KTM 250 SX-F US 2015 User manual

SETUP INSTRUCTIONS 2015
250 SX‑F EU
250 SX‑F US
250 XC‑F US
Art. no. 3213193en

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, misprints, and other errors. The models portrayed partly contain special equip-
ment that does not belong to the regular scope of supply.
© 2014 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

1 MEANS OF REPRESENTATION 2
1.1 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).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
M00075-10
Packaging 2
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of supply
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Carefully loosen and remove the tension belt of the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
402050-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
M00075-11
Package 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of supply
is complete on the basis of the enclosed packing list.
402051-01
–Have a lift stand available.
Lift stand (54829055000)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
M00077-10
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten screw cap .
Guideline
Nut, frame to linkage lever M14x1.5 80 Nm (59 lbf ft)
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M10 60 Nm
(44.3 lbf ft)
Loctite®2701™

2 SETUP 4
B00534-10
–Position FI warning lamp with holder . Mount and tighten screw.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Attach connector to the wiring harness.
–Mount cable holder to the frame.
B00535-10
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm
(8.9 lbf ft)
Info
Grooves are milled into the side of the top end of the fork legs. The sec-
ond milled groove (from the top) in the fork leg must be flush with the
upper edge of the upper triple clamp.
Position bleeder screws toward the front.
B00375-11
–Remove screws . Take off the handlebar clamps.
–Remove screws . Remove the handlebar holders.
–Place the handlebar holders in the required position. Mount and tighten
screws .
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar holders evenly.
101020-10
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
101017-01
–Position the controls on the right half of the handlebar.
Info
The routing of the cables is shown in the figure.

2 SETUP 5
101018-01
–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. 7)
–Install the front wheel. ( p. 6)
–Correctly mount the fuel tank breather.
C00138-01
–Mount the handlebar cushion.
–Install the start number plate. ( p. 7)
101019-01
–Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers 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 sparks and open flames away from the battery. Only charge 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. 9)
–Install the battery. ( p. 8)
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
–Apply the label included in the delivery (optional).
–Refuel. ( p. 11)
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

3 WORK 6
3.1 Raising the motorcycle with the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
401942-01
–Raise the motorcycle at the frame underneath the engine.
The wheels must no longer touch the ground.
–Secure the motorcycle against falling over.
Lift stand (54829055000)
3.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
0
0
11
402001-10
(All SX‑F models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand into the left side of the wheel
spindle.
Info
Remove the plug-in stand before starting on a trip.
401943-10
(XC‑F US)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand to the ground with your foot and
lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with
the rubber band.
3.3 Installing 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.
M00064-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing.
–Clean and grease the shaft seal rings and contact surface of the spacers.
Long-life grease ( p. 14)
–Insert the spacers.
–Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.

3 WORK 7
M00024-11
–Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
–Activate the hand brake lever multiple times until the brake linings are in contact
with the brake disc.
–Remove the motorcycle from the lift stand. ( p. 6)
–Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
3.4 Installing the front fender
B01470-10
Main work
–Position the front fender. Mount and tighten screws and .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Finishing work
–Install the start number plate. ( p. 7)
3.5 Installing the start number plate
C00418-10
–Position the start number plate. Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
The holding lugs engage.
–Position the brake line and clamp. Mount and tighten screw .

3 WORK 8
3.6 Removing the seat
M00035-10
–Remove screw .
–Lift up the seat at the rear, pull it back and then remove it from above.
3.7 Mounting the seat
M00036-01
–Hook in the front of the seat at the collar bushing 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 fixation.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.8 Installing the battery
C00452-10
Main work
–Insert the battery into the battery compartment with the terminals facing to the
front.
(All SX‑F models)
Battery (YTX4L-BS)
(XC‑F US)
Battery (YTX5L-BS)
–Reconnect rubber band .
Info
Contact disk must be mounted between screw and cable socket 
with the claws facing down.
–Position the positive cable and mount and tighten the screw.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
–Slide positive terminal cover over the positive terminal.
–Position the negative cable and mount and tighten the screw.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
Finishing work
–Mount the seat. ( p. 8)