KTM EXC-F SIX DAYS manual

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 250 SX-F 250 XC-F, XCF-W 250 EXC-F, EXC-F SIX DAYS OWNER’S MANUAL 2008 3211228 en *3211228en* 3211228en[...]

ENGLISH 1 INTRODUCTION » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services,[...]

ENGLISH 2 IMPORTANT INFORMATION » INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. The SX-F and XC-F models are prohibited on p[...]

ENGLISH 3 IMPORTANT INFORMATION » The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifi[...]

TABLE OF CONTENTS » ENGLISH 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . .[...]

SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. ENGLISH 5 OPERATION IN[...]

OPERATION INSTRUMENTS » ENGLISH 6 A B C Combination switch The light switch has 2, respectively 3 switch positions. [A] = Light off (this function is not available in all models) [B] = Low beam on [C] = High beam on Y ou may use button [3] to actuate the horn. The red short circuit button [4] serves to switch off the engine. Leave the switch press[...]

OPERATION INSTRUMENTS » ENGLISH 7 1 2 3 4 5 Starter button Pushing the red starter button [1] will actuate the E-starter . Emergency OFF switch (EXC-F Australia) The red emergency-OFF switch [2] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter a[...]

OPERATION INSTRUMENTS » ENGLISH 8 WS (wheel size) The display changes and the circumference of the front wheel is briefly dis- played in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires). Afterwards the display will return to the previous display mode. SPEED display mode / H (service hours) Only the[...]

OPERATION INSTRUMENTS » ENGLISH 9 SPEED / LAP (lap time) display mode Y ou can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds. + button Starts and stops the stop watch, lap time is not reset to 0 – button Stops th[...]

OPERATION INSTRUMENTS » ENGLISH 10 SPEED / TR2 display mode (tripmaster 2) The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the displayed figure can be changed using the + and – buttons. This is a very use- ful function for trips taken according to a roadbook. + button increases the TR2 figure – button decreases the TR2 [...]

OPERATION INSTRUMENTS » ENGLISH 11 Kilometers or miles The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly . The TR1, A1, S1, TR2 and A2 figures will be cleared. T o select the unit, select the SPEED/H mode and hold the | button for 3 sec- onds to access the SETUP menu. Press the | button u[...]

OPERATION INSTRUMENTS » ENGLISH 12 Fuel tap (XC-F, XCF-W, EXC-F) OFF In this position the fuel tap is closed. No fuel can flow to the carburetor . ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor . With the twist grip in this position the tank will be emptied until only the reserve is lef[...]

OPERATION INSTRUMENTS » ENGLISH 13 1 2,3,4 (5,6) 1 N Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear . Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swiv[...]

OPERATION INSTRUMENTS » ENGLISH 14 6 Compression damping of fork (XCF-W, EXC-F, EXC-F Six Days) Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap [4] . T urn the adjusting screws [5] clockwise [...]

OPERATION INSTRUMENTS » ENGLISH 15 Compression damping of shock absorber The shock absorber on these models can synchronize the compression damp- ing in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The[...]

OPERATION INSTRUMENTS » – W ear suitable clothing when driving a motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regard- less of whether driving all day or just for a short trip. The protective clothing should be brightly colored so that other vehicles can see you as early as possible. – Do not drive after havi[...]

DRIVING INSTRUCTIONS » ENGLISH 17 A B 2 Check the following before each start When you start off, the motorcycle must be in perfect technical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK THE OIL LEVEL Insufficient oil re[...]

DRIVING INSTRUCTIONS » ENGLISH 18 Starting when the engine is cold 1 Open the fuel tap [1] . 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke [2] . 5 Leave throttle closed and kick the kickstarter briskly ALL THE W A Y or actu- ate the E-starter . – If you want to start the engine, make sure that you alwa[...]

DRIVING INSTRUCTIONS » ENGLISH 19 35 mm NOTE: dedicated to nothing but offroad racing, these models make no compromises in their design. As such, they do not include any radiator fan, and the size of the radiator is dimensioned for opti- mum ergonomics. In normal racing, the cooling system is sufficient. If you use your motorbike in other conditio[...]

PERIODIC MAINTENANCE » ENGLISH 20 250 SX-F/XC-F 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20 l fuel every 20 hours or 140 l fuel or 1 race ENGINE Change engine oil, oil filter z z Clean oil screen and drain plug magnet z z Replace spark plug (after 30 hours) Check and adjust valve clearance[...]

PERIODIC MAINTENANCE » ENGLISH 21 NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. 250 SX-F/XC-F 2008 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use at least once a year Check oil level z Check bra[...]

PERIODIC MAINTENANCE » ENGLISH 22 Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider . 250 XCF-W/EXC-F 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20[...]

PERIODIC MAINTENANCE » ENGLISH 23 NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. 250 XCF-W/EXC-F 2008 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use at least once a year Check oil level z Check b[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 24 A 3 1 2 Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring [1] . For this purpose, you should dismount the shock absorber and clean it thoroughly . NOTE: – Before changing the spring preload note down the basic setting, e.g. how [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 25 Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the fork, shock absorber , swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery , KTM's offroad motorcycle[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 26 Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons. Similar to the shock absorber , smaller deviations in your weight can be compensated by adjusting the spring preload. However , if your telescopic fork bumps fre[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 27 1 Cleaning the dust sleeves of the telescopic fork The dust-protection bellows are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust- protection bellows. If this dirt is not removed, the oil sealing rings located behind it[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 28 B A 2 1 3 2 5 4 3 4 5 2 Changing the fork offset (caster) (SX-F, XC-F, XCF-W USA, EXC-F Six Days) * The fork offset [A] in these models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course. Remove the[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 29 15 mm 3,5 mm 1 2 3 4 Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw . T ighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 30 8-10 mm / 0.3-0.4 in A 2 3 1 4 B 2 B 3 4 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 8 - 10 mm (0.3[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 31 250 XC-F , XCF-W , EXC-F: NOTE: The position of the chain guide must be adjusted due to the large number of rear sprockets available. Up to 44 teeth, insert the retaining screw on the chain guide in the lower hole [C] , from 45 teeth in the upper hole [D] . Loosen both screws on the chain guide a[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 32 15 KG 33 lbs max. 272 mm 1 2 3 16 17 18 Chain maintenance For a long chain life, good maintenance is very important. Chains without X-rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (e.g. Motorex Chainlube 622). X-ring chains on the oth[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 33 A 1 General information about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series use a „floating“ mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to „float“ for maximum braking contact. Secure the screws of the c[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 34 5 mm min. 3 mm 1 3 2 4 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw [1] . In this way , the position of the point of pressure (i.e. the resis-tance you feel on the hand brake lever when the brake pads are pressed[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 35 Checking the front brake pads The brake pads can be inspected from below . The linings must be at least 1 mm (0.04 in) thick. At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure. For your own safety don’t put off having your bra[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 36 Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motor- cycle on the rear brake cylinder . No air bubble should be visible in inspection glass [A] when the vehicle is parked in a vertical position. If the brake fluid level drops below t[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 37 Replacing the rear brake pads * Push the brake caliper [1] toward the chain wheel in order to move the brake piston into its basic position. Remove the clips [2] , pull out the bolt [3] , and remove the brake pads. Thoroughly clean the brake caliper with compressed air and check the sleeves of th[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 38 Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Remove the collar nut [1] , remove the chain tensioner [2] and pull out the wheel spindle [3] until you can push the rear wheel forwards. T ake the chain off the rear s[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 39 1 2 3 1 Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motor -cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – T ire size can be found in the technical specifications and in the homolo- gati[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 40 VOL T 2 3 1 Battery The battery is located under the seat and is maintenance-free. Maintenance-free means you will not need to check the acid level. Clean the battery terminals regularly and grease with acid-free grease if necessary . The charge condition and type of charge are very important for[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 41 2 A 1 3 4 6 5 5 Fuse The fuse [1] is located in the starter relay of the E-starter [2] underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover [A] , you will be able to see the fuse. The following loads are connected to it: – E-starte[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 42 Cooling system Coolant is circulated by a water pump [1] located in the engine. When the engine is cold the coolant only circulates through the cylinder and the cylin- der head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat opens and the coolant is a[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 43 A XC-F/XCF-W/EXC-F 1 1 1 2 2 3 3 4 5 5 SX-F 4 Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material f[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the throttle cables * The throttle grip should always provide for a backlash of 3-5mm. Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. T o adjust the throttle cables, dismount the seat and the tank together with spoiler[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 45 Checking the oil level of the hydraulic clutch T o check the oil level in the master cylinder of the clutch remove the cover . For this purpose, remove screws [2] and cover [3] together with the rubber boot [4] . The oil level in the horizontal-standing master cylinder should be 4 mm below the up[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 46 Carburetor – Adjust idling (Keihin-FCRMX 39) * Idling adjustment of the carburetor strongly affects the engine’ s starting behavior . That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly . The idle spee[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 47 A B 1 Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard. Whereas car engin[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 48 Changing the engine oil * NOTE: When changing the engine oil, it is necessary to clean the short and long oil screens and to replace the oil filter . Engine oil has be changed with the engine at an operating temperature. An engine at operating temperature and the engine oil it contains are very h[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 49 3 2 4 1 1 Changing the oil filters * Place a receptacle underneath the engine to collect the drained oil. Remove the 2 screws [1] and dismount the oil filter cover . Using circlip pliers, pull the oil-filter insert [2] out of the housing. Clean the oil filter cover , the sealing surface of the O-[...]

TROUBLESHOOTING » ENGLISH 50 If you had the specified maintenance work on your motorcycle carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the troubleshooting chart in order to find the cause of error . W e would like to point out that many operations cannot be performed by yourself. In cas[...]

TROUBLESHOOTING » ENGLISH 51 TROUBLE CAUSE REMEDY Engine does not rev up Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition timing faulty Dismount carburetor and check if worn out T ighten jets Have ignition system checked Engine will not reach full power Fuel supply partially i[...]

CLEANING » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. If using a power washer , do not point the water j[...]

ENGLISH 53 TECHNICAL DATA – ENGINE »» Engine oil Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T 10W/50. Poor oil quality or minor quantity cause early engine-wear . ENGINE 250 SX-F, XC-F 250 XCF-W, EXC-F Design Liquid-cooled single cylinder 4-s[...]

TECHNICAL DATA – ENGINE » ENGLISH 54 TIGHTENING TORQUES – ENGINE Hexagon collar screw , engine case, clutch cover , ignition cover , water pump cover M6 10 Nm Oil drain plug M12x1.5 20 Nm Allen head plug, oil screen short M16x1.5 Oil + 10 Nm Hexagon plug, oil screen long M20x1.5 15 Nm Collar screw for oil filter cover M5 6 Nm Plug pressure val[...]

TECHNICAL DATA – CHASSIS » ENGLISH 55 CHASSIS 250-F Frame Central tube chrome-moly-steel frame Fork WP Suspension – 4860 MXMA CC / MXMA + P A Wheel travel front/rear 300/335 mm Rear suspension WP Suspension – 5018 PDS DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear [...]

TECHNICAL DATA – CHASSIS » ENGLISH 56 TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm Brake disks M6 14 Nm Clamping screws, upper fork bridge XCF-W ZA, EXC-F M8 20 Nm Clamping screws, lower fork bridge XCF-W ZA, EXC-F M8 15 Nm Clamping screws, upper fork bridge SX-F , X[...]

WIRING DIAGRAM » ENGLISH 57 p u k c i p G 3 r o t a r e n e g n o t t u b p o t s C D I l i o c n o i t i n g i 3 / M A _ C 3 / R A _ C n o i t i s o p e l t t o r h t r o s n e s 1 2 3 0 0 1 . 2 3 0 . 9 3 . 4 9 5 s s e n r a h I D C 1 2 7 5 6 1 1 0 1 2 1 4 1 3 1 red-white red-black d e r n e e r g e t i h w - e u l b n w o r b k c a l b - w o l l[...]

WIRING DIAGRAM » ENGLISH 58 m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 1 . 5 7 0 . 1 1 . 4 9 5 p u k c i p l i o c n o i t i n g i G 3 r o t a r e n e g rear light/brakelight v r o s n e s d e e p s h c t i w s r a b e l d n a h ) l a n o i t p o ( S P T M A 0 1 y r e t t a b y a l e r t r a t s r o t o m r e t r a t s n o t t u b t r a[...]

WIRING DIAGRAM » ENGLISH 59 m a r g a i d g n i r i w s s e n r a h n i a m h c t i w s r e h s a l f 3 / T B _ C 3 / G B _ C p u k c i p h c t i w s e k a r b r a e r 2 / H A _ C 2 / K A _ C r e h s a l f t n o r f t f e l r e h s a l f t n o r f t h g i r r e h s a l f r a e r t h g i r r e h s a l f r a e r t f e l driving light lamp flasher co[...]

WIRING DIAGRAM » ENGLISH 60 CABLE COLOURS bl: black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple[...]

HEAD WORD INDEX » ENGLISH 61 Activating and deactivating display modes . . . . . . . . . . . . . .8 Adapting the chain guide to the number of rear sprocket teeth .31 Adjusting the free travel at the hand brake lever . . . . . . . . .34 Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . . . .44 Basic information on carburetor wea[...]

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 250 SX-F 250 XC-F, XCF-W 250 EXC-F, EXC-F SIX DAYS OWNER’S MANUAL 2008 3211228 en *3211228en* 3211228en[...]