KTM 250 SX-F 2005 Operating instructions

250 SX-F, EXC-F, EXC-F SIX DAYS SIX DAYS
XCF-W, XC-F, SXS-F
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.052-E
REPAIRMANUAL2005-2008

REPAIRMANUAL2005-2008 250 SX-F, EXC-F, EXC-F Six Days, XCF-W, XC-F, SXS-F
KTM Group Partner

1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING ENGINE
7 ELECTRICAL
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 TECHNICAL SPECIFICATIONS
11 PERIODIC MAINTENANCE SCHEDULE
12 WIRING DIAGRAMS
13
14
15
16

IMPORTANT INFORMATION/UPDATING INSTRUCTIONS
To be able to continue using the existing loose-leaf repair instructions, simply print the
following pages and insert them in the existing repair instructions:
1,3,7,9,20,21,40,55,68,69,74,75,80,81,87-94,111-114-151
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of
the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page at the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in
the right bottom corner of each page.
Example: page no. 3-5 3 = chapter 3 5 = page 5
For example: All pages with a page number that begins with the digit 3, must be put under the index heading “Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can
be entered in the list of contents.
Remove page (s)) Replace by page (s) Insert page (s) after page
2-5 to 2-6 2-5 to 2-6
4-7 4-7
5-8 5-8
5-21 to 5-22 5-21 to 5-22
6-3 to 6-4 6-3 to 6-4
6-9 to 6-10 6-9 to 6-10
7-1 to 7-5 7-1 to 7-7
9-1 to 9-3 9-1 to 9-3
10-1 to 10-6 10-1 to 10-12
11-1 to 11-3 11-1 to 11-11
12-1 to 12-3 12-1 to 12-10

EXPLANATION - UPDATING
Edition: 10/2007
3.206.027-E Repair Manual 250 SX-F 5/2005
Basic version Model year 2005/06
(Engine number with first digit "5" and "6")
3.206.052-E Updating of Rep.Manual 3.206.027-E 10/2007
Model year 2007/08
(Engine number with first digit "7" and "8")
Modification / Updating:
Technical Details Models EXC, XC-W, XC, 2007/08, Technical Specifications,
Tightening torques, Periodic Maintenance Schedule

INTRODUCTION
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes
the latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety
rules common in the work shop have also not been listed. We take it for granted that the repairs
are made by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.

WARNING

STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES
UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work
is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality
assurance processes that lead to the highest possible product quality.
KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications,
colors, materials, services offered and rendered, and the like so as to adapt them to local
conditions without previous announcement and without giving reasons, or to cancel any of the
above items without substituting them with others. It shall be acceptable to stop manufacturing a
certain model without previous announcement. In the event of such modifications, please ask your
local KTM dealer for information.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

REPLY FAX FOR REPAIR MANUALS
Item no. of repair manual Page Current text Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman Company/work shop
We have made every effort to make our repair manuals as accurate as possible but it is always possible
for a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us
as follows:
If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed
form to us at 0043/7742/6000/5349.
NOTE to table:
– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.052-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
– Enter the corresponding page number in the repair manual (e.g.: 5-7) in column 2.
– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write
your text in German or English if possible.
– Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.

GENERAL INFORMATION
Repair manual KTM 250 -F Art.-No. 3.206.052-E
2-1
2
BLEEDING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
CHANGING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
ADJUSTING THE THROTTLE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
SPECIAL TOOLS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
INDEX

Bleeding the cooling system
The cooling liquid can be drained by removing the screw 1on the
water pump cover.
To bleed the cooling system add approx. 1 liter of cooling liquid and
remove the bleeder screw 2. Do not replace the bleeder screw until
cooling liquid starts to leak out of the hole without bubbles. Now add
cooling liquid until it reaches a level of approx. 10 mm above the
radiator fins. Take a short ride and check the cooling liquid level again.
Changing the oil filter
– Place a vessel under the engine to catch the used oil. Remove the 2
screws 3and take off the oil filter cover.
– Use circlip pliers to pull the oil filter insert 4out of the case.
– Clean the oil filter cover, the sealing area on the O-ring and the
engine case. Check the O-ring in the oil filter cover for damage and
replace if necessary.
– Lay the motorcycle down and fill the oil filter case about half full
with engine oil. Fill the oil filter up with oil and insert the oil filter in
the case.
– Grease the O-ring in the oil filter cover and mount the cover 5.
Mount the screws and tighten to 6 Nm.
– Put the motorcycle in an upright position again.
– Remove the screw cap 6from the clutch cover and add 1.1 liters of
fully synthetic engine oil (Motorex Power Synt 4T 10W/50).
– Start the engine and check all screw connections and the oil filter
cover for leaks.
– Finally, check the engine oil level and correct if necessary.
Repair manual KTM 250 -F Art.-No. 3.206.052-E
2-2
1
2
3
3
4
5
6

2-3
Oil circuit
Oil circuit
The oil pump 1draws the engine oil from the transmission oil sump through the long oil screen 2and conveys it to the oil filter
3, where any contamination is filtered out. The cleansed engine oil is pumped past the bypass valve 4through the hole in the
crankshaft 5to the conrod bearing 6and sprayed onto the piston 8from below through a jet 7.
Two other oil ducts lead into the cylinder head. One duct supplies the hydraulic chain tensioner 9, the other duct leads to the
camshaft bearing bridge bk, where the camshaft bearings and the cam lever are supplied with oil (via spraying nozzles).
The second oil pump bl draws the engine oil out of the crankcase through the short oil screen bm and uses it to grease the
transmission gears bn.
13
4
5
6
7
8
9
bk
bl
bm
bn
2

2-4
Repair manual KTM 250 -F Art.-No. 3.206.052-E
Checking the oil level of the hydraulic clutch
To check the oil level in the master cylinder of the clutch remove the
cover. For this purpose, remove bolts 1and cover together with the
rubber boot 2. The oil level in the horizontal-standing master cylinder
should be 4 mm (0,157 in) below the upper edge. If necessary add
SAE 10 biodegradable hydraulic oil (Motorex Kupplungs-Fluid 75).
! CAUTION !
ONLY USE SAE 10 BIODEGRADABLE HYDRAULIC OIL (MOTOREX KUPPLUNGS-
FLUID 75) TO REFILL THE MASTER CYLINDER. NEVER USE BRAKE FLUID!
Bleeding of the hydraulic clutch
– For bleeding, the cover of the master cylinder of the clutch needs to
be removed. For this purpose, remove screws 1and take off cover
together with rubber bellows 2.
– At the slave cylinder of the clutch, remove the bleeder nipple. At its
place, mount the bleeder syringe 3which is filled with
biodegradable hydraulic oil (Motorex Kupplungs-Fluid 75).
– Refill oil, until oil is discharged from the bore Aof the master
cylinder in a bubble-free state. Make sure that the oil does not
overflow.
! CAUTION !
HAVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL
LEVEL IN THE MASTER CYLINDER IS CORRECT. FOR FILLING OF THE MASTER
CYLINDER, USE SAE 10 BIODEGRADABLE HYDRAULIC OIL (MOTOREX KUPPLUNGS-
FLUID 75) ONLY. NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC
OILS WITH MINERAL OILS.
Adjusting the throttle cables
The throttle grip should always provide for a backlash of 3-5 mm.
Besides, with the engine running, the idling speed must not change if
you turn the handlebar all the way to the left or right.
To adjust the throttle cables, dismount the seat and the tank together
with spoilers. Slide back the protection cover 4. Loosen the counter
nut 5and turn the adjusting screw 6accordingly. Turning the
adjusting screw counterclockwise will reduce the backlash, turning the
adjusting screw clockwise will increase the backlash.
Tighten the counter nut and check whether the throttle grip can be
actuated smoothly. Mount tank and seat.
– After a short, careful test ride, check engine oil and coolant level
once more.
1
2
3
A
4
56

2-5
SPECIAL TOOLS – ENGINE 250 -F
4
2
bk
bl
bm
bn bo
bp bq br bs
1
3
5
6
7
89
25
20
30
15
10
12
5
35
bt ck cl