KTM 2012 250 EXC-F SIX DAYS, Owner'S Manual

Page 1: ...OWNER S MANUAL 2012 250 EXC F EU 250 EXC F AUS 250 EXC F SIX DAYS EU 250 XCF W USA Art no 3211719en ...

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Page 3: ...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 p...

Page 4: ... sand 26 Preparing for rides on wet sand 26 Preparing for rides on wet and muddy surfaces 27 Preparing for rides at high temperature and slow speed 27 Preparing for rides at low temperatures or in snow 28 RIDING INSTRUCTIONS 29 Checks and maintenance work when preparing for use 29 Starting 29 Starting off 30 Shifting riding 30 Braking 30 Stopping parking 31 Refueling 31 SERVICE SCHEDULE 33 Service...

Page 5: ...e rear brake linings 71 Changing the rear brake linings x 72 WHEELS TIRES 74 Removing the front wheel x 74 Installing the front wheel x 74 Removing the rear wheel x 75 Installing the rear wheel x 75 Checking the tire condition 76 Checking tire air pressure 77 Checking spoke tension 77 ELECTRICAL SYSTEM 79 Removing the battery x 79 Installing the battery x 79 Charging the battery x 79 Changing the ...

Page 6: ...l understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required 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 Denotes a prop...

Page 7: ...e schedule is reached Pay careful attention to the prescribed running in period and service intervals If you observe these exactly you will ensure a much longer service life for your motorcycle Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer s service record and in the KTM dealer net otherwise all warranty cl...

Page 8: ...fixed to the vehicle Do not remove information warning labels If they are miss ing you or others may not recognize potential hazards and may therefore be injured Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious inj...

Page 9: ...VIEW OF VEHICLE 7 3 1 View of vehicle front left example 101433 10 1 Filler cap 2 Air filter box lid 3 Fork compression adjustment 4 Shift lever p 21 5 Engine number p 9 6 Side stand p 22 ...

Page 10: ...gnal switch p 12 2 Emergency OFF switch p 12 2 Electric starter button p 13 3 Throttle grip p 11 4 Fork rebound adjustment and spring preload adjustment 5 Shock absorber rebound adjustment 6 Level viewer for brake fluid rear 7 Shock absorber compression adjustment 8 Level viewer engine oil 9 Foot brake lever p 22 10 Kick starter p 22 ...

Page 11: ...label is fixed to the front of the steering head 4 3 Key number All EXC F models 500125 10 The key number is stamped on the key strap 4 4 Engine number 101435 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 5 Fork part number B00265 01 The fork part number is stamped on the inner side of the fork stub ...

Page 12: ...SERIAL NUMBERS 10 4 6 Shock absorber part number 101436 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 13: ...on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 5 5 Kill switch All EXC F models 101297 10 Kill switch is fitted on the left side of the handlebar Possib...

Page 14: ...299 10 Turn signal switch is fitted on the left side of the handlebar Possible states Turn signal light off Turn signal switch is in the central position Turn signal light left on Turn signal switch is turned to the left Turn signal light right on Turn signal switch is turned to the right 5 9 Emergency OFF switch EXC F AUS 101300 10 The emergency OFF switch is fitted on the right side of the handl...

Page 15: ...DAYS 101431 10 The Map Select switch for vehicle operation is fitted on the right side of the handle bar Possible states Standard STANDARD Mapping is always activated in this setting SOFT or ADVANCED The mapping that is set on the Map Select switch for the basic setting is activated in this setting The Map Select switch for vehicle operation is used to change the engine characteris tics on the han...

Page 16: ...ctions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated 5 18 Speedometer activation and test 400313 01 Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor Display test For the function test of the display all display segments light up briefly 400314 01 WS wheel size A...

Page 17: ...s pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu is closed 5 21 Setting the clock Condition The motorcycle is stationary 400330 01 Press the button briefly and repeatedly until CLK appears at the bottom right of the display Press the button for 3 5 seconds The hour display flashes Set the hour display with the butto...

Page 18: ...play changes to the next function All desired functions are activated or deactivated accordingly Press the button for 3 5 seconds The settings are stored and the Setup menu is closed Info If no button is pressed for 20 seconds or if a pulse arrives from the wheel speed sensor the settings are stored automatically and the Setup menu is closed 5 23 Querying lap time Info This function can be called ...

Page 19: ...de The H display mode is suppressed during the journey Press the button No function Press the button No function Press the button for 3 5 seconds The display changes to the Setup menu of the speedometer functions Press the button briefly Next display mode 5 26 Display mode SPEED CLK clock 400319 01 Press the button briefly and repeatedly until CLK appears at the bottom right of the display The tim...

Page 20: ...9 9 is exceeded the values of TR1 A1 and S1 are automatically reset to 0 0 Press the button No function Press the button No function Press the button for 3 5 seconds The TR1 A1 and S1 displays are reset to 0 0 Press the button briefly Next display mode 5 30 Display mode SPEED TR2 trip master 2 400324 01 Press the button briefly and repeatedly until TR2 appears at the top right of the display TR2 t...

Page 21: ...the button No function Press the button No function Press the button for 3 5 seconds Press the button briefly Next display mode 5 33 Display mode SPEED S1 stop watch 1 400327 01 Press the button briefly and repeatedly until S1 appears at the top right of the display S1 stop watch 1 displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor T...

Page 22: ...Displays of S2 and A2 are reset to 0 0 Next display mode Table of conditions and menu activation Display The motorcycle is stationary Menu can be acti vated Display mode SPEED H operating hours Display mode SPEED CLK clock Display mode SPEED LAP lap time Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Display mode SPEED A1 average speed 1 Display mode SPEED A2 average spe...

Page 23: ... throttle valve body at the top left The idle speed adjusting screw has two functions Turning it controls the idle speed Pulling it out all the way raises the idle speed during a cold start Possible states RPM increase activated Idle speed adjusting screw is pulled out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 5 38 Shift lever 101437 10 Shift lever is...

Page 24: ... Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 5 41 Side stand 101441 10 The side stand is on the left side of the vehicle 101442 10 The side stand is used to park the motorcycle Info When you are riding the side stand must be folded up and secured with the rubber band 5 42 Steering lock All EXC F models 101313 10 Steering lock i...

Page 25: ... to the right Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 5 44 Unlocking the steering All EXC F models 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info ...

Page 26: ...ar brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using...

Page 27: ...he throttle 6 3 Preparing the vehicle for difficult riding conditions Info Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached KTM recommends that you use the specified engine oil for difficult riding co...

Page 28: ...ver on the air filter Sand protection device for air filter 59006022000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and the setting Info The specific carburetor tuning can be recommended by your authorized KTM workshop 600868 01 Clean the chain Chain cleaner p 112 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator ...

Page 29: ...ce for air filter 59006021000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and setting Info Recommendations on the carburetor setting are available from your autho rized KTM workshop 600868 01 Fit the steel sprocket Clean the motorcycle p 95 Straighten bent radiator fins carefully 6 7 Preparing for rides at high temperature and slow speed 600872 10 Check the radia...

Page 30: ... cleaner p 112 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 87 6 8 Preparing for rides at low temperatures or in snow 600870 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 59006021000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and setting Info Recommendations on the carburetor sett...

Page 31: ... and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 7 2 Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an ...

Page 32: ...ngine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine...

Page 33: ...e could be damaged and the motorcycle could fall over Brake the motorcycle Shift transmission to neutral XCF W Press and hold the kill switch while the engine is idling until the engine stops All EXC F models Press and hold the kill switch while the engine is idling until the engine stops Park the motorcycle on firm ground 7 7 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the ...

Page 34: ... 32 A A 401226 10 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx 9 5 l 2 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 111 Close the filler cap p 21 ...

Page 35: ...check for smooth operation x Check the fluid level of the hydraulic clutch p 63 Check the front brake fluid level p 66 Check the free travel of the hand brake lever p 65 Check the steering head bearing play p 49 Check the valve clearance x Check the clutch x Check the fuel pressure x Check all hoses e g fuel cooling bleeding drainage and sleeves for cracking leaks and incorrect routing x Check the...

Page 36: ...d spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Check the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the oil pressure regulator valve x Check the oil pumps and lubrication system x Check the timing asse...

Page 37: ...r wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and l...

Page 38: ...absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Full payload 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 9 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitro...

Page 39: ...ween measurements and Check the static sag Static sag 33 35 mm 1 3 1 38 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 38 9 8 Checking the riding sag of the shock absorber 0 0 A A 0 0 C C 400990 10 Measure distance of rear wheel unloaded p 37 With another person holding the motorcycle the rider wearing full protective cloth ing sit...

Page 40: ...eload Comfort 7 mm 0 28 in Standard 7 mm 0 28 in Sport 7 mm 0 28 in Full payload 8 mm 0 31 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Install the shock absorber x p 51 9 10 Adjusting the riding sag x Remove shock absorber x p 51 After removing...

Page 41: ...the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Full payload 20 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection covers 9 13 Adjusting the rebound dampi...

Page 42: ...0 A A 0 0 A A 101318 10 On the upper triple clamp there are two holes at a distance of to each other Hole distance 15 mm 0 59 in The holes on the handlebar supports are placed at a distance of from the center Hole distance 3 5 mm 0 138 in The handlebar supports can be mounted in four different positions 9 16 Adjusting handlebar position x Warning Danger of accidents Handlebar breakage If the handl...

Page 43: ...ebar supports evenly Position the handlebars Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Fit and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even ...

Page 44: ...ust be folded up and secured with the rubber band 10 3 Bleeding fork legs Raise the motorcycle with the lift stand p 42 101319 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the lift stand p 42 10 4 Cleaning the dust boots of the fork legs Raise the motorcycle with the lift stand p 42 Loosen the...

Page 45: ...10 Nm 7 4 lbf ft Position the wiring harness Position the brake line Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 7 Removing the fork legs Remove the headlight mask with the headlight p 83 Remove the front wheel x p 74 101322 10 Remove screws and take off the clamp...

Page 46: ...n screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 101326 10 Position brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder Refit the headlight mask with the headlight p 83 Position the brake line wiring harness and clamp Mount and tighten ...

Page 47: ...or to one side Remove screw and screw Take off the upper triple clamp with the handlebar and set it aside Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and lines 101329 10 Remove O ring Remove protective ring Take out the lower triple clamp with the steering stem Take out the upper steering head bearing 10 12 Removing the lower triple clamp ...

Page 48: ...the upper steering head bearing Check whether the top steering head seal is correctly positioned Slide on protective ring and O ring 101427 10 Position the upper triple clamp with the steering Mount screw but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 101332 10 Position the fork le...

Page 49: ...lder 101326 11 Position the brake caliper Mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder Position the brake line wiring harness and clamp Mount and tighten screws Install the front fender p 51 Mount the handlebar cushion Refit the headlight mask with the headlight p 83 Install the front wheel x p 74 Check that the wiring harness cab...

Page 50: ...ring and O ring 101337 10 Position the upper triple clamp with the steering Mount screw but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 101338 10 Position the fork legs Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp Position ...

Page 51: ... 10 15 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Your authorized KTM workshop will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Raise the mo...

Page 52: ...4 8 lbf ft Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Check the steering head bearing play p 49 10 17 Adjusting the play of the steering head bearing x EXC F SIX DAYS Raise the motorcycle with the lift stand p 42 101342 10 Loosen screws Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on ...

Page 53: ...nd tighten screw Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Remove the motorcycle from the lift stand p 42 10 21 Removing the front fender 101345 10 ...

Page 54: ... lid 101445 10 Pull off the air filter box lid in area to the side and remove to the front 10 26 Installing the air filter box lid 101446 10 Insert the air filter box lid into the rear area and clip it into the front area 10 27 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter sin...

Page 55: ...e Install the air filter box lid p 52 10 29 Cleaning the air filter and air filter box x Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 52...

Page 56: ...he air and the silencer burns out Not only is the noise level higher the performance characteristic changes Remove the main silencer p 54 0 0 1 1 0 0 2 2 0 0 4 4 0 0 5 5 0 0 6 6 0 0 8 8 0 0 7 7 0 0 3 3 0 0 4 4 0 0 8 8 101425 10 All EXC F models Remove screws of connecting cap Take off the connecting cap with the perforated pipe O ring and glass fiber yarn filling Remove screws and take off silence...

Page 57: ...er 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 a...

Page 58: ...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 Chan...

Page 59: ...ystem Mount the seat p 52 10 35 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 57 10 36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grea...

Page 60: ...e lower chain section must be taut When the chain guard is mounted it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p 58 Remove the motorc...

Page 61: ...chain rear sprocket engine sprocket and chain guide Raise the motorcycle with the lift stand p 42 400227 01 Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together 1 2 3 16 17 18 0 0 0 B B 0 0 A A 400987...

Page 62: ...is in line with or below the chain sliding piece Change the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear is visible on the front of the chain guide If the light part of the chain guide is worn Ch...

Page 63: ... Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the nut on screw and tighten Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft 10 41 Checking the frame x 401340 01 Check the frame for cracking and deformation If the frame exhibits cracking or deformation due to a mechanical impact Change the frame x Info A frame that has been damaged due to a mechanical impact must always be changed Repair ...

Page 64: ...062030051 p 113 10 45 Additionally securing the rubber grip Check the rubber grip p 62 401198 01 Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps U6907854 The twisted wire ends face away from the hands and are bent toward the rub ber grip 10 46 Adjusting the basic position of the clutch lever 101364 10 Adjust the basic setting of the clutc...

Page 65: ...substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 101365 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane 101450 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5...

Page 66: ...IX DAYS 101451 10 Turn quick release counterclockwise until it disengages Remove the engine guard 10 50 Installing the engine guard EXC F AUS EXC F SIX DAYS 101452 10 Attach the engine guard on the frame at the rear and swing up at the front Turn quick release clockwise all the way ...

Page 67: ...ravel of the hand brake lever p 65 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing screw Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the ...

Page 68: ...t brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101373 10 Move the brake fluid reservoir mounted on the handlebar to a h...

Page 69: ...osition the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 11 7 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 101375 10 Check the brake linings for minimum thickness ...

Page 70: ...valid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brak...

Page 71: ...lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust free travel on foot brake lever according to specifications 101453 10 Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free trav...

Page 72: ...e riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101379 10 Stand the vehicle upright Check the brake fluid level in the viewer When in the viewer an air bubble is visible Add bra...

Page 73: ...ks paint Use only clean brake fluid from a sealed container 101380 10 Stand the vehicle upright Remove screw cap with membrane and the O ring Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 110 Mount the screw cap with the membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water 11 13 Checking the rear brake linings Warning Danger of accidents Reduced braki...

Page 74: ... for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warn...

Page 75: ...ngs insert the bolt and mount the locking split pins Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point 101380 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 110 Mount screw cap with membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 76: ... fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 101388 10 Remove spacers 12 2 Installing the front wheel x 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 nece...

Page 77: ...disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Holding the rear wheel withdraw the wheel spin...

Page 78: ... the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Remove the motorcycle from the lift stand p 42 12 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have a significant ...

Page 79: ...ls Front 1 5 bar 22 psi Rear 2 0 bar 29 psi If the tire pressure does not meet specifications Correct the tire air pressure Fit the dust cap 12 7 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke can cause wheel imbalance which leads to mor...

Page 80: ...WHEELS TIRES 78 Torque wrench with various accessories in set 58429094000 ...

Page 81: ...m Lift the battery up and out 13 2 Installing the battery x 101394 10 Insert battery into the battery compartment with the terminals facing to the front Battery YTX4L BS p 105 Reconnect rubber band Connect positive cable and negative cable Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Info Contact disks must be mounted between battery terminals and cable sockets with the claws facing up S...

Page 82: ...stroying the battery The battery is maintenance free which means that the acid level does not need to be checked Switch off all power consumers and switch off the engine Remove the seat p 52 Disconnect the negative cable of the battery to avoid damage to the onboard elec tronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can a...

Page 83: ...ipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the bracket and lay the cable Position the rear fairing Mount and tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the air filter box lid p 52 13 5 Changing the fuses of individual power consumers Info The fuse box contain...

Page 84: ...s with the correct rating only Fuse 58011109110 p 105 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Mount the seat p 52 13 6 Changing the fuse of the radiator fan EXC F SIX DAYS Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the ...

Page 85: ...ask and fix it with the rubber band Info Ensure that the retaining lugs engage in the fender Position the brake line and wiring harness Put the clamp on mount and tighten screw Check the headlight setting p 84 13 9 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it fre...

Page 86: ...ition the vehicle vertically a distance away from the wall Guideline Distance 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 driver If the light dark border does not meet specifications Adjust the headlight range p 84 13 11 Adjusting the headlight rang...

Page 87: ...Check that the O ring of the locking cap is seated properly 101407 10 Position locking cap and using a coin turn it clockwise all the way Press any button on the speedometer The speedometer is activated Position the speedometer in the bracket Mount and tighten the screws with washers Refit the headlight mask with the headlight p 83 Set kilometers or miles p 15 Adjust the speedometer functions p 16...

Page 88: ...ne and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedi...

Page 89: ...evel does not meet specifications Correct the coolant level Alternative 1 Coolant p 110 Alternative 2 Coolant mixed ready to use p 110 Mount the radiator cap 14 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow t...

Page 90: ...iately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 101457 10 Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 110 Coolant mixed ready to use p ...

Page 91: ...ed changes Adjust the play in the throttle cable x p 89 15 2 Adjusting the play in the throttle cable x Check the throttle cable routing p 62 101458 10 Move the handlebar to the straight ahead position Push back sleeves Loosen nut Turn adjusting screw in as far as possible Loosen nut Turn adjusting screw so that there is play in the throttle cable at the throttle grip Guideline Play in throttle ca...

Page 92: ...r to position I SOFT Condition The Map Select switch for the basic setting is at position 1 Turn lever to position II ADVANCED Condition The Map Select switch for the basic setting is at position 2 Turn lever to position II Mount the seat p 52 15 4 Adjusting the idle speed x 401342 10 Run the engine warm and push the idle speed adjusting screw all the way in Set the desired idle speed by turning t...

Page 93: ... the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Mount and tighten the screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 94: ... the engine oil is not up to the middle of the level viewer Add engine oil p 94 16 2 Changing the engine oil and oil filter cleaning the oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substa...

Page 95: ...ith magnet M12x1 5 20 Nm 14 8 lbf ft 100944 10 Insert the short oil screen into the screw plug mount it with the O ring and tighten Guideline Plug for oil screen short M16x1 5 10 Nm 7 4 lbf ft Lubricated with engine oil 101465 10 Place the long oil screen with the O rings onto a pin wrench Info The larger inside diameter of the oil screen must face the engine case Push the pin wrench through the o...

Page 96: ...ng Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight EXC F AUS EXC F SIX DAYS Install the engine guard p 64 C...

Page 97: ...normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 112 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleani...

Page 98: ...e brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake dis...

Page 99: ...cycle p 95 Change the engine oil and oil filter and clean the oil screens x p 92 Check the antifreeze and coolant level p 86 Drain the fuel from the tank into a suitable container Check the tire air pressure p 77 Remove the battery x p 79 Charge the battery x p 79 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subject...

Page 100: ...the EFI control device ignition pulse generator or ignition coil is oxidized Clean the plug connection and treat it with contact spray Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Ignition system defective Ignition coil check the second...

Page 101: ...iag nostics tool x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 92 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screens x p 92 Piston and cylinder worn Piston cylinder determine the mounting clear ance x Battery discharged Battery is not bein...

Page 102: ...g lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rollover sensor A D type input signal too high Blink code FI warning ...

Page 103: ...arning lamp MIL flashes 4x long 5x short Error level condition EXC F EU EXC F SIX DAYS Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit EXC F EU EXC F SIX DAYS Lambda sensor heater cylinder 1 sensor 1 input signal too high ...

Page 104: ...ion Pressure circulation lubrication with two rotary pumps Primary transmission 22 68 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 13 33 2nd gear 17 33 3rd gear 19 29 4th gear 23 28 5th gear 23 23 6th gear 26 22 Alternator Light coil and charging coil 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment ty...

Page 105: ...otor M6 10 Nm 7 4 lbf ft Screw timing chain securing guide M6 8 Nm 5 9 lbf ft Loctite 243 Screw timing chain tensioning rail M6 8 Nm 5 9 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Nut camshaft bearing bridge M7 15 Nm 11 1 lbf ft Lubricated with engine oil Screw camshaft bearing bridge ...

Page 106: ...TORQUES 104 Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M18LHx1 5 130 Nm 95 9 lbf ft Loctite 243 Plug for oil screen long M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft ...

Page 107: ...5 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 482 10 mm 58 35 0 39 in Seat height unloaded 970 mm 38 19 in Ground clearance unloaded 345 mm 13 58 in Weight without fuel approx All EXC F models 107 5 kg 237 lb Weight without fuel approx XCF W 106 kg 234 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 33...

Page 108: ... M C 65M M S TT Metzeler MEC 6 DAYS EXTREME XCF W 80 100 21 51M TT Dunlop GEOMAX MX51 100 100 18 59M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel tank capacity approx 9 5 l 2 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 111 Fuel reserve approx 1 5 l 1 6 qt ...

Page 109: ...urns Sport 2 turns Full payload 4 turns Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 513 mm 20 2 in Weight of rider 75 85 kg 165 187 lb 513 mm 20 2 in Weight of rider 85 95 kg 187 209 lb 513 mm 20 2 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 0 N mm 22 8 lb in Weight of rider 75 85 kg 165 187 lb 4 2 N mm 24 lb in Weight of rider 85 95 kg 187 209 lb 4 4 N mm 25 1...

Page 110: ...28 clicks Standard 24 clicks Sport 22 clicks Full payload 22 clicks Spring preload Comfort 7 mm 0 28 in Standard 7 mm 0 28 in Sport 7 mm 0 28 in Full payload 8 mm 0 31 in Spring rate Weight of rider 65 75 kg 143 165 lb 66 N mm 377 lb in Weight of rider 75 85 kg 165 187 lb 69 N mm 394 lb in Weight of rider 85 95 kg 187 209 lb 72 N mm 411 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 ps...

Page 111: ...US M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 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 attachment M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem EXC F SIX DAYS ...

Page 112: ...n inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 114 SAE p 114 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex pro...

Page 113: ...ing to SAE p 114 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to 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 ...

Page 114: ...products Supplier Motorex Protect Shine High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offr...

Page 115: ...hes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 116: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 117: ...sic position adjusting 62 Compression damping fork adjusting 39 Compression damping high speed shock absorber adjusting 36 Compression damping low speed shock absorber adjusting 35 Coolant draining 87 refilling 88 Coolant level checking 86 87 Cooling system 86 D Difficult riding conditions 25 dry sand 26 high temperature 27 low temperatures 28 muddy surfaces 27 slow speed 27 snow 28 wet sand 26 we...

Page 118: ...s fiber yarn filling changing 54 installing 54 removing 54 Map Select switch engine characteristics setting 89 for the basic setting 13 for vehicle operation 13 Motorcycle cleaning 95 raising with lift stand 42 removing from lift stand 42 O Oil filter changing 92 Oil screens cleaning 92 Overview of indicator lamps 13 14 Owner s manual 6 P Play in throttle cable checking 89 Preparing for use advice...

Page 119: ...61 T Technical data chassis 105 106 chassis tightening torques 109 engine 102 engine tightening torques 103 104 fork 107 shock absorber 108 Throttle cable play adjusting 89 Throttle cable routing checking 62 Throttle grip 11 Tire condition checking 76 Tire pressure checking 77 Transport 6 Troubleshooting 98 99 Turn signal switch 12 Type label 9 U Use definition 5 V View of vehicle front left 7 rea...

Page 120: ... 3211719en 3211719en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 05 2011 Photo Mitterbauer ...