KTM 250 XC-F User Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE »
ENGLISH
33
8-10 mm / 0.3-0.4 in
A
2
3
1
4
B
2
B
3
4
Check chain tension
Jack the motorcycle up on its frame so that the rear wheel no longer touches
the ground.
Press the chain upward at the end of the chain sliding component. The
distance between the chain and the swing arm should be approx. 8 - 10 mm
(0.31 - 0.39 in). In the course of this procedure, the upper chain portion [A]
must be taut (see drawing). If necessary, correct the chain tension.
– Excessive tensioning of the chain will put additional load on the compo-
nents of the secondary drivetrain (chain, bearings of transmission and rear
wheel). Aside from resulting premature wear, if worst comes to worst the
chain may rupture or the countershaft of the transmission may break.
– Too much slack in the chain, on the other hand, can result in the chain
jumping off the chain wheels. If this happens, the chain could also block
the rear wheel or damage the engine.
– In either case the operator is likely to lose control of the motorcycle.
Correct chain tension
Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting
screws [3] equally far. Tighten lock nuts.
To ensure the correct alignment of the rear wheel, the marks at the left and
right chain adjusters must be positioned identically in relation to the
reference marks [B]. Tighten the counter nut of the adjusting screws.
Clean and grease the adjusting screws regularly (Motorex Long Term Grease
2000). Before tightening the collar nut, verify that the chain adjusters [4] are
sitting close to the adjusting screws and that the rear wheel has been aligned
with the front wheel.
Tighten collar nut [1] to 80 Nm.
– If you don’t happen to have a torque wrench at hand, make sure you have
the tightening torque corrected by a KTM dealer as soon as possible. A
loose axle may lead to an unstable driving behavior of your motorcycle.
– Tighten the collar nut with the required torque. A loose wheel spindle may
lead to an unstable behavior of your motorcycle.
NOTE:
The large adjusting range of the chain adjusters (32mm) allows you to use
different secondary ratios in combination with the same chain length. The
chain adjusters [4] can be rotated by 180°.

KTM 250 XC-F Specifications

General

Engine Type	Single Cylinder, 4-Stroke
Displacement	249.9 cm³
Bore x Stroke	78 mm x 52.3 mm
Starter	Electric starter
Transmission	6-speed
Cooling	Liquid cooled
Front Suspension	WP XACT-USD, Ø 48 mm
Rear Suspension	WP XACT Monoshock with linkage
Front Brake	Disc brake
Rear Brake	Disc brake
Seat Height	950 mm
Ground Clearance	370 mm
Frame	Central double-cradle type, 25CrMo4 steel
Fuel Tank Capacity	8.5 liters

Summary

IMPORTANT INFORMATION

INTENDED PURPOSE

Defines the intended use and limitations of KTM sports motorcycles for off-road competition.

SERVICE

Emphasizes the importance of proper maintenance for faultless operation and avoiding premature wear.

WARRANTY

Details warranty conditions, emphasizing adherence to service schedules and authorized dealer work.

OPERATION INSTRUMENTS

Electronic speedometer

Introduces the electronic speedometer and its basic operation with buttons.

Activating and deactivating display modes

Guides on how to access the setup menu and activate/deactivate display modes.

Setting the clock

Provides instructions on how to set the digital clock on the speedometer.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Compression damping of fork

Explains how to adjust the fork's compression damping using external screws.

Rebound damping of fork

Describes how to adjust the fork's rebound damping using the REB screw.

Compression damping of shock absorber (XC, EXC SIXDAYS)

Details adjusting low and high-speed compression damping on the rear shock.

Compression damping of shock absorber (XC-W, EXC)

Explains adjusting compression damping on XC-W/EXC shock absorbers.

Rebound damping of shock absorber

Describes adjusting rebound damping on XC-W/EXC shock absorbers.

Changing the spring preload on the telescopic fork (XC, EXC SIXDAYS)

Guides on adjusting fork spring preload using the adjuster screw.

Changing the spring preload on the telescopic fork (XC-W/EXC)

Explains adjusting XC-W/EXC fork spring preload using spacers.

Checking and adjusting the steering head bearing *

Describes how to check for play and adjust the steering head bearings.

Changing the fork offset (caster) (XC, EXC SIXDAYS) *

Explains how to change fork offset (18 or 20mm) for handling optimization.

Check chain tension

Explains how to check the chain tension by measuring slack.

Correct chain tension

Guides on adjusting chain tension and aligning the rear wheel.

General information about KTM disc brakes

Checking the brake fluid level - front brake

Refilling the front brake fluid reservoir *

Replacing the front brake pads *

Checking the rear brake fluid level

Refilling the rear brake fluid reservoir *

Replacing the rear brake pads *

Dismounting and mounting the front wheel

Provides step-by-step instructions for removing and installing the front wheel.

Dismounting and mounting the rear wheel

Details the process for removing and installing the rear wheel.

Tires, air pressure

Battery

Charging the battery

Cooling system

Explains the function of the cooling system and its components.

Checking the coolant level

Bleeding the cooling system (400/450/525)

Bleeding the cooling system (250-F)

Cleaning the air filter *

Provides instructions on how to clean the air filter and filter box.

Adjusting the throttle cables *

Checking the oil level of the hydraulic clutch (400/450/525)

Checking the oil level of the hydraulic clutch (250-F)

Bleeding of the hydraulic clutch *

Carburetor - Adjust idling (Keihin-FCRMX 37/39/41) *

Guides on adjusting engine idling speed and mixture control screw.

Adjusting the mixture control screw *

Checking the float level (float height) *

Oil circuit (400/450/525)

Oil circuit (250-F)

Checking the engine oil level

Guides on checking the engine oil level, whether the engine is cold or warm.

Changing the engine oil *

Provides instructions for changing the engine oil, including cleaning screens.

Changing the oil filters

Details the procedure for changing engine oil filters.

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for initial operation

Running in the XC/EXC models

Details the engine break-in procedure for new XC/EXC models, including RPM limits.

DRIVING INSTRUCTIONS

Check the following before each start

Lists essential pre-ride checks for safety and optimal motorcycle condition.

Starting when the engine is cold

Shifting/Riding

Braking

Details braking techniques, including front/rear brake use and conditions.

TROUBLESHOOTING

Engine doesn't crank (E-starter).

Lists causes and remedies for an engine that won't crank using the electric starter.

Engine cranks but doesn't start (E-starter).

Addresses issues when the engine cranks but fails to start via electric starter.

Engine will not start (Kickstarter).

Provides solutions for when the engine fails to start using the kickstarter.

Engine fails to idle

Lists causes and remedies for an engine that does not idle correctly.

Engine does not rev high

Addresses issues preventing the engine from reaching higher RPMs.

Engine will not reach full power

Explains why the engine might not deliver full power and how to fix it.

Engine stops or splutters in carburetor

Details common causes for the engine stopping or sputtering.

Engine gets too hot

Lists reasons for engine overheating and potential solutions.

High oil consumption

The battery is discharged

TECHNICAL DATA – ENGINE

ENGINE SPECIFICATIONS

Provides detailed technical specifications for the engine, including dimensions and components.

JASO T903 MA ENGINE OIL

BASIC CARBURETOR SETTINGS

Lists carburetor settings such as main jet, needle, and air jets for various models.

TECHNICAL DATA – CHASSIS

CHASSIS SPECIFICATIONS

Details chassis specifications like frame, suspension, brakes, and dimensions.

STANDARD FORK ADJUSTMENTS

STANDARD SHOCK ABSORBER ADJUSTMENTS

TIGHTENING TORQUES – CHASSIS