KTM 250 SX-F EU 2012 User manual

OWNER'S MANUAL 2012
250 SX‑F EU
250 SX‑F ROCZEN REPLICA EU
250 SX‑F USA
250 XC-F USA
Art. no. 3211813en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
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 in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 9) Dealer's stamp
Engine number ( p. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can, however, not be completely excluded.
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.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, 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

TABLE OF CONTENTS 2
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT INFORMATION ................................................ 5
VIEW OF VEHICLE............................................................... 7
View of vehicle, front left (example)................................... 7
View of vehicle, rear right (example) .................................. 8
SERIAL NUMBERS.............................................................. 9
Chassis number............................................................... 9
Type label....................................................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
CONTROLS....................................................................... 10
Clutch lever .................................................................. 10
Hand brake lever ........................................................... 10
Throttle grip.................................................................. 10
Kill switch .................................................................... 10
Electric starter button .................................................... 10
Overview of indicator lamps............................................ 11
Opening the filler cap .................................................... 11
Closing the filler cap...................................................... 11
Factory Start (SX‑F ROCZEN REPLICA) ........................... 12
Idle speed adjusting screw ............................................. 12
Shift lever..................................................................... 12
Kick starter (XC‑F) ......................................................... 13
Foot brake lever............................................................. 13
Plug-in stand (All SX‑F models) ...................................... 13
Side stand (XC‑F) .......................................................... 13
Service hour counter (SX‑F ROCZEN REPLICA) ................ 14
PREPARING FOR USE....................................................... 15
Advice on first use......................................................... 15
Running in the engine.................................................... 16
Preparing the vehicle for difficult riding conditions ........... 16
Preparing for rides on dry sand ....................................... 17
Preparing for rides on wet sand....................................... 17
Preparing for rides on wet and muddy surfaces................. 18
Preparing for rides at high temperatures and low speeds ... 18
Preparing for rides at low temperatures or in snow ............ 18
RIDING INSTRUCTIONS .................................................... 19
Checks and maintenance before putting into operation...... 19
Starting ........................................................................ 19
Starting off ................................................................... 20
Shifting, riding.............................................................. 20
Applying the brakes ....................................................... 20
Stopping, parking .......................................................... 20
Refueling...................................................................... 21
SERVICE SCHEDULE......................................................... 22
Service schedule ........................................................... 22
Service work (as additional order).................................... 23
TUNING THE CHASSIS...................................................... 24
Checking the basic chassis setting with the rider's
weight .......................................................................... 24
Compression damping of the shock absorber .................... 24
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 24
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 25
Adjusting the rebound damping of the shock absorber....... 26
Measuring rear wheel sag unloaded ................................. 26
Checking the static sag of the shock absorber .................. 27
Checking the riding sag of the shock absorber .................. 27
Adjusting the spring preload of the shock absorber x...... 27
Adjusting the riding sag x............................................. 28
Checking the basic setting of the fork.............................. 29
Adjusting the compression damping of the fork ................ 29
Adjusting the rebound damping of the fork....................... 30
Handlebar position ........................................................ 30
Adjusting the handlebar position x................................ 30
Activating the Factory Start (SX‑F ROCZEN REPLICA)....... 31
SERVICE WORK ON THE CHASSIS..................................... 32
Raising the motorcycle with the lift stand ........................ 32
Removing the motorcycle from the lift stand .................... 32
Bleeding the fork legs .................................................... 32
Cleaning the dust boots of the fork legs ........................... 33
Loosening the fork protection.......................................... 33
Positioning the fork protection ........................................ 33
Removing the fork legs x.............................................. 34
Installing the fork legs x............................................... 34
Removing the fork protector x....................................... 35
Installing the fork protector x....................................... 35
Removing the lower triple clamp x................................ 35
Installing the lower triple clamp x................................. 36
Checking the steering head bearing play .......................... 37
Adjusting the play of the steering head bearing x............ 38
Greasing the steering head bearing x............................. 38
Removing the start number plate .................................... 39
Installing the start number plate ..................................... 39
Removing the front fender.............................................. 39
Installing the front fender............................................... 39
Removing the shock absorber x..................................... 39
Installing the shock absorber x..................................... 40
Removing the seat......................................................... 41
Mounting the seat ......................................................... 41
Removing the air filter box lid......................................... 41
Installing the air filter box lid.......................................... 41
Removing the air filter x............................................... 42
Installing the air filter x............................................... 42
Cleaning the air filter and air filter box x........................ 42
Removing the main silencer............................................ 43
Installing the main silencer ............................................ 43
Changing the glass fiber yarn filling of the main
silencer x................................................................... 43
Removing the fuel tank x............................................. 44
Installing the fuel tank x.............................................. 45
Checking for chain dirt accumulation .............................. 46
Cleaning the chain......................................................... 47
Checking the chain tension ............................................ 47
Adjusting the chain tension ............................................ 48
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 48
Adjusting the chain guide x.......................................... 50
Checking the frame x................................................... 50
Checking the swingarm x............................................. 51
Checking the throttle cable routing.................................. 51
Checking the rubber grip................................................ 51
Additionally securing the rubber grip ............................... 51
Adjusting the basic position of the clutch lever................. 52
Checking the fluid level of the hydraulic clutch ................ 52
Changing the hydraulic clutch fluid x............................ 52
Removing the engine guard (SX‑F ROCZEN REPLICA)....... 53
Installing the engine guard (SX‑F ROCZEN REPLICA) ....... 53
BRAKES........................................................................... 54
Checking the free travel of the hand brake lever ............... 54
Adjusting the basic position of the hand brake lever.......... 54

TABLE OF CONTENTS 3
Checking the brake discs................................................ 54
Checking the front brake fluid level ................................. 55
Adding front brake fluid x............................................ 55
Checking the front brake linings...................................... 56
Changing the front brake linings x................................. 56
Checking the free travel of foot brake lever....................... 58
Adjusting the basic position of the foot brake lever x...... 58
Checking the rear brake fluid level .................................. 59
Adding rear brake fluid x.............................................. 59
Checking the rear brake linings....................................... 60
Changing the rear brake linings x.................................. 60
WHEELS, TIRES ............................................................... 62
Removing the front wheel x.......................................... 62
Installing the front wheel x........................................... 62
Removing the rear wheel x........................................... 63
Installing the rear wheel x............................................ 64
Checking the tire condition............................................. 64
Checking the tire air pressure ......................................... 65
Checking the spoke tension ............................................ 65
ELECTRICAL SYSTEM ....................................................... 67
Removing the battery x................................................ 67
Installing the battery x................................................. 67
Recharging the battery x.............................................. 68
Changing the main fuse ................................................. 69
COOLING SYSTEM ............................................................ 70
Cooling system .............................................................. 70
Checking the antifreeze and coolant level ........................ 70
Checking the coolant level.............................................. 70
Draining the coolant x.................................................. 71
Refilling coolant x....................................................... 71
TUNING THE ENGINE ....................................................... 73
Checking the play in the throttle cable............................. 73
Adjusting the play in the throttle cable x....................... 73
Adjusting the idle speed x............................................ 73
Checking the basic position of the shift lever.................... 74
Adjusting the basic position of the shift lever x.............. 74
SERVICE WORK ON THE ENGINE ...................................... 75
Changing the fuel screen x........................................... 75
Checking the engine oil level .......................................... 76
Changing the engine oil and oil filter, cleaning the oil
screen x..................................................................... 76
Adding engine oil .......................................................... 78
CLEANING, CARE ............................................................. 80
Cleaning the motorcycle................................................. 80
STORAGE ......................................................................... 81
Storage......................................................................... 81
Putting into operation after storage ................................. 81
TROUBLESHOOTING......................................................... 82
BLINK CODE .................................................................... 84
TECHNICAL DATA - ENGINE.............................................. 85
Capacity - engine oil ...................................................... 86
Capacity - coolant.......................................................... 86
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 87
TECHNICAL DATA - CHASSIS ............................................ 89
Lighting equipment ....................................................... 89
Tires ............................................................................ 90
Capacity - fuel............................................................... 90
TECHNICAL DATA - FORK.................................................. 91
All SX‑F EU models ....................................................... 91
SX‑F USA ..................................................................... 91
XC‑F............................................................................. 92
TECHNICAL DATA - SHOCK ABSORBER ............................. 93
All SX‑F EU models ....................................................... 93
SX‑F USA ..................................................................... 93
XC‑F............................................................................. 94
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 95
SUBSTANCES................................................................... 96
AUXILIARY SUBSTANCES.................................................. 98
STANDARDS................................................................... 100
INDEX ............................................................................ 101

MEANS OF REPRESENTATION 4
Symbols used
The meaning of specific symbols is described below.
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).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop! There, your motorcycle will be ser-
viced optimally by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand available on the open market.

IMPORTANT INFORMATION 5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and
chassis is properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and chassis can lead to
damage and breakage of components.
Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components
such as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise
you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are required for some work. These are not part of the vehicle standard equipment, but they can be ordered with the item
number stated in parentheses. Ex.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash-
ers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the operating safety of the vehicle.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
–Switch off the engine.
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT INFORMATION 6
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-
mation and many tips on how to operate and handle your motorcycle. Only then will you learn how to best customize the motorcy-
cle for your own use and to protect yourself from injury. The owner's manual also contains important information on servicing the
motorcycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.

VIEW OF VEHICLE 7
3.1View of vehicle, front left (example)
101282-10
1 Hand brake lever ( p. 10)
2 Clutch lever ( p. 10)
3 Filler cap
4 Fork rebound adjustment
5 Idle speed adjusting screw ( p. 12)
6 Shift lever ( p. 12)
7 Air filter box lid
8 Plug-in stand ( p. 13)

VIEW OF VEHICLE 8
3.2View of vehicle, rear right (example)
101283-10
1 Kill switch ( p. 10)
2 Electric starter button ( p. 10)
3 Throttle grip ( p. 10)
4 Fork compression adjustment
5 Level viewer for brake fluid, rear
6 Shock absorber rebound adjustment
7 Shock absorber compression adjustment
8 Level viewer, engine oil
9 Foot brake lever ( p. 13)