KTM 250 XC-F 2017 Manual

SETUP INSTRUCTIONS 2017

250 SX-F

250 XC‑F

Art. no. 3213576en

INTRODUCTION 1

*3213576en*

3213576en

10/2016

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, devi-

ations from illustrations 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)

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 GmbH

5230 Mattighofen, Austria

This document is valid for the following models:

250 SX‑F EU (F8101Q5)

250 SX‑F US (F8175Q5)

250 XC‑F US (F8175Q0)

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.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

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

M00075-10

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 palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

M00075-11

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.

402051-01

–Have a lift stand available.

Lift stand (78129955100)

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

–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 screw cap 1.

Guideline

Nut, frame to linkage 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.

2 SETUP 4

K00686-01

–Route the clutch line with the clutch master cylinder toward the front between the

upper and lower triple clamps.

S00867-14

–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)

The air release screw 3of the right fork leg is positioned to the front.

The left fork leg valve Ais positioned approx. 20 ° further forward.

Info

Grooves are milled into the side of the upper end of the fork legs. The sec-

ond 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.

Position the bleeder screw of the right fork leg and the valve of the left fork

leg facing forward.

K00620-11

–Remove screws 4. Remove 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, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

–Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

2 SETUP 5

–Position the handlebar clamp.

–Mount screws 4, but do not tighten yet.

–First bolt the handlebar support 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)

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™

–Install the front fender. ( p. 10)

–Install the front wheel. ( p. 9)

K00687-10

–Position the malfunction indicator lamp using holder 9. Mount and tighten screw.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–Connect plug-in connector bk.

–Connect plug-in connector bl.

–Correctly mount the fuel tank breather.

M01069-01

–Mount the handlebar cushion.

D00674-10

Left and right footrest (All SX‑F models)

–Position the new footrest and pin.

Info

Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 6

K00621-12

–Position spring as shown.

Spring Bengages in area C.

K00622-12

–Press the spring with special tool bm.

Pliers for footrest spring (79029083000)

The special tool is applied to area Don the footrest.

–Mount pin bn.

K00623-12

–Mount the washer and split pin bo.

–Repeat these steps on the opposite side.

D00674-10

Right footrest (XC‑F US)

–Position the right footrest and pin.

Info

Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 7

K00621-12

–Position spring as shown.

Spring Bengages in area C.

K00622-12

–Press the spring with special tool bm.

Pliers for footrest spring (79029083000)

The special tool is applied to area Don the footrest.

–Mount pin bn.

K00623-12

–Mount the washer and split pin bo.

R00757-10

Left footrest (XC‑F US)

–Position the left footrest and pin.

Info

Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 8

K00688-10

–Position spring as shown.

Spring Eengages in area F.

K00689-10

–Press the spring with special tool bm.

Pliers for footrest spring (79029083000)

The special tool is applied to area Gon the footrest.

–Mount pin bp.

K00690-10

–Mount the washer and split pin bq.

–Install the start number plate. ( p. 10)

–Recharge the battery. ( p. 12)

–Install the battery. ( p. 12)

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts fitting instructions.

–Apply the label included in the delivery (optional).

–Refuel. ( p. 14)

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

Guideline

Screw, fixed grip M4 5 Nm

(3.7 lbf ft)

Loctite®243™

–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-

dover to the customer.

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