KTM 250 XC-F 2017 Manual

SETUP INSTRUCTIONS 2017
250 SX-F
250 XC‑F
Art. no. 3213576en

INTRODUCTION 1
*3213576en*
3213576en
10/2016
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 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 assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
250 SX‑F EU (F8101Q5)
250 SX‑F US (F8175Q5)
250 XC‑F US (F8175Q0)

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.
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
M00075-10
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 on the basis of the enclosed packing 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 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 (78129955100)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
K00613-10
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten screw cap 1.
Guideline
Nut, frame to linkage 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.

2 SETUP 4
K00686-01
–Route the clutch line with the clutch master cylinder toward the front between the
upper and lower triple clamps.
S00867-14
–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)
The air release screw 3of the right fork leg is positioned to the front.
The left fork leg valve Ais positioned approx. 20 ° further forward.
Info
Grooves are milled into the side of the upper end of the fork legs. The sec-
ond 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.
Position the bleeder screw of the right fork leg and the valve of the left fork
leg facing forward.
K00620-11
–Remove screws 4. Remove 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 5. Take off handlebar supports 6.
–Position rubber bushings 7and push through nuts 8from 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 5.
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.

2 SETUP 5
–Position the handlebar clamp.
–Mount screws 4, but do not tighten yet.
–First bolt the handlebar support with screws 4onto the longer, higher side of the
handlebar supports so that both parts touch.
–Tighten screws 4evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
K00645-10
–Position the controls on the right half of the handlebar.
K00646-10
–Position the controls on the left half of the handlebar.
Guideline
Screw, fixed grip M4 5 Nm
(3.7 lbf ft)
Loctite®243™
–Install the front fender. ( p. 10)
–Install the front wheel. ( p. 9)
K00687-10
–Position the malfunction indicator lamp using holder 9. Mount and tighten screw.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Connect plug-in connector bk.
–Connect plug-in connector bl.
–Correctly mount the fuel tank breather.
M01069-01
–Mount the handlebar cushion.
D00674-10
Left and right footrest (All SX‑F models)
–Position the new footrest and pin.
Info
Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 6
K00621-12
–Position spring as shown.
Spring Bengages in area C.
K00622-12
–Press the spring with special tool bm.
Pliers for footrest spring (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin bn.
K00623-12
–Mount the washer and split pin bo.
–Repeat these steps on the opposite side.
D00674-10
Right footrest (XC‑F US)
–Position the right footrest and pin.
Info
Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 7
K00621-12
–Position spring as shown.
Spring Bengages in area C.
K00622-12
–Press the spring with special tool bm.
Pliers for footrest spring (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin bn.
K00623-12
–Mount the washer and split pin bo.
R00757-10
Left footrest (XC‑F US)
–Position the left footrest and pin.
Info
Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 8
K00688-10
–Position spring as shown.
Spring Eengages in area F.
K00689-10
–Press the spring with special tool bm.
Pliers for footrest spring (79029083000)
The special tool is applied to area Gon the footrest.
–Mount pin bp.
K00690-10
–Mount the washer and split pin bq.
–Install the start number plate. ( p. 10)
–Recharge the battery. ( p. 12)
–Install the battery. ( p. 12)
–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. 14)
–Position all controls in their exact positions on the handlebar. Tighten all screws.
Guideline
Screw, fixed grip M4 5 Nm
(3.7 lbf ft)
Loctite®243™
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 WORK 9
3.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
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
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level 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 1into 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 1to 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 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.
H00935-10
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the front wheel bearing.
–Clean and grease shaft seal rings 1and contact surface Aof the spacers.
Long-life grease ( p. 19)
–Insert the spacers.

3 WORK 10
–Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
F00141-11
–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 linings are seated cor-
rectly against the brake disc.
–Remove the motorcycle from the lift stand. ( p. 9)
–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)
3.4 Installing the front fender
S01218-10
Main work
–Position the 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. 10)
3.5 Installing the start number plate
S01235-10
–Position the brake line in holders Aon the start number plate.
–Position the start number plate. Mount and tighten screw 1.
The holding lugs engage in the fender.

3 WORK 11
3.6 Removing the seat
S01230-10
–Remove screws 1.
S01231-01
–Raise the rear of the seat, pull the seat back, and lift it off.
3.7 Mounting the seat
S01231-11
–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.
S01230-10
–Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

3 WORK 12
3.8 Installing the battery
H00386-10
Main work
–Insert the battery into the battery compartment with the terminals facing forward
and secure with holding bracket 1.
(All SX‑F models)
Battery (C22S)
(XC‑F US)
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 terminal M5 2.5 Nm
(1.84 lbf ft)
–Connect negative cable 4to the battery.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
Contact disks Amust be mounted under screws 5and cable sockets 6with
the claws toward the battery terminal.
–Slide positive terminal cover 7over the positive terminal.
Finishing work
–Mount the seat. ( p. 11)
3.9 Recharging the battery
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 regu-
lations.

3 WORK 13
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 sulfated, destroying the
battery.
The battery is maintenance-free.
Preparatory work
–Remove the seat. ( p. 11)
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)
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. 11)
3.10 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.

3 WORK 14
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.
S01197-10
(All SX‑F models)
–Turn filler cap 1counterclockwise and lift it off.
S01265-10
(XC‑F US)
–Press release button 1, turn the filler cap counterclockwise, and lift it off.
3.11 Closing the filler cap
S01198-10
(All SX‑F models)
–Mount filler cap 1and turn it clockwise until the fuel tank is tightly closed.
Info
Route fuel tank breather hose 2without kinks.
S01266-10
(XC‑F US)
–Replace the filler cap and turn clockwise until release button 1locks in
place.
Info
Route fuel tank breather hose 2without kinks.
3.12 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.

3 WORK 15
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.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the
fuel system.
–Refuel only with clean fuel that meets the specified standards.
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. 13)
AA
401522-10
–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‑F models)
7 l (1.8 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 18)
Total fuel tank
capacity, approx.
(XC‑F US)
8.5 l
(2.25 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 18)
–Close the filler cap. ( p. 14)

4 TECHNICAL DATA 16
4.1 Chassis tightening torques
Screw, air filter box cover EJOT PT®K60x20-Z 3 Nm (2.2 lbf ft) –
Screw, combination switch EJOT PT®K50x18 3 Nm (2.2 lbf ft) –
Screw, intake air temperature sensor EJOT DELTA PT®45x12‑Z 1 Nm (0.7 lbf ft) –
Screw, pressure regulator EJOT PT®K60x25‑Z 3 Nm (2.2 lbf ft) –
Screw, fixed grip M4 5 Nm (3.7 lbf ft) Loctite®243™
Screw, service hour counter M4 1 Nm (0.7 lbf ft) –
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) –
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M5 5 Nm (3.7 lbf ft) –
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) –
Screw, frame protector M5 3 Nm (2.2 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Nut, electric starter cable connection M6 4 Nm (3 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 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) Loctite®243™
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, throttle grip M6 5 Nm (3.7 lbf ft) –
Fuel connection on fuel tank M8 10 Nm (7.4 lbf ft) –
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw side stand attachment
(XC‑F US)
M8 35 Nm (25.8 lbf ft) Loctite®2701™
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 25 Nm (18.4 lbf ft) Loctite®243™
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, subframe M8 35 Nm (25.8 lbf ft) Loctite®2701™
Screw, top steering stem M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine carrying screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701™
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701™
Nut, fuel pump M12 15 Nm (11.1 lbf ft) –
Nut, frame to linkage lever M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) –

4 TECHNICAL DATA 17
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft) –

5 SUBSTANCES 18
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).