Change the conrod bearing. x
Change the crankshaft main bearing. x
Fully check the transmission. x
Check the shift mechanism. x

Check the spring length of the oil pressure regu-

lator valve. x

Change the glass fiber yarn filling of the main

silencer. x
Change the foot brake cylinder seals. x
Check/adjust the carburetor components. x

• • • • • • •

• • • • •

• • • • •

• • •

• • •

• • •

• • •

• •

• •

• • •

• • •

• • •

• • •

• •

• • •

• • •

• • •

• • • • •

• • • • • •

• •

•

• •

• •

• •

• •

• •

S10A: Every 10 service hours / after every race
S20A: Every 20 service hours
S40A: Every 40 service hours
S80A: Every 80 service hours
J1A: annually
J2A: every 2 years

SERVICE SCHEDULE (XC‑F, SX‑F) 34

11SERVICESC HEDULE(XC‑F, SX‑F)

11.1Important maintenance work to be carried out by an authorized KTM workshop.

S3N S10A S30A

Engine

Change the engine oil and oil filter, clean the oil screen. x ( p. 86)

Replace the spark plug. •

Check the valve clearance. x

Check the engine mounting screws for tightness. • • •
Clean the spark plug connectors and check for tightness. • • •
Check that the screws in the shift lever and the kickstarter are tight. • • •

Carburetor Check the carburetor connection boots for cracks and leakage. • •

Check the vent hoses for damage and routing without sharp bends. • • •
Check the idle. • • •

Attachments Check the cooling system for leakage. • • •

Check the antifreeze and coolant level. ( p. 80) • • •
Check the exhaust system for leakage and looseness. • •
Check the Bowden cables for damage, smooth operation and routing without sharp

bends.
Check the fluid level of the hydraulic clutch. ( p. 62) • • •

Clean the air filter. x ( p. 83)

Check the cables for damage and routing without sharp bends. • •

Brakes Check the front brake linings. ( p. 66) • • •

Check the rear brake linings. ( p. 70) • • •
Check the brake discs. ( p. 64) • • •
Check the front brake fluid level. ( p. 65) • • •
Check the rear brake fluid level. ( p. 69) • • •
Check the brake lines for damage and leakage. • • •
Check the free travel of the hand brake lever. ( p. 64) • • •
Check the free travel of the foot brake lever. ( p. 68) • • •
Check the brake system function. • • •
Check the screws and guide bolts of the brake system for tightness. • • •

Chassis

Check the shock absorber and fork for leakage and functioning. x

Clean dust boots of fork legs. ( p. 46) • •
Bleed fork legs. ( p. 45) • •
Check the swingarm bearing. • •
Check play of steering head bearing. ( p. 46) • • •
Check all screws to see if they are tight. • • •

Wheels Check the spoke tension. ( p. 75) • • •

Check the rim run-out. • • •
Check the tire condition. ( p. 74) • • •
Check the tire air pressure. ( p. 75) • • •
Check the chain wear. ( p. 59) • • •
Check the chain tension. ( p. 58) • • •
Clean the chain. ( p. 57) • • •
Check the wheel bearing for play. • • •
Clean and grease the adjusting screws of the chain adjuster. • • •

• • •

• • •

• • •

• • •

• • •

S3N: After 3 service hours - corresponds to about 21 liters (5.55 US gal) of fuel
S10A: Every 10 service hours - corresponds to about 70 liters (18.5 US gal) of fuel / after every race
S30A: Every 30 service hours - corresponds to about 210 liters (55.5 US gal) of fuel

SERVICE SCHEDULE (XC‑F, SX‑F) 35

11.2Important maintenance work to be carried out by an authorized KTM workshop (as additional order).

S10A S20A S40A S80A J1A J2A

Carry out a complete fork service. x
Carry out a complete shock absorber service. x
Grease the steering head bearing. x ( p. 53)

Treat electric contacts with contact spray. • •

Change the hydraulic clutch fluid. x ( p. 63)
Change the front brake fluid. x
Change the rear brake fluid. x
Check the clutch discs for wear. x
Check the clutch. x
Check the cylinder and piston for wear. x
Check the camshafts. x
Check the valve spring seat. x
Check the valves. x
Change the valves. x

Check wear of valve guides. •

Change the valve springs. x
Check the timing-chain tensioner function. x
Check the crankshaft run-out at the bearing pin. x
Change the conrod bearing. x
Change the crankshaft main bearing. x
Fully check the transmission. x
Check the shift mechanism. x
Check the spring length of the oil pressure regulator valve. x
Change the glass fiber yarn filling of the main silencer. x
Change the foot brake cylinder seals. x
Check/adjust the carburetor components. x

• • • •

• • •

• • •

• •

• •

• •

• •

•

• •

• •

• •

• •

•

• •

• •

• •

• • •

• • • •

• •

•

• •

• •

• •

• •

S10A: Every 10 service hours - corresponds to about 70 liters (18.5 US gal) of fuel / after every race
S20A: Every 20 service hours - corresponds to about 140 liters (37 US gal) of fuel
S40A: Every 40 service hours - corresponds to about 280 liters (74 US gal) of fuel
S80A: Every 80 service hours - corresponds to about 560 liters (148 US gal) of fuel
J1A: annually
J2A: every 2 years

SERVICE SCHEDULE FOR RIDER 36

12SERVICESC HEDULEFOR RIDER

12.1Important checks and maintenance work to be carried out by the rider.

NB1A

Check the engine oil level. ( p. 86) •
Check the front brake fluid level. ( p. 65) •
Check the rear brake fluid level. ( p. 69) •
Check the front brake linings. ( p. 66) •
Check the rear brake linings. ( p. 70) •
Check and adjust Bowden cables. •
Bleed fork legs. ( p. 45) •
Clean dust boots of fork legs. ( p. 46) •
Clean the chain. ( p. 57) •
Check the chain tension. ( p. 58) •
Check the chain wear. ( p. 59) •
Check the rear sprocket / engine sprocket for wear. ( p. 59) •

Clean the air filter. x ( p. 83)

Check the tire air pressure. ( p. 75) •
Check the tire condition. ( p. 74) •
Check the coolant level. ( p. 80) •

Empty the carburetor float chamber. x ( p. 85)

Check that all operating elements for smooth operation. •
Check braking. •
Check all screws, nuts and hose clamps regularly for tightness. •

•

•

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE 37

13MAINTENANCE WORKON CHASSIS ANDENGINE

13.1Jacking up the motorcycle

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

– Jack up the motorcycle underneath the engine. The wheels must no longer touch

the ground.

Work stand (54829055000)

600697-01

13.2Removing the motorcycle from the work stand

– Secure the motorcycle against falling over.

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

– Always place the vehicle on a firm and even surface.

– Remove the motorcycle from the work stand.
– Remove the work stand.

13.3Checking 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, swing arm and frame, the basic set-

tings of the suspension components must match your body weight.

– As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).

Guideline

Standard rider weight 75… 85 kg (165… 187 lb.)

– If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accord-

ingly.

– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the

springs must be replaced.

13.4Compression damping of shock absorber

The shock absorber can regulate compression damping separately in the low-speed and high-speed ranges (Dual Compression Control).
The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motor­cycle.
The low-speed and high-speed technology works non-specifically.

13.5Adjusting high-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

MAINTENANCE WORK ON CHASSIS AND ENGINE 38

– Turn adjusting screw  clockwise with a ring wrench until it stops.

Info

Do not loosen nut !

– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline

Compression damping, high-speed (EXC‑F, EXC‑F SIX DAYS, XCF-W)

600667-10

Comfort 2 turns
Standard 1.5 turns
Sport 1 turn

Compression damping, high-speed (250 XC-F USA)

Comfort 1 turn
Standard 1 turn
Sport 3/4 turn

Compression damping, high-speed (250 SX-F EU)

Comfort 1.5 turns
Standard 1.5 turns
Sport 1 turn

Compression damping, high-speed (250 SX-F USA)

Comfort 1 turn
Standard 1 turn
Sport 3/4 turn

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

13.6Adjusting the low-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

– Turn adjusting screw  clockwise with a screwdriver until it stops.

Info

Do not loosen nut !

600667-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 39

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

absorber type.
Guideline

Compression damping, low-speed (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

Compression damping, low-speed (250 XC-F USA)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Compression damping, low-speed (250 SX-F EU)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Compression damping, low-speed (250 SX-F USA)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

13.7Adjusting the rebound damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

– Turn adjusting screw  clockwise until it stops.

Info

Do not loosen nut !

400210-10

00AA

000BB

0

0

AA

MAINTENANCE WORK ON CHASSIS AND ENGINE 40

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

absorber type.
Guideline

Rebound damping (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Comfort 26 clicks
Standard 24 clicks
Sport 22 clicks

Rebound damping (250 XC-F USA)

Comfort 25 clicks
Standard 25 clicks
Sport 23 clicks

Rebound damping (250 SX-F EU)

Comfort 24 clicks
Standard 22 clicks
Sport 21 clicks

Rebound damping (250 SX-F USA)

Comfort 25 clicks
Standard 24 clicks
Sport 22 clicks

13.8Measuring rear wheel sag unloaded

– Jack up the motorcycle. ( p. 37)
– Measure the distance – as vertical as possible – between the rear axle and a fixed

point, for example, a mark on the side cover.

– Make a note of the value as measurement .
– Remove the motorcycle from the work stand. ( p. 37)

400220-10

13.9Checking the static sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 40)
– Ask someone to help you by holding the motorcycle upright.
– Measure the distance between the rear axle and the fixed point again.
– Make a note of the value as measurement .

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

400221-10

Info

The static sag is the difference between measurements  and .

– Check the static sag.

Static sag (EXC‑F, EXC‑F SIX DAYS,
XCF-W)

Static sag (250 XC-F USA) 33 mm (1.3 in)
Static sag (250 SX-F EU) 33 mm (1.3 in)
Static sag (250 SX-F USA) 33 mm (1.3 in)

» If the static sag is less or more than the specified value:

–

Adjust the spring preload of the shock absorber. x ( p. 41)

35 mm (1.38 in)

CC

0

0

AA

AA

22
11

MAINTENANCE WORK ON CHASSIS AND ENGINE 41

13.10Checking the riding sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 40)
– With another person holding the motorcycle, sit on the saddle with full protective

clothing in a normal sitting position (feet on footrests) and bounce up and down a
few times until the rear suspension levels out.

– The other person now has to measure the distance between the rear axle and a

fixed point.

– Make a note of the value as measurement .

Info

The riding sag is the difference between measurements  and .

– Check the riding sag.

Riding sag (EXC‑F, EXC‑F SIX DAYS,
XCF-W)

Riding sag (250 XC-F USA) 112 mm (4.41 in)
Riding sag (250 SX-F EU) 105 mm (4.13 in)
Riding sag (250 SX-F USA) 107 mm (4.21 in)

» If the riding sag differs from the specified measurement:

400222-10

13.11Adjusting the spring preload of the shock absorber x

–

Adjust the riding sag. x ( p. 42)

105 mm (4.13 in)

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Info

Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

–

Remove shock absorber. x ( p. 42)

– After removing the shock absorber, clean it thoroughly.
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.

400216-10

Combination wrench (50329080000)
Hook wrench (T106S)

–

Measure the overall spring length when not under tension.

– Tighten the spring by turning adjusting ring  to measurement .

Guideline

Spring preload (EXC‑F,
EXC‑F SIX DAYS, XCF-W)

Spring preload (250 XC-F USA) 5 mm (0.2 in)
Spring preload (250 SX-F EU) 6 mm (0.24 in)
Spring preload (250 SX-F USA) 7 mm (0.28 in)

9 mm (0.35 in)

Info

Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.

– Tighten screw .

Guideline

Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft)

–

Install the shock absorber. x ( p. 42)

MAINTENANCE WORK ON CHASSIS AND ENGINE 42

13.12Adjusting the riding sag x

–

Remove shock absorber. x ( p. 42)

– After removing the shock absorber, clean it thoroughly.
– Choose and mount a suitable spring.

Guideline

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in)

Info

The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.

–

Install the shock absorber. x ( p. 42)

– Check the static sag of the shock absorber. ( p. 40)
– Check the riding sag of the shock absorber. ( p. 41)
– Adjust the rebound damping of the shock absorber. ( p. 39)

13.13Removing the shock absorber x

– Jack up the motorcycle. ( p. 37)
– Remove screw  and lower the rear wheel with the swing arm as far as possible

without blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw , push splash protector  to the side, and remove the shock

absorber.

600668-10

13.14Installing the shock absorber x

600668-11

– Push splash protector  to the side and position the shock absorber. Mount and

tighten screw .
Guideline

Screw, top shock absorber M12 80 Nm

Loctite®243™

(59 lbf ft)

– Mount and tighten screw .

Guideline

Screw, bottom shock
absorber

M12 80 Nm

(59 lbf ft)

Loctite®243™

Info

The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis­solve the Teflon coating, thereby drastically reducing the service life.

– Remove the motorcycle from the work stand. ( p. 37)

MAINTENANCE WORK ON CHASSIS AND ENGINE 43

13.15Checking basic setting of fork

Info

For various reasons, no exact riding sag can be determined for the forks.

– As with the shock absorber, smaller weight differences can be compensated by the

spring preload.

– However, if your fork is often overloaded (hard end stop on compression), you must

fit harder springs to avoid damage to the fork and frame.

400189-01

13.16Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Remove protection covers .
– Turn adjusting screws  clockwise until they stop.

100020-10

Info

The adjusting screws  are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork

type.
Guideline

Compression damping

Comfort 26 clicks
Standard 22 clicks
Sport 20 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.

– Mount protection covers .

(SX‑F, 250 XC-F USA)

– Turn adjusting screws  clockwise until they stop.

Info

The adjusting screws  are located at the top end of the fork legs.
Make the same adjustment on both fork legs.

600669-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 44

– Turn back counterclockwise by the number of clicks corresponding to the fork

type.
Guideline

Compression damping (250 XC-F USA)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Compression damping (250 SX-F EU)

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

Compression damping (250 SX-F USA)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.

13.17Adjusting the rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn adjusting screws  clockwise until they stop.

Info

The adjusting screws  are located at the top end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork

type.

600670-10

Guideline

Rebound damping

Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.

(SX‑F, 250 XC-F USA)

– Remove protection covers .
– Turn adjusting screws  clockwise until they stop.

100020-10

Info

The adjusting screws  are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

MAINTENANCE WORK ON CHASSIS AND ENGINE 45

– Turn back counterclockwise by the number of clicks corresponding to the fork

type.
Guideline

Rebound damping (250 XC-F USA)

Comfort 22 clicks
Standard 21 clicks
Sport 21 clicks

Rebound damping (250 SX-F EU)

Comfort 21 clicks
Standard 20 clicks
Sport 20 clicks

Rebound damping (250 SX-F USA)

Comfort 22 clicks
Standard 22 clicks
Sport 20 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.

– Mount protection covers .

13.18Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn adjusting screws counterclockwise until they stop.

Info

Make the same adjustment on both fork legs.

– Turn back clockwise by the number of turns corresponding to the fork type.

Guideline

Spring preload - Preload Adjuster

600671-01

Comfort 0 turn
Standard 1 turn
Sport 3 turns

Info

Turn clockwise to increase spring preload, turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.

13.19Bleeding fork legs

– Jack up the motorcycle. ( p. 37)
– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.
– Remove the motorcycle from the work stand. ( p. 37)

100021-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 46

13.20Cleaning dust boots of fork legs

– Jack up the motorcycle. ( p. 37)
– Loosen the fork protection. ( p. 46)
– Push dust boots  of both fork legs downwards.

Info

The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.

Warning

600691-10

– Clean and oil the dust boots and inner fork tube of both fork legs.

– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 46)
– Remove the motorcycle from the work stand. ( p. 37)

Danger of accidents Reduced braking due to oil or grease on the brake
discs.

– Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

Universal oil spray ( p. 118)

13.21Loosening the fork protection

500087-11

13.22Positioning the fork protection

500087-10

– Remove screws  and take off clamp.
– Remove screws  on left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Position the wiring harness.

– Position the brake line. Put the clamp on, mount and tighten screws .
– Position the fork protection on the right fork leg. Mount and tighten the screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

13.23Checking play of steering head bearing

Warning

Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play.

– The steering head bearing play should be adjusted immediately in an authorized KTM workshop.

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can
be damaged after time.

– Jack up the motorcycle. ( p. 37)

MAINTENANCE WORK ON CHASSIS AND ENGINE 47

– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

–

Adjust play of the steering head bearing. x ( p. 47)

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

–

400387-10

– Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.

» If click positions are noticeable:

– Remove the motorcycle from the work stand. ( p. 37)

13.24Adjusting play of steering head bearing x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Jack up the motorcycle. ( p. 37)
– Loosen screws  and .
– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

Adjust play of the steering head bearing. x ( p. 47)

(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

–

Adjust play of the steering head bearing. x ( p. 47)

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

–

Adjust play of the steering head bearing. x ( p. 47)

– Check the steering head bearing and replace if required.

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw .

Guideline

100022-10

Screw, top triple clamp M8 20 Nm

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

– Check play of steering head bearing. ( p. 46)

13.25Adjusting play of steering head bearing x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

– Jack up the motorcycle. ( p. 37)
– Loosen screw . Remove screw .
– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw .

Guideline

500103-11

Screw, top triple clamp M8 17 Nm

(14.8 lbf ft)

(14.8 lbf ft)

(12.5 lbf ft)

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

– Check play of steering head bearing. ( p. 46)

Loctite®243™

(12.5 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 48

13.26Fork offset (XCF‑W USA, XC‑F, SX‑F)

You can see the currently set offset if you remove screw .
The fork offset  has an impact on the handling of the vehicle. It is calculated from
the center of the fork leg to the center of the steering head bearing.
The fork offset can optionally be adjusted.
Marking  to the front gives greater stability on fast racetracks.

Fork offset

Front marking 18 mm (0.71 in)

Marking  to the rear (condition at delivery) gives better handling in bends.

Fork offset

Rear marking 20 mm (0.79 in)

800009-10

13.27Setting the fork offset x (XCF‑W USA, XC‑F, SX‑F)

–

Remove the lower triple clamp. x ( p. 50)

– Remove screw . Remove the steering stem.
– Clean the parts and check for damage.
– Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten

screw .
Guideline

Screw, bottom steering
head

–

500104-10

13.28Removing the fork legs

Install the lower triple clamp. x ( p. 51)

–

Remove the front wheel. x ( p. 72)

– Remove screws  and take off clamp.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Remove cable clip .

– Remove screws  and take off brake caliper.
– Hang the brake caliper and the brake line loosely to the side.

M20x1.5 60 Nm

(44.3 lbf ft)

Loctite®243™

500093-10

500094-10

(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

– Loosen screw . Remove the fork leg on the left.
– Loosen screw . Remove the fork leg on the right.

MAINTENANCE WORK ON CHASSIS AND ENGINE 49

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Loosen screw . Remove the fork leg on the left.
– Loosen screw . Remove the fork leg on the right.

100023-11

13.29Installing the fork legs x

– Position the fork legs.

Info

The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position the bleeder screw  to the front.

100021-10

(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

– Fully tighten screw .

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

500094-11

100023-10

500093-11

– Fully tighten screw .

Guideline

Screw, bottom triple clamp M8 12 Nm

(8.9 lbf ft)

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Fully tighten screw .

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Fully tighten screw .

Guideline

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

– Position brake caliper, mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

Loctite®243™

(18.4 lbf ft)

(EXC

‑F, EXC‑F SIX DAYS, XCF-W)

– Mount cable clip .
– Position the wiring harness.

– Position the brake line. Put the clamp on, mount and tighten screws .

–

Install the front wheel. x ( p. 72)

MAINTENANCE WORK ON CHASSIS AND ENGINE 50

13.30Removing the fork protector x

– Remove the fork legs. ( p. 48)
– Remove screws  on the left fork leg. Remove the fork protector upwards.
– Remove the screws on the right fork leg. Remove the fork protector upwards.

500105-10

13.31Installing the fork protector x

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Position the fork protection on the right fork leg. Mount and tighten the screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–

Install the fork legs. x ( p. 49)

500105-10

13.32Removing the lower triple clamp x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

– Remove the fork legs. ( p. 48)
(XCF‑W USA, XC‑F, SX‑F)

– Dismount the start number plate. ( p. 54)

(250 EXC-F SIX DAYS EU)

– Remove the headlight mask with the headlight. ( p. 53)

– Dismount the front fender. ( p. 53)
– Remove screws  and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

– Remove screw . Remove screw , take off the top triple clamp with the handle-

bar and place it on one side.

Info

500099-10

– Remove O-ring . Remove protector ring .
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.

500100-10

0022
0

0

11

0

0

33

MAINTENANCE WORK ON CHASSIS AND ENGINE 51

13.33Removing the lower triple clamp x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Remove the fork legs. ( p. 48)
– Remove the headlight mask with the headlight. ( p. 53)
– Dismount the front fender. ( p. 53)
– Remove screws  and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

– Remove screw . Loosen screw . Take off top triple clamp with the handlebar

and place it on one side.

Info

500149-10

– Remove protector ring .
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.

500150-10

13.34Installing the lower triple clamp x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

– Clean the bearing and sealing elements, check for damage, and grease.

Long-life grease ( p. 117)

– Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

Info

Check whether the top steering head seal  is correctly positioned.

– Push up protective ring  and O-ring .

500098-10

– Position the upper triple clamp with the steering.
– Mount and tighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

500099-11

– Position the clutch line, wiring harness and CDI control unit. Mount and tighten

screws .
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Install the front fender. ( p. 53)

(XCF‑W USA, XC‑F, SX‑F)

– Install the start number plate. ( p. 54)

0022
0

0

11

MAINTENANCE WORK ON CHASSIS AND ENGINE 52

(250 EXC-F SIX DAYS EU)

– Refit the headlight mask with the headlight. ( p. 54)

–

Install the fork legs. x ( p. 49)

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

(12.5 lbf ft)

– Check the cable harness, cable, brake and clutch line for free movement and free

laying.

– Check play of steering head bearing. ( p. 46)

500103-10

13.35Installing the lower triple clamp x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Clean the bearing and sealing elements, check for damage, and grease.

Long-life grease ( p. 117)

– Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

Info

Check whether the top steering head seal  is correctly positioned.

Loctite®243™

500151-10

500149-11

– Push on protective ring .

– Position the upper triple clamp with the steering.
– Mount and tighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

– Position the clutch line, wiring harness and CDI control unit. Mount and tighten

screws .
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Install the front fender. ( p. 53)
– Refit the headlight mask with the headlight. ( p. 54)

–

Install the fork legs. x ( p. 49)

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

(14.8 lbf ft)

100022-11

– Check the cable harness, cable, brake and clutch line for free movement and free

laying.

– Check play of steering head bearing. ( p. 46)

MAINTENANCE WORK ON CHASSIS AND ENGINE 53

13.36Greasing the steering head bearing x

(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)

–

Remove the lower triple clamp. x ( p. 50)

–

Install the lower triple clamp. x ( p. 51)

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

–

Remove the lower triple clamp. x ( p. 51)

–

Install the lower triple clamp. x ( p. 52)

800010-10

13.37Dismounting the front fender

– Remove screws . Remove the front fender.
– Make sure that the distance bushings remain in place.

600692-10

13.38Installing the front fender

– Ensure that the spacing sleeves are mounted in the fender.
– Position the front fender. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

Take care with the contact between the holding lugs and the start number
plate or headlight mask.

600692-10

13.39Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA)

– Switch off all electrical equipment.
– Remove screw  and take off clamp.
– Loosen the rubber band . Push up the headlight mask and swing it forwards.

600703-10

600702-10

– Pull out the electric plug connector  and remove the headlight mask with the

headlight.

00BB 00BB

0

0

AA 00AA

MAINTENANCE WORK ON CHASSIS AND ENGINE 54

13.40Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA)

– Connect the electric plug connector .

600702-11

– Position the headlight mask and fix it with the rubber band .

Info

Take care with the contact of the holding lug at the fender.

– Position the brake line and cable harness. Put the clamp on, mount and tighten

screw .

– Check the headlamp setting.

600703-11

13.41Dismount the start number plate (XCF‑W USA, XC‑F, SX‑F)

– Remove screw  and take off clamp.
– Remove screw  with the spacing sleeve. Remove the start number plate.

500101-10

13.42Installing the start number plate (XCF‑W USA, XC‑F, SX‑F)

– Position the start number plate. Mount and tighten screw  with the spacing

sleeve.
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

Take care with the contact of the holding lug at the fender.

500101-11

– Position the brake line and cable harness. Put the clamp on, mount and tighten

screw .

13.43Handlebar position

400223-11

On the upper triple clamp, there are 2 holes at a distance of  to each other.

Distance  between holes 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of  from the center.

Distance  between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.

(250 EXC-F SIX DAYS EU)

The handlebar supports can also be mounted at 2 different heights (with and with­out spacer).

Thick spacer 9 mm (0.35 in)

0022

0

0

11

0

0

22

0

0

11

0

0

33

0

0

22

0

0

11

0

0

44
0

0

55

0

0

66
0

0

77
0

0

88
0

0

99

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

13.44Adjusting the handlebar position x

(EXC‑F EU, EXC‑F AUS, XCF‑W, XC‑F, SX‑F)

– Remove the four screws . Remove the handlebar clamp. Remove the handle-

bar and lay it to one side.

Info

Protect the motorcycle and its attachments from damage by covering
them.
Do not bend the cables and lines.

400223-10

– Remove the two screws . Remove the handlebar support.
– Place the handlebar support in the required position. Mount and tighten the

two screws .
Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Info

Position evenly the left and right handlebar supports.

– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Mount and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 20 Nm

Info

Make sure the gap width is even.

(250 EXC-F SIX DAYS EU)

– Remove the four screws . Remove the handlebar clamps  with rubber wash-

ers  and elastomeres .

– Remove the handlebar and lay it to one side.

Loctite®243™

(14.8 lbf ft)

400343-10

Info

Protect the motorcycle and its attachments from damage by covering
them.
Do not bend the cables and lines.

– Remove lower shells .
– Remove clamp bar  with rubber cones .
– Remove the two screws . Remove the handlebar support.
– Place the handlebar support in the required position. Mount and tighten the

two screws .
Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Condition

Spacer  fitted:

Use a M10x35 screw

Condition

without spacer :

Use a M10x25 screw

Info

Position evenly the left and right handlebar supports.

Loctite®243™

– Mount rubber cones  and clamp bar .

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

– Mount lower shells .
– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

– Position handlebar clamps  with rubber washers  and elastomeres .

Elastomer kit green - soft quality (SXS05125203)
Elastomer kit yellow - medium quality (standard) (SXS05125204)
Elastomer kit red - hard quality (SXS05125205)

Info

The elastomeres are available in different versions.

– Mount and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 16 Nm

(11.8 lbf ft)

Info

Make sure the gap width is even.

13.45Checking gas Bowden cable route

600672-10

13.46Checking play in the gas Bowden cable

– The two gas Bowden cables must run parallel behind the handlebar down to the

frame. They must be routed directly on the frame above the tank bearing to the car­buretor.

– Move the handlebar to the straight-ahead position. Move the throttle grip back and

forth slightly to ascertain the play in the gas Bowden cable.

400192-10

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

» If the gas Bowden cable play does not meet specifications:

–

Adjust the gas Bowden cable play. x ( p. 57)

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

– When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

– Start the engine and let it run idle. Move the handlebar to and fro over the entire

steering range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the gas Bowden cable play. x ( p. 57)

13.47Adjusting the gas Bowden cable play x

–

Dismount the fuel tank. x ( p. 78)

– Check gas Bowden cable route. ( p. 56)
– Move the handlebar to the straight-ahead position.
– Push back bellows .
– Loosen nut . Turn adjusting screw  in as far as possible.
– Loosen nut . Turn adjusting screw  so that there is play in the gas Bowden

cable at the throttle grip.
Guideline

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

600673-10

– Tighten nut .
– Press and hold the throttle grip in the closed setting. Turn adjusting screw  out

until there is no play in the Bowden cable .

– Tighten nut .
– Push bellows  on. Check the throttle grip for smooth operation.

–

Install the fuel tank. x ( p. 79)

– Check play in the gas Bowden cable. ( p. 56)

13.48Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 57)

800012-10

13.49Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

MAINTENANCE WORK ON CHASSIS AND ENGINE 58

Info

The service life of the chain depends largely on its maintenance.

– Clean the chain regularly and then treat with chain spray.

Chain cleaner ( p. 117)
Offroad chain spray ( p. 117)

13.50Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.

– Jack up the motorcycle. ( p. 37)
– Push the chain at the end of the chain sliding component upwards to measure the

chain tension .

Info

The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension 8… 10 mm (0.31… 0.39 in)

400213-10

» If the chain tension does not meet specifications:

– Adjusting chain tension - after checking. ( p. 60)

– Remove the motorcycle from the work stand. ( p. 37)

13.51Checking the chain tension when fitting rear wheel

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.

– Make sure that the chain adjusters are fitted correctly on the adjusting screws.
– Push the chain at the end of the chain sliding component upwards to measure

chain tension .

400213-10

Info

The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension 8… 10 mm (0.31… 0.39 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension when fitting rear wheel. ( p. 61)

00

0

BB

0

0

AA

1 2 3 16 17 18

MAINTENANCE WORK ON CHASSIS AND ENGINE 59

13.52Checking the rear sprocket / engine sprocket for wear

– Check the rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Replace rear sprocket / engine sprocket.

Info

When fitting the chain joint, always make sure that the closed side
of the joint faces forward (riding direction).
The engine sprocket, rear sprocket and chain should always be
replaced together.

400227-01

13.53Checking chain wear

– Check that the chain guide is firmly seated and not worn.

– Jack up the motorcycle. ( p. 37)
– Shift gear to neutral.
– Pull the upper chain section with the specified weight .

Guideline

Weight of chain wear measurement 10… 15 kg (22… 33 lb.)

– Measure distance  of 18 chain links in the lower chain section.

Info

Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Maximum distance  at the longest
chain section

» If the distance  is greater than the specified measurement:

– Replace the chain.

272 mm (10.71 in)

Info

When you replace the chain, you should also replace the rear
sprocket and the engine sprocket.

400226-10

– Remove the motorcycle from the work stand. ( p. 37)

13.54Adjusting the chain tension

New chains wear out faster on old, worn sprockets.

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.

– Jack up the motorcycle. ( p. 37)
– Push the chain at the end of the chain sliding component upwards to measure

chain tension .

Info

The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

400213-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the left and right adjusting screws .

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the left and right adjusting screws  so that the markings on the left and

right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.

– Tighten nuts .
– Make sure that chain adjusters  are fitted correctly on the adjusting screws .
– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.

400225-10

– Remove the motorcycle from the work stand. ( p. 37)

Chain adjusters  can be turned by 180°.

13.55Adjusting chain tension - after checking

400225-13

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws  left and right so that the markings on the left and

right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.

– Tighten nuts .
– Make sure that the chain adjusters  are fitted correctly on the adjusting

screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters  can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE 61

13.56Adjusting chain tension - fitting rear wheel

– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws  left and right so that the markings on the left and

right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.

– Tighten nuts .

400225-11

13.57Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Remove screws  and . Take off the chain guide.

Condition

Number of teeth: ≤ 44 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .

Guideline

Remaining screws, chassis M6 10 Nm

Condition

Number of teeth: ≥ 45 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .

Guideline

Remaining screws, chassis M6 10 Nm

400252-10

(7.4 lbf ft)

(7.4 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

13.58Adjusting the chain guide x (SX‑F)

– Loosen screw . Remove screw . Push the chain guide down.

Condition

Number of teeth: ≤ 44 teeth
– Insert collar sleeve  in hole . Position the chain guide.
– Mount and tighten screw . Tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

Condition

Number of teeth: ≥ 45 teeth
– Insert collar sleeve  in hole . Position the chain guide.
– Mount and tighten screw . Tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

400224-10

13.59Adjusting basic position of clutch lever

– Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.

500133-11

13.60Checking the fluid level of hydraulic clutch

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

400339-10

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Check the fluid level.

Fluid level under top level of container. 4 mm (0.16 in)

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

MAINTENANCE WORK ON CHASSIS AND ENGINE 63

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt fluid immediately with water.

13.61Changing the hydraulic clutch fluid x

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

400339-10

600683-10

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– On the slave cylinder, remove bleeder screw  and mount bleeding syringe .

– Inject the liquid into the system until it escapes from bore hole  of the master

cylinder without bubbles.

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level under top level of container. 4 mm (0.16 in)

400340-10

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt fluid immediately with water.

A

A

MAINTENANCE WORK ON CHASSIS AND ENGINE 64

13.62Checking the brake discs

Warning

Danger of accidents Reduced braking due to worn brake discs.

– Worn brake discs should be replaced immediately in an authorized KTM workshop.

– Check the thickness of the front and rear brake discs at several places on the disc

to see if it conforms to measurement .

Info

Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Wear limit of brake discs

Front 2.5 mm (0.098 in)

400257-10

13.63Checking free travel of hand brake lever

Rear 3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake

can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

(XCF‑W, XC‑F, SX‑F)

– Push the hand brake lever forwards and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– Adjust the basic position of handbrake lever. ( p. 64)

400196-11

(EXC-F, EXC‑F SIX DAYS)

– Push the hand brake to the handlebar and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– Adjust the free travel of the handbrake lever. ( p. 65)

400196-13

13.64Adjusting basic position of handbrake lever (XCF‑W, XC‑F, SX‑F)

– Adjust the basic setting of the handbrake lever to your hand size by turning adjust-

ing screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
handbrake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the handbrake lever and the handlebar.
The range of adjustment is limited.

400196-12

– Check the free travel of the hand brake lever. ( p. 64)

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

13.65Adjusting free travel of handbrake lever (EXC-F, EXC‑F SIX DAYS)

– Adjust the free travel of the handbrake lever with the adjustment screw .

Info

Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.

400196-12

– Check the free travel of the hand brake lever. ( p. 64)

13.66Checking the front brake fluid level

Warning

Danger of accidents Brake system failure.

– MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Do not make any adjustments while riding!

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .

» If the brake fluid is below the MIN mark:

–

Add front brake fluid. x ( p. 65)

400231-10

13.67Adding front brake fluid x

Warning

Danger of accidents Brake system failure.

– MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 66

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Add brake fluid to level .

Guideline

Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

13.68Checking the front brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized KTM workshop.

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings. x ( p. 67)

400235-10

13.69Removing the front brake linings x

Warning

Danger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized KTM workshop.

– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

500089-11

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

– Remove locking split pins , withdraw bolt , and take out the brake pads.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Remove cable clip .

– Remove screws  and take off brake caliper.
– Clean the brake caliper and brake caliper support.

MAINTENANCE WORK ON CHASSIS AND ENGINE 67

13.70Installing the front brake linings x

Warning

Danger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 64)
– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500091-10

– Fit the brake pads, insert bolt , and mount locking split pins .
– Position the brake caliper, and mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Mount cable clip .

– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc

500089-12

13.71Changing the front brake linings x

and there is a tight spot.

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Loctite®243™

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 68

–

Remove the front brake linings. x ( p. 66)

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Install the front brake linings. x ( p. 67)

– Add brake fluid to level .

Guideline

Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

13.72Checking free travel of foot brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

– Disconnect spring .
– Move the foot brake lever backwards and forwards between the end stop and the

foot brake cylinder piston bracket and check free travel .
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the footbrake lever. x ( p. 68)

600704-10

13.73Adjusting basic position of footbrake lever x

– Reconnect spring .

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

– Disconnect spring .
– Loosen nut  and with push rod , turn it back until you have maximum free

travel.

– To adjust the basic position of the footbrake lever individually, lossen nut  and

turn screw  accordingly.

600705-10

Info

The range of adjustment is limited.

– Turn push rod  accordingly until you have free travel . If necessary, adjust the

basic position of the footbrake lever.
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

MAINTENANCE WORK ON CHASSIS AND ENGINE 69

– Hold screw  and tighten nut .

Guideline

Remaining nuts, chassis M8 30 Nm

(22.1 lbf ft)

– Hold push rod  and tighten nut .

Guideline

Remaining nuts, chassis M6 15 Nm

(11.1 lbf ft)

– Reconnect spring .

13.74Checking the rear brake fluid level

Warning

Danger of accidents Brake system failure.

– MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

– Stand the vehicle upright.
– Check the brake fluid level in the viewer .

» When in the viewer  an air bubble is visible:

–

Add brake fluid for the rear brake. x ( p. 69)

400234-10

13.75Adding brake fluid for the rear brake x

Warning

Danger of accidents Brake system failure.

– MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 70

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.
– Add brake fluid to level .

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Mount the screw cap with the membrane and the O-ring.

Info

400233-10

13.76Checking the rear brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized KTM workshop.

– Check the brake linings for minimum thickness .

Clean up overflowed or spilt brake fluid immediately with water.

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings. x ( p. 71)

400238-10

13.77Removing rear brake linings x

Warning

Danger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized KTM workshop.

– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove the locking split pins , withdraw the bolt , and take out the brake

pads.

400236-10

13.78Installing the rear brake linings x

– Clean brake caliper and brake caliper support.

Warning

Danger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 64)

MAINTENANCE WORK ON CHASSIS AND ENGINE 71

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500122-10

– Fit the brake pads, insert bolt , and mount locking split pins .

Info

Make sure that the decoupling plate  is mounted on the piston side of the
brake pad.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

400237-10

13.79Changing the rear brake linings x

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

–

Remove the rear brake linings. x ( p. 70)

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Install the rear brake linings. x ( p. 70)

– Add brake fluid to level .

400233-10

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Mount the screw cap with the membrane and the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE WORK ON CHASSIS AND ENGINE 72

13.80Removing the front wheel x

– Jack up the motorcycle. ( p. 37)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

500089-10

– Remove screw .
– Loosen screw .

500084-10

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

the fork.

Info

Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

500085-10

– Remove spacing sleeves .

500086-10

13.81Installing the front wheel x

Warning

Danger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

500086-11

– Clean and grease shaft seal rings  and bearing surface  of the spacing sleeves.

Long-life grease ( p. 117)

– Insert the spacing sleeves.

MAINTENANCE WORK ON CHASSIS AND ENGINE 73

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .

Guideline

Screw, front wheel spindle M24x1.5 45 Nm

(33.2 lbf ft)

– Operate the hand brake lever several times until the brake pads are lying correctly

on the brake disc.

500084-11

13.82Removing rear wheel x

– Remove the motorcycle from the work stand. ( p. 37)
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Fully tighten screw .

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

– Jack up the motorcycle. ( p. 37)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

400258-10

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove nut .
– Remove chain adjuster . Withdraw the wheel spindle  only enough to allow the

rear wheel to be pushed forward.

– Push the rear wheel forward as far as possible. Remove the chain from the rear

sprocket.

– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the

swing arm.

Info

Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

– Remove the spacing sleeves .

400260-11

13.83Installing the rear wheel x

Warning

Danger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

MAINTENANCE WORK ON CHASSIS AND ENGINE 74

– Clean and grease shaft seal rings  and bearing surface  of the spacing sleeves.

Long-life grease ( p. 117)

– Insert the spacing sleeves.

400260-10

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
– Put the chain on.

400259-10

– Position the chain adjuster . Mount nut , but do not tighten it yet.
– Check the chain tension when fitting rear wheel. ( p. 58)
– Make sure that the chain adjusters  are fitted correctly on the adjusting

screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters  can be turned by 180°.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

– Remove the motorcycle from the work stand. ( p. 37)

400225-12

13.84Tire condition checking

Info

Only mount tires approved or recommended by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.

– Examine the front and rear tires for cuts, foreign bodies and other damage.

» If you find cuts, foreign bodies or other damage on a tire:

– Change the tire.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum allowable depth:

– Change the tire.

MAINTENANCE WORK ON CHASSIS AND ENGINE 75

13.85Checking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove dust cap.
– Check tire air pressure when tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)

Road tire pressure (EXC-F, EXC‑F SIX DAYS)

Front 1.5 bar (22 psi)

400241-01

– Mount dust cap.

13.86Checking spoke tension

Rear 2.0 bar (29 psi)

» If the tire pressure does not meet specifications:

– Correct tire pressure.

Warning

Danger of accidents Unstable riding behavior due to loose spokes.

– If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– To check spoke tension, tap each spoke with a screwdriver.

Guideline

You should hear a high note.

Spoke nipple, front wheel M4,5 5 Nm (3.7 lbf ft)
Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft)

Info

400228-01

13.87Removing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

If you hear different tone frequencies from different spokes, this is an indi­cation of different spoke tensions.

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 77)

MAINTENANCE WORK ON CHASSIS AND ENGINE 76

– Disconnect the negative (minus) cable  of the battery.
– Pull back the plus pole cover  and disconnect the positive (plus) cable of the bat-

tery.

– Hang the rubber band  out to the bottom.
– Lift the battery up.

500069-10

13.88Installing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Place the battery in the battery holder.

4Ah battery (YTX5L-BS) ( p. 99)

– Reconnect the rubber band .
– Attach the plus cable and replace the plus pole cover .
– Attach the minus cable .
– Mount the seat. ( p. 78)

500069-11

13.89Recharging the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Warning

Environmental hazard Components and battery acid are a danger to the environment.

– Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 77)
– Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.

MAINTENANCE WORK ON CHASSIS AND ENGINE 77

– Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the bat­tery.

Info

Never remove the lid .

400240-10

– Switch off the charger after charging. Disconnect the battery.

– Mount the seat. ( p. 78)

13.90Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Switch off all power consumers and switch off the engine.
– Dismount the air filter box lid. ( p. 82)
– Remove the protection cover .

Charge the battery with at most 10% of the capacity specified on the bat­tery .

Guideline

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the

3 months

motorcycle is not in use.

Info

The fuse  is located in the starter relay  under the filter box cover.

– Remove the fuse .

400270-10

13.91Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

Warning

Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

– Refit the fuse.

Fuse (58011109110)

Info

A reserve fuse  is located in the starter relay.
Replace a burned-out fuse  only by an equivalent fuse.
If the new fuse burns out, contact an authorized KTM workshop.

400273-10

– Replace the protection cover.
– Install the air filter box lid. ( p. 82)

13.92Removing the seat

– Remove screw . Lift up the seat at the rear, pull it back and then remove from

above.

500080-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 78

13.93Mounting the seat

– Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear

and simultaneously push it forward.

– Make sure that the seat is correctly locked in.
– Mount and tighten the screw of the seat fixing.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

600674-01

13.94Dismounting the fuel tank x

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up 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 specifications on filling up with fuel.

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.

600678-10

600675-11

– Remove the seat. ( p. 77)

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

– Pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

– Remove screws  with the collar sleeve.

(EXC-F, EXC‑F SIX DAYS)

– Hang the horn and horn bracket to one side.

– Remove screw  with the collar sleeve.
– Remove the tube from the fuel tank vent line.

– Pull both spoilers to the side of the radiator bracket  and take the fuel tank away

upward.

600677-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 79

13.95Installing the fuel tank x

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up 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 specifications on filling up with fuel.

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 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.

– Position the fuel tank and install the two spoilers to the side of the radiator fixing.
– Make sure that no cables or Bowden cables are trapped or damaged.

13.96Cooling system

600676-01

– Mount the fuel tank vent hose.
– Mount and tighten screw  with the collar sleeve.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

(EXC-F, EXC‑F SIX DAYS)

– Position the horn with the horn bracket.

600675-10

– Mount and tighten screws  with the collar sleeve.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Connect the fuel hose.
– Mount the seat. ( p. 78)

600678-11

The water pump  in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve
in the radiator cap . The specified coolant temperature is therefore permissible with­out danger of function problems.

600679-10

120 °C (248 °F)

Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool­ing effect.

(250 EXC-F SIX DAYS EU, 250 XCF-W ZA)

The radiator fan provides extra cooling. It is controlled by a thermoswitch.

MAINTENANCE WORK ON CHASSIS AND ENGINE 80

13.97Checking antifreeze and coolant level

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the cooling liquid does not meet specifications:

– Correct antifreeze of coolant.

– Check the coolant level in the radiator.

400243-10

Coolant level  above radiator fins. 10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 116)

Alternative 2

Coolant (mixed ready to use) ( p. 116)

– Refit the radiator cap.

13.98Checking the coolant level

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.

400243-10

Coolant level  above radiator fins. 10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 116)

Alternative 2

Coolant (mixed ready to use) ( p. 116)

– Refit the radiator cap.

MAINTENANCE WORK ON CHASSIS AND ENGINE 81

13.99Draining the coolant x

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the vehicle upright.
– Place a suitable container under the water pump cover.
– Remove screw . Remove radiator cap .
– Completely drain the coolant.
– Mount screw  with a new seal and tighten it.

Guideline

Screw, water pump cover M6 10 Nm (7.4 lbf ft)

600679-11

13.100Refilling coolant x

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Make sure that the screw  is tightened.
– Stand the vehicle upright.
– Pour coolant in up to measurement  above the radiator fins.

Guideline

10 mm (0.39 in)

Coolant 1.2 l (1.3 qt.) Coolant ( p. 116)

Coolant (mixed ready to use)

600680-10

– Refit the radiator cap.
– Make a short test ride.
– Check the coolant level. ( p. 80)

( p. 116)

13.101Glass fiber yarn filling of main silencer

The main silencer is filled with glass fiber yarn.
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.

MAINTENANCE WORK ON CHASSIS AND ENGINE 82

13.102Removing main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Disconnect spring .
– Remove screws  and take off main silencer.

600681-11

13.103Installing the main silencer

– Mount the main silencer. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

600681-10

13.104Dismounting the air filter box lid

600682-10

13.105Installing the air filter box lid

– Reconnect spring .

– Pull off the air filter box lid in area  to the side and remove to the front.

– Insert the air filter box lid into the rear area  and clip it into the front area .

600682-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 83

13.106Removing the air filter x

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

– Dismount the air filter box lid. ( p. 82)
– Hang the air filter holder  out to the bottom and swing it to the side. Remove the

air filter with the air filter support.

– Remove the air filter from the air filter support.

500107-10

13.107Installing the air filter x

– Mount the clean air filter onto the air filter support.
– Put in both parts together, position them and fix them with the air filter support .

Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.

– Install the air filter box lid. ( p. 82)

500107-10

13.108Cleaning air filter x

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

–

Remove the air filter. x ( p. 83)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 117)

Info

Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high/quality filter oil.

Oil for foam air filter ( p. 118)

– Clean the air filter box.
– Check carburetor connection boot for damage and tightness.

–

Install the air filter. x ( p. 83)

MAINTENANCE WORK ON CHASSIS AND ENGINE 84

13.109Carburetor - idle

The idle setting of the carburetor has a big influence on the starting behavior, stable
idling and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.

Info

The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.

13.110Carburetor - adjusting idle x

600684-10

600684-10

The idle speed is adjusted with the adjustment screw .
The idle mixture is adjusted with the idle mixture adjustment screw .

– Screw in the idle adjusting screw  until it stops and then to the prescribed basic

setting.
Guideline

Idle mixture adjusting screw (EXC‑F, EXC‑F SIX DAYS, SX‑F)

Open 1.25 turns

Idle mixture adjusting screw (250 XCF-W ZA, 250 XC-F USA)

Open 1.0 turn

Idle mixture adjusting screw (250 XCF-W USA)

Open 1.5 turns

Adjustment tool for mixture control screw (77329034000)

– Run the engine until warm.

Guideline

Warm-up time ≥ 5 min

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

– When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

– Adjust the idle speed with adjusting screw .

Guideline

Choke function deactivated – The choke lever is pushed in to the stop.
(EXC‑F AUS, XCF‑W, XC‑F, SX‑F) ( p. 23)

Choke function deactivated – The choke lever is pushed back to the stop. (EXC­F EU, EXC‑F SIX DAYS) ( p. 23)

Idle speed 1,400… 1,500 rpm

– Turn the idle adjusting screw  slowly until the idle speed begins to fall.
– Note the position and turn the idle adjusting screw slowly counterclockwise until

the idle speed falls.

– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extreme sport motorcyclist will set the mixture about ¼ of a turn back
from this ideal value (leaner, in a clockwise direction) since the engine
becomes hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to mount a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.

MAINTENANCE WORK ON CHASSIS AND ENGINE 85

– Adjust the idle speed with adjusting screw .

Guideline

Choke function deactivated – The choke lever is pushed in to the stop.
(EXC‑F AUS, XCF‑W, XC‑F, SX‑F) ( p. 23)

Choke function deactivated – The choke lever is pushed back to the stop. (EXC­F EU, EXC‑F SIX DAYS) ( p. 23)

Idle speed 1,400… 1,500 rpm

Info

Following extreme air temperature or altitude changes, adjust the idle speed
again.

13.111Emptying the carburetor float chamber x

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up 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 specifications on filling up with fuel.

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.

Info

Carry out this work with a cold engine.

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

No more fuel flows from the tank to the carburetor.

– Guide the hose coming down behind the engine into a suitable container.

Info

Water in the float chamber results in malfunctioning.

– Undo screw  (turn it counterclockwise) a few turns and drain the fuel from the

float chamber.

– Tighten screw .

600684-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 86

13.112Checking the engine oil level

– Stand the motorcycle upright on a horizontal surface.

Condition

The engine is cold.
– Check the engine oil level.

The engine oil level is at the bottom edge of level viewer .

» If the engine oil level is below the specified level:

– Add engine oil. ( p. 89)

Condition

600685-11

13.113Changing the engine oil and oil filter, cleaning the oil screen x

–

Drain the engine oil. x ( p. 86)

–

Clean the oil screens. x ( p. 87)

–

Remove the oil filter. x ( p. 88)

–

Install the oil filter. x ( p. 88)

–

Fill up with engine oil. x ( p. 89)

The engine is warm.
– Check the engine oil level.

The engine oil level is at the top edge of level viewer .

» If the engine oil level is below the specified level:

– Add engine oil. ( p. 89)

13.114Draining the engine oil x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Drain the engine oil only when the engine is warm.

– Stand the motorcycle on its side stand on a horizontal surface.
– Place a suitable container under the engine.
– Remove oil drain plug .
– Completely drain the engine oil.
– Thoroughly clean the oil drain plug with the magnet.
– Clean the sealing area on the engine.
– Mount and tighten oil drain plug  with the seal ring.

Guideline

600686-10

Oil drain plug with magnet M12x1.5 20 Nm

(14.8 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 87

13.115Cleaning the oil screens x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

– Place a suitable container under the engine.
– Remove plug  with oil screen  and the O-rings.

600693-10

– Remove plug  with oil screen  and the O-rings.
– Drain the remaining engine oil.
– Thoroughly clean parts and sealing area.

600694-10

600695-10

600696-10

– Position oil screen  with the O-rings.
– Mount and tighten plug  with the O-ring.

Guideline

Plug for oil screen, long M20x1.5 15 Nm

– Position the oil screen with the O-rings.
– Mount and tighten plug  with the O-ring.

Guideline

Plug for oil screen, short M16x1.5 10 Nm

(7.4 lbf ft)

(11.1 lbf ft)

lubricated with
engine oil

MAINTENANCE WORK ON CHASSIS AND ENGINE 88

13.116Removing the oil filter x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

– Place a suitable container under the engine.
– Remove screws . Remove oil filter cover  with O-ring.

600687-10

– Pull the oil filter insert  out of the oil filter casing.

13.117Installing the oil filter x

Circlip pliers reverse (51012011000)

– Completely drain the engine oil.
– Thoroughly clean parts and sealing area.

600688-10

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with

engine oil.

– Fill oil filter  with engine oil and place it in the oil filter container.
– Lubricate O-ring  of the oil filter cover.

600689-10

– Mount oil filter cover .
– Mount and tighten screws .

Guideline

Screw, oil filter cover M5 6 Nm (4.4 lbf ft)

600687-11

– Stand the motorcycle up.

MAINTENANCE WORK ON CHASSIS AND ENGINE 89

13.118Filling up with engine oil x

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove screw connection  on the clutch cover and fill up with engine oil.

Engine oil 1.10 l (1.16 qt.) Engine oil (SAE 10W/50) ( p. 116)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

600690-10

– Start the engine and check that it is oil-tight.
– Check the engine oil level. ( p. 86)

13.119Adding engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

600690-10

– Remove screw cap  from the clutch cover and fill up with engine oil.

Engine oil (SAE 10W/50) ( p. 116)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

– When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

– Start the engine and check that it is oil-tight.
– Check the engine oil level. ( p. 86)

TROUBLESHOOTING 90

14TROUBLESHOOTING

Faults Possible cause Action

The engine cannot be cranked (electric
starter).
EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F

Engine turns but does not start. Operating error – Go through the steps of starting the

Engine has no idle. Idling jet blocked – Check/adjust the carburetor compo-

Engine does not speed up. Carburetor running over because float

Operating error – Go through the steps of starting the

engine. ( p. 28)

Battery discharged –

Fuse blown – Remove the fuse. ( p. 77)

Starter relay defective –
Starter motor defective –

Motorcycle was out of use for a long time
and there is old fuel in the float chamber

Fuel feed interrupted – Check the fuel tank breather.

Engine flooded – Clean and dry the spark plug or replace

Spark plug oily or wet – Clean and dry the spark plug or replace

Electrode distance (plug gap) of spark
plug too wide

Defect in ignition system –
Short-circuit cable in cable harness

frayed, short-circuit button or emergency
OFF switch defective

Plug connector of CDI control device,
pulse generator or ignition coil oxidized.

Water in carburetor or jets blocked – Check/adjust the carburetor compo-

Adjusting screws on carburetor distorted –

Spark plug defective – Change spark plug.
Ignition system defective –

needle dirty or worn.
Loose carburetor jets – Check/adjust the carburetor compo-

Ignition system defective –

Recharge the battery. x ( p. 76)

–

Check the charging voltage. x

–

Check the closed current. x

–

Check the generator. x

– Replace the fuse. ( p. 77)

Check the starter relay. x
Check the starter motor. x

engine. ( p. 28)

– Empty the carburetor float

chamber. x ( p. 85)

– Clean the fuel tap.
– Check/adjust the carburetor compo-

nents. x

if necessary.

if necessary.

– Adjust the plug gap.

Guideline
Spark plug electrode gap

0.7 mm (0.028 in)

Check the ignition system. x

– Check the wiring harness (visual

check).

– Check the electrical system.
– Clean the plug connector and treat it

with contact spray.

nents. x
nents. x

Carburetor - adjust the idle speed. x

( p. 84)

Check the ignition coil. x

–

Check the CDI unit. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

– Check/adjust the carburetor compo-

nents. x
nents. x

Check the ignition coil. x

–

Check the CDI unit. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

TROUBLESHOOTING 91

Faults Possible cause Action

Engine has too little power. Fuel feed interrupted – Check the fuel tank breather.

– Clean the fuel tap.
– Check/adjust the carburetor compo-

nents. x

Air filter very dirty –
Exhaust system leaky, deformed or too lit-

tle glass fiber yarn filling in main silencer

Valve clearance too little –
Ignition system defective –

Engine stalls or is popping into the carbu­retor

Engine overheats. Too little coolant in cooling system – Check the cooling system for leakage.

High oil consumption Engine vent hose bent – Route the vent hose without bends or

Battery discharged The battery does not charge –

Speedometer values deleted (time, stop
watch, lap times)

Lack of fuel

Engine takes in bad air – Check rubber sleeves and carburetor

Too little air stream – Switch off engine when standing.
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system –

Bent radiator hose –
Thermostat defective –

Defect in radiator fan system (250 EXC­F SIX DAYS EU, 250 XCF-W ZA)

Engine oil level too high – Check the engine oil level. ( p. 86)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter,

Piston or cylinder is worn – Piston/cylinder - determine the mount-

Undesired power consumer –
The battery in the speedometer is empty. – Change the battery in the speedometer.

Clean the air filter. x ( p. 83)

– Check exhaust system for damage.
– Change glass fiber yarn filling of main

silencer. x
Adjust the valve clearance. x
Check the ignition coil. x

–

Check the CDI unit. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

– Turn handle  of the fuel

tap to the ON position.

(Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel

tap to the ON position.

(Figure 500178-10 p. 22)

– Fill up with fuel. ( p. 30)

for tightness.

– Check the coolant level. ( p. 80)

Drain the coolant. x ( p. 81)

–

Refill the coolant. x ( p. 81)
Change the radiator hose. x
Check the thermostat. x

Guideline
Opening temperature: 70 °C (158 °F)

– Check the radiator fan fuse.

–

Check the radiator fan. x

–

Check the thermostat. x

replace it if necessary.

clean the oil screen. x ( p. 86)
ing clearance x

Check the charging voltage. x

–

Check the charging current. x

–

Check the generator. x
Check the closed current. x

CLEANING 92

15CLEANING

15.1Cleaning motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-

cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

– Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
– First remove coarse dirt particles with a gentle water spray.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner ( p. 117)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

–

Empty the carburetor float chamber. x ( p. 85)

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

– Push back the protection covers on the handlebar instruments to allow water to evaporate.
– After the motorcycle has cooled off, oil or grease all moving parts and bearings.
– Clean the chain. ( p. 57)
– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 117)

– Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 117)

– To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( p. 117)

(EXC-F, EXC‑F SIX DAYS)

– Lubricate the steering lock.

Universal oil spray ( p. 118)

STORAGE 93

16STORAGE

16.1Storage

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.

Info

If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– Clean the motorcycle. ( p. 92)

–

Change the engine oil and oil filter, clean the oil screen. x ( p. 86)

– Check the antifreeze and coolant level. ( p. 80)
– Drain the fuel from the tank into a suitable container.

–

Empty the carburetor float chamber. x ( p. 85)

– Check the tire air pressure. ( p. 75)

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

–

Remove the battery. x ( p. 75)

(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

–

Recharge the battery. x ( p. 76)

Guideline

Storage temperature of battery without direct sunlight. 0… 35 °C (32… 95 °F)

– The storage place should be dry and not subject to large temperature fluctuations.

Info

KTM recommends jacking up the motorcycle.

– Jack up the motorcycle. ( p. 37)
– Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Info

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.

16.2Putting into operation after storage

– Remove the motorcycle from the work stand. ( p. 37)
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

–

Install the battery. x ( p. 76)

– Fill up with fuel. ( p. 30)
– Checks before putting into operation ( p. 28)
– Make a test ride.

TECHNICAL DATA - ENGINE 94

17TECHNICAL DATA- ENGINE

Design 1-cylinder 4-stroke engine, water-cooled
Displacement 248.60 cm³ (15.1706 cu in)
Stroke 54.80 mm (2.1575 in)
Bore 76 mm (2.99 in)
Compression ratio 12.8:1
Idle speed 1,400… 1,500 rpm
Control DOHC, four valves controlled via cam lever, drive via tooth-wheel

chain
Valve diameter, intake 30.0 mm (1.181 in)
Valve diameter, exhaust 26.0 mm (1.024 in)
Valve clearance

Exhaust at: 20 °C (68 °F) 0.12… 0.17 mm (0.0047… 0.0067 in)

Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with two rotary pumps
Primary transmission 22:68
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission ratio (EXC‑F, EXC‑F SIX DAYS, XCF-W)

1st gear 13:33

2nd gear 17:33

3rd gear 19:29

4th gear 23:28

5th gear 23:23

6th gear 26:22
Transmission ratio (SX‑F, 250 XC-F USA)

1st gear 13:32

2nd gear 15:30

3rd gear 17:28

4th gear 19:26

5th gear 21:25

6th gear 22:24
Generator (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)

Light coil and charging coil 12 V, 80 W
Generator (SX‑F)

Light coil and charging coil none
Ignition Contactless controlled fully electronic ignition with digital igni-

tion adjustment, type Kokusan
Spark plug NGK CR 9 EKB
Spark plug electrode gap 0.7 mm (0.028 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) Electric starter/kickstarter
Starting aid (SX‑F) Kickstarter

TECHNICAL DATA - ENGINE 95

17.1Capacity- engine oil

Engine oil 1.10 l (1.16 qt.) Engine oil (SAE 10W/50) ( p. 116)

17.2Capacity - coolant

Coolant 1.2 l (1.3 qt.) Coolant ( p. 116)

Coolant (mixed ready to use) ( p. 116)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 96

18TECHNICAL DATA- ENGINETIGHT ENINGTORQUES

Oil jet, conrod lubrication M4
Oil jet for cam lever lubrication M5 4 Nm (3 lbf ft)
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Screw, freewheel hub M5 7 Nm (5.2 lbf ft)
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft)
Screw, stator bracket (SX‑F) M5 6 Nm (4.4 lbf ft)
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft)
Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft)
Screw, cover plate of valve cover M6 3 Nm (2.2 lbf ft)
Screw, kickstarter stop M6 10 Nm (7.4 lbf ft)
Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft)
Screw, exhaust flange M6 10 Nm (7.4 lbf ft)
Screw, starter motor (EXC‑F,

EXC‑F SIX DAYS, XCF‑W, XC‑F)
Screw, generator cover M6 10 Nm (7.4 lbf ft) –
Screw, cable holder in generator cover M6 6 Nm (4.4 lbf ft)
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Locking screw for bearing M6 6 Nm (4.4 lbf ft)
Screw, engine housing M6 10 Nm (7.4 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Screw, shift lever M6 10 Nm (7.4 lbf ft)
Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft)
Screw, stator bracket (EXC‑F,

EXC‑F SIX DAYS, XCF‑W, XC‑F)
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, cylinder head M6 10 Nm (7.4 lbf ft) –
Nut, camshaft bearing bridge M7 15 Nm (11.1 lbf ft) lubricated with engine oil
Screw, camshaft bearing bridge M7 15 Nm (11.1 lbf ft) lubricated with engine oil
Stud, camshaft bearing bridge M7
Screw, kickstarter M8 25 Nm (18.4 lbf ft)
Screw, timing chain guide rail M8 10 Nm (7.4 lbf ft)
Plug, crankshaft location M8 20 Nm (14.8 lbf ft) –
Screw, unlocking of timing chain ten-

sioner
Screw, engine sprocket M10 60 Nm (44.3 lbf ft)
Screw, cylinder head M10 Tightening sequence:

Spark plug M10 10… 12 Nm (7.4…

Nut, rotor M12x1 60 Nm (44.3 lbf ft) –
Screw, camshaft gear M12x1 80 Nm (59 lbf ft)
Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) –
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Plug for oil screen, short M16x1.5 10 Nm (7.4 lbf ft) lubricated with engine oil

M6 10 Nm (7.4 lbf ft) –

M6 8 Nm (5.9 lbf ft)

M10x1 10 Nm (7.4 lbf ft) –

Tighten diagonally, begin­ning with the rear screw on
the chain shaft.
Step 1
40 Nm (29.5 lbf ft)
Step 2
50 Nm (36.9 lbf ft)

8.9 lbf ft)

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

lubricated with engine oil

–

Loctite®243™

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 97

Nut, inner clutch hub M18x1.5 120 Nm (88.5 lbf ft)
Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft)
Plug for oil screen, long M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –

Loctite®243™

Loctite®243™

TECHNICAL DATA - CARBURETOR 98

19TECHNICAL DATA- CARBURETOR

19.1EXC-F, EXC‑F SIX DAYS

Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3900H
Needle position 3rd position from top
Idle mixture adjusting screw

Open 1.25 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 168
Jet needle OBDYS (OBETP)
Idling jet 42
Idle air jet 100
Cold start jet 65 (85)
Leakage nozzle 70
Slide stop present

19.2XCF‑W, 250 XC-F USA

Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3900K
Needle position (250 XCF-W USA) 3rd position from top
Needle position (250 XCF-W ZA, 250 XC-F USA) 5th position from top
Idle mixture adjusting screw (250 XCF-W ZA, 250 XC-F USA)

Open 1.0 turn
Idle mixture adjusting screw (250 XCF-W USA)

Open 1.5 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 168
Jet needle (250 XCF-W USA) OBEKT
Jet needle (250 XCF-W ZA, 250 XC-F USA) OBETP
Idling jet 42
Idle air jet 100
Cold start jet 85
Leakage nozzle 50

19.3SX‑F

Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3925I
Needle position 4th position from top
Idle mixture adjusting screw

Open 1.25 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 175
Jet needle OBEKP
Idling jet 40
Idle air jet 100
Cold start jet 85
Leakage nozzle 50