KTM 250 SX Manual

SETUP INSTRUCTIONS 2021

250 SX

Art. no. 3214365en

INTRODUCTION

*3214365en*

3214365en

02/2021

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 contained herein 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 produc-

tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-

ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that

does not belong to the regular scope of supply.

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)

KTM applies quality assurance processes that lead to the highest possible product quality as

defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

250 SX (F6301U0)

1 MEANS OF REPRESENTATION

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.

SETUP 2

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 using the enclosed pack-

ing list.

Info

The procedure in the event of missing parts is

described in the customer service manual.

–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.

Info

The procedure in the event of transport damage is

described in the customer service manual.

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 using the enclosed pack-

ing list.

Info

The procedure in the event of missing parts is

described in the customer service manual.

2 SETUP

–Have a lift stand available.

Lift stand (78129955100)

–Together with an assistant, take the vehicle off the pallet.

402051-01

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

Info

The procedure in the event of transport damage is

described in the customer service manual.

A00001-11

–Remove the cardboard from around the shock absorber.

–Position the angle lever and linkage lever.

–Mount and tighten fitting 1.

Guideline

Nut, linkage lever

on angle lever

M14x1.5 60 Nm

(44.3 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.

–Route the clutch line with the clutch master cylinder

toward the front between the upper and lower triple

clamps.

–Install the fork legs. ( p. 9)

SETUP 2

K00620-10

–Remove screws 3. 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 4. Take off handlebar supports 5.

–Position rubber bushings 6and push through nuts 7from

below.

–Place handlebar supports in 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 4.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

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.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamp.

–Mount screws 3, but do not tighten yet.

–First bolt the handlebar clamp with screws 3onto the longer,

higher side of the handlebar supports so that both parts touch.

–Tighten screws 3evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

2 SETUP

K00938-10

–Position the controls on the right half of the handlebar.

K00616-10

–Position the controls on the left handlebar half.

–Mount the cable ties.

–Mount the fuel tank breather.

–Install the front wheel. ( p. 10)

–Install front fender. ( p. 11)

–Install the start number plate. ( p. 11)

F01708-01

–Mount the handlebar cushion.

R01229-10

Left and right footrest

–Position the new footrest and pin.

Info

Only insert the pin to the extent that the spring can

still be mounted.

SETUP 2

K00621-10

–Position spring as shown.

Spring Aengages in area B.

K00622-10

–Press the spring with special tool 8.

Footrest spring plier (79029083000)

The special tool is applied to area Con the footrest.

–Mount pin 9.

K00623-10

–Mount the washer and splint bk.

–Repeat these steps on the opposite side.

V02037-10

–Position the left frame protector.

–Insert the right frame protector from below and push it to the

rear.

–Mount and tighten screws bl with washers.

Guideline

Screw, frame protec-

tor

M5 3 Nm (2.2 lbf ft)

–Mount and tighten screw bm.

Guideline

Screw, frame protec-

tor

M5 3 Nm (2.2 lbf ft)

–Mount the cable ties.

2 SETUP

–Attach the stickers included in the scope of supply (optional).

–Refuel. ( p. 13)

–Position all controls in their exact positions on the handlebar.

Tighten all screws.

–Remove the remaining film, padding, the corrugated card-

board, and the other packaging material.

–Prepare the vehicle according to the specifications in

KTM Dealer.net for handover to the customer.

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