KTM 250 SX-F EU Setup Instructions

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

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.

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)

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.

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)

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.

– 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) A 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)

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) –

According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

Supplier Motorex® – Fett 2000

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