User manual KTM 250 SX-F

[. . . ] OWNER'S MANUAL 2010 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF-W ZA 250 SX-F EU 250 SX-F USA Art. 3211465en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment riding this vehicle! Enter the serial numbers of your vehicle below. [. . . ] (EXCF EU, EXCF AUS, XCFW ZA) ­ Adjust play of the steering head bearing. x( p. 49) ­ Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. » If click positions are noticeable: (SXF, 250 EXC-F SIX DAYS EU) ­ Adjust the play of the steering head bearing. (EXCF EU, EXCF AUS, XCFW ZA) ­ Adjust play of the steering head bearing. ( Adjusting play of steering head bearing 13. 24 x (EXCF EU, EXCF AUS, XCFW ZA) ­ ­ ­ Jack up the motorcycle. Guideline Screw, top steering stem ­ Check the steering head bearing play. 49) 20 Nm (14. 8 lbf ft) M8 20 Nm (14. 8 lbf ft) M20x1. 5 10 Nm (7. 4 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. 40) 100022-10 MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play of the steering head bearing 13. 25 50 x (SXF, 250 EXC-F SIX DAYS EU) p. Guideline Screw, top steering head ­ ­ 800022-10 M20x1. 5 10 Nm (7. 4 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. Guideline Screw, top triple clamp M8 17 Nm (12. 5 lbf ft) ­ Mount and tighten screw . Guideline Screw, top steering stem M8 17 Nm (12. 5 lbf ft) Loctite® 243TM (SXF) ­ Loosen screws . Guideline Screw, top steering head ­ ­ 600876-10 M20x1. 5 10 Nm (7. 4 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. Guideline Screw, top triple clamp M8 17 Nm (12. 5 lbf ft) ­ Mount and tighten screw . 49) 17 Nm (12. 5 lbf ft) Loctite® 243TM ­ Check the steering head bearing play. ( Removing the fork legs 13. 26 ­ ­ Remove front wheel. x( p. 69) Remove screws and take off the clamp. (EXCF, EXCF SIX DAYS, XCF-W) ­ Remove cable clip . Hang the brake caliper and the brake line loosely to the side. 100802-10 (EXCF EU, EXCF AUS, XCFW ZA) ­ Loosen screws . Remove the fork leg on the right. 100804-10 MAINTENANCE WORK ON CHASSIS AND ENGINE (250 EXC-F SIX DAYS EU) ­ Loosen screws . Remove the fork leg on the right. 51 100803-10 (SXF) ­ Loosen screws . Remove the fork leg on the right. 600877-10 Installing the fork legs 13. 27 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 bleeder screws toward the front. 100021-10 (EXCF EU, EXCF AUS, XCFW ZA) ­ Fully tighten screws . [. . . ] 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 12. 18. 7J. 04 WP Suspension PDS 5018 DCC 22 clicks 20 clicks 15 clicks 2 turns 1. 5 turns 1. 25 turns 26 clicks 24 clicks 22 clicks 8 mm (0. 31 in) 66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 35 mm (1. 38 in) 105 mm (4. 13 in) 411 mm (16. 18 in) SXF 22. 2 Shock absorber part number Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Spring rate Weight of rider: 65. . . 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 12. 18. 7J. 03 WP Suspension PDS 5018 DCC 17 clicks 15 clicks 13 clicks 2 turns 1. 5 turns 1 turn 24 clicks 22 clicks 22 clicks 6 mm (0. 24 in) 66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 33 mm (1. 3 in) 105 mm (4. 13 in) 411 mm (16. 18 in) TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS Spoke nipple, front wheel Spoke nipple, rear wheel Remaining nuts, chassis Remaining screws, chassis Screw, ball joint of push rod on footbrake cylinder Screw, front brake disc Screw, rear brake disc Screw, shock absorber adjusting ring Nut, rear sprocket screw Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, bottom triple clamp (SXF, 250 EXC-F SIX DAYS EU) Screw, bottom triple clamp (EXCF EU, EXCF AUS, XCFW ZA) Screw, engine brace Screw, fork stub Screw, front brake caliper Screw, handlebar clamp Screw, side stand fixing Screw, subframe Screw, top steering stem (SXF, 250 EXC-F SIX DAYS EU) Screw, top steering stem (EXCF EU, EXCF AUS, XCFW ZA) Screw, top triple clamp (SXF, 250 EXC-F SIX DAYS EU) Screw, top triple clamp (EXCF EU, EXCF AUS, XCFW ZA) Engine attachment bolt Remaining nuts, chassis Remaining screws, chassis Screw, handlebar support Screw, bottom shock absorber Screw, top shock absorber Nut, seat fixing Nut, swingarm pivot Nut, rear wheel spindle Screw, bottom steering head (SXF) Screw, top steering head Screw-in nozzles, cooling system Screw, front wheel spindle M4. 5 M5 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M12 M12 M12x1 M16x1. 5 M20x1. 5 M20x1. 5 M20x1. 5 M20x1. 5 M24x1. 5 5. . . 4. 4 lbf ft) 15 Nm (11. 1 lbf ft) 10 Nm (7. 4 lbf ft) 10 Nm (7. 4 lbf ft) 14 Nm (10. 3 lbf ft) 14 Nm (10. 3 lbf ft) 5 Nm (3. 7 lbf ft) 35 Nm (25. 8 lbf ft) 10 Nm (7. 4 lbf ft) 30 Nm (22. 1 lbf ft) 25 Nm (18. 4 lbf ft) 12 Nm (8. 9 lbf ft) 15 Nm (11. 1 lbf ft) 33 Nm (24. 3 lbf ft) 15 Nm (11. 1 lbf ft) 25 Nm (18. 4 lbf ft) 20 Nm (14. 8 lbf ft) 40 Nm (29. 5 lbf ft) 35 Nm (25. 8 lbf ft) 17 Nm (12. 5 lbf ft) 20 Nm (14. 8 lbf ft) 17 Nm (12. 5 lbf ft) 20 Nm (14. 8 lbf ft) 60 Nm (44. 3 lbf ft) 50 Nm (36. 9 lbf ft) 45 Nm (33. 2 lbf ft) 40 Nm (29. 5 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 20 Nm (14. 8 lbf ft) 100 Nm (73. 8 lbf ft) 80 Nm (59 lbf ft) 60 Nm (44. 3 lbf ft) 10 Nm (7. 4 lbf ft) 12 Nm (8. 9 lbf ft) 45 Nm (33. 2 lbf ft) ­ ­ ­ ­ ­ ­ ­ ­ Loctite® 243TM ­ ­ ­ ­ ­ ­ ­ Loctite® 243TM ­ Loctite® 243TM Loctite® 243TM Loctite® 243TM ­ ­ ­ ­ ­ ­ Loctite® 243TM Loctite® 243TM Loctite® 243TM ­ ­ ­ Loctite® 243TM ­ Loctite® 243TM ­ 105 WIRING DIAGRAM Wiring diagram (EXC-F EU, EXCF SIX DAYS) 24. 1 106 H18 H2 H4 bu br H15 P1 H7 H11 bl pu CX/2 CW/2 CZ/3 CY/3 DB/4 DA/4 S2 AK1/2 CW3/2 CX3/2 DG/4 BP/4 CW2/2 CX2/2 AH1/2 1 3 2 1 2 3 1 2 4 v B3 br-bl bu re br br ye-re wh S5 bl bl 1 2 1 2 1 pu 2 br bl-wh br bu-wh L2 1 2 BU/18 1 gn EH/1 bu-wh br gr ye-bl re-wh 3 wh 2. 1 4 br EI/1 2 ye bl br wh-gn bu 3 wh bu gn ye re br ye-bl gr ye-bl 1 BF1/1 BA1/1 BC/6 AC/6 S6 64 5 1 2 S7 re ye-re BA/1 BF/1 K2 ye-bl ye-re br ye-re BO/2 BV/2 H13 ye-re or 2 1 2 AH2/2 G br 1 CD I A6 AM/3 AR/3 4 5 7 6 11 10 12 13 14 3 2 1 S8 3 re-bl gn re bu ye bl M H14 br bl or pu bl ye-bl BT/3 BG/3 br t br bl S10 2 1 BA2/1 E6 5A bl ye bu ye-re br bl br ye-re BR/4 BK/4 1 2 wh-re B1 br 3 bl 2 1 re gn br L1 M1 4 AL/2 AT/2 3 G G2 CX1/2 CW1/2 re-bl re-wh ye K1 wh bl ye 1 3 wh-gn BG1/3 2 1 AT1/2 CR/1 CR1/1 AL1/2 M 43 AJ1/3 pu 2 bl AF/4 br 12 AH/2 AK/2 wh-re ye-re S1 10 A 2 G1 br ye-re 1 ye wh 2 4 3 bl br pu 1 br CA/4 br 1 2 wh-gn wh CE/4 2 3 2. 2 2. 1 wh br 2 DI/2 BV/2 BS/2 CX/2 2 1 AJ/3 BG/3 CW/2 1 H5 U H9 H3 H1 N2 600699-01 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H1 H2 H3 H4 H5 H7 H9 H11 H13 H14 H15 H18 K1 K2 L1 L2 M1 N2 P1 S1 S2 S5 S6 S7 S8 S10 Cable colors bl bl-wh br br-bl bu bu-wh gn gr or pu re re-bl re-wh wh wh-gn wh-re ye ye-bl Black Black-white Brown Brown-black Blue Blue-white Green Gray Orange Violet Red Red-black Red-white White White-green White-red Yellow Yellow-black CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC-F SIX DAYS) Battery Generator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC-F SIX DAYS) Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Rear brake light switch Front brake light switch Tripmaster switch (optional) Light switch Horn button, short circuit button Turn signal switch Electric starter button 107 WIRING DIAGRAM ye-re Yellow-red 108 WIRING DIAGRAM 109 WIRING DIAGRAM Wiring diagram (EXCF AUS) 24. 2 110 H18 P1 CE/4 CE/4 H15 bu br CE/4 CE/4 bl pu CX/2 CW/2 CZ/3 CY/3 DB/4 DA/4 1 1 3 3 2 2 2 1 4 CE/4 v bu re br-bl br br ye-re wh AK1/2 CW3/2 CX3/2 DG/4 BP/4 CW2/2 CX2/2 AH1/2 B3 S5 bl bl 2 1 1 2 2 br br bu-wh S1 1 pu 1 gn 3 wh 2 ye wh-gn br bl bu S6 4 br 3 wh bu gn ye re br ye-bl BC/6 AC/6 64 5 12 BA1/1 BF1/1 S7 ye-bl BA/1 BF/1 re H13 ye-re ye-bl ye-re br ye-re br K2 bu-wh br ye-bl re-wh ye-re or 1 2 5 7 6 11 10 12 13 14 BO/2 2 2 BV/2 AH2/2 BU/18 G 1 1 3 S8 re-bl gn re bu ye or pu bl BT/3 BG/3 2 1 S10 bl ye-re BR/4 BK/4 1 S1 wh-re bl br 2 3 2 1 AR/3 AM/3 3 ye bu bl ye-bl 4 BA/1 BF/1 1 S1 S11 br S1 M1 2 1 re ye-re gn br AL/2 AT/2 21 M BS/2 K1 bl 43 AF/4 3 CR/1 AL1/2 2 1 re-bl re-wh AT1/2 wh-re ye-re 10 A 2 G S1 CX1/2 CW1/2 ye G1 wh CR1/1 BG1/3 AJ1/3 pu 2 bl 3 ye wh-gn br 1 br 12 AK/2 S1 AH/2 br ye-re ye CA/4 CE/4 wh 2 1 4 3 bl pu 1 br br 1 2 wh wh-gn 2 3 CX/2 2 AJ/3 BG/3 1 CW/2 2. 2 2. 1 wh br 2 DI/2 BV/2 BS/2 U N2 1 H9 H5 H3 H1 600878-01 WIRING DIAGRAM Components A6 B1 B3 G1 G2 H1 H2 H3 H4 H5 H7 H9 H11 H13 H15 H18 K1 K2 L1 L2 M1 N2 P1 S1 S2 S5 S6 S7 S8 S10 S11 Cable colors bl br br-bl bu bu-wh gn or pu re re-bl re-wh wh wh-gn wh-re ye ye-bl ye-re Black Brown Brown-black Blue Blue-white Green Orange Violet Red Red-black Red-white White White-green White-red Yellow Yellow-black Yellow-red CDI controller Throttle position sensor Wheel speed sensor Battery Generator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Rear brake light switch Front brake light switch Tripmaster switch (optional) Light switch Horn button, short circuit button Turn signal switch Electric starter button Emergency OFF switch 111 WIRING DIAGRAM Wiring diagram (XCF-W) 24. 3 112 P1 H7 H11 v re bu wh br B3 bl bl br ye-re wh br wh S5 S12 br ye-bl S6 wh bl-wh L2 S10 ye bu-wh br ye-bl re-wh re-bl gn re bu ye bl ye-re wh-re black ye-bl CD I A6 B1 L1 br H14 br bl E6 M br t bl 5A ye bu ye-re br bl br bl br M1 re M gn K1 re-bl re-wh ye br wh-re 3 G G2 10 A ye-re G1 wh br ye-re ye wh br wh U N2 H5 600700-01 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H5 H7 H11 H14 K1 L1 L2 M1 N2 P1 S5 S6 S10 S12 Cable colors bl bl-wh br bu bu-wh gn re re-bl re-wh wh wh-re ye ye-bl ye-re Black Black-white Brown Blue Blue-white Green Red Red-black Red-white White White-red Yellow Yellow-black Yellow-red CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XCF-W ZA) Battery Generator Brake/tail light (XCF-W ZA) Parking light (XCF-W ZA) Low beam (XCF-W ZA) Radiator fan (XCF-W ZA) Starter relay with main fuse Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Tripmaster switch (optional) Light switch Electric starter button Short circuit button 113 114 G 3 S12 G2 bl ye-bl re-wh re-bl gn re br bu-wh 12576 11 10 12 13 14 CD I A6 3 AM/3 AR/3 2 1 WIRING DIAGRAM B1 L1 L2 Wiring diagram (SXF) 24. 4 600701-01 WIRING DIAGRAM Components A6 B1 G2 L1 L2 S12 Cable colors bl br bu-wh gn re re-bl re-wh ye-bl Black Brown Blue-white Green Red Red-black Red-white Yellow-black CDI controller Throttle position sensor Generator Pulse generator Ignition coil Short circuit button 115 SUBSTANCES Brake fluid DOT 4 / DOT 5. 1 according to ­ DOT 116 Guideline ­ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. Supplier Castrol ­ RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® ­ Brake Fluid DOT 5. 1 Coolant Guideline ­ Use only suitable coolant (also in countries with high temperatures). [. . . ]