KTM 250 SX-F EU Manual

SETUP INSTRUCTIONS 2010
250 SX-F EU
250 SX-F USA
Art. no. 3211544en

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.
© 2009 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.
Identifies an expected reaction (e.g. of a work step or a function).
Identifies 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 below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand available on the open market.

SET‑UP 3
2.1Unpacking and setting up the vehicle
600821-10
–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
plastic 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)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a work stand.
–Check the vehicle for transport damage.
600824-10
–Mount the handlebar.
The scale on the handlebar should be in the center of the handlebar clamp.
–Position the handlebar clamp. Mount and evenly tighten the four screws.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
600822-10
–Position the controls on the right half of the handlebar.
Info
The routing of the cables and throttle cables can be seen in the figure.
600823-10
–Position the controls 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. 6)
–Correctly mount the fuel tank breather.
–Install the start number plate. ( p. 6)
–Install the front wheel. ( p. 5)

SET‑UP 4
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
600808-10
–Mount the frame protector.
Info
Read the accompanying KTM PowerParts installation instructions.
(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.
–Refuel. ( p. 6)
–Position all controls exactly on the handlebar. Tighten all screws.
–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 efficiency 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 spacers.
Long-life grease ( p. 10)
–Insert the spacers.
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 linings 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 spacers 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
Make sure the holding lugs engage in the start number plate or headlight
mask.
3.5Installing the start number plate
500101-11
–Position the start number plate. Mount and tighten screw with the spacer.
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 wiring harness. Put the clamp on, mount and tighten
screw .
3.6Opening filler cap
400199-10
–Press release button , turn filler cap counterclockwise and lift it upwards and
remove.
3.7Closing filler cap
400199-11
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Route the fuel tank breather hose without kinking.
3.8Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel 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 the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with 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.

WORK 7
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.
–Switch off engine.
–Open the filler cap. ( p. 6)
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.
8.0 l
(2.11 US gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 9)
–Close the filler cap. ( p. 6)

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 8
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 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 M8 12 Nm (8.9 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 M8 20 Nm (14.8 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 M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine attachment bolt 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 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 9
Super unleaded (ROZ 95 / RON 95 / PON 91)
According to
–DIN EN 228 (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 10
Long-life grease
Guideline
–KTM recommends Motorex®products.
Supplier
Motorex®
–Fett 2000

*3211544en*
3211544en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
06/2009
Photo: Mitterbauer