KTM 250 EXC-F AUS 2009 Manual

SETUP INSTRUCTIONS 2009
250 EXC‑F AUS
250 XCF‑W ZA
250 SX‑F EU
ART. NO. 3211405en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, 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 misprints and other errors. The models portrayed partly contain spe-
cial 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)
According to 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

MEANS OF REPRESENTATION 2
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).
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.
Name Indicates a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

SET‑UP 3
2.1Unpacking and setting up the vehicle
600811-10
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during assembly, leave the protective film
on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery is
complete on the basis of the enclosed packing list.
–Set up the work stand.
Work stand (54829055000)
600812-10
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a work stand.
–Check the vehicle for transport damage.
600813-10
–Install the shock absorber. ( p. 8)
600814-10
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp
(250 EXC‑F AUS, 250 XCF‑W ZA)
M8 20 Nm
(14.8 lbf ft)
Screw, top triple clamp (250 SX‑F EU) M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp
(250 EXC‑F AUS, 250 XCF‑W ZA)
M8 15 Nm
(11.1 lbf ft)
Screw, bottom triple clamp
(250 SX‑F EU)
M8 12 Nm (8.9 lbf ft)
Info
The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the front.

SET‑UP 4
600824-10
–Mount the handlebar.
The scale on the handlebar should be in the center of the handlebar clamp.
–Position the handlebar clamps. Mount and evenly tighten the four screws.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
600816-10
–Position the operating elements on the right half of the handlebar.
Info
The routing of cables and Bowden cables can be seen in the figure.
600817-10
–Position the operating elements on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
–Install the front fender. ( p. 8)
600818-10
(250 EXC‑F AUS)
–Attach the retaining bracket for the connector, the flasher bracket with the
flasher and the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Connect the connector.
600819-10
(250 XCF‑W ZA)
–Attach the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Connect the connector.
–Correctly mount the fuel tank breather.
(250 SX‑F EU)
–Install the start number plate. ( p. 8)
(250 EXC‑F AUS, 250 XCF‑W ZA)
–Refit the headlight mask with the headlight. ( p. 8)

SET‑UP 5
–Install the front wheel. ( p. 7)
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
800035-10
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 con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
(250 EXC‑F AUS, 250 XCF‑W ZA)
–Recharge the battery. ( p. 9)
(250 EXC‑F AUS, 250 XCF‑W ZA)
–Install the battery. ( p. 10)
600808-10
–Mount the frame protector.
Info
Read the accompanying KTM PowerParts installation instructions.
600810-10
(250 EXC‑F AUS)
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
–Mount the reflector.
(250 EXC‑F AUS, 250 SX‑F EU)
–Mount the engine guard.
Info
Read the accompanying KTM PowerParts installation instructions.
–Mount the hand guard.
Info
Read the accompanying KTM PowerParts installation instructions.

SET‑UP 6
400572-01
(250 SX‑F EU)
–Apply the label.
–Position all operating elements exactly on the handlebar. Tighten all screws.
–Fill up with fuel. ( p. 10)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 7
3.1Removing the seat
500080-10
–Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
3.2Mounting the seat
600674-01
–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 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)
3.3Installing the front wheel
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. 14)
–Insert the spacing sleeves.
500084-11
–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)
–Operate the hand brake lever several times until the brake pads are lying correctly
on the brake disc.
–Remove the motorcycle from the work stand.
–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)

WORK 8
3.4Installing the front fender
600692-10
–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.
3.5Refitting the headlight mask with the headlight (250 EXC‑F AUS, 250 XCF‑W ZA)
600702-11
–Connect the electric plug connector .
600703-11
–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.
3.6Installing the start number plate (250 SX‑F EU)
500101-11
–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.
–Position the brake line and cable harness. Put the clamp on, mount and tighten
screw .
3.7Installing the shock absorber
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
(59 lbf ft)
Loctite®243™