KTM 250 EXC-F EU 2009 Manual

SETUP INSTRUCTIONS 2009
250 EXC‑F EU
250 EXC‑F SIX DAYS EU
250 XCF‑W USA
250 XC‑F USA
ART. NO. 3211404en

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
600809-10
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during assembly, leave the protective film
on the vehicle until you have finished.
–Check the vehicle for transport damage.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
800034-10
–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.
600824-10
–Position 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
(250 EXC‑F EU, 250 XCF‑W USA,
250 XC‑F USA)
M8 20 Nm
(14.8 lbf ft)
Screw, handlebar clamp
(250 EXC‑F SIX DAYS EU)
M8 16 Nm
(11.8 lbf ft)
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
–Remove the protective plastic.
–Carefully loosen and remove the tensioning belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Set up the work stand.
Work stand (54829055000)
–Together with an assistant, take the vehicle off the palette.
–Install the front wheel. ( p. 5)

SET‑UP 4
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.
–Recharge the battery. ( p. 6)
–Install the battery. ( p. 7)
–Install the front fender. ( p. 6)
(250 EXC‑F SIX DAYS EU)
–Mount the engine guard.
Info
Read the accompanying KTM PowerParts installation instructions.
–Mount the front axle pull.
–Mount the brake lining support bolt.
–Mount the fork bleeding set.
–Mount the handlebar cushion.
600808-10
–Mount the frame protector.
Info
Read the accompanying KTM PowerParts installation instructions.
600810-10
(EXC-F EU, EXC‑F SIX DAYS)
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
–Mount the reflector.
(EXC‑F SIX DAYS, XCF‑W USA, XC‑F)
–Mount the hand guard.
Info
Read the accompanying KTM PowerParts installation instructions.
–Position all operating elements exactly on the handlebar. Tighten all screws.
–Fill up with fuel. ( p. 7)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 5
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. 11)
–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 6
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.
3.5Recharging the battery
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 contact a physician.
Warning
Environmental hazard Components and battery acid are a danger to the environment.
–Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Environmental hazard Problem materials cause environmental damage.
–Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations.
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 5)
–Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.
400240-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid .
Charge the battery with at most 10% of the capacity specified on the bat-
tery .

WORK 7
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use.
3 months
–Mount the seat. ( p. 5)
3.6Installing the battery
500069-11
–Place the battery in the battery holder.
4Ah battery (YTX5L-BS)
–Reconnect the rubber band .
–Attach the plus cable and replace the plus pole cover .
–Attach the minus cable .
–Mount the seat. ( p. 5)
3.7Opening filler cap
400199-10
–Press release button , turn filler cap counterclockwise and lift it free.
3.8Closing filler cap
400199-11
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Run the fuel tank breather hose without kinks.
3.9Refueling
Danger
Fire hazard Fuel can easily catch fire.
–Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoning 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 imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.

WORK 8
–Switch off the engine.
–Open the filler cap. ( p. 7)
AA
400382-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Total fuel tank
capacity, approx.
9.2 l
(2.43 US gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 10)
–Close the filler cap. ( p. 7)

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 9
Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) –
Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot-
brake cylinder
M6 10 Nm (7.4 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) –
Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®243™
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp
(EXC‑F SIX DAYS, XCF‑W USA, XC‑F)
M8 12 Nm (8.9 lbf ft) –
Screw, bottom triple clamp
(250 EXC‑F EU)
M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp
(250 EXC‑F EU, 250 XCF‑W USA,
250 XC‑F USA)
M8 20 Nm (14.8 lbf ft) –
Screw, handlebar clamp
(250 EXC‑F SIX DAYS EU)
M8 16 Nm (11.8 lbf ft) –
Screw, side stand fixing M8 40 Nm (29.5 lbf ft) Loctite®243™
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®243™
Screw, top steering stem
(EXC‑F SIX DAYS, XCF‑W USA, XC‑F)
M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top steering stem
(250 EXC‑F EU)
M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp
(EXC‑F SIX DAYS, XCF‑W USA, XC‑F)
M8 17 Nm (12.5 lbf ft) –
Screw, top triple clamp
(250 EXC‑F EU)
M8 20 Nm (14.8 lbf ft) –
Engine carrying screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite®243™
Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite®243™
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, bottom steering head
(250 XCF‑W USA, 250 XC‑F USA)
M20x1.5 60 Nm (44.3 lbf ft) Loctite®243™
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

SUBSTANCES 10
Super unleaded (ROZ 95 / RON 95 / PON 91)
According to
–DIN EN 228 (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 11
Long-life grease
Specification
–KTM recommends Motorex®products.
Supplier
Motorex®
–Fett 2000

*3211404en*
3211404en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
09/2008 Photo: Mitterbauer