KTM 250 EXC-F 2019, Setup Instructions

Page 1: ...SETUP INSTRUCTIONS 2019 250 EXC F 250 EXC F Six Days Art no 3213969en ...

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Page 3: ...out 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 2018 KTM Sportmotorcycle...

Page 4: ... 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 availa...

Page 5: ...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 damag...

Page 6: ... a lift stand available Lift stand 78129955100 402051 01 Together with an assistant take the vehicle off the pallet Position the vehicle on a lift stand Check the vehicle and components for transport damage Install the shock absorber p 22 H01768 10 Position the turn signal indicator lamp 1 in the combina tion instrument bracket 402736 10 Position the connector board and combination instrument on t...

Page 7: ...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 dam aged or bent Position handlebar Info Make sure the cables and wiring are positioned cor rectly Position handlebar clamps Mount and tighten the screws evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf...

Page 8: ...s 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 dam aged or bent Position handlebar Info Make sure the cables and wiring are positioned cor rectly Position handlebar clamps Mount and tighten the screws evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 l...

Page 9: ...d use and the insurance coverage If the combination switch is installed the vehicle s approval for road use is invalidated Only operate the vehicle in closed off areas remote from public road traffic if the combina tion switch is installed Optional Mount combination switch on the left side Info The figure shows a possible installation position of the left side combination switch S01410 01 250 EXC ...

Page 10: ...g Voiding of the government approval for road use and the insurance coverage If the combination switch is installed the vehicle s approval for road use is invalidated Only operate the vehicle in closed off areas remote from public road traffic if the combina tion switch is installed Optional Remove the protection cap and join the plug in connector of the left combination switch S01412 10 Route the...

Page 11: ...SETUP 2 9 H01060 01 Mount the mirror clamps on both sides E00474 01 Mount both rear mirrors with the adapter E00852 01 Preassemble the hand guards on the left and right ...

Page 12: ...gases cause serious chemical burns Keep 12 V batteries out of the reach of chil dren Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the 12 V battery Only charge 12 V batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes ...

Page 13: ...n signal using the black and brown cables of the turn signal cable har ness Connect the plug in connector of the left turn signal using the violet and brown cable colors of the turn signal cable harness Info Pay attention to where the brake line is routed when doing so Connect plug in connector of the headlight Connect plug in connector of the turn signal switch Secure turn signal relay 5 with a c...

Page 14: ... washers and take off the main silencer S01417 10 Pull off the engine control unit from the holder and hang to the side Disconnect plug in connector bk on main wiring harness and take off Join the turn signal cable harness plug in connector to the main wiring harness plug in connector E00489 10 Remove screw bl with the collar bushing Remove screw bm Remove screw bn with negative cable and contact ...

Page 15: ...s bp and hang the tail light to the side Drill a hole at marking C to the size of the marking E00492 10 Route the turn signal cable harness toward the rear and pass through the frame paying attention to the plugs as you do so Route turn signal cable harness on the license plate holder and pass turn signal cable harness through the drill hole Position tail light on license plate holder and mount an...

Page 16: ...Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw bm Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw bn with negative cable and con tact disk Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft E00498 10 Connect the tail light plug in connector to the main wiring harness plug in connector Mount the engine control unit on the holder Inf...

Page 17: ...l tank p 34 E00496 10 Position turn signal on both sides mount nuts with wash ers and tighten Position license plate lamp on the license plate holder and mount and tighten screws bq Mount reflector br on license plate holder Pass cable through the license plate holder E00497 10 Position the license plate holder on the license plate sup port Join the plug in connector of the license plate lamp Conn...

Page 18: ...e spring with special tool bs Footrest spring plier 79029083000 The special tool is applied to area F on the footrest Mount pin bt S01397 10 Mount the washer and splint ck S01398 10 Position the left footrest and pin Info Only insert the pin to the extent that the spring can still be mounted ...

Page 19: ...ea I on the footrest Mount pin cl F01081 10 Mount the washer and splint cm F01079 10 Position the frame protectors on both sides Mount and tighten screws cn Guideline Screw frame protec tor M5 3 Nm 2 2 lbf ft Mount and tighten screws co with the washers Guideline Screw frame protec tor M5 3 Nm 2 2 lbf ft Mount the cable tie 250 EXC F AU 250 EXC F Six Days EU Install the engine guard p 37 ...

Page 20: ...cope of supply optional Set the kilometers or miles p 39 Set the combination instrument p 40 Set the clock p 40 Refuel p 38 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 Info Transport mode must be deactivated to be able to start the motorcycle ...

Page 21: ...away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 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 rubber strap 3 3 Removing the headlight mask with the headlight V00458 10 EXC F EU AU A...

Page 22: ... and take off the headlight mask with the headlight 3 4 Installing the headlight mask with the headlight S01328 11 Main work EXC F EU AU AR BR EXC F Six Days Join plug in connectors 1 V00458 11 Position the headlight mask and secure it with rubber straps 2 The holding lugs engage in the fender Position the brake line and wiring harness in the brake line guide V00459 11 250 EXC F US Join plug in co...

Page 23: ...n the vehicle vertically at a distance A away from the wall Guideline Distance A 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider If the boundary between light and dark does not meet specifications Adjust the headlight range p 21 3 6 Adjusting the ...

Page 24: ...Teflon coated It must not be lubricated with grease nor with any other lubricants Lubricants dissolve the Teflon coating thereby drastically reducing the service life Finishing work Remove the motorcycle from the lift stand p 19 3 8 Installing the fork legs 402556 10 Main work EXC F EU AU US AR BR Position the fork legs Bleeder screws 1 are positioned toward the front Info The rebound damping is l...

Page 25: ... side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp E00378 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 15 Nm 11 1 lbf ft K00546 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 ...

Page 26: ...e Long life grease p 45 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned V00364 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 lin ings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 19 Operate the front brak...

Page 27: ...hten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S01321 10 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 20 Check the headlight setting p 21 3 11 Removing the seat V00342 10 Remove screws 1 Raise the rear of the seat pull the seat back and lift it off ...

Page 28: ...lly hazardous materials Do not dispose of 12 V batteries as household waste Dispose of 12 V batteries at a collection point for used batteries Note 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 Preparatory work EXC F EU AU AR BR EXC F Six Days Press...

Page 29: ...nflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of 12 V batteries with less than the minimum voltage correctly Disconnect negative cable 1 from the 12 V battery Pull back positive terminal cover 2 and disconnect th...

Page 30: ...he eyes Disconnect negative cable 1 from the 12 V battery Pull back positive terminal cover 2 and disconnect the positive cable from the 12 V battery Remove screw 3 Pull holding bracket 4 forward and remove the 12 V bat tery upwards 3 14 Installing the 12 V battery H00386 10 Main work Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bra...

Page 31: ...batteries as household waste Dispose of 12 V batteries at a collection point for used batteries Note 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 12 V battery it discharges steadily The charging level and the ...

Page 32: ... The charging current charging voltage and charging time must not be exceeded Recharge the 12 V battery regularly when the motorcy cle is not being used 3 months Finishing work Install the 12 V battery p 28 Mount the seat p 26 3 16 Charging the 12 V battery 250 EXC F BR Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep 12 V batteries out of the reach of childr...

Page 33: ...attery must be charged immediately If the 12 V battery is left in a discharged state for an extended period it will become deeply discharged and sulfating occurs destroying the battery The 12 V battery is maintenance free i e the acid level does not have to be checked Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the seat p 25 Remove the 1...

Page 34: ...sult 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 Preparatory work Remove the seat p 25 K00555 1...

Page 35: ...rt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel line Mount wash cap set 2 Wash cap set 81212016100 K00558 10 Remove screws 3 with the collar bushings Hang the horn and horn bracket to one side K00556 11 Remove screw 4 with the rubber bushing K00559 10 Pull both spoilers laterally off the radiator and take...

Page 36: ... 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 Main work Check throttle cable routing p 35 Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracke...

Page 37: ...line at a safe distance from the exhaust system E00509 10 250 EXC F US Plug in connector 3 for the fuel pump Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 4 for the fuel line Info...

Page 38: ...sup port If the throttle cable routing is not as specified Correct throttle cable routing S01404 01 250 EXC F US Check throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars and above the fuel tank bracket to the throttle valve body Both throttle cables must be secured behind the rubber strap of the fuel tank sup port If the throttle cable routing is ...

Page 39: ...illed 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...

Page 40: ...lth 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...

Page 41: ...cordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds The Setup menu is displayed and the active functions are shown Repeatedly press the button briefly until Km h Mph flashes Adjusting the Km h ...

Page 42: ... setup menu is closed Repeatedly press the button briefly until the desired func tion flashes The selected function flashes Activating the function Press the button The symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappears in the display and the next function appears 3 26 Setting the clock Condition The motorcycle is ...

Page 43: ... 3 41 Info The seconds can only be set to zero If no button is pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed ...

Page 44: ...djusting ring M5 5 Nm 3 7 lbf ft Screw turn signal switch M5 1 Nm 0 7 lbf ft Nut cable on starter motor 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 14 Nm 10 3 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loct...

Page 45: ... triple clamp 250 EXC F Six Days EU M8 17 Nm 12 5 lbf ft Screw top triple clamp EXC F EU AU US AR BR M8 20 Nm 14 8 lbf ft Engine attachment bolt 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 handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Screw bottom shock absorber M12 80 Nm 5...

Page 46: ...M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded type C ROZ 95 RON 95 PON 91 Standard classification ANP Agência Nacional do Petróleo 57 ROZ 95 RON 95 PON 91 Guideline Only use super unleaded fuel that matches or is equivalent to the following specifications Super unleaded fuel with an ethanol content of 19 to 27 is permissible Info Do not use fuel made of methanol e g M15 ...

Page 47: ...AUXILIARY SUBSTANCES 6 45 Long life grease Recommended supplier MOTOREX Bike Grease 2000 ...

Page 48: ... 3213969en 3213969en 06 2018 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...