KTM 250 XCF-W (2012) manual

OWN ER'S MAN UAL 2012 250 EXC -F EU 250 EXC -F AUS 250 EXC -F SIX DA YS EU 250 XCF ‑ W USA Art. no. 32117 19en[...]

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DEAR KTM CUSTOME R 1 DEAR KTMCUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Ch[...]

TABLE OF CONTENTS 2 TABLE OFCONTENTS MEANS OF REPRESENTAT ION ............................ ................ 4 IMPORTANT INFORMATION .............................................. .. 5 VIEW OF VEHICLE ............................ ............................ ....... 7 View of vehicle, front left (example)................................... 7 View of[...]

TABLE OF CONTENTS 3 Installing the shock absorber x ............................... ...... 51 Removing the front fender .......... ............................ ........ 51 Installing the front fender ..................... .......................... 51 Removing the seat ..................................................... .... 52 Mounting the seat [...]

MEANS O F REPRES ENTATIO N 4 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g., to a work step or a function). Indicates an unexpected reaction (e.g., to a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own[...]

IMPORTA NT INFOR MATION 5 Use definition (All EXC ‑ F models ) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public road t[...]

IMPORTA NT INFOR MATION 6 Transport Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard   Som e vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on [...]

VIEW OF VEHICLE 7 3.1 View of vehicl e, front left (ex ample) 101433-10 1 Filler cap 2 Air filter box lid 3 Fork compression adjustment 4 Shift lever ( p. 21) 5 Engine number ( p. 9) 6 Side stand ( p. 22)[...]

VIEW OF VEHICLE 8 3.2 View of vehicl e, rear right (ex ample) 101434-10 1 Kill switch ( p. 11) 1 Horn button ( p. 12) 1 Light switch ( p. 12) 1 Turn signal switch ( p. 12) 2 Emergency OFF switch ( p. 12) 2 Electric starter button ( p. 13) 3 Throttle grip ( p. 11) 4 Fork rebound adjustment and spring preload adjustment 5 Shock absorber rebound adjus[...]

SERIAL N UMBERS 9 4.1 Chassis numb er 101289-10 The chassis number  is stamped on the steering head on the right. 4.2 Type label 101290-10 The type label  is fixed to the front of the steering head. 4.3 Key number (A ll EXC ‑ F models) 500125-10 The key number  is stamped on the key strap. 4.4 Engine numbe r 101435-10 The engine number ?[...]

SERIAL N UMBERS 10 4.6 Shock absorbe r part number 101436-10 The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring on the engine side.[...]

CONTROL S 11 5.1 Clutch lever 101293-10 The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 5.2 Hand brake lev er 101294-10 Hand brake lever  is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. 5.3 Throttle grip 101295-10 T[...]

CONTROL S 12 5.6 Horn button (Al l EXC ‑ F models) 101297-11 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. 5.7 Light switch (A ll EXC ‑ F models) 101298-10 The light switch  is fitted on the left side of t[...]

CONTROL S 13 5.11 Electric starter button (XCF ‑ W, EXC ‑ F EU, EXC-F SIX DA YS) 101301-10 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. 5.12 Map ‑ Select swi[...]

CONTROL S 14 5.16 Overview of in dicator lamps (All EXC ‑ F models) 101304-01 Possible states High beam indicator light lights up blue – High beam is switched on. FI warning lamp ( MIL ) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The fuel level warning lamp lights up orange – The fuel level has re[...]

CONTROL S 15 5.20 Setting kilome ters 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. Condition The motorcycle is stationary. 400329-01 – Press the button briefly and repeatedly until H appears at the bottom[...]

CONTROL S 16 5.22 Adjusting the s peedometer fu nctions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. 400318-01 – 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 me[...]

CONTROL S 17 5.24 Display mode SPEED (spe ed) 400317-02 – 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 [...]

CONTROL S 18 Press the button briefly. Next display mode 5.28 Display mode SPEED/ODO (odometer) 400317-01 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. The total distance traveled is displayed in the ODO display mode. Press the button . No function Press the button . No function Press the button f[...]

CONTROL S 19 5.31 Display mode SPEED/A1 (a verage speed 1) 400325-01 – 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 mas- ter 1) and S1 (stop watch 1). The calculation of this value is activated by the first impulse of the[...]

CONTROL S 20 Table of functions Display Press the button . Press the button . Press the button for 3 - 5 seconds. Press the button briefly. Display mode SPEED/H (operating hours) No function No function The display changes to the Setup menu of the speedometer functions. Next display mode Display mode SPEED/CLK (clock) No function No function The di[...]

CONTROL S 21 101305-10 – Press release button  , turn filler cap counterclockwise and lift it upwards and remove. 5.36 Closing filler c ap 101306-10 – Replace the filler cap and turn clockwise until the release button  locks in place. Info Route the fuel tank breather hose  without kinking. 5.37 Idle speed adj usting screw 401342-10 Id[...]

CONTROL S 22 5.39 Kick starter 101439-10 The kick starter  is fitted on the right of the engine. The engine can be started with either the kick starter or the electric starter. The upper part of the kick starter can be swung out. Info Before riding, swing the upper part of the kick starter inwards towards the engine. 5.40 Foot brake lev er 10144[...]

CONTROL S 23 5.43 Locking the st eering (All EXC ‑ F mod els) Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. 400732-01 – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press [...]

PREPARIN G FOR US E 24 6.1 Advice on first use Danger Danger of acciden ts   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Mi ssing or poor protective clothing present a[...]

PREPARIN G FOR US E 25 – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – 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 [...]

PREPARIN G FOR US E 26 6.4 Preparing for ri des on dry san d 600872-10 – Check the radiator cap. Value on radiator cap 1.8 bar (26 psi) » If the displayed value does meet specifications: Warning Danger of scaldin g   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses[...]

PREPARIN G FOR US E 27 – Change the radiator cap. 600870-01 – Fit a rain cover on the air filter. Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and the setting. Info The specific carburetor tuning can be recommended by your authorized KTM workshop. 600868-01[...]

PREPARIN G FOR US E 28 – Change the radiator cap. 600868-01 – Adjust the secondary drive to the road conditions. Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive. – Clean the chain. Chain cleaner ( p. 112) – Clean the radiator fins. – Straighten bent radiator fins [...]

RIDING IN STRUCTIO NS 29 7.1 Checks and m aintenance wo rk when prepar ing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 92) – Check the electrical system. – Check the front brake fluid level. ( p. 66) ?[...]

RIDING IN STRUCTIO NS 30 7.3 Starting off 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 thrott[...]

RIDING IN STRUCTIO NS 31 7.6 Stopping, park ing Warning Risk of misapprop riation   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 component s become very hot when the vehicle is operated. – Do not touch hot [...]

RIDING IN STRUCTIO NS 32 A A 401226-10 – Fill the fuel tank with fuel up to measurement  . Guideline Measurement of  35 mm (1.38 in) Total fuel tank capacity, approx. 9.5 l (2.51 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 111) – Close the filler cap. ( p. 21)[...]

SERVICE SCHEDULE 33 8.1 Service sched ule S1N S15A S30A Read out the fault memory using the KTM diagnostics tool. x • • • Check that the electrical equipment is functioning properly. • • • Check and charge the battery. x • • Change the engine oil and oil filter and clean the oil screens. x ( p. 92) • • • Check the front brake [...]

SERVICE SCHEDULE 34 8.2 Service work (a s additional o rder) S15N S45A S105A J1A Change the front brake fluid. x • Change the rear brake fluid. x • Change the foot brake cylinder seals. x (XCF ‑ W, EXC ‑ F EU, EXC ‑ F AUS) • Change the hydraulic clutch fluid. x ( p. 63) • Grease the steering head bearing. x ( p. 50) • Clean the spar[...]

TUNING T HE CHASS IS 35 9.1 Checking the b asic suspens ion setting aga inst the rider's weight Info When adjusting the basic suspension setting, first adjust the shock absorber and then the fork. 401030-01 – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of[...]

TUNING T HE CHASS IS 36 Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 9.4 Adjusting the h igh-speed com pression dam ping of the sh ock absorber Caution Danger of acciden ts   Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the descri[...]

TUNING T HE CHASS IS 37 9.6 Measuring rea r wheel sag un loaded – Raise the motorcycle with the lift stand. ( p. 42) 0 0 A A 400988-10 – Measure the distance – as vertically as possible – between the rear axle and a fixed point, such as a mark on the side cover. – Make note of the value as measurement  . – Remove the motorcycle from [...]

TUNING T HE CHASS IS 38 9.9 Adjusting the s pring preload of the shoc k absorber x Caution Danger of acciden ts   Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring[...]

TUNING T HE CHASS IS 39 9.11 Checking basi c setting of for k Info For various reasons, no exact riding sag can be determined for the forks. 401000-01 – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression),[...]

TUNING T HE CHASS IS 40 Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 9.14 Adjusting the s pring preload of the fork 101317-01 – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. – Turn back clockwise by the number of turns corresponding to the fork typ[...]

TUNING T HE CHASS IS 41 Info Position the left and right handlebar supports evenly. – Position the handlebars. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamps. Fit and evenly tighten the four screws  . Guideline Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) Info Make sure the gap width is even.[...]

SERVICE WORK ON T HE CHASS IS 42 10.1 Raising the mo torcycle with t he lift stand 101443-01 Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels should no longer touch the gro[...]

SERVICE WORK ON T HE CHASS IS 43 – Press the dust boots back into their normal position. – Remove excess oil. – Position the fork protection. ( p. 43) – Remove the motorcycle from the lift stand. ( p. 42) 10.5 Loosening the fork protec tor 101321-10 – Remove screws  and remove the clamp. – Remove screws  on the left fork leg. Push[...]

SERVICE WORK ON T HE CHASS IS 44 10.8 Installing the f ork legs x 101325-10 – Position the fork legs. Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws  toward the front. 101323-11 (XCF ‑ W, EXC ‑ F EU, EXC ‑ F AUS) – Tighten screws  . Guideline Screw, t[...]

SERVICE WORK ON T HE CHASS IS 45 10.10 Installing the f ork protector x 101327-10 – 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[...]

SERVICE WORK ON T HE CHASS IS 46 101336-10 – Remove O-ring  . Remove protective ring  . – Take out the lower triple clamp with the steering stem. – Take out the upper steering head bearing. 10.13 Installing the l ower triple clam p x (XCF ‑ W, EXC ‑ F EU, EXC ‑ F AUS) 0 0 2 2 0 0 1 1 0 0 3 3 101330-10 – Clean the bearing and sea[...]

SERVICE WORK ON T HE CHASS IS 47 101428-10 – Tighten screw  . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 101334-11 – Tighten screw  . Guideline Screw, top steering stem M8 20 Nm (14.8 lbf ft) 101333-11 – Tighten screws  . Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) – Secure the wiring harness with ca[...]

SERVICE WORK ON T HE CHASS IS 48 10.14 Installing the l ower triple clam p x (EXC-F SIX DAYS) 0 0 2 2 0 0 1 1 0 0 3 3 101331-10 – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 112) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether t[...]

SERVICE WORK ON T HE CHASS IS 49 101341-10 – Mount and tighten screw  . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ 101339-11 – Tighten screws  . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Secure the wiring harness with cable holder  . 101326-11 – Position the brake caliper. Mount [...]

SERVICE WORK ON T HE CHASS IS 50 » If click positions are noticeable: (EXC-F SIX DAYS) – Adjust the play of the steering head bearing. x ( p. 50) (XCF ‑ W, EXC ‑ F EU, EXC ‑ F AUS) – Adjust the play of the steering head bearing. x ( p. 50) – Check the steering head bearing and replace if required. – Remove the motorcycle from the lif[...]

SERVICE WORK ON T HE CHASS IS 51 10.19 Removing the shock abso rber x – Raise the motorcycle with the lift stand. ( p. 42) 101444-10 – 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,[...]

SERVICE WORK ON T HE CHASS IS 52 10.23 Removing the seat 101346-10 – Remove screw  . – Lift up the seat at the rear, pull it back and then remove it from above. 10.24 Mounting the s eat 101347-01 – 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 tha[...]

SERVICE WORK ON T HE CHASS IS 53 101350-10 – Detach air filter holder  at the bottom and swing it to one side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. 10.28 Installing the a ir filter x 101351-10 – Mount the clean air filter onto the air filter support. – Apply grease to the[...]

SERVICE WORK ON T HE CHASS IS 54 10.30 Removing mai n 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. 101353-10 – Disconnect spring  . – Remove screws  and take off main silencer. 10.31 Installing the m ain silencer 10[...]

SERVICE WORK ON T HE CHASS IS 55 – Mount and tighten the screws. 0 0 1 1 0 0 2 2 0 0 4 4 0 0 6 6 0 0 bk bk 7 7 0 0 3 3 0 0 4 4 0 0 bk bk 0 0 5 5 0 0 9 9 0 0 8 8 101426-10 (XCF ‑ W) – Remove screws  of connecting cap  . – Take off the connecting cap with the perforated pipe, O-ring  and glass fiber yarn filling  . – Remove scre[...]

SERVICE WORK ON T HE CHASS IS 56 101356-10 – Remove screws  with the collar bushings and horn. 101357-10 – Remove screw  with the rubber bushing. 101358-01 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 10.34 Installing the f uel tank x Danger Fire hazard   Fuel is highly flammable. – Never[...]

SERVICE WORK ON T HE CHASS IS 57 101356-11 – Position the horn, and fit and tighten screws  with collar bushings. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 101448-10 – Connect the electrical plug-in connection  . – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances [...]

SERVICE WORK ON T HE CHASS IS 58 400725-01 – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 112) Off-road chain spray ( p. 112) 10.37 Checking the c hain tension Warning Danger of acciden ts   Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power trai[...]

SERVICE WORK ON T HE CHASS IS 59 101360-10 – Loosen nut  . – Loosen nuts  . – Adjust the chain tension by turning the adjusting screws  left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws  on the left and right so that the markings on the left and right chain adjusters are in the same positi[...]

SERVICE WORK ON T HE CHASS IS 60 401343-01 – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. x – Check that the chain sliding guard is firmly seated. » If the chain sliding guard is loose: – Tighten the chain sliding guard. G[...]

SERVICE WORK ON T HE CHASS IS 61 10.40 Adjusting the c hain guide x 101362-10 – Remove the nut of screw  . – 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[...]

SERVICE WORK ON T HE CHASS IS 62 10.43 Checking the t hrottle cable ro uting – Remove the fuel tank. x ( p. 55) 101449-10 – Check the throttle cable routing. Both throttle cables must be routed to the carburetor side by side behind the handlebars and above the tank bearing. » If the throttle cable is not routed as specified: – Correct the th[...]

SERVICE WORK ON T HE CHASS IS 63 10.47 Checking the f luid level of th e hydraulic clu tch Info The fluid level rises with increased wear of the clutch lining discs. 101365-10 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with membrane  . – Check the fluid le[...]

SERVICE WORK ON T HE CHASS IS 64 10.49 Removing the engine gua rd (EXC ‑ F AUS, EXC-F S IX DAYS) 101451-10 – Turn quick release  countercloc kwise until it disengages. Remove the engine guard. 10.50 Installing the e ngine guard (E XC ‑ F AUS, EXC-F SIX D AYS) 101452-10 – Attach the engine guard on the frame at the rear and swing up at th[...]

BRAKES 65 11.1 Checking free travel of ha nd brake lever Warning Danger of acciden ts   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications. 101370-10 (XCF ‑ W) [...]

BRAKES 66 11.4 Checking the b rake discs Warning Danger of acciden ts   Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) A A 400257-10 – Check the thickness of the front and rear brake discs at several places on the disk to see if it confo[...]

BRAKES 67 Warning Danger of acciden ts   Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental ha zard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel,[...]

BRAKES 68 Warning Danger of acciden ts   Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of acciden ts   Reduced braking efficiency due to oil or grease on the brake discs. – Always ke[...]

BRAKES 69 100398-10 – Fit the brake linings, insert the bolt, and mount the locking split pins. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. 101374-12 – Correct the brake fluid quantity to level  . Guideline Measurement of  5 mm (0.2 in) Brake fluid D[...]

BRAKES 70 101454-10 – Disconnect spring  . – Loosen nut  and, with push rod  , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever individually, loosen nut  and turn screw  accordingly. Info The range of adjustment is limited. – Turn push rod  accordingly until you have f[...]

BRAKES 71 Warning Danger of acciden ts   Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental ha zard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel,[...]

BRAKES 72 11.14 Changing the r ear brake linin gs x Warning Danger of acciden t   Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation   Bra ke fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and k[...]

BRAKES 73 100407-10 – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. 101384-01 – Fit the brake linings, insert the bolt, and mount the locking split pins. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a[...]

WHEELS, TIRES 74 12.1 Removing the front wheel x – Raise the motorcycle with the lift stand. ( p. 42) 101385-01 – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. 101386-10 – Remove screw ?[...]

WHEELS, TIRES 75 101386-11 – 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) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. – Remove the motorcycle from t[...]

WHEELS, TIRES 76 101390-11 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. x – Clean and grease shaft seal rings  and bearing surface  of the spacers. Long-life grease ( p. 112) – Insert the spacers. 101391-10 – Lift the rear wheel into the swing arm, position it[...]

WHEELS, TIRES 77 – Change the tire. – Check the tire age. Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires be changed a[...]

WHEELS, TIRES 78 Torque wrench with various accessories in set (584290940 00)[...]

ELECTRIC AL SYST EM 79 13.1 Removing the battery x Warning Risk of injury   Ba ttery 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 flames. C[...]

ELECTRIC AL SYST EM 80 Warning Environmental ha zard   The battery contains elements that are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning E[...]

ELECTRIC AL SYST EM 81 101395-10 – Remove screw  . 101396-10 – Lift rear fairing  slightly and pull starter relay  out of the bracket. 101397-10 – Remove protection caps  . – Remove the faulty main fuse  . Info A defective fuse can be identified by the burned-out fuse wire  . A reserve fuse  is located in the starter re[...]

ELECTRIC AL SYST EM 82 101399-10 – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan (optional) Fuse 5 - not used Fuses res - 10 A - spare fuses Info A defect[...]

ELECTRIC AL SYST EM 83 13.7 Removing hea dlight mask wi th headlight 101401-10 – Switch off all electrical equipment . – Remove screw  and take off clamp. – Loosen the rubber band  . Push up the headlight mask and swing it forwards. 101402-10 – Pull out the electric plug connector  and remove the headlight mask with the headlight. [...]

ELECTRIC AL SYST EM 84 100862-10 – Press headlight bulb  into the lamp socket lightly, turn it counterclockwi se all the way and pull it out. – Insert a new headlight bulb. Headlight (S2 / socket BA20d) ( p. 105) – Insert the rubber cap together with the lamp socket into the reflector and turn it clockwise all the way. Info Ensure that the[...]

ELECTRIC AL SYST EM 85 101406-10 – Using a coin, turn locking cap  counterclockwise all the way and remove it. – Remove speedometer battery  . – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p. 105) – Check that the O-ring of the locking cap is seated properly. 101407-10 – Position locking cap [...]

COOLING SYSTEM 86 14.1 Cooling system 101455-10 Water pump  in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap  . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions. 120 °C (248 °F) C[...]

COOLING SYSTEM 87 14.3 Checking the c oolant level Warning Danger of scaldin g   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse im[...]

COOLING SYSTEM 88 14.5 Refilling coola nt x Warning Danger of poisoni ng   Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, conta[...]

TUNING T HE ENGIN E 89 15.1 Checking the p lay in the thro ttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3… 5 mm (0.12… 0.2 in) » If the throttle cab[...]

TUNING T HE ENGIN E 90 101432-10 On the Map ‑ Select switch for the basic settin g: – Pull off rubber cap  of Map ‑ Select . – Turn adjusting wheel  until the desired number is aligned with marking  . SOFT: – Set the adjusting wheel to position 1 . Soft – The mapping with reduced peak performance for better rideability is activ[...]

TUNING T HE ENGIN E 91 15.6 Adjusting the b asic position of the shift lever x 101459-10 – Remove screw  and take off shift lever  . 101460-10 – Clean gear teeth  of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The[...]

SERVICE WORK ON T HE ENGIN E 92 16.1 Checking the e ngine oil leve l Info The engine oil level can be checked when the engine is cold or warm. – Stand the motorcycle upright on a horizontal surface. 101461-10 Condition The engine is cold. – Check the engine oil level. The engine oil level is up to the middle  of the level viewer. » If the e[...]

SERVICE WORK ON T HE ENGIN E 93 101464-10 – Remove screw plug  with the long oil screen  . 101468-10 – Remove screws  . Remove the oil filter cover with the O-ring. 101469-10 – Pull oil filter  out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts an[...]

SERVICE WORK ON T HE ENGIN E 94 101470-10 – 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 housing. – Oil the O-ring of the oil filter cover and mount it with the oil filter cover  . – Mount and tighten the screws. Guid[...]

CLEANING , CARE 95 17.1 Cleaning the m otorcycle 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, socket connects, throttle cables, and bearings, etc[...]

CLEANING , CARE 96 17.2 Checks and m aintenance ste ps for winter o peration Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of s[...]

STORAGE 97 18.1 Storage Warning Danger of poisoni ng   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 immediate ly with soap and water. If fuel is swallowed, con-[...]

TROUBLE SHOOTING 98 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) Operating error – Carry out the start procedure. ( p. 29) Battery is discharged – Charge the battery. x ( p. 79) – Check the charging voltage. x – Check the closed current. x – Check the stator winding of the alternator. x Main fuse blown ?[...]

TROUBLE SHOOTING 99 Faults Possible cause Action Engine overheats Insufficient airflow – Switch off engine when stationary. Radiator fins very dirty – Clean radiator fins. Foam formation in cooling system – Drain the coolant. x ( p. 87) – Refill the coolant. x ( p. 88) Bent radiator hose – Change the radiator hose. x Thermostat defective [...]

BLINK CO DE 100 Blink code FI warn ing lamp (MIL) 02 FI warning lamp ( MIL ) flashes 2x short Error level conditi on Crankshaft position sensor - circuit fault Blink code FI warn ing lamp (MIL) 06 FI warning lamp ( MIL ) flashes 6x short Error level conditi on Throttle position sensor circuit A - input signal too low Throttle position sensor circui[...]

BLINK CO DE 101 Blink code FI warn ing lamp (MIL) 45 FI warning lamp ( MIL ) flashes 4x long, 5x short Error level conditi on EXC ‑ F EU, EXC-F SIX DAY S Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit EXC ‑ F EU, EXC-F SIX DAY S Lambda sensor heater cylinder 1, sensor 1 - input signal too high[...]

TECHNICA L DATA - ENGINE 102 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 13.2:1 Idle speed 2,050… 2,150 rpm Control DOHC, four valves controlled via cam lever, drive via tooth-wheel chain Valve diameter, intake 30.0 mm (1.181 in) Valve [...]

TECHNICA L DATA - ENGINE TIG HTENING TORQUES 103 Jet, crank chamber ventilation M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil jet for alternator cooling M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil jet for cam lever lubrication M5 4 Nm (3 lbf ft) Loctite ® 243™ Screw, ignition pulse g[...]

TECHNICA L DATA - ENGINE TIG HTENING TORQUES 104 Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ Nut, primary gear M18LHx1.5 130 Nm (95.9 lbf ft) Loctite ® 243™ 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) –[...]

TECHNICA L DATA - CHASSIS 105 Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 20 mm (0.79 in) Shock absorber WP Suspension PDS 5018 DCC Brake system Disc brakes, brake calipers on floating bearings Brake discs - [...]

TECHNICA L DATA - CHASSIS 106 23.2 Tires Validity Front tire Rear tire (All EXC ‑ F models) 90/90 - 21 M/C 54M M+S TT Metzeler MEC 6 DAYS EXTREME 120/90 - 18 M/C 6 5M M+S TT Metzeler MEC 6 DAYS EXTREME (XCF ‑ W) 8 0/100 - 21 51M T T Dunlop GEOMAX MX51 100/100 - 18 59M TT Dunlop GEOMAX MX51 Additional information is available in the Service sect[...]

TECHNICA L DATA - FORK 107 Fork part number 14.18.7L.63 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Full payload 18 clicks Spring preload - Preload Adjuster Comfort 1 turn Standard 2 t[...]

TECHNICA L DATA - SHOCK ABS ORBER 108 Shock absorber part number 12.18.7L.63 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Full payload 1.25 turns Rebound damping [...]

TECHNICA L DATA - TIGHTENIN G TORQUE S FOR CH ASSIS 109 Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) – Screw, intake air temperature sensor M5 2 Nm (1.5 lbf ft) – Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) – Screw, spoiler on fuel tank (XCF ‑ W) M5x12 1.5 Nm [...]

SUBSTAN CES 110 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® – Br[...]

SUBSTAN CES 111 Fork oil (SAE 5 ) According to – SAE ( p. 114) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex ® products. Supplier Motorex ® – Racing Fork Oil Shock absorbe r oil (SAE 2.5) (50180342S 1) Acc[...]

AUXILIAR Y SUBSTA NCES 112 Air filter cleane r Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Re mover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and p reserving mat erials for meta l, rubber and p lastic Guideline – KTM recommends Motor[...]

AUXILIAR Y SUBSTA NCES 113 Paint cleaner a nd polish for h igh-gloss and matte finis hes, bare meta l and plastic s urfaces Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Clean & Polish Rubber grip ad hesive (00062 030051) Supplier KTM-Sportmotorcy cle AG – GRIP GLUE Universal oil s pray Guideline – KTM recommends[...]

STANDAR DS 114 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. Whereas long service intervals are demanded for a[...]

INDEX 115 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 A[...]

INDEX 116 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Frame checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Front w[...]

INDEX 117 battery, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 function description . . . . . . . . . . . . . . . . . . . . . . . . . 14 kilometers or miles, setting . . . . . . . . . . . . . . . . . . . . 15 Spoke tension checking . . . . . . . . . [...]

*321 171 9en* 3211719en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 05/2011 Photo: Mitterbauer[...]