KTM 250 SX Series Manual

SETUP INSTRUCTIONS 2018
250 SX
250 XC
300 XC
Art. no. 3213726en

INTRODUCTION
*3213726en*
3213726en
05/2017
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest 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 GmbH specifically reserves the right to modify or delete
technical specifications, 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 figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2017 KTM Sportmotorcycle GmbH, 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 assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
250 SX EU (F6301R0)
250 SX US (F6375R0)
250 XC US (F6375R5)
300 XC US (F6475R5)

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.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

2 SETUP
3
2.1 Unpacking and setting up the vehicle
E00851-10
Package 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 using the enclosed pack-
ing list.
–Have a lift stand available.
Lift stand (78129955100)
–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 pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
E00850-10
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 using the enclosed pack-
ing list.
–Have a lift stand available.
Lift stand (78129955100)
–Together with an assistant, take the vehicle off the pallet.

2 SETUP
4
402051-01
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
A00001-11
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten fitting 1.
Guideline
Nut, linkage lever
to angle lever
M14x1.5 80 Nm (59 lbf ft)
–Mount and tighten screw 2.
Guideline
Screw, bottom
shock absorber
M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Info
Raise the wheel slightly to be able to mount the
screw more easily.
–Route the clutch line with the clutch master cylinder
toward the front between the upper and lower triple
clamps.
–Install the fork legs. ( p. 11)
K00620-10
–Remove screws 3. Take off the handlebar clamp. Remove
the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–Remove screws 4. Take off handlebar supports 5.
–Position rubber bushings 6and push through nuts 7from
below.
–Place the handlebar supports in the required position.
Info
The handlebar supports are longer and higher on one
side.
Position the left and right handlebar supports evenly.
–Mount and tighten screws 4.
Guideline
Screw, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
–Position the handlebar.

2 SETUP
5
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamp.
–Mount screws 3but do not tighten yet.
–First bolt the handlebar clamp with screws 3onto the longer,
higher side of the handlebar supports so that both parts touch.
–Tighten screws 3evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
K00938-10
(All SX models)
–Position the controls on the right half of the handlebar.
K00615-10
(All XC models)
–Position the controls on the right half of the handlebar.
K00616-10
–Position the controls on the left half of the handlebar.
–Mount cable tie(s).
–Mount the fuel tank breather.
–Install the front wheel. ( p. 11)
–Install front fender. ( p. 12)
–Install the start number plate. ( p. 15)

2 SETUP
6
K00617-10
–Mount the handlebar cushion.
R01229-10
Left and right footrest (All SX models)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.
K00621-10
–Position spring as shown.
Spring Aengages in area B.
K00622-10
–Press the spring with special tool 8.
Pliers for footrest spring (79029083000)
The special tool is applied to area Con the footrest.
–Mount pin 9.

2 SETUP
7
K00623-10
–Mount the washer and split pin bk.
–Repeat these steps on the opposite side.
R00757-10
Left footrest (All XC models)
–Raise the motorcycle with a lift stand. ( p. 10)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.
K00624-10
–Position spring as shown.
Spring Aengages in area B.
K00625-10
–Press the spring with special tool 8.
Pliers for footrest spring (79029083000)
The special tool is applied to area Con the footrest.
–Mount pin 9.

2 SETUP
8
K00626-10
–Mount the washer and split pin bk.
–Remove the motorcycle from the lift stand. ( p. 10)
R01229-10
Right footrest (All XC models)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.
K00621-11
–Position spring as shown.
Spring Dengages in area E.
K00622-11
–Press the spring with special tool 8.
Pliers for footrest spring (79029083000)
The special tool is applied to area Fon the footrest.
–Mount pin bl.

2 SETUP
9
K00623-11
–Mount the washer and split pin bm.
K00618-10
(All XC models)
–Recharge the battery. ( p. 13)
–Install the battery. ( p. 14)
K00937-10
–Position the frame protectors on the left and right.
–Mount and tighten screws bn with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws bo.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount cable tie(s).
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Apply the sticker included in the delivery (optional).
–Refuel. ( p. 16)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

3 WORK
10
3.1 Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
–Park the vehicle on a firm and level surface.
–Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
401942-01
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
–Park the vehicle on a firm and level surface.
–Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
0
0
11
402001-10
(All SX models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand 1into the
left side of the wheel spindle.
Info
Remove the plug-in stand before riding.
401943-10
(All XC models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground
with your foot and lean the motorcycle on it.
Info
While riding, the side stand must be folded up and
secured with the rubber band.

3 WORK
11
3.3 Installing the fork legs
H01182-10
Main work
–Position the fork legs.
Air release screw 1of the right fork leg is positioned to
the front.
Valve Aof the left fork leg faces the front.
Info
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the top edge of the upper triple clamp.
The air suspension is located in the left fork leg. The
pressure and rebound damping is located in the right
fork leg.
F00011-11
–Tighten screws 2.
Guideline
Screw, top triple
clamp
M8 17 Nm (12.5 lbf ft)
–Tighten screws 3.
Guideline
Screw, bottom triple
clamp
M8 12 Nm (8.9 lbf ft)
A00022-11
–Position the brake caliper. Mount and tighten screws 4.
Guideline
Screw, front
brake caliper
M8 25 Nm (18.4 lbf ft)
Loctite®243™
–Position the brake line and clamp. Mount and tighten
screws 5.
Finishing work
–Install the front wheel. ( p. 11)
3.4 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–Always keep the brake discs free of oil and grease.
–Clean the brake discs with brake cleaner when necessary.

3 WORK
12
H00935-10
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change front wheel bearing.
–Clean and grease shaft seal rings 1and contact surface A
of the spacers.
Long-life grease ( p. 22)
–Insert the spacers.
–Clean and grease the wheel spindle.
Long-life grease ( p. 22)
K00454-11
–Lift the front wheel into the fork, position it, and insert the
wheel spindle.
The brake linings are correctly positioned.
–Mount and tighten screw 2.
Guideline
Screw, front wheel
spindle
M20x1.5 35 Nm (25.8 lbf ft)
–Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
–Remove the motorcycle from the lift stand. ( p. 10)
–Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
–Tighten screws 3.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
3.5 Installing front fender
M01144-10
Main work
–Position front fender. Mount and tighten screws 1and 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
Finishing work
–Install the start number plate. ( p. 15)

3 WORK
13
3.6 Recharging the battery (All XC models)
Warning
Risk of injury Batteries contain harmful substances.
–Keep batteries out of the reach of children.
–Keep sparks and open flames away from the batteries.
–Only charge batteries in well-ventilated rooms.
–Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
–Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
–Dispose of batteries with less than the minimum voltage correctly.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed.
If the battery is depleted by repeated starting, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-
fated, destroying the battery.
The battery is maintenance-free.
Preparatory work
–Remove the seat. ( p. 15)
311910-10
Main work
–Connect the battery charger to the battery. Set the battery
charger.
Alternative 1
Battery charger XCharge-professional EU
(00029095050)
Alternative 2
Battery charger XCharge-professional US
(00029095051)
Alternative 3
Battery charger XCharge-professional GB
(00029095052)

3 WORK
14
Alternative 4
Battery charger XCharge-professional CH
(00029095053)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Charge the battery regularly
when the motorcycle is not
in use
3 months
Finishing work
–Mount the seat. ( p. 15)
3.7 Installing the battery (All XC models)
H00386-10
Main work
–Position the battery in the battery compartment with the termi-
nals facing forward, and secure with holding bracket 1.
Battery (HJTZ5S-FP)
–Mount and tighten screw 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Connect positive cable 3to the battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
Contact disks Amust be mounted under screws 5and
cable sockets 6with the claws toward the battery termi-
nal.
–Slide positive terminal cover 7over the positive terminal.
–Connect negative cable 4to the battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
Finishing work
–Mount the seat. ( p. 15)

3 WORK
15
3.8 Installing the start number plate
F00013-10
–Connect the brake line at the start number plate.
–Position the start number plate.
The holding lugs engage in the fender.
–Mount and tighten screw 1.
3.9 Removing the seat
F00017-10
–Remove screws 1.
–Raise the rear of the seat, pull the seat back, and lift it off.
3.10 Mounting the seat
F00016-10
–Mount the front of the seat on the collar bushing of the fuel
tank, lower the seat at the rear, and push the seat forward.
–Make sure that the seat is correctly locked in.
F00017-10
–Mount and tighten screws 1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)

3 WORK
16
3.11 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–Switch off the engine.
–Open the filler cap. ( p. 17)
400382-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Total fuel tank
capacity, approx. (All
SX models)
7 l
(1.8 US gal)
Super unleaded
(95 octane) mixed
with 2-stroke
engine oil (1:60)
( p. 21)
Total fuel tank
capacity, approx. (All
XC models)
10 l
(2.6 US gal)
Super unleaded
(95 octane) mixed
with 2-stroke
engine oil (1:60)
( p. 21)
Engine oil, 2-stroke ( p. 21)
–Close the filler cap. ( p. 18)

3 WORK
17
3.12 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
F00003-10
(All SX models)
–Turn filler cap 1counterclockwise and lift it off.
K00508-10
(All XC models)
–Press release button 1, turn the filler cap counterclock-
wise, and lift it off.

3 WORK
18
3.13 Closing the filler cap
F00003-11
(All SX models)
–Mount filler cap 1and turn it clockwise until the fuel
tank is tightly closed.
Info
Run the fuel tank breather hose 2without kinks.
K00508-11
(All XC models)
–Mount filler cap 1and turn it clockwise until the release
button engages.
Info
Run the fuel tank breather hose 2without kinks.