KTM 250 XC-F 2018 Manual

SETUP INSTRUCTIONS 2018
250 SX-F
250 XC‑F
Art. no. 3213710en

INTRODUCTION
*3213710en*
3213710en
04/2017
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‑F EU (F8101R5)
250 SX‑F US (F8175R5)
250 XC‑F US (F8175R0)

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 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 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 on the basis of the
enclosed packing list.

2 SETUP
4
402051-01
–Have a lift stand available.
Lift stand (78129955100)
–Together with an assistant, take the vehicle off the pallet.
–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 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.
K00686-01
–Route the clutch line with the clutch master cylinder toward
the front between the upper and lower triple clamps.

2 SETUP
5
F01064-10
–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)
Air release screw 3of 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.
K00620-11
–Remove screws 4. 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 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, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
F01066-01
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.

2 SETUP
6
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamp.
–Mount screws 4but do not tighten yet.
–First bolt the handlebar clamp 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)
Info
The markings on the handlebar should be at the center
of the handlebar clamps.
Keep the gap widths equal when tightening.
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™

2 SETUP
7
F01067-01
(XC‑F US)
–Preassemble the hand guards on the left and right.
F01068-01
–Mount the left hand guard.
–Mount the right hand guard.
F01069-10
(All SX‑F models)
–Position indicator lamp attachment 9with malfunction
indicator lamp. Mount and tighten screw bk.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Join plug-in connector bl.
–Join plug-in connector bm.
–Route the cable without tension and secure with cable tie.
–Correctly mount the fuel tank breather.

2 SETUP
8
F01070-10
(XC‑F US)
–Position indicator lamp attachment 9with malfunction
indicator lamp and fuel level warning lamp. Mount and
tighten screw bk.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Join plug-in connector bl.
–Join plug-in connector bm.
–Route the cable without tension and secure with cable tie.
–Correctly mount the fuel tank breather.
F01076-10
–Mount the handlebar cushion.
–Install front fender. ( p. 15)
–Install the front wheel. ( p. 14)
–Install the start number plate. ( p. 15)
F01075-01
(SX‑F EU)
–WARNING‑Apply sticker to the rear fender.
D00674-10
Left and right footrest (All SX‑F models)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.