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REPAIRMANUAL2005-2010 BEDIENUNGSANLEITUNG
REPARATURANLEITUNG
FEDERBEIN
GABEL
OWNER’S MANUAL MANUALE O’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES
REPAIR MANUAL MANUALE DI REPARAZIONE MANUEL DE REPARATION MANUAL DE REPARACION
SHOCK ABSORBER AMMORTIZZATORE AMMORTISSEUR AMORTIGUADOR
FORK FORCELLA FOURCHE HORQUILLA
OWNERS MANUAL2009/10 2009
2010
OWNER'S MANUAL 2009 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF-W USA 250 XCF-W ZA 250 XC-F USA 250 SX-F EU 250 SX-F USA ART. NO. 3211348en
CONTENTS CONTENTS
MEANS OF REPRESENTATION ............................................ 5 IMPORTANT NOTES ............................................................ 6 VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example) ................. 8 View of the vehicle from the right rear (example) ................ 9 LOCATION OF SERIAL NUMBERS ...................................... 10 Chassis number............................................................. 10 Type label..................................................................... 10 Key number (EXC-F, EXC‑F SIX DAYS)............................. 10 Engine number.............................................................. 10 Fork part number........................................................... 10 Shock absorber part number........................................... 11 CONTROLS ....................................................................... 12 Clutch lever .................................................................. 12 Hand brake lever ........................................................... 12 Short circuit button (XCF‑W, XC‑F, SX‑F) ......................... 12 Short circuit button (EXC-F, EXC‑F SIX DAYS).................. 12 Emergency OFF switch (250 EXC-F AUS) ........................ 12 Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 13 Electric starter button (250 EXC-F AUS).......................... 13 Light switch (EXC-F, EXC‑F SIX DAYS) ............................ 13 Light switch (XCF‑W) ..................................................... 13 Horn button (EXC-F, EXC‑F SIX DAYS)............................. 13 Flasher switch (EXC-F, EXC‑F SIX DAYS) ......................... 14 Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) ...... 14 CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) ...................... 15 Speedometer................................................................. 15 Speedometer activation and test ..................................... 15 Tripmaster switch .......................................................... 15 Setting kilometers or miles ............................................. 15 Setting the clock ........................................................... 16 Adjusting the speedometer functions............................... 16 Querying the lap time .................................................... 17 SPEED display mode (speed).......................................... 17 SPEED/H display mode (service hours) ............................ 17 SPEED/CLK display mode (time)..................................... 18 SPEED/LAP display mode (lap time)................................ 18 SPEED/ODO display mode (odometer) ............................. 18 SPEED/TR1 display mode (trip master 1)......................... 18 SPEED/TR2 display mode (trip master 2)......................... 19 SPEED/A1 display mode (average speed 1) ...................... 19 SPEED/A2 display mode (average speed 2) ...................... 19 SPEED/S1 display mode (stop watch 1)........................... 20 SPEED/S2 display mode (stop watch 2)........................... 20 CONTROLS ....................................................................... 22 Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F).............. 22 Fuel tap (SX‑F).............................................................. 22 Opening filler cap .......................................................... 22 Closing filler cap ........................................................... 23 Choke (EXC-F EU, EXC‑F SIX DAYS)................................ 23 Choke (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) .......................... 23 Shift lever..................................................................... 23 Foot brake pedal ........................................................... 24 Kickstarter .................................................................... 24 Side stand (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) .......... 24 Plug-in stand (SX‑F) ...................................................... 24 Steering lock (EXC-F, EXC‑F SIX DAYS) ........................... 25 Locking the steering (EXC-F, EXC‑F SIX DAYS)................. 25 Unlocking the steering (EXC-F, EXC‑F SIX DAYS).............. 25
2 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... Advice on first use ......................................................... Running in the engine.................................................... RIDING INSTRUCTIONS .................................................... Checks before putting into operation ............................... Starting ........................................................................ Starting up ................................................................... Shifting, riding .............................................................. Braking ........................................................................ Stopping, parking .......................................................... Refueling...................................................................... SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)........ Important maintenance work to be carried out by an authorized KTM workshop. ............................................. Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. SERVICE SCHEDULE (XC‑F, SX‑F) ...................................... Important maintenance work to be carried out by an authorized KTM workshop. ............................................. Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. SERVICE SCHEDULE FOR RIDER....................................... Important checks and maintenance work to be carried out by the rider. ............................................................ MAINTENANCE WORK ON CHASSIS AND ENGINE.............. Jacking up the motorcycle .............................................. Removing the motorcycle from the work stand.................. Checking the basic chassis setting with the rider's weight .......................................................................... Compression damping of shock absorber.......................... Adjusting high-speed compression damping of the shock absorber ....................................................................... Adjusting the low-speed compression damping of the shock absorber .............................................................. Adjusting the rebound damping of the shock absorber....... Measuring rear wheel sag unloaded ................................. Checking the static sag of the shock absorber .................. Checking the riding sag of the shock absorber .................. Adjusting the spring preload of the shock absorber ...... Adjusting the riding sag ............................................. Removing the shock absorber ..................................... Installing the shock absorber ..................................... Checking basic setting of fork ......................................... Adjusting the compression damping of the fork ................ Adjusting the rebound damping of fork ............................ Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... Bleeding fork legs.......................................................... Cleaning dust boots of fork legs ...................................... Loosening the fork protection.......................................... Positioning the fork protection ........................................ Checking play of steering head bearing ............................ Adjusting play of steering head bearing (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. Adjusting play of steering head bearing (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ..................... Fork offset (XCF‑W USA, XC‑F, SX‑F)............................... Setting the fork offset (XCF‑W USA, XC‑F, SX‑F).......... Removing the fork legs................................................... Installing the fork legs ............................................... Removing the fork protector ....................................... Installing the fork protector .......................................
x
x
x x
x x
x x
x x
26 26 27 28 28 28 29 29 29 30 30 32 32 33 34 34 35 36 36 37 37 37 37 37 37 38 39 40 40 41 41 42 42 42 43 43 44 45 45 46 46 46 46 47 47 48 48 48 49 50 50
CONTENTS
3
Removing the lower triple clamp (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ................................................ Removing the lower triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. Installing the lower triple clamp (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) ................................................ Installing the lower triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. Greasing the steering head bearing ............................. Dismounting the front fender .......................................... Installing the front fender............................................... Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) .......................................... Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) .......................................... Dismount the start number plate (XCF‑W USA, XC‑F, SX‑F)............................................................................ Installing the start number plate (XCF‑W USA, XC‑F, SX‑F)............................................................................ Handlebar position ........................................................ Adjusting the handlebar position ................................ Checking gas Bowden cable route ................................... Checking play in the gas Bowden cable ........................... Adjusting the gas Bowden cable play .......................... Checking for chain dirt accumulation .............................. Cleaning the chain......................................................... Checking the chain tension ............................................ Checking the chain tension when fitting rear wheel........... Checking the rear sprocket / engine sprocket for wear ....... Checking chain wear ...................................................... Adjusting the chain tension ............................................ Adjusting chain tension - after checking .......................... Adjusting chain tension - fitting rear wheel ...................... Adjusting the chain guide (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ Adjusting the chain guide (SX‑F) ................................ Adjusting basic position of clutch lever............................ Checking the fluid level of hydraulic clutch...................... Changing the hydraulic clutch fluid ............................ Checking the brake discs................................................ Checking free travel of hand brake lever........................... Adjusting basic position of handbrake lever (XCF‑W, XC‑F, SX‑F) ...................................................... Adjusting free travel of handbrake lever (EXC-F, EXC‑F SIX DAYS)............................................... Checking the front brake fluid level ................................. Adding front brake fluid ............................................ Checking the front brake linings...................................... Removing the front brake linings ................................ Installing the front brake linings ................................. Changing the front brake linings ................................. Checking free travel of foot brake lever ............................ Adjusting basic position of footbrake lever ................... Checking the rear brake fluid level .................................. Adding brake fluid for the rear brake .......................... Checking the rear brake linings ....................................... Removing rear brake linings ....................................... Installing the rear brake linings .................................. Changing the rear brake linings .................................. Removing the front wheel .......................................... Installing the front wheel ........................................... Removing rear wheel .................................................
x x x x x
x
x
x x
x
x
x x x
x
x
x
x x
x x
x
50 51 51 52 53 53 53 53 54 54 54 54 55 56 56 57 57 57 58 58 59 59 59 60 61 61 62 62 62 63 64 64 64 65 65 65 66 66 67 67 68 68 69 69 70 70 70 71 72 72 73
Installing the rear wheel ............................................ 73 Tire condition checking.................................................. 74 Checking tire air pressure ............................................... 75 Checking spoke tension.................................................. 75 Removing the battery (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 75 Installing the battery (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 76 Recharging the battery (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) ................................................................ 76 Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)............................................................................ 77 Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)............................................................................ 77 Removing the seat ......................................................... 77 Mounting the seat ......................................................... 78 Dismounting the fuel tank ......................................... 78 Installing the fuel tank .............................................. 79 Cooling system .............................................................. 79 Checking antifreeze and coolant level .............................. 80 Checking the coolant level.............................................. 80 Draining the coolant .................................................. 81 Refilling coolant ....................................................... 81 Glass fiber yarn filling of main silencer ............................ 81 Removing main silencer ................................................. 82 Installing the main silencer ............................................ 82 Dismounting the air filter box lid..................................... 82 Installing the air filter box lid.......................................... 82 Removing the air filter ............................................... 83 Installing the air filter ............................................... 83 Cleaning air filter ...................................................... 83 Carburetor - idle ............................................................ 84 Carburetor - adjusting idle ......................................... 84 Emptying the carburetor float chamber ....................... 85 Checking the engine oil level .......................................... 86 Changing the engine oil and oil filter, cleaning the oil screen ..................................................................... 86 Draining the engine oil .............................................. 86 Cleaning the oil screens ............................................ 87 Removing the oil filter ............................................... 88 Installing the oil filter ............................................... 88 Filling up with engine oil ........................................... 89 Adding engine oil .......................................................... 89 TROUBLESHOOTING......................................................... 90 CLEANING........................................................................ 92 Cleaning motorcycle ...................................................... 92 STORAGE ......................................................................... 93 Storage......................................................................... 93 Putting into operation after storage ................................. 93 TECHNICAL DATA - ENGINE .............................................. 94 Capacity- engine oil ....................................................... 95 Capacity - coolant.......................................................... 95 TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 96 TECHNICAL DATA - CARBURETOR..................................... 98 EXC-F, EXC‑F SIX DAYS ................................................. 98 XCF‑W, 250 XC-F USA................................................... 98 SX‑F............................................................................. 98 TECHNICAL DATA - CHASSIS ............................................ 99 Lighting equipment ..................................................... 100 Tires .......................................................................... 100 Capacity - fuel............................................................. 100
x
x x x
x
x
x
x
x x
x
x
x
x
x x x x x
CONTENTS TECHNICAL DATA - FORK................................................ EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 250 XC-F USA ............................................................ 250 SX-F EU .............................................................. 250 SX-F USA ............................................................ TECHNICAL DATA - SHOCK ABSORBER ........................... EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 250 XC-F USA ............................................................ 250 SX-F EU .............................................................. 250 SX-F USA ............................................................ TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... WIRING DIAGRAM .......................................................... Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)................. Wiring diagram (250 EXC-F AUS) ................................. Wiring diagram (XCF‑W, 250 XC-F USA) ........................ Wiring diagram (SX‑F) .................................................. SUBSTANCES................................................................. AUXILIARY SUBSTANCES................................................ STANDARDS................................................................... INDEX ............................................................................
4 101 101 101 102 102 103 103 103 104 104 105 106 106 110 112 114 116 117 119 120
MEANS OF REPRESENTATION MEANS OF REPRESENTATION 1
Symbols used The symbols used are explained in the following. 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).
All work marked with this symbol requires specialist knowledge and technical 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 in the following. Specific name
Identifies a specific name.
Name®
Identifies a protected name.
Brand™
Identifies a brand in merchandise traffic.
5
IMPORTANT NOTES
6
IMPORTANT NOTES 2
Use definition (EXC-F, EXC‑F SIX DAYS) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on secluded property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Use definition (XCF‑W, XC‑F, SX‑F) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info The motorcycle must be used only on secluded property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components. Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached. Pay careful attention to the prescribed running-in period, inspection and maintenance 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 in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com
Work rules When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts. Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle.
Transport Note Danger of damage Danger of damage by the vehicle running away or falling over. –
Always place the vehicle on a firm and even surface.
Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running. –
Do not place the vehicle where there are flammable or explosive substances.
–
Switch off the engine.
IMPORTANT NOTES
7
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
–
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
Notes/warnings Be sure to pay attention to the notes and warnings given here.
Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are missing, you or others may not recognize dangers and may therefore be injured.
Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death.
Warning Danger that will probably lead to severe and permanent injury or death.
Note Danger of serious damage to machine or material.
Warning Risk of environmental damage.
OWNER'S MANUAL –
It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
–
The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
VIEW OF VEHICLE
8
VIEW OF VEHICLE 3
View of the vehicle from the left front (example)
3.1
600657-10
1
Hand brake lever
2
Filler cap
3
Clutch lever
4
Fuel tap
5
Shift lever
6
Air filter box lid
7
Chain guide
VIEW OF VEHICLE
9
View of the vehicle from the right rear (example) 3.2
600656-10
1
Rubber band for the side stand
2
Shock absorber, compression adjustment
3
Chassis number
4
Fork protector
5
Shock absorber, rebound adjustment
6
Level viewer, rear brake fluid
7
Level viewer, engine oil
8
Kickstarter
LOCATION OF SERIAL NUMBERS LOCATION OF SERIAL NUMBERS 4
Chassis number
4.1
The chassis number is stamped on the steering head on the right.
500127-10
Type label 4.2
The type label is fixed to the front of the steering head.
500128-10
Key number (EXC-F, EXC‑F SIX DAYS) 4.3
The key number is stamped on the key strap.
500125-10
Engine number 4.4
The engine number is stamped on the left side of the engine under the engine sprocket.
600661-12
Fork part number 4.5
The fork part number is stamped on the inner side of the fork stub.
500082-10
10
LOCATION OF SERIAL NUMBERS
11
Shock absorber part number 4.6
The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.
500129-10
CONTROLS
12
CONTROLS 5
Clutch lever 5.1
The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.
600659-10
Hand brake lever 5.2
Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake.
400196-10
Short circuit button (XCF‑W, XC‑F, SX‑F) 5.3
The short circuit button is fitted on the left side of the handlebar. Possible states • Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started. • Short circuit button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
500132-10
Short circuit button (EXC-F, EXC‑F SIX DAYS) 5.4
The short circuit button is fitted on the left side of the handlebar. Possible states • Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started. • Short circuit button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
500134-10
Emergency OFF switch (250 EXC-F AUS) 5.5
The emergency OFF switch is fitted on the left side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. Ignition on – In this position, the ignition circuit is closed, and the engine can be started.
500131-10
CONTROLS
13
Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W, XC‑F) 5.6
The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button
in basic position pressed – In this position, the electric starter is actuated.
400198-10
Electric starter button (250 EXC-F AUS) 5.7
The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button
in basic position pressed – In this position, the electric starter is actuated.
500131-11
Light switch (EXC-F, EXC‑F SIX DAYS) 5.8
The light switch is fitted on the left side of the handlebar. Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned to the left. In this position, the high beam and the tail light are switched on. 500134-12
Light switch (XCF‑W) 5.9
The light switch is on the right of the speedometer. Possible states (250 XCF-W ZA) • Light off – Light switch is pressed in up to the stop. In this position, the light is switched off. • Light on – Light switch is pulled out to the stop. In this position, the low beam and the tail light are switched on.
500146-10
(250 XCF-W USA) • The light switch has no function when delivered. – It can be used if lighting is fitted later.
Horn button (EXC-F, EXC‑F SIX DAYS) 5.10
The horn button is fitted on the left side of the handlebar. Possible states • Horn button • Horn button
500134-11
in neutral position pressed – The horn is operated in this position.
CONTROLS
14
Flasher switch (EXC-F, EXC‑F SIX DAYS) 5.11
Flasher switch is fitted on the left side of the handlebar. Possible states Flasher light off – Flasher switch is in the central position. Flasher light, left, on – Flasher switch turned to the left. Flasher light, right, on – Flasher switch turned to the right.
500145-10
Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) 5.12
Possible states High beam indicator lamp lights up blue – High beam is switched on. Flasher indicator lamp flashes green – Flasher light is switched on.
500147-01
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
15
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 6
Speedometer
6.1
–
Press the key
–
Press the button
to control different functions.
–
Press the button
to control different functions.
to change the display mode or change to one of the setup menus.
Info In its condition at delivery, the display mode SPEED/H and SPEED/ODO is activated. 400312-01
Speedometer activation and test 6.2
Activating the speedometer: The speedometer is activated when one of the keys 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.
400313-01
WS (wheel size) After the display function test, the wheel size WS is displayed briefly.
Info 2205 mm corresponds to the size of the 21" front wheel with a series production tire. The display then changes to the last selected mode. 400314-01
Tripmaster switch 6.3
(Option: Tripmaster switch) You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info The trip master is an optional accessory.
Setting kilometers or miles 6.4
Info If you change the unit of measure, the ODO value is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed. Condition The motorcycle is standing. –
Press the button display.
briefly and repeatedly until H appears at the bottom right of the
–
Press the button
for 3 - 5 seconds.
–
Press the button
The Setup menu opens and the active functions are displayed.
400329-01
repeatedly until the Km/h/Mph display flashes.
Adjusting Km/h – Press the button
.
Adjusting Mph – Press the button
.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) –
Press the button
16
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
Info If no button is 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.
Setting the clock 6.5
Condition The motorcycle is standing. –
Press the button the display.
briefly and repeatedly until CLK appears at the bottom right of
–
Press the button
for 3 - 5 seconds.
–
Set the hour display with the button
–
Press the button
–
You can set the following segments in the same way as the hours by pressing the button and the button .
The hour display flashes. and/or button
.
briefly.
The next segment of the display flashes and can be set. 400330-01
Info The seconds can only be set to zero. –
Press the button
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
Info If no button is 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.
Adjusting the speedometer functions 6.6
Info Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is standing. –
Press the button display.
briefly and repeatedly until H appears at the bottom right of the
–
Press the button
for 3 - 5 seconds.
–
Switch to the function you require by briefly pressing the button
The Setup menu opens and the active functions are displayed. .
The selected function flashes. Activating a function – Press the button 400318-01
.
The icon remains in the display and the display changes to the next function. Deactivating a function – Press the button
.
The icon disappears from the display and the display changes to the next function. –
Activate or deactivate all functions accordingly.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) –
Press the button
17
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
Info If no button is 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.
Querying the lap time 6.7
Info This function can be called only if lap times are measured. Condition The motorcycle is standing. –
Press the button the display.
briefly and repeatedly until LAP appears at the bottom right of
–
Press the button
briefly.
LAP 1 appears on the left side of the display. –
Laps 1-10 can be displayed by pressing the button
–
The
–
Press the button
.
button has no function briefly.
Next display mode
400321-01
Info If an impulse is received from the wheel speed sensor, the left side of the display changes back to the SPEED mode.
SPEED display mode (speed) 6.8
–
Press the button the display.
briefly and repeatedly until SPEED appears on the left side of
The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph.
Info Making the setting according to the country. When an impulse comes from the front wheel, the left side of the speedometer display changes to the SPEED mode and the current speed is shown.
400317-02
SPEED/H display mode (service hours) 6.9
Condition • Vehicle at a standstill –
Press the button display.
briefly and repeatedly until H appears at the bottom right of the
The number of service hours of the engine is shown in the H display mode. The service hour counter stores the total traveling time.
Info 400316-01
The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals. If the speedometer is in the H display mode at the start of the trip, it automatically changes to the ODO display mode. The H display mode is suppressed during travel. Press the button . No function Press the button . No function Press the button The display changes to the Setup menu of the speedometer for 3 - 5 seconds. functions.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) Press the button briefly.
18
next display mode
SPEED/CLK display mode (time) 6.10
–
Press the button the display.
briefly and repeatedly until CLK appears at the bottom right of
The time is displayed in the CLK display mode.
400319-01
Press the button . No function Press the button . No function Press the button The display changes to the Setup menu of the clock. for 3 - 5 seconds. Press the button next display mode briefly.
SPEED/LAP display mode (lap time) 6.11
–
Press the button the display.
briefly and repeatedly until LAP appears at the bottom right of
In the LAP display mode, up to ten laps can be timed with the stop watch.
Info If the lap time continues after you press the button already occupied. Lap 10 must be timed with the button . 400320-01
Press the button Press the button Press the button for 3 - 5 seconds. Press the button briefly.
, 9 memory locations are
. Starts or stops the clock. . Stops the current lap time and saves it, and the stop watch starts the next lap. The stop watch and the lap time are reset. next display mode
SPEED/ODO display mode (odometer) 6.12
–
Press the button the display.
briefly and repeatedly until ODO appears at the bottom right of
The total number of kilometers ridden is shown in the ODO display mode.
400317-01
Press the button . No function Press the button . No function Press the button – for 3 - 5 seconds. Press the button next display mode briefly.
SPEED/TR1 display mode (trip master 1) 6.13
–
Press the button display.
briefly and repeatedly until TR1 appears at the top right of the
TR1 (trip master 1) runs constantly and counts to 999.9. You can use it to measure trips or the distance between refueling stops. TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info 400323-01
If 999.9 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 The TR1, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds. Press the button next display mode briefly.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
19
SPEED/TR2 display mode (trip master 2) 6.14
–
Press the button display.
briefly and repeatedly until TR2 appears at the top right of the
TR2 (trip master 2) runs constantly and counts to 999.9. The displayed value can be set manually with the button practical function for rides by the road book.
and the button
. A very
Info The TR2 value can also be corrected manually during the trip using the button and the button . If 999.9 is exceeded, TR2 is automatically reset to 0.0.
400324-01
Press the button . Increases value TR2. Press the button . Decreases value TR2. Press the button Clears value TR2. for 3 - 5 seconds. Press the button next display mode briefly.
SPEED/A1 display mode (average speed 1) 6.15
–
Press the button display.
briefly and repeatedly until A1 appears at the top right of the
A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip master 1) and S1 (stop watch 1). The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.
400325-01
Press the button . No function Press the button . No function Press the button The TR1, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds. Press the button next display mode briefly.
SPEED/A2 display mode (average speed 2) 6.16
–
Press the button display.
briefly and repeatedly until A2 appears at the top right of the
A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.
Info The displayed value can differ from the actual average speed if S2 is not stopped after the ride. 400326-01
Press the button . No function Press the button . No function Press the button – for 3 - 5 seconds. Press the button next display mode briefly.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
20
SPEED/S1 display mode (stop watch 1) 6.17
–
Press the button display.
briefly and repeatedly until S1 appears at the top right of the
S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running when an impulse is received from the wheel speed sensor. The calculation of this value starts with the first impulse of the wheel speed sensor and ends three seconds after the last impulse. Press the button . No function Press the button . No function Press the button The TR1, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds. Press the button next display mode briefly.
400327-01
SPEED/S2 display mode (stop watch 2) 6.18
–
Press the button display.
briefly and repeatedly until S2 appears at the top right of the
S2 (stop watch 2) is a manual stop watch. If S2 is running in the background, the S2 display flashes in the speedometer display. Press the button . Starts or stops S2. Press the button . No function Press the button The S2 and A2 displays are reset to 0.0. for 3 - 5 seconds. Press the button next display mode briefly.
400328-01
Table of functions Display
Press the button
.
Press the button
.
Press the button 5 seconds.
for 3 -
Press the button briefly.
SPEED/H display mode (service hours)
No function
No function
The display changes to the Setup menu of the speedometer functions.
next display mode
SPEED/CLK display mode (time)
No function
No function
The display changes to the Setup menu of the clock.
next display mode
SPEED/LAP display mode (lap time)
Starts or stops the clock.
Stops the current lap time and saves it, and the stop watch starts the next lap.
The stop watch and the lap time are reset.
next display mode
SPEED/ODO display mode (odometer)
No function
No function
–
next display mode
SPEED/TR1 display mode (trip master 1)
No function
No function
The TR1, A1 and S1 displays are reset to 0.0.
next display mode
SPEED/TR2 display mode (trip master 2)
Increases value TR2.
Decreases value TR2.
Clears value TR2.
next display mode
SPEED/A1 display mode (average speed 1)
No function
No function
The TR1, A1 and S1 displays are reset to 0.0.
next display mode
SPEED/A2 display mode (average speed 2)
No function
No function
–
next display mode
SPEED/S1 display mode (stop watch 1)
No function
No function
The TR1, A1 and S1 displays are reset to 0.0.
next display mode
SPEED/S2 display mode (stop watch 2)
Starts or stops S2.
No function
The S2 and A2 displays are reset to 0.0.
next display mode
Table of conditions and activability Display SPEED/H display mode (service hours)
Vehicle at a standstill
Menu can be activated
•
SPEED/CLK display mode (time)
•
SPEED/LAP display mode (lap time)
•
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
21
Table of conditions and activability Display
Vehicle at a standstill
Menu can be activated
SPEED/TR1 display mode (trip master 1)
•
SPEED/TR2 display mode (trip master 2)
•
SPEED/A1 display mode (average speed 1)
•
SPEED/A2 display mode (average speed 2)
•
SPEED/S1 display mode (stop watch 1)
•
SPEED/S2 display mode (stop watch 2)
•
CONTROLS
22
CONTROLS 7
Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) 7.1
The fuel tap is on the left side of the fuel tank. Using tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. • Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve. • Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.
500137-10
Fuel tap (SX‑F) 7.2
The fuel tap is on the left side of the fuel tank. Using tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. • Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.
500178-10
Opening filler cap 7.3
–
400199-10
Press release button , turn filler cap counterclockwise and lift it free.
CONTROLS
23
Closing filler cap 7.4
–
Replace the filler cap and turn clockwise until the release button locks in place.
Info Run the fuel tank breather hose without kinks.
400199-11
Choke (EXC-F EU, EXC‑F SIX DAYS) 7.5
The flasher switch is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info If the engine is warm, the choke function must be deactivated.
500136-10
Possible states • Choke function activated – The choke lever is pulled to the stop. • Choke function deactivated – The choke lever is pushed back to the stop.
Choke (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) 7.6
Choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info If the engine is warm, the choke function must be deactivated.
600660-10
Possible states • Choke function activated – The choke lever is pulled out to the stop. • Choke function deactivated – The choke lever is pushed in to the stop.
Shift lever 7.7
Shift lever is mounted on the left side of the engine.
600661-13
The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.
600661-10
CONTROLS
24
Foot brake pedal 7.8
Foot brake pedal is located in front of the right footrest. The foot brake pedal is used to activate the rear brake.
600664-10
Kickstarter 7.9
Kickstarter is fitted on the right of the engine. The engine can be started with either the kickstarter or the electric starter. The upper part of the kickstarter can be swung out.
Info Before riding, swing the upper part of the kickstarter inward toward the engine.
600664-11
Side stand (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) 7.10
Note Danger of damage Danger of damage by the vehicle running away or falling over. –
Always place the vehicle on a firm and even surface.
Note Material damage Damage and destruction of components by excessive load. – 500140-10
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
To park the motorcycle, press the side stand to the ground with your foot and lean the motorcycle on it. When you are riding, the side stand must be folded up and secured with the rubber band .
600665-10
Plug-in stand (SX‑F) 7.11
Note Danger of damage Danger of damage by the vehicle running away or falling over. –
Always place the vehicle on a firm and even surface.
To park the motorcycle, insert plug-in stand into the left side of the wheel spindle.
Info 400203-10
Remove the plug-in stand before starting on a trip.
CONTROLS
25
Steering lock (EXC-F, EXC‑F SIX DAYS) 7.12
Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.
500126-10
Locking the steering (EXC-F, EXC‑F SIX DAYS) 7.13
Note Danger of damage Danger of damage by the vehicle running away or falling over. –
Always place the vehicle on a firm and even surface.
–
Park the motorcycle.
–
Turn the handlebar as far as possible 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.
Unlocking the steering (EXC-F, EXC‑F SIX DAYS) 7.14
–
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 Never leave the key in the steering lock.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
26
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 8
Advice on first use
8.1
Danger Danger of accidents Danger from insufficient traffic competence. –
Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.
Warning Risk of injury Risk of injury by missing/inadequate protective clothing. –
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be in perfect condition and meet legal requirements.
Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels. –
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning Danger of accidents Critical riding behavior due to inappropriate riding. –
Adapt your riding speed to the road conditions and your riding ability.
Warning Danger of accidents Accident risk caused by presence of a passenger. –
Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning Danger of accidents Brake system failure. –
If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake.
Warning Danger of accidents Unstable riding behavior. –
Do not exceed the maximum permitted 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 your motorcycle, remember that others may feel disturbed by excessive noise. –
Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
–
Before your first trip, read the entire operating instructions carefully.
–
Get to know the controls.
–
Adjust the basic position of clutch lever. (
p. 62)
(XCF‑W, XC‑F, SX‑F) – Adjust the basic position of handbrake lever. (
p. 64)
(EXC-F, EXC‑F SIX DAYS) – Adjust the free travel of the handbrake lever. (
p. 65)
–
Adjust the basic position of the footbrake lever.
–
Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
x(
p. 68)
Info Offroad, you should be accompanied by another person on another machine so that you can help each other. –
Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
–
Do not make any offroad trips that over-stress your ability and experience.
–
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION –
If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.
Info Motorcycles react sensitively to any changes of weight distribution. –
Do not exceed the overall maximum permitted weight and the axle loads. Guideline
–
Maximum permissible overall weight
335 kg (739 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Run the engine in.
Running in the engine 8.2
–
During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline Maximum engine speed During the first 3 service hours
7,000 rpm
Maximum engine performance during the running-in period
–
27
During the first 3 service hours
≤ 50 %
During the next 12 service hours
≤ 75 %
Avoid fully opening the throttle!
RIDING INSTRUCTIONS
28
RIDING INSTRUCTIONS 9
Checks before putting into operation
9.1
Info Make sure that the motorcycle is in a perfect technical condition before use.
Info In the interests of riding safety, make a habit of making a general check before you ride. –
Check the engine oil level. (
–
Check the chain tension. (
–
Check for chain dirt accumulation. (
–
Check the tire condition. (
–
Check the tire air pressure. (
–
Check the front brake fluid level. (
–
Check the rear brake fluid level. (
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check brake system function.
–
Check the coolant level. (
–
Check that all operating elements are correctly adjusted and free to move.
–
Check the functioning of the electrical equipment.
p. 86) p. 58) p. 57)
p. 74) p. 75) p. 65) p. 69) p. 66) p. 70)
p. 80)
Starting 9.2
Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.
Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. –
Always warm up the engine at low engine speeds.
Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again. Engine has been out of use for more than 1 week – Empty the carburetor float chamber. (
x
p. 85)
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the ON position. (Figure 500137-10
p. 22)
Fuel can flow from the fuel tank to the carburetor. (SX‑F) – Turn handle of the fuel tap to the ON position. (Figure 500178-10 Fuel can flow from the fuel tank to the carburetor. –
Remove the motorcycle from the stand.
–
Shift gear to neutral.
(250 EXC-F AUS) – Turn the emergency OFF switch to the position The engine is cold (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) – Pull the choke lever out as far as possible. (EXC-F EU, EXC‑F SIX DAYS) – Pull the choke lever to the stop.
.
p. 22)
RIDING INSTRUCTIONS –
29
Press the electric starter button or press the kickstarter robustly through its full range.
Info Don't open the throttle.
Starting up 9.3
Info If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber band. –
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
Shifting, riding 9.4
Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. –
When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
–
If the choke function was activated, deactivate it after the engine has warmed up.
–
When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range; the speed hardly drops, but the fuel consumption falls considerably.
–
Always open the throttle only as much as the engine 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 oil, the engine and the cooling system.
–
Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
Braking 9.5
Warning Danger of accidents If you brake too hard, the wheels can lock. –
Adapt your braking to the traffic situation and the road conditions.
Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. –
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning Danger of accidents Reduced braking due to wet or dirty brakes. –
Clean or dry dirty or wet brakes by riding and braking gently.
–
On sandy, wet or slippery surfaces, use the rear brake.
–
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
–
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.
RIDING INSTRUCTIONS
30
Stopping, parking 9.6
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.
Warning Danger of burns Some vehicle components get very hot when the machine is driven. –
Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.
Note Danger of damage Danger of damage by the vehicle running away or falling over. –
Always place the vehicle on a firm and even surface.
Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running. –
Do not place the vehicle where there are flammable or explosive substances.
Note Material damage Damage and destruction of components by excessive load. –
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
–
Brake the motorcycle.
–
Shift gear to neutral.
(XCF‑W, XC‑F, SX‑F) – Press and hold the short circuit button
while the engine is idling until the engine stops.
(EXC-F, EXC‑F SIX DAYS) – Press and hold the short circuit button
while the engine is idling until the engine stops.
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
–
Park the motorcycle on firm ground.
Refueling 9.7
Danger Fire hazard Fuel can easily catch fire. –
Never fill up 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 specifications on filling up with fuel.
Warning Danger of poisoning Fuel is poisonous and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning Environmental hazard Improper handling of fuel is a danger to the environment. –
Do not allow fuel to get into the ground water, the ground, or the sewage system. –
Switch off the engine.
–
Open the filler cap. (
p. 22)
RIDING INSTRUCTIONS
31 –
Fill the fuel tank with fuel up to measurement . Guideline Measurement of
35 mm (1.38 in)
A
Total fuel tank capacity, approx. (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
9.2 l (2.43 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 116)
400382-10
Total fuel tank capacity, approx. (SX‑F)
8.0 l (2.11 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 116)
–
Close the filler cap. (
p. 23)
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)
32
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) 10
Important maintenance work to be carried out by an authorized KTM workshop.
10.1
Engine
S3N
S20A
•
•
•
•
Check the engine mounting screws for tightness.
•
•
Clean the spark plug connectors and check for tightness.
•
•
Check that the screws in the shift lever and the kickstarter are tight.
•
•
Change the engine oil and oil filter, clean the oil screen.
x(
p. 86)
Replace the spark plug.
•
Check the valve clearance.
Carburetor
Attachments
x
Check the carburetor connection boots for cracks and leakage.
•
Check the vent hoses for damage and routing without sharp bends.
•
•
Check the idle.
•
•
Check the cooling system for leakage.
•
•
•
•
Check the antifreeze and coolant level. (
p. 80)
Check the exhaust system for leakage and looseness.
•
Check the Bowden cables for damage, smooth operation and routing without sharp bends.
•
•
Check the fluid level of the hydraulic clutch. (
•
•
•
•
Clean the air filter.
x(
p. 62)
p. 83)
Check the cables for damage and routing without sharp bends.
•
Check the functioning of the electrical equipment.
•
Check the headlamp setting. Brakes
Check the brake discs. (
p. 66) p. 70)
p. 64)
Check the front brake fluid level. ( Check the rear brake fluid level. (
p. 65) p. 69)
Check the brake lines for damage and leakage. Check the free travel of the hand brake lever. ( Check the free travel of the foot brake lever. (
p. 64)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the screws and guide bolts of the rake system for tightness.
•
•
Check the shock absorber and fork for leakage and functioning.
•
•
Bleed fork legs. (
p. 68)
•
Check the brake system function.
Clean dust boots of fork legs. (
x
p. 46)
•
p. 45)
•
Check the swingarm bearing.
•
Check play of steering head bearing. ( Wheels
• •
Check the front brake linings. ( Check the rear brake linings. (
Chassis
•
•
Check all screws to see if they are tight.
•
•
Check the spoke tension. (
•
•
p. 46)
•
•
•
•
•
•
•
•
•
•
p. 75)
Check the rim run-out. Check the tire condition. (
p. 74)
Check the tire air pressure. ( Check the chain wear. (
p. 75)
p. 59)
Check the chain tension. ( Clean the chain. (
p. 58)
•
•
Check the wheel bearing for play.
•
•
Clean and grease the adjusting screws of the chain adjuster.
•
•
S3N: After 3 service hours S20A: Every 20 service hours S30A: Every 30 service hours
S30A
p. 57)
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)
33
Important maintenance work to be carried out by an authorized KTM workshop (as additional order). 10.2
Competition use S10A
S20A
S40A
Hobby use S80A
S20A
S40A
Carry out a complete fork service.
x Carry out a complete shock absorber service. x Grease the steering head bearing. x ( p. 53) Treat electric contacts with contact spray. Change the hydraulic clutch fluid. x ( p. 63) Change the front brake fluid. x Change the rear brake fluid. x Clean the spark arrestor. x (250 XCF-W USA) Check the clutch discs for wear. x Check the clutch. x Check the cylinder and piston for wear. x Check the camshafts. x Check the valve spring seat. x Check the valves. x Change the valves. x Check wear of valve guides. x Change the valve springs. x Check the timing-chain tensioner function. x Check the crankshaft run-out at the bearing pin. x Change the conrod bearing. x Change the crankshaft main bearing. x Fully check the transmission. x Check the shift mechanism. x Check the spring length of the oil pressure regulator valve. x Change the glass fiber yarn filling of the main silencer. x Change the foot brake cylinder seals. x Check/adjust the carburetor components. x S10A: Every 10 service S20A: Every 20 service S40A: Every 40 service S80A: Every 80 service J1A: annually J2A: every 2 years
hours / after every race hours hours hours
J1A
J2A
•
•
S80A •
•
•
•
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SERVICE SCHEDULE (XC‑F, SX‑F)
34
SERVICE SCHEDULE (XC‑F, SX‑F) 11
Important maintenance work to be carried out by an authorized KTM workshop.
11.1
Engine
S3N
S10A
S30A
•
•
•
•
•
•
Check the engine mounting screws for tightness.
•
•
•
Clean the spark plug connectors and check for tightness.
•
•
•
Check that the screws in the shift lever and the kickstarter are tight.
•
•
•
Change the engine oil and oil filter, clean the oil screen.
x(
p. 86)
Replace the spark plug.
•
Check the valve clearance.
Carburetor
Attachments
x
Check the carburetor connection boots for cracks and leakage.
•
•
Check the vent hoses for damage and routing without sharp bends.
•
•
•
Check the idle.
•
•
•
Check the cooling system for leakage.
•
•
•
•
•
•
•
•
Check the antifreeze and coolant level. (
p. 80)
Check the exhaust system for leakage and looseness. Check the Bowden cables for damage, smooth operation and routing without sharp bends.
•
•
•
Check the fluid level of the hydraulic clutch. (
•
•
•
•
•
•
Clean the air filter.
x(
p. 62)
p. 83)
Check the cables for damage and routing without sharp bends. Brakes
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the screws and guide bolts of the brake system for tightness.
•
•
•
Check the shock absorber and fork for leakage and functioning.
•
•
•
•
•
•
•
•
•
Check the front brake linings. (
p. 66)
Check the rear brake linings. ( Check the brake discs. (
p. 70)
p. 64)
Check the front brake fluid level. ( Check the rear brake fluid level. (
p. 65) p. 69)
Check the brake lines for damage and leakage. Check the free travel of the hand brake lever. ( Check the free travel of the foot brake lever. (
p. 64) p. 68)
Check the brake system function. Chassis
Clean dust boots of fork legs. ( Bleed fork legs. (
x
p. 46)
p. 45)
Check the swingarm bearing. Check play of steering head bearing. ( Wheels
•
•
•
Check all screws to see if they are tight.
p. 46)
•
•
•
Check the spoke tension. (
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the wheel bearing for play.
•
•
•
Clean and grease the adjusting screws of the chain adjuster.
•
•
•
p. 75)
Check the rim run-out. Check the tire condition. (
p. 74)
Check the tire air pressure. ( Check the chain wear. ( Check the chain tension. ( Clean the chain. (
p. 75)
p. 59) p. 58)
p. 57)
S3N: After 3 service hours - corresponds to about 21 liters (5.55 US gal) of fuel S10A: Every 10 service hours - corresponds to about 70 liters (18.5 US gal) of fuel / after every race S30A: Every 30 service hours - corresponds to about 210 liters (55.5 US gal) of fuel
SERVICE SCHEDULE (XC‑F, SX‑F)
35
Important maintenance work to be carried out by an authorized KTM workshop (as additional order). 11.2
S10A
S20A
S40A
S80A
Carry out a complete fork service.
x x Grease the steering head bearing. x ( p. 53) Treat electric contacts with contact spray. Change the hydraulic clutch fluid. x ( p. 63) Change the front brake fluid. x Change the rear brake fluid. x Check the clutch discs for wear. x Check the clutch. x Check the cylinder and piston for wear. x Check the camshafts. x Check the valve spring seat. x Check the valves. x Change the valves. x Check wear of valve guides. Change the valve springs. x Check the timing-chain tensioner function. x Check the crankshaft run-out at the bearing pin. x Change the conrod bearing. x Change the crankshaft main bearing. x Fully check the transmission. x Check the shift mechanism. x
J1A
J2A
•
• •
Carry out a complete shock absorber service.
Change the foot brake cylinder seals.
x
Check/adjust the carburetor components. S10A: Every 10 service S20A: Every 20 service S40A: Every 40 service S80A: Every 80 service J1A: annually J2A: every 2 years
hours hours hours hours
-
•
•
•
•
•
•
•
•
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•
•
to to to to
about about about about
•
•
•
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•
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x
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
x
x
corresponds corresponds corresponds corresponds
•
•
Check the spring length of the oil pressure regulator valve. Change the glass fiber yarn filling of the main silencer.
•
•
70 liters (18.5 US gal) of fuel / after every race 140 liters (37 US gal) of fuel 280 liters (74 US gal) of fuel 560 liters (148 US gal) of fuel
SERVICE SCHEDULE FOR RIDER
36
SERVICE SCHEDULE FOR RIDER 12
Important checks and maintenance work to be carried out by the rider.
12.1
NB1A Check the engine oil level. (
p. 86)
Check the front brake fluid level. ( Check the rear brake fluid level. ( Check the front brake linings. (
• p. 65)
•
p. 69)
•
p. 66)
Check the rear brake linings. (
•
p. 70)
•
Check and adjust Bowden cables.
•
Bleed fork legs. (
•
p. 45)
Clean dust boots of fork legs. ( Clean the chain. (
p. 46)
•
p. 57)
•
Check the chain tension. ( Check the chain wear. (
p. 58)
•
p. 59)
•
Check the rear sprocket / engine sprocket for wear. ( Clean the air filter.
x(
Check the coolant level. (
p. 75)
•
p. 74)
•
p. 80)
Empty the carburetor float chamber.
• •
p. 83)
Check the tire air pressure. ( Check the tire condition. (
p. 59)
•
x(
p. 85)
•
Check that all operating elements for smooth operation.
•
Check braking.
•
Check all screws, nuts and hose clamps regularly for tightness.
•
NB1A: Depending on conditions of use according to requirements.
MAINTENANCE WORK ON CHASSIS AND ENGINE
37
MAINTENANCE WORK ON CHASSIS AND ENGINE 13
Jacking up the motorcycle
13.1
Note Danger of damage Danger of damage by the vehicle running away or falling over. – –
Always place the vehicle on a firm and even surface.
Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground. Work stand (54829055000)
600697-01
–
Secure the motorcycle against falling over.
Removing the motorcycle from the work stand 13.2
Note Danger of damage Danger of damage by the vehicle running away or falling over. –
Always place the vehicle on a firm and even surface.
–
Remove the motorcycle from the work stand.
–
Remove the work stand.
Checking the basic chassis setting with the rider's weight 13.3
Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. –
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of the suspension components must match your body weight.
–
As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Guideline Standard rider weight
75… 85 kg (165… 187 lb.)
–
If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accordingly.
–
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.
Compression damping of shock absorber 13.4
The shock absorber can regulate compression damping separately in the low-speed and high-speed ranges (Dual Compression Control). The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle. The low-speed and high-speed technology works non-specifically.
Adjusting high-speed compression damping of the shock absorber 13.5
Danger Danger of accidents The shock absorber is under high pressure. –
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
Info The high-speed setting can be seen during the fast compression of the shock absorber.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
38
Turn adjusting screw clockwise with a ring wrench until it stops.
Info Do not loosen nut ! –
Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed (EXC‑F, EXC‑F SIX DAYS, XCF-W)
600667-10
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Compression damping, high-speed (250 XC-F USA) Comfort
1 turn
Standard
1 turn
Sport
3/4 turn
Compression damping, high-speed (250 SX-F EU) Comfort
1.5 turns
Standard
1.5 turns
Sport
1 turn
Compression damping, high-speed (250 SX-F USA) Comfort
1 turn
Standard
1 turn
Sport
3/4 turn
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting the low-speed compression damping of the shock absorber 13.6
Danger Danger of accidents The shock absorber is under high pressure. –
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. –
Turn adjusting screw clockwise with a screwdriver until it stops.
Info Do not loosen nut !
600667-11
MAINTENANCE WORK ON CHASSIS AND ENGINE –
39
Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed (EXC‑F, EXC‑F SIX DAYS, XCF-W) Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Compression damping, low-speed (250 XC-F USA) Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping, low-speed (250 SX-F EU) Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping, low-speed (250 SX-F USA) Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting the rebound damping of the shock absorber 13.7
Danger Danger of accidents The shock absorber is under high pressure. –
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself. –
Turn adjusting screw clockwise until it stops.
Info Do not loosen nut !
400210-10
MAINTENANCE WORK ON CHASSIS AND ENGINE –
40
Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (EXC‑F, EXC‑F SIX DAYS, XCF-W) Comfort
26 clicks
Standard
24 clicks
Sport
22 clicks
Rebound damping (250 XC-F USA) Comfort
25 clicks
Standard
25 clicks
Sport
23 clicks
Rebound damping (250 SX-F EU) Comfort
24 clicks
Standard
22 clicks
Sport
21 clicks
Rebound damping (250 SX-F USA) Comfort
25 clicks
Standard
24 clicks
Sport
22 clicks
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Measuring rear wheel sag unloaded 13.8
A 0
–
Jack up the motorcycle. (
–
Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover.
–
Make a note of the value as measurement .
–
Remove the motorcycle from the work stand. (
p. 37)
p. 37)
400220-10
Checking the static sag of the shock absorber 13.9
A 0
–
Measure distance of rear wheel unloaded. (
–
Ask someone to help you by holding the motorcycle upright.
–
Measure the distance between the rear axle and the fixed point again.
–
Make a note of the value as measurement .
p. 40)
Info The static sag is the difference between measurements and . –
B 0
Check the static sag.
»
Static sag (EXC‑F, EXC‑F SIX DAYS, XCF-W)
35 mm (1.38 in)
Static sag (250 XC-F USA)
33 mm (1.3 in)
Static sag (250 SX-F EU)
33 mm (1.3 in)
Static sag (250 SX-F USA)
33 mm (1.3 in)
If the static sag is less or more than the specified value: –
400221-10
Adjust the spring preload of the shock absorber.
x(
p. 41)
MAINTENANCE WORK ON CHASSIS AND ENGINE
41
Checking the riding sag of the shock absorber 13.10
0 A
–
Measure distance of rear wheel unloaded. (
–
With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out.
–
The other person now has to measure the distance between the rear axle and a fixed point.
–
Make a note of the value as measurement .
p. 40)
Info The riding sag is the difference between measurements and . –
Check the riding sag.
C »
Riding sag (EXC‑F, EXC‑F SIX DAYS, XCF-W)
105 mm (4.13 in)
Riding sag (250 XC-F USA)
112 mm (4.41 in)
Riding sag (250 SX-F EU)
105 mm (4.13 in)
Riding sag (250 SX-F USA)
107 mm (4.21 in)
If the riding sag differs from the specified measurement: –
400222-10
Adjust the riding sag.
Adjusting the spring preload of the shock absorber 13.11
x(
p. 42)
x
Danger Danger of accidents The shock absorber is under high pressure. –
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
2 1
–
Remove shock absorber.
–
After removing the shock absorber, clean it thoroughly.
–
Loosen screw .
–
Turn adjusting ring until the spring is no longer under tension.
x(
p. 42)
Combination wrench (50329080000)
A
Hook wrench (T106S) –
Measure the overall spring length when not under tension.
–
Tighten the spring by turning adjusting ring to measurement . Guideline Spring preload (EXC‑F, EXC‑F SIX DAYS, XCF-W)
9 mm (0.35 in)
Spring preload (250 XC-F USA)
5 mm (0.2 in)
Spring preload (250 SX-F EU)
6 mm (0.24 in)
Spring preload (250 SX-F USA)
7 mm (0.28 in)
Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. 400216-10
–
Tighten screw . Guideline Screw, shock absorber adjusting ring
–
Install the shock absorber.
x(
p. 42)
M6
5 Nm (3.7 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
42
Adjusting the riding sag –
x Remove shock absorber. x (
–
After removing the shock absorber, clean it thoroughly.
–
Choose and mount a suitable spring.
13.12
p. 42)
Guideline 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)
Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. –
Install the shock absorber.
–
Check the static sag of the shock absorber. (
p. 40)
–
Check the riding sag of the shock absorber. (
p. 41)
–
Adjust the rebound damping of the shock absorber. (
x(
Removing the shock absorber 13.13
p. 42)
p. 39)
x –
Jack up the motorcycle. (
–
Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position.
–
Remove screw , push splash protector to the side, and remove the shock absorber.
–
Push splash protector to the side and position the shock absorber. Mount and tighten screw .
p. 37)
600668-10
Installing the shock absorber 13.14
x Guideline Screw, top shock absorber –
M12
80 Nm (59 lbf ft)
Loctite® 243™
M12
80 Nm (59 lbf ft)
Loctite® 243™
Mount and tighten screw . Guideline Screw, bottom shock absorber
600668-11
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 dissolve the Teflon coating, thereby drastically reducing the service life. –
Remove the motorcycle from the work stand. (
p. 37)
MAINTENANCE WORK ON CHASSIS AND ENGINE
43
Checking basic setting of fork 13.15
Info For various reasons, no exact riding sag can be determined for the forks. –
As with the shock absorber, smaller weight differences can be compensated by the spring preload.
–
However, if your fork is often overloaded (hard end stop on compression), you must fit harder springs to avoid damage to the fork and frame.
400189-01
Adjusting the compression damping of the fork 13.16
Info The hydraulic compression damping determines the fork suspension behavior. (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove protection covers . –
Turn adjusting screws clockwise until they stop.
Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – 100020-10
Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Comfort
26 clicks
Standard
22 clicks
Sport
20 clicks
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. –
Mount protection covers .
(SX‑F, 250 XC-F USA) – Turn adjusting screws clockwise until they stop.
Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs.
600669-10
MAINTENANCE WORK ON CHASSIS AND ENGINE –
44
Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping (250 XC-F USA) Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping (250 SX-F EU) Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Compression damping (250 SX-F USA) Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting the rebound damping of fork 13.17
Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn adjusting screws clockwise until they stop.
Info The adjusting screws are located at the top 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
600670-10
Rebound damping Comfort
24 clicks
Standard
22 clicks
Sport
22 clicks
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. (SX‑F, 250 XC-F USA) – Remove protection covers . –
Turn adjusting screws clockwise until they stop.
Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.
100020-10
MAINTENANCE WORK ON CHASSIS AND ENGINE –
45
Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping (250 XC-F USA) Comfort
22 clicks
Standard
21 clicks
Sport
21 clicks
Rebound damping (250 SX-F EU) Comfort
21 clicks
Standard
20 clicks
Sport
20 clicks
Rebound damping (250 SX-F USA) Comfort
22 clicks
Standard
22 clicks
Sport
20 clicks
Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. –
Mount protection covers .
Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.18
–
Turn adjusting screws counterclockwise until they stop.
Info Make the same adjustment on both fork legs. –
Turn back clockwise by the number of turns corresponding to the fork type. Guideline Spring preload - Preload Adjuster
600671-01
Comfort
0 turn
Standard
1 turn
Sport
3 turns
Info Turn clockwise to increase spring preload, turn counterclockwise to reduce spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload.
Bleeding fork legs 13.19
–
Jack up the motorcycle. (
–
Remove bleeder screws briefly.
–
Mount and tighten bleeder screws.
–
Remove the motorcycle from the work stand. (
p. 37)
Any excess pressure escapes from the interior of the fork.
100021-10
p. 37)
MAINTENANCE WORK ON CHASSIS AND ENGINE
46
Cleaning dust boots of fork legs 13.20
–
Jack up the motorcycle. (
–
Loosen the fork protection. (
–
Push dust boots of both fork legs downwards.
p. 37) p. 46)
Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.
600691-10
– –
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray (
p. 118)
–
Press the dust boots back into their normal position.
–
Remove excess oil.
–
Position the fork protection. (
–
Remove the motorcycle from the work stand. (
–
Remove screws and take off clamp.
–
Remove screws on left fork leg. Push the fork protection downwards.
–
Remove the screws on the right fork leg. Push the fork protection downwards.
–
Position the fork protection on the left fork leg. Mount and tighten screws .
p. 46) p. 37)
Loosening the fork protection 13.21
500087-11
Positioning the fork protection 13.22
Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – 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
500087-10
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Checking play of steering head bearing 13.23
Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. –
The steering head bearing play should be adjusted immediately in an authorized KTM workshop.
Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. –
Jack up the motorcycle. (
p. 37)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
47
Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. »
If there is noticeable play present: (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) – Adjust play of the steering head bearing.
400387-10
(EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Adjust play of the steering head bearing. –
x( x(
p. 47) p. 47)
Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. »
If click positions are noticeable: (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) – Adjust play of the steering head bearing.
x( (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Adjust play of the steering head bearing. x ( – –
Adjusting play of steering head bearing 13.24
p. 47) p. 47)
Check the steering head bearing and replace if required.
Remove the motorcycle from the work stand. (
p. 37)
x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) –
Jack up the motorcycle. (
p. 37)
–
Loosen screws and .
–
Loosen and retighten screw . Guideline Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
–
Fully tighten screw . Guideline Screw, top triple clamp
100022-10
–
M8
20 Nm (14.8 lbf ft)
M8
20 Nm (14.8 lbf ft)
Tighten screw . Guideline Screw, top steering stem
–
Adjusting play of steering head bearing 13.25
Check play of steering head bearing. (
p. 46)
x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) –
Jack up the motorcycle. (
–
Loosen screw . Remove screw .
–
Loosen and retighten screw .
p. 37)
Guideline Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
–
Fully tighten screw . Guideline Screw, top triple clamp
500103-11
–
M8
17 Nm (12.5 lbf ft)
Mount and tighten screw . Guideline Screw, top steering stem
–
M8
Check play of steering head bearing. (
17 Nm (12.5 lbf ft) p. 46)
Loctite® 243™
MAINTENANCE WORK ON CHASSIS AND ENGINE
48
Fork offset (XCF‑W USA, XC‑F, SX‑F) 13.26
You can see the currently set offset if you remove screw . The fork offset has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing. The fork offset can optionally be adjusted. Marking to the front gives greater stability on fast racetracks. Fork offset Front marking
18 mm (0.71 in)
Marking to the rear (condition at delivery) gives better handling in bends. Fork offset Rear marking
20 mm (0.79 in)
800009-10
Setting the fork offset 13.27
x (XCF‑W USA, XC‑F, SX‑F) –
Remove the lower triple clamp.
–
Remove screw . Remove the steering stem.
–
Clean the parts and check for damage.
–
Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten screw .
x(
p. 50)
Guideline Screw, bottom steering head
M20x1.5
–
Install the lower triple clamp.
–
Remove the front wheel.
–
Remove screws and take off clamp.
500104-10
x(
60 Nm (44.3 lbf ft)
p. 51)
Removing the fork legs 13.28
x(
p. 72)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove cable clip . –
Remove screws and take off brake caliper.
–
Hang the brake caliper and the brake line loosely to the side.
500093-10
(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) – Loosen screw . Remove the fork leg on the left. –
500094-10
Loosen screw . Remove the fork leg on the right.
Loctite® 243™
MAINTENANCE WORK ON CHASSIS AND ENGINE
49
(EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Loosen screw . Remove the fork leg on the left. –
Loosen screw . Remove the fork leg on the right.
100023-11
Installing the fork legs 13.29
x –
Position the fork legs.
Info The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp. Position the bleeder screw to the front.
100021-10
(EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) – Fully tighten screw . Guideline Screw, top triple clamp –
M8
17 Nm (12.5 lbf ft)
M8
12 Nm (8.9 lbf ft)
M8
20 Nm (14.8 lbf ft)
M8
15 Nm (11.1 lbf ft)
Fully tighten screw . Guideline Screw, bottom triple clamp
500094-11
(EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Fully tighten screw . Guideline Screw, top triple clamp –
Fully tighten screw . Guideline Screw, bottom triple clamp
100023-10
–
Position brake caliper, mount and tighten screws . Guideline Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Mount cable clip . – 500093-11
Position the wiring harness.
–
Position the brake line. Put the clamp on, mount and tighten screws .
–
Install the front wheel.
x(
p. 72)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork protector 13.30
50
x –
Remove the fork legs. (
–
Remove screws on the left fork leg. Remove the fork protector upwards.
–
Remove the screws on the right fork leg. Remove the fork protector upwards.
–
Position the fork protection on the left fork leg. Mount and tighten screws .
p. 48)
500105-10
Installing the fork protector 13.31
x Guideline Remaining screws, chassis –
M6
10 Nm (7.4 lbf ft)
Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis
–
Install the fork legs.
x(
M6
10 Nm (7.4 lbf ft)
p. 49)
500105-10
Removing the lower triple clamp 13.32
x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) –
Remove the fork legs. (
p. 48)
(XCF‑W USA, XC‑F, SX‑F) – Dismount the start number plate. (
p. 54)
(250 EXC-F SIX DAYS EU) – Remove the headlight mask with the headlight. (
p. 53)
–
Dismount the front fender. (
–
Remove screws and hang the CDI control unit to the side.
p. 53)
Info Do not unplug the CDI control unit. –
Remove screw . Remove screw , take off the top triple clamp with the handlebar and place it on one side.
Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.
500099-10
500100-10
–
Remove O-ring . Remove protector ring .
–
Remove the lower triple clamp with the steering stem.
–
Remove the upper steering head bearing.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp 13.33
51
x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) –
Remove the fork legs. (
–
Remove the headlight mask with the headlight. (
–
Dismount the front fender. (
–
Remove screws and hang the CDI control unit to the side.
p. 48) p. 53)
p. 53)
Info Do not unplug the CDI control unit. –
Remove screw . Loosen screw . Take off top triple clamp with the handlebar and place it on one side.
Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.
500149-10
–
Remove protector ring .
–
Remove the lower triple clamp with the steering stem.
–
Remove the upper steering head bearing.
500150-10
Installing the lower triple clamp 13.34
x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) –
Clean the bearing and sealing elements, check for damage, and grease. Long-life grease (
3 0 2 0 1 0
–
p. 117)
Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
Info Check whether the top steering head seal is correctly positioned. –
Push up protective ring and O-ring .
–
Position the upper triple clamp with the steering.
–
Mount and tighten screw .
500098-10
Guideline Screw, top steering head –
M20x1.5
10 Nm (7.4 lbf ft)
Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws . Guideline Remaining screws, chassis
500099-11
–
Install the front fender. (
M6 p. 53)
(XCF‑W USA, XC‑F, SX‑F) – Install the start number plate. (
p. 54)
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
52
(250 EXC-F SIX DAYS EU) – Refit the headlight mask with the headlight. ( –
Install the fork legs.
–
Mount and tighten screw .
x(
p. 54)
p. 49)
Guideline Screw, top steering stem
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
–
Check the cable harness, cable, brake and clutch line for free movement and free laying.
–
Check play of steering head bearing. (
p. 46)
500103-10
Installing the lower triple clamp 13.35
x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) –
Clean the bearing and sealing elements, check for damage, and grease. Long-life grease (
–
2 0 1 0
p. 117)
Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
Info Check whether the top steering head seal is correctly positioned. –
Push on protective ring .
–
Position the upper triple clamp with the steering.
–
Mount and tighten screw .
500151-10
Guideline Screw, top steering head –
M20x1.5
10 Nm (7.4 lbf ft)
Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws . Guideline Remaining screws, chassis
500149-11
M6
–
Install the front fender. (
–
Refit the headlight mask with the headlight. (
–
Install the fork legs.
–
Tighten screw .
x(
10 Nm (7.4 lbf ft)
p. 53) p. 54)
p. 49)
Guideline Screw, top steering stem
100022-11
M8
20 Nm (14.8 lbf ft)
–
Check the cable harness, cable, brake and clutch line for free movement and free laying.
–
Check play of steering head bearing. (
p. 46)
MAINTENANCE WORK ON CHASSIS AND ENGINE Greasing the steering head bearing 13.36
53
x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F) – Remove the lower triple clamp.
x ( p. 50) Install the lower triple clamp. x ( p. 51) (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Remove the lower triple clamp. x ( p. 51) – Install the lower triple clamp. x ( p. 52) –
800010-10
Dismounting the front fender 13.37
–
Remove screws . Remove the front fender.
–
Make sure that the distance bushings remain in place.
–
Ensure that the spacing sleeves are mounted in the fender.
600692-10
Installing the front fender 13.38
–
Position the front fender. Mount and tighten screws . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Info Take care with the contact between the holding lugs and the start number plate or headlight mask. 600692-10
Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) 13.39
–
Switch off all electrical equipment.
–
Remove screw and take off clamp.
–
Loosen the rubber band . Push up the headlight mask and swing it forwards.
–
Pull out the electric plug connector and remove the headlight mask with the headlight.
600703-10
600702-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
54
Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA) 13.40
–
Connect the electric plug connector .
–
Position the headlight mask and fix it with the rubber band .
600702-11
Info Take care with the contact of the holding lug at the fender. –
Position the brake line and cable harness. Put the clamp on, mount and tighten screw .
–
Check the headlamp setting.
600703-11
Dismount the start number plate (XCF‑W USA, XC‑F, SX‑F) 13.41
–
Remove screw and take off clamp.
–
Remove screw with the spacing sleeve. Remove the start number plate.
500101-10
Installing the start number plate (XCF‑W USA, XC‑F, SX‑F) 13.42
–
Position the start number plate. Mount and tighten screw with the spacing sleeve. Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Info Take care with the contact of the holding lug at the fender. 500101-11
–
Position the brake line and cable harness. Put the clamp on, mount and tighten screw .
Handlebar position 13.43
On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes
15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of from the center.
0 A
B 0
A 0
B 0 400223-11
Distance between holes
3.5 mm (0.138 in)
The handlebar supports can be mounted in 4 different positions. (250 EXC-F SIX DAYS EU) The handlebar supports can also be mounted at 2 different heights (with and without spacer). Thick spacer
9 mm (0.35 in)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar position 13.44
x
0 1 2 0
1 0 2 0
55
(EXC‑F EU, EXC‑F AUS, XCF‑W, XC‑F, SX‑F) – Remove the four screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side.
Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.
400223-10
–
Remove the two screws . Remove the handlebar support.
–
Place the handlebar support in the required position. Mount and tighten the two screws . Guideline Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite® 243™
Info Position evenly the left and right handlebar supports. –
Position the handlebar.
Info Make sure cables and wiring are positioned correctly. –
Position the handlebar clamp. Mount 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. (250 EXC-F SIX DAYS EU) – Remove the four screws . Remove the handlebar clamps with rubber washers and elastomeres .
0 1 2 0 3 0 4 0 0 5
–
Remove the handlebar and lay it to one side.
Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.
0 6 7 0 8 0 9 0
–
Remove lower shells .
–
Remove clamp bar with rubber cones .
–
Remove the two screws . Remove the handlebar support.
–
Place the handlebar support in the required position. Mount and tighten the two screws . Guideline Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Condition Spacer fitted:
400343-10
Use a M10x35 screw Condition without spacer : Use a M10x25 screw
Info Position evenly the left and right handlebar supports. –
Mount rubber cones and clamp bar .
Loctite® 243™
MAINTENANCE WORK ON CHASSIS AND ENGINE –
Mount lower shells .
–
Position the handlebar.
56
Info Make sure cables and wiring are positioned correctly. –
Position handlebar clamps with rubber washers and elastomeres . Elastomer kit green - soft quality (SXS05125203) Elastomer kit yellow - medium quality (standard) (SXS05125204) Elastomer kit red - hard quality (SXS05125205)
Info The elastomeres are available in different versions. –
Mount and evenly tighten the four screws . Guideline Screw, handlebar clamp
M8
16 Nm (11.8 lbf ft)
Info Make sure the gap width is even.
Checking gas Bowden cable route 13.45
–
The two gas Bowden cables must run parallel behind the handlebar down to the frame. They must be routed directly on the frame above the tank bearing to the carburetor.
–
Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain the play in the gas Bowden cable.
600672-10
Checking play in the gas Bowden cable 13.46
Play in gas Bowden cable »
If the gas Bowden cable play does not meet specifications: –
400192-10
3… 5 mm (0.12… 0.2 in)
Adjust the gas Bowden cable play.
x(
p. 57)
MAINTENANCE WORK ON CHASSIS AND ENGINE
57
Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.
Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. »
If the idle speed changes: –
Adjusting the gas Bowden cable play 13.47
Adjust the gas Bowden cable play.
x(
p. 57)
x –
Dismount the fuel tank.
–
Check gas Bowden cable route. (
–
Move the handlebar to the straight-ahead position.
–
Push back bellows .
–
Loosen nut . Turn adjusting screw in as far as possible.
–
Loosen nut . Turn adjusting screw so that there is play in the gas Bowden cable at the throttle grip.
x(
p. 78) p. 56)
Guideline Play in gas Bowden cable 600673-10
3… 5 mm (0.12… 0.2 in)
–
Tighten nut .
–
Press and hold the throttle grip in the closed setting. Turn adjusting screw out until there is no play in the Bowden cable .
–
Tighten nut .
–
Push bellows on. Check the throttle grip for smooth operation.
–
Install the fuel tank.
–
Check play in the gas Bowden cable. (
–
Check the chain for coarse dirt accumulation.
x(
p. 79) p. 56)
Checking for chain dirt accumulation 13.48
»
If the chain is very dirty: –
Clean the chain. (
p. 57)
800012-10
Cleaning the chain 13.49
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 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 necessary.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
MAINTENANCE WORK ON CHASSIS AND ENGINE
58
Info The service life of the chain depends largely on its maintenance. –
Clean the chain regularly and then treat with chain spray. Chain cleaner (
p. 117)
Offroad chain spray (
p. 117)
Checking the chain tension 13.50
Warning Danger of accidents Danger caused by incorrect chain tension. –
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. –
Jack up the motorcycle. (
–
Push the chain at the end of the chain sliding component upwards to measure the chain tension .
p. 37)
Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension 400213-10
»
If the chain tension does not meet specifications: –
–
8… 10 mm (0.31… 0.39 in)
Adjusting chain tension - after checking. (
Remove the motorcycle from the work stand. (
p. 60)
p. 37)
Checking the chain tension when fitting rear wheel 13.51
Warning Danger of accidents Danger caused by incorrect chain tension. –
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. –
Make sure that the chain adjusters are fitted correctly on the adjusting screws.
–
Push the chain at the end of the chain sliding component upwards to measure chain tension .
Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension
400213-10
»
8… 10 mm (0.31… 0.39 in)
If the chain tension does not meet specifications: –
Adjust the chain tension when fitting rear wheel. (
p. 61)
MAINTENANCE WORK ON CHASSIS AND ENGINE
59
Checking the rear sprocket / engine sprocket for wear 13.52
–
Check the rear sprocket / engine sprocket for wear. »
If the rear sprocket / engine sprocket are worn: –
Replace rear sprocket / engine sprocket.
Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be replaced together. 400227-01
–
Check that the chain guide is firmly seated and not worn.
–
Jack up the motorcycle. (
–
Shift gear to neutral.
Checking chain wear 13.53
–
p. 37)
Pull the upper chain section with the specified weight . Guideline
0 A
Weight of chain wear measurement –
10… 15 kg (22… 33 lb.)
Measure distance of 18 chain links in the lower chain section.
Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance at the longest chain section »
1 2 3
If the distance is greater than the specified measurement: –
B 0
272 mm (10.71 in)
Replace the chain.
Info When you replace the chain, you should also replace the rear sprocket and the engine sprocket. New chains wear out faster on old, worn sprockets.
16 17 18
400226-10
–
Remove the motorcycle from the work stand. (
p. 37)
Adjusting the chain tension 13.54
Warning Danger of accidents Danger caused by incorrect chain tension. –
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. –
Jack up the motorcycle. (
–
Push the chain at the end of the chain sliding component upwards to measure chain tension .
p. 37)
Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.
400213-10
MAINTENANCE WORK ON CHASSIS AND ENGINE –
Loosen nut .
–
Loosen nuts .
–
60
Adjust the chain tension by turning the left and right adjusting screws . Guideline Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. –
Tighten nuts .
–
Make sure that chain adjusters are fitted correctly on the adjusting screws .
–
Tighten nut . Guideline Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. Chain adjusters can be turned by 180°.
400225-10
–
Remove the motorcycle from the work stand. (
–
Loosen nut .
–
Loosen nuts .
–
Adjust the chain tension by turning the adjusting screws left and right.
p. 37)
Adjusting chain tension - after checking 13.55
Guideline Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. –
Tighten nuts .
–
Make sure that the chain adjusters are fitted correctly on the adjusting screws .
–
Tighten nut . Guideline Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info 400225-13
The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°.
MAINTENANCE WORK ON CHASSIS AND ENGINE
61
Adjusting chain tension - fitting rear wheel 13.56
–
Loosen nuts .
–
Adjust the chain tension by turning the adjusting screws left and right. Guideline Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. –
Tighten nuts .
400225-11
Adjusting the chain guide 13.57
x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) –
Remove screws and . Take off the chain guide.
Condition Number of teeth: ≤ 44 teeth – –
Insert nut in hole . Position the chain guide. Mount and tighten screws and . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Condition Number of teeth: ≥ 45 teeth – –
Insert nut in hole . Position the chain guide. Mount and tighten screws and . Guideline Remaining screws, chassis
400252-10
M6
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain guide 13.58
62
x (SX‑F) –
Loosen screw . Remove screw . Push the chain guide down.
Condition Number of teeth: ≤ 44 teeth –
Insert collar sleeve in hole . Position the chain guide.
–
Mount and tighten screw . Tighten screw . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Condition Number of teeth: ≥ 45 teeth –
Insert collar sleeve in hole . Position the chain guide.
–
Mount and tighten screw . Tighten screw . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
400224-10
Adjusting basic position of clutch lever 13.59
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw .
Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!
500133-11
Checking the fluid level of hydraulic clutch 13.60
Warning Skin irritations Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! –
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Check the fluid level. Fluid level under top level of container. »
If the level of the fluid does not meet specifications: –
400339-10
4 mm (0.16 in)
Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 (
p. 116)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
63
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt fluid immediately with water.
Changing the hydraulic clutch fluid 13.61
x
Warning Skin irritations Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! –
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Fill bleeding syringe with the appropriate hydraulic fluid.
400339-10
Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 (
p. 116)
–
On the slave cylinder, remove bleeder screw and mount bleeding syringe .
–
Inject the liquid into the system until it escapes from bore hole of the master cylinder without bubbles.
–
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
–
Remove the bleeding syringe. Mount and tighten screws bleeder screw.
–
Correct the fluid level of the hydraulic clutch.
600683-10
Guideline Fluid level under top level of container. 400340-10
–
4 mm (0.16 in)
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt fluid immediately with water.
MAINTENANCE WORK ON CHASSIS AND ENGINE
64
Checking the brake discs 13.62
Warning Danger of accidents Reduced braking due to worn brake discs. –
Worn brake discs should be replaced immediately in an authorized KTM workshop. –
Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement .
Info
A
Wear reduces the thickness of the brake disc around the area used by the brake linings. Wear limit of brake discs
400257-10
»
Front
2.5 mm (0.098 in)
Rear
3.5 mm (0.138 in)
If the brake disc thickness is less than the specified value: –
Change the brake disc.
Checking free travel of hand brake lever 13.63
Warning Danger of accidents Brake system failure. –
If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications. (XCF‑W, XC‑F, SX‑F) – Push the hand brake lever forwards and check free travel . Free travel of hand brake lever »
≥ 3 mm (≥ 0.12 in)
If the free travel does not meet specifications: –
Adjust the basic position of handbrake lever. (
p. 64)
400196-11
(EXC-F, EXC‑F SIX DAYS) – Push the hand brake to the handlebar and check free travel . Free travel of hand brake lever »
≥ 3 mm (≥ 0.12 in)
If the free travel does not meet specifications: –
Adjust the free travel of the handbrake lever. (
p. 65)
400196-13
Adjusting basic position of handbrake lever (XCF‑W, XC‑F, SX‑F) 13.64
–
Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw .
Info Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!
400196-12
–
Check the free travel of the hand brake lever. (
p. 64)
MAINTENANCE WORK ON CHASSIS AND ENGINE
65
Adjusting free travel of handbrake lever (EXC-F, EXC‑F SIX DAYS) 13.65
–
Adjust the free travel of the handbrake lever with the adjustment screw .
Info Turn the adjustment screw clockwise to reduce free travel. The pressure point moves away from the handlebar. Turn the adjustment screw counterclockwise to increase free travel. The pressure point moves towards the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!
400196-12
–
Check the free travel of the hand brake lever. (
p. 64)
Checking the front brake fluid level 13.66
Warning Danger of accidents Brake system failure. –
MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning Danger of accidents Reduced braking due to old brake fluid. –
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. –
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Check the brake fluid level in the viewer . »
If the brake fluid is below the MIN mark: –
Add front brake fluid.
x(
p. 65)
400231-10
Adding front brake fluid 13.67
x
Warning Danger of accidents Brake system failure. –
MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning Skin irritations Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking due to old brake fluid. –
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Never user 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. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!
MAINTENANCE WORK ON CHASSIS AND ENGINE
66
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Add brake fluid to level . Guideline Measurement of Brake fluid DOT 4 / DOT 5.1 (
–
5 mm (0.2 in) p. 116)
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt brake fluid immediately with water.
600706-10
Checking the front brake linings 13.68
Warning Danger of accidents Reduced braking due to worn brake linings. –
Worn brake linings should be replaced immediately in an authorized KTM workshop. –
Check the brake linings for minimum thickness . Minimum thickness »
≥ 1 mm (≥ 0.04 in)
If the minimum thickness is less than specified: –
Change the front brake linings.
x(
p. 67)
400235-10
Removing the front brake linings 13.69
x
Warning Danger of accidents Improper brake maintenance and repair. –
Always have your brake system maintained and repaired in an authorized KTM workshop. –
Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.
Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. – 500089-11
Remove locking split pins , withdraw bolt , and take out the brake pads.
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove cable clip . –
Remove screws and take off brake caliper.
–
Clean the brake caliper and brake caliper support.
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the front brake linings 13.70
67
x
Warning Danger of accidents Reduced braking 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 necessary.
Warning Danger of accidents Reduced braking due to use of non-approved brake linings. –
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. –
Check the brake discs. (
–
Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly.
p. 64)
Info The arrow on the leaf spring points in the rotation direction of the brake disc.
500091-10
–
Fit the brake pads, insert bolt , and mount locking split pins .
–
Position the brake caliper, and mount and tighten screws . Guideline Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Mount cable clip . – 500089-12
Changing the front brake linings 13.71
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.
x
Warning Skin irritations Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking due to old brake fluid. –
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Never user 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. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!
MAINTENANCE WORK ON CHASSIS AND ENGINE
68
–
Remove the front brake linings.
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
x(
p. 66)
–
Remove cover with membrane .
–
Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
–
Install the front brake linings.
–
Add brake fluid to level .
x(
p. 67)
Guideline Measurement of Brake fluid DOT 4 / DOT 5.1 ( –
5 mm (0.2 in) p. 116)
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt brake fluid immediately with water.
600706-10
Checking free travel of foot brake lever 13.72
Warning Danger of accidents Brake system failure. –
If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications. –
Disconnect spring .
–
Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel . Guideline Free travel at foot brake lever »
If the free travel does not meet specifications: –
600704-10
–
Adjusting basic position of footbrake lever 13.73
3… 5 mm (0.12… 0.2 in)
Adjust the basic position of the footbrake lever.
x(
p. 68)
Reconnect spring .
x
Warning Danger of accidents Brake system failure. –
If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications. –
Disconnect spring .
–
Loosen nut and with push rod , turn it back until you have maximum free travel.
–
To adjust the basic position of the footbrake lever individually, lossen nut and turn screw accordingly.
Info The range of adjustment is limited. 600705-10
–
Turn push rod accordingly until you have free travel . If necessary, adjust the basic position of the footbrake lever. Guideline Free travel at foot brake lever
3… 5 mm (0.12… 0.2 in)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
69
Hold screw and tighten nut . Guideline Remaining nuts, chassis
–
M8
30 Nm (22.1 lbf ft)
M6
15 Nm (11.1 lbf ft)
Hold push rod and tighten nut . Guideline Remaining nuts, chassis
–
Reconnect spring .
Checking the rear brake fluid level 13.74
Warning Danger of accidents Brake system failure. –
MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning Danger of accidents Reduced braking due to old brake fluid. –
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. –
Stand the vehicle upright.
–
Check the brake fluid level in the viewer . »
When in the viewer an air bubble is visible: –
Add brake fluid for the rear brake.
x(
p. 69)
400234-10
Adding brake fluid for the rear brake 13.75
x
Warning Danger of accidents Brake system failure. –
MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning Skin irritations Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking due to old brake fluid. –
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Never user 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. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!
MAINTENANCE WORK ON CHASSIS AND ENGINE –
70
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. 116)
Mount the screw cap with the membrane and the O-ring.
Info Clean up overflowed or spilt brake fluid immediately with water.
400233-10
Checking the rear brake linings 13.76
Warning Danger of accidents Reduced braking due to worn brake linings. –
Worn brake linings should be replaced immediately in an authorized KTM workshop. –
Check the brake linings for minimum thickness . ≥ 1 mm (≥ 0.04 in)
Minimum thickness »
If the minimum thickness is less than specified: –
Change the rear brake linings.
x(
p. 71)
400238-10
Removing rear brake linings 13.77
x
Warning Danger of accidents Improper brake maintenance and repair. –
Always have your brake system maintained and repaired in an authorized KTM workshop. –
Press the brake caliper by hand on to the brake 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.
400236-10
Installing the rear brake linings 13.78
–
Remove the locking split pins , withdraw the bolt , and take out the brake pads.
–
Clean brake caliper and brake caliper support.
x
Warning Danger of accidents Reduced braking 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 necessary.
Warning Danger of accidents Reduced braking due to use of non-approved brake linings. –
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. –
Check the brake discs. (
p. 64)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
71
Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly.
Info The arrow on the leaf spring points in the rotation direction of the brake disc.
500122-10
–
Fit the brake pads, insert bolt , and mount locking split pins .
Info Make sure that the decoupling plate is mounted on the piston side of the brake pad. –
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.
400237-10
Changing the rear brake linings 13.79
x
Warning Skin irritations Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking due to old brake fluid. –
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Never user 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. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!
400233-10
–
Remove the rear brake linings.
–
Stand the vehicle upright.
–
Remove screw cap with membrane and the O-ring.
–
Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
–
Install the rear brake linings.
–
Add brake fluid to level .
x(
x(
Brake fluid DOT 4 / DOT 5.1 ( –
p. 70)
p. 70) p. 116)
Mount the screw cap with the membrane and the O-ring.
Info Clean up overflowed or spilt brake fluid immediately with water.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the front wheel 13.80
72
x –
Jack up the motorcycle. (
–
Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.
p. 37)
Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
500089-10
–
Remove screw .
–
Loosen screw .
–
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.
500084-10
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 damaged.
500085-10
–
Remove spacing sleeves .
500086-10
Installing the front wheel 13.81
x
Warning Danger of accidents Reduced braking 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 necessary. –
Clean and grease shaft seal rings and bearing surface of the spacing sleeves. Long-life grease (
–
500086-11
p. 117)
Insert the spacing sleeves.
MAINTENANCE WORK ON CHASSIS AND ENGINE
73
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
–
Mount and tighten screw . Guideline Screw, front wheel spindle
500084-11
M24x1.5
45 Nm (33.2 lbf ft)
–
Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.
–
Remove the motorcycle from the work stand. (
–
Pull the front wheel brake and push down hard on the fork several times to align the fork legs.
–
Fully tighten screw .
p. 37)
Guideline Screw, fork stub
Removing rear wheel 13.82
M8
15 Nm (11.1 lbf ft)
x –
Jack up the motorcycle. (
–
Press the brake caliper by hand on to the brake disc in order to press back the brake piston.
p. 37)
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 the 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 spindle. Take the rear wheel out of the swing arm.
Info Do not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged. 400258-10
–
Remove the spacing sleeves .
400260-11
Installing the rear wheel 13.83
x
Warning Danger of accidents Reduced braking 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 necessary.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
74
Clean and grease shaft seal rings and bearing surface of the spacing sleeves. Long-life grease (
p. 117)
–
Insert the spacing sleeves.
–
Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
–
Put the chain on.
–
Position the chain adjuster . Mount nut , but do not tighten it yet.
–
Check the chain tension when fitting rear wheel. (
–
Make sure that the chain adjusters are fitted correctly on the adjusting screws .
–
Tighten nut .
400260-10
400259-10
p. 58)
Guideline Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°. –
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.
–
Remove the motorcycle from the work stand. (
p. 37)
400225-12
Tire condition checking 13.84
Info Only mount tires approved or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be mounted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces. –
Examine the front and rear tires for cuts, foreign bodies and other damage. »
If you find cuts, foreign bodies or other damage on a tire: –
–
Change the tire.
Check the depth of the tread.
Info Note local national regulations concerning the minimum tread depth. Minimum tread depth »
If the tread depth is less than the minimum allowable depth: –
Change the tire.
≥ 2 mm (≥ 0.08 in)
MAINTENANCE WORK ON CHASSIS AND ENGINE
75
Checking tire air pressure 13.85
Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. –
Remove dust cap.
–
Check tire air pressure when tires are cold. Tire air pressure off road Front
1.0 bar (15 psi)
Rear
1.0 bar (15 psi)
Road tire pressure (EXC-F, EXC‑F SIX DAYS) 400241-01
»
Front
1.5 bar (22 psi)
Rear
2.0 bar (29 psi)
If the tire pressure does not meet specifications: –
–
Correct tire pressure.
Mount dust cap.
Checking spoke tension 13.86
Warning Danger of accidents Unstable riding behavior due to loose spokes. –
If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.
Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. –
To check spoke tension, tap each spoke with a screwdriver. Guideline You should hear a high note. Spoke nipple, front wheel
M4,5
5 Nm (3.7 lbf ft)
Spoke nipple, rear wheel
M5
5 Nm (3.7 lbf ft)
Info If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.
400228-01
Removing the battery 13.87
x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
Warning Risk of injury Battery acid and battery gases cause serious chemical burns. –
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician. –
Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 77)
MAINTENANCE WORK ON CHASSIS AND ENGINE
76
–
Disconnect the negative (minus) cable of the battery.
–
Pull back the plus pole cover and disconnect the positive (plus) cable of the battery.
–
Hang the rubber band out to the bottom.
–
Lift the battery up.
500069-10
Installing the battery 13.88
x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) –
Place the battery in the battery holder. 4Ah battery (YTX5L-BS) (
–
p. 99)
Reconnect the rubber band .
–
Attach the plus cable and replace the plus pole cover .
–
Attach the minus cable .
–
Mount the seat. (
p. 78)
500069-11
Recharging the battery 13.89
x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
Warning Risk of injury Battery acid and battery gases cause serious chemical burns. –
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.
Warning Environmental hazard Components and battery acid are a danger to the environment. –
Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced. If the battery is discharged from starting, it must be recharged immediately. If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed. The battery is maintenance-free, i.e., the acid level does not have to be checked. –
Switch off all power consumers and switch off the engine.
–
Remove the seat. (
–
Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics.
p. 77)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
77
Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery.
Info Never remove the lid . Charge the battery with at most 10% of the capacity specified on the battery .
400240-10
–
Switch off the charger after charging. Disconnect the battery. Guideline The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use.
–
Mount the seat. (
3 months
p. 78)
Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) 13.90
–
Switch off all power consumers and switch off the engine.
–
Dismount the air filter box lid. (
–
Remove the protection cover .
p. 82)
Info The fuse is located in the starter relay under the filter box cover. –
Remove the fuse .
400270-10
Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) 13.91
Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. –
Use only fuses with the prescribed amperage. Never by-pass or repair fuses. –
Refit the fuse. Fuse (58011109110)
Info A reserve fuse is located in the starter relay. Replace a burned-out fuse only by an equivalent fuse. If the new fuse burns out, contact an authorized KTM workshop. 400273-10
–
Replace the protection cover.
–
Install the air filter box lid. (
–
Remove screw . Lift up the seat at the rear, pull it back and then remove from above.
p. 82)
Removing the seat 13.92
500080-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
78
Mounting the seat 13.93
–
Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward.
–
Make sure that the seat is correctly locked in.
–
Mount and tighten the screw of the seat fixing. Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
600674-01
Dismounting the fuel tank 13.94
x
Danger Fire hazard Fuel can easily catch fire. –
Never fill up 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 specifications on filling up with fuel.
Warning Danger of poisoning Fuel is poisonous and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. –
Remove the seat. (
p. 77)
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
–
Pull off the fuel hose.
Info Remaining fuel may flow out of the fuel hose. 600678-10
–
Remove screws with the collar sleeve.
(EXC-F, EXC‑F SIX DAYS) – Hang the horn and horn bracket to one side. –
Remove screw with the collar sleeve.
–
Remove the tube from the fuel tank vent line.
–
Pull both spoilers to the side of the radiator bracket and take the fuel tank away upward.
600675-11
600677-10
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 13.95
79
x
Danger Fire hazard Fuel can easily catch fire. –
Never fill up 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 specifications on filling up with fuel.
Warning Danger of poisoning Fuel is poisonous and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. –
Position the fuel tank and install the two spoilers to the side of the radiator fixing.
–
Make sure that no cables or Bowden cables are trapped or damaged.
–
Mount the fuel tank vent hose.
–
Mount and tighten screw with the collar sleeve.
600676-01
Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
(EXC-F, EXC‑F SIX DAYS) – Position the horn with the horn bracket.
600675-10
–
Mount and tighten screws with the collar sleeve. Guideline Remaining screws, chassis
–
Connect the fuel hose.
–
Mount the seat. (
M6
10 Nm (7.4 lbf ft)
p. 78)
600678-11
Cooling system 13.96
The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . The specified coolant temperature is therefore permissible without danger of function problems. 120 °C (248 °F) Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 600679-10
(250 EXC-F SIX DAYS EU, 250 XCF-W ZA) The radiator fan provides extra cooling. It is controlled by a thermoswitch.
MAINTENANCE WORK ON CHASSIS AND ENGINE
80
Checking antifreeze and coolant level 13.97
Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. –
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning Danger of poisoning Coolants are poisonous and a health hazard. –
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. –
Stand the motorcycle upright on a horizontal surface.
–
Remove the radiator cap.
–
Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) »
If the antifreeze of the cooling liquid does not meet specifications: –
–
Correct antifreeze of coolant.
Check the coolant level in the radiator.
400243-10
Coolant level above radiator fins. »
10 mm (0.39 in)
If the level of the cooling liquid does not meet specifications: –
Correct the coolant level. Alternative 1 Coolant (
p. 116)
Alternative 2 Coolant (mixed ready to use) ( –
p. 116)
Refit the radiator cap.
Checking the coolant level 13.98
Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. –
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning Danger of poisoning Coolants are poisonous and a health hazard. –
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. –
Stand the motorcycle upright on a horizontal surface.
–
Remove the radiator cap.
–
Check the coolant level in the radiator. Coolant level above radiator fins. »
10 mm (0.39 in)
If the level of the cooling liquid does not meet specifications: –
Correct the coolant level. Alternative 1 Coolant (
400243-10
p. 116)
Alternative 2 Coolant (mixed ready to use) ( –
Refit the radiator cap.
p. 116)
MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the coolant 13.99
81
x
Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. –
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning Danger of poisoning Coolants are poisonous and a health hazard. –
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. –
Stand the vehicle upright.
–
Place a suitable container under the water pump cover.
–
Remove screw . Remove radiator cap .
–
Completely drain the coolant.
–
Mount screw with a new seal and tighten it. Guideline Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
600679-11
Refilling coolant 13.100
x
Warning Danger of poisoning Coolants are poisonous and a health hazard. –
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. –
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. 116)
Coolant (mixed ready to use) ( p. 116)
600680-10
–
Refit the radiator cap.
–
Make a short test ride.
–
Check the coolant level. (
p. 80)
Glass fiber yarn filling of main silencer 13.101
The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes.
MAINTENANCE WORK ON CHASSIS AND ENGINE
82
Removing main silencer 13.102
Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –
Allow the exhaust system to cool down. Do not touch hot components. –
Disconnect spring .
–
Remove screws and take off main silencer.
–
Mount the main silencer. Mount and tighten screws .
600681-11
Installing the main silencer 13.103
Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
Reconnect spring .
–
Pull off the air filter box lid in area to the side and remove to the front.
–
Insert the air filter box lid into the rear area and clip it into the front area .
600681-10
Dismounting the air filter box lid 13.104
600682-10
Installing the air filter box lid 13.105
600682-11
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter
83
x
13.106
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 since dust and dirt can get into the engine and result in increased wear.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. –
Dismount the air filter box lid. (
–
Hang the air filter holder out to the bottom and swing it to the side. Remove the air filter with the air filter support.
–
Remove the air filter from the air filter support.
–
Mount the clean air filter onto the air filter support.
–
Put in both parts together, position them and fix them with the air filter support .
p. 82)
500107-10
Installing the air filter 13.107
x Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. –
Install the air filter box lid. (
p. 82)
500107-10
Cleaning air filter 13.108
x
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. –
Remove the air filter.
–
Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner (
x(
p. 83)
p. 117)
Info Only press the air filter to dry it, never wring it out. –
Oil the dry air filter with a high/quality filter oil. Oil for foam air filter (
p. 118)
–
Clean the air filter box.
–
Check carburetor connection boot for damage and tightness.
–
Install the air filter.
x(
p. 83)
MAINTENANCE WORK ON CHASSIS AND ENGINE
84
Carburetor - idle 13.109
The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.
Info The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.
600684-10
Carburetor - adjusting idle 13.110
The idle speed is adjusted with the adjustment screw . The idle mixture is adjusted with the idle mixture adjustment screw .
x –
Screw in the idle adjusting screw until it stops and then to the prescribed basic setting. Guideline Idle mixture adjusting screw (EXC‑F, EXC‑F SIX DAYS, SX‑F) Open
1.25 turns
Idle mixture adjusting screw (250 XCF-W ZA, 250 XC-F USA) Open
1.0 turn
Idle mixture adjusting screw (250 XCF-W USA)
600684-10
Open
1.5 turns
Adjustment tool for mixture control screw (77329034000) –
Run the engine until warm. Guideline Warm-up time
≥ 5 min
Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.
Adjust the idle speed with adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in to the stop. (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) ( p. 23) Choke function deactivated – The choke lever is pushed back to the stop. (EXCF EU, EXC‑F SIX DAYS) ( p. 23) Idle speed
1,400… 1,500 rpm
–
Turn the idle adjusting screw slowly until the idle speed begins to fall.
–
Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls.
–
Adjust to the point between these two positions with the highest idle speed.
Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motorcyclist will set the mixture about ¼ of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle adjusting screw to the end without any change of engine speed, you have to mount a smaller idling jet. The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet. After changing the idling jet, start from the beginning with the adjusting steps.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
85
Adjust the idle speed with adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in to the stop. (EXC‑F AUS, XCF‑W, XC‑F, SX‑F) ( p. 23) Choke function deactivated – The choke lever is pushed back to the stop. (EXCF EU, EXC‑F SIX DAYS) ( p. 23) Idle speed
1,400… 1,500 rpm
Info Following extreme air temperature or altitude changes, adjust the idle speed again.
Emptying the carburetor float chamber 13.111
x
Danger Fire hazard Fuel can easily catch fire. –
Never fill up 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 specifications on filling up with fuel.
Warning Danger of poisoning Fuel is poisonous and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Warning Environmental hazard Improper handling of fuel is a danger to the environment. –
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info Carry out this work with a cold engine. (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
No more fuel flows from the tank to the carburetor. –
Guide the hose coming down behind the engine into a suitable container.
Info Water in the float chamber results in malfunctioning.
600684-11
–
Undo screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber.
–
Tighten screw .
MAINTENANCE WORK ON CHASSIS AND ENGINE
86
Checking the engine oil level 13.112
–
Stand the motorcycle upright on a horizontal surface.
Condition The engine is cold. –
Check the engine oil level. The engine oil level is at the bottom edge of level viewer . »
If the engine oil level is below the specified level: –
600685-11
Add engine oil. (
p. 89)
Condition The engine is warm. –
Check the engine oil level. The engine oil level is at the top edge of level viewer . »
If the engine oil level is below the specified level: –
Add engine oil. (
Changing the engine oil and oil filter, cleaning the oil screen 13.113
–
Drain the engine oil.
–
Clean the oil screens.
p. 89)
x
x ( p. 86) x ( p. 87) – Remove the oil filter. x ( p. 88) – Install the oil filter. x ( p. 88) – Fill up with engine oil. x ( p. 89) Draining the engine oil x 13.114
Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info Drain the engine oil only when the engine is warm. –
Stand the motorcycle on its side stand on a horizontal surface.
–
Place a suitable container under the engine.
–
Remove oil drain plug .
–
Completely drain the engine oil.
–
Thoroughly clean the oil drain plug with the magnet.
–
Clean the sealing area on the engine.
–
Mount and tighten oil drain plug with the seal ring. Guideline
600686-10
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the oil screens 13.115
87
x
Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. –
Place a suitable container under the engine.
–
Remove plug with oil screen and the O-rings.
600693-10
–
Remove plug with oil screen and the O-rings.
–
Drain the remaining engine oil.
–
Thoroughly clean parts and sealing area.
–
Position oil screen with the O-rings.
–
Mount and tighten plug with the O-ring.
600694-10
Guideline Plug for oil screen, long
M20x1.5
15 Nm (11.1 lbf ft)
600695-10
–
Position the oil screen with the O-rings.
–
Mount and tighten plug with the O-ring. Guideline Plug for oil screen, short
600696-10
M16x1.5
10 Nm (7.4 lbf ft)
lubricated with engine oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 13.116
88
x
Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. –
Place a suitable container under the engine.
–
Remove screws . Remove oil filter cover with O-ring.
–
Pull the oil filter insert out of the oil filter casing.
600687-10
Circlip pliers reverse (51012011000) –
Completely drain the engine oil.
–
Thoroughly clean parts and sealing area.
–
Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil.
–
Fill oil filter with engine oil and place it in the oil filter container.
–
Lubricate O-ring of the oil filter cover.
–
Mount oil filter cover .
–
Mount and tighten screws .
600688-10
Installing the oil filter 13.117
x
600689-10
Guideline Screw, oil filter cover –
600687-11
Stand the motorcycle up.
M5
6 Nm (4.4 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with engine oil 13.118
89
x
Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –
Remove screw connection on the clutch cover and fill up with engine oil. Engine oil
–
1.10 l (1.16 qt.)
Engine oil (SAE 10W/50) (
p. 116)
Mount and tighten screw cap .
Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – 600690-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
–
Start the engine and check that it is oil-tight.
–
Check the engine oil level. (
p. 86)
Adding engine oil 13.119
Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –
Remove screw cap from the clutch cover and fill up with engine oil. Engine oil (SAE 10W/50) (
–
p. 116)
Mount and tighten screw cap .
Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – 600690-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
–
Start the engine and check that it is oil-tight.
–
Check the engine oil level. (
p. 86)
TROUBLESHOOTING
90
TROUBLESHOOTING 14
Faults
Possible cause
Action
The engine cannot be cranked (electric starter). EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F
Operating error
–
Go through the steps of starting the engine. ( p. 28)
Battery discharged
–
Recharge the battery.
–
Check the charging voltage.
–
Check the closed current.
–
Check the generator.
x
–
Remove the fuse. (
p. 77)
–
Replace the fuse. (
p. 77)
Starter relay defective
–
Check the starter relay.
Starter motor defective
–
Check the starter motor.
Operating error
–
Go through the steps of starting the engine. ( p. 28)
Motorcycle was out of use for a long time and there is old fuel in the float chamber
–
Empty the carburetor float chamber. ( p. 85)
Fuel feed interrupted
–
Check the fuel tank breather.
–
Clean the fuel tap.
–
Check/adjust the carburetor components.
Fuse blown
Engine turns but does not start.
x(
p. 76)
x x
x x
x
x
Engine has no idle.
Engine flooded
–
Clean and dry the spark plug or replace if necessary.
Spark plug oily or wet
–
Clean and dry the spark plug or replace if necessary.
Electrode distance (plug gap) of spark plug too wide
–
Adjust the plug gap.
Defect in ignition system
–
Check the ignition system.
Short-circuit cable in cable harness frayed, short-circuit button or emergency OFF switch defective
–
Check the wiring harness (visual check).
–
Check the electrical system.
Plug connector of CDI control device, pulse generator or ignition coil oxidized.
–
Clean the plug connector and treat it with contact spray.
Water in carburetor or jets blocked
–
Check/adjust the carburetor components.
Guideline Spark plug electrode gap 0.7 mm (0.028 in)
Idling jet blocked
–
Adjusting screws on carburetor distorted
–
x Check/adjust the carburetor components. x Carburetor - adjust the idle speed. x (
Engine does not speed up.
x
p. 84)
Spark plug defective
–
Change spark plug.
Ignition system defective
–
Check the ignition coil.
–
Check the CDI unit.
–
Check the spark plug connector.
–
Check the ignition pulse generator.
x
x x x
–
Check the generator.
Carburetor running over because float needle dirty or worn.
–
Check/adjust the carburetor components.
Loose carburetor jets
–
Ignition system defective
– – – – –
x
x Check/adjust the carburetor components. x Check the ignition coil. x Check the CDI unit. x Check the spark plug connector. x Check the ignition pulse generator. x Check the generator. x
TROUBLESHOOTING
91
Faults
Possible cause
Action
Engine has too little power.
Fuel feed interrupted
–
Check the fuel tank breather.
–
Clean the fuel tap.
–
Check/adjust the carburetor components.
x
Air filter very dirty
–
Clean the air filter.
Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer
–
Check exhaust system for damage.
–
Change glass fiber yarn filling of main silencer.
Valve clearance too little
–
Adjust the valve clearance.
Ignition system defective
–
Check the ignition coil.
–
Check the CDI unit.
–
Check the spark plug connector.
x(
p. 83)
x
– – Engine stalls or is popping into the carburetor
Lack of fuel
x
x
x
x Check the ignition pulse generator. x Check the generator. x
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Turn handle of the fuel tap to the ON position. (Figure 500137-10 p. 22) (SX‑F) – Turn handle of the fuel tap to the ON position. (Figure 500178-10 p. 22)
Engine overheats.
–
Fill up with fuel. (
Engine takes in bad air
–
Check rubber sleeves and carburetor for tightness.
Too little coolant in cooling system
–
Check the cooling system for leakage.
p. 30)
–
Check the coolant level. (
Too little air stream
–
Switch off engine when standing.
Radiator fins very dirty
–
Clean radiator fins.
Foam formation in cooling system
–
Drain the coolant.
–
x( Refill the coolant. x (
Bent radiator hose
–
Change the radiator hose.
Thermostat defective
–
Check the thermostat.
p. 80)
p. 81) p. 81)
x
x
Guideline Opening temperature: 70 °C (158 °F) –
Check the radiator fan fuse.
–
Check the radiator fan.
–
Check the thermostat.
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. (
Engine oil too thin (low viscosity)
–
Change the engine oil and oil filter, clean the oil screen. ( p. 86)
Piston or cylinder is worn
–
Piston/cylinder - determine the mounting clearance
The battery does not charge
–
Check the charging voltage.
–
Check the charging current.
Defect in radiator fan system (250 EXCF SIX DAYS EU, 250 XCF-W ZA) High oil consumption
x x p. 86)
x
x
Battery discharged
Undesired power consumer
–
x x Check the generator. x Check the closed current. x
The battery in the speedometer is empty.
–
Change the battery in the speedometer.
– Speedometer values deleted (time, stop watch, lap times)
CLEANING
92
CLEANING 15
Cleaning motorcycle
15.1
Note Material damage Damage and destruction of components by high-pressure cleaning equipment. –
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.
Warning Environmental hazard Problem materials cause environmental damage. –
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning. –
Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
–
First remove coarse dirt particles with a gentle water spray.
–
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush. Motorcycle cleaner (
p. 117)
Info Use warm water containing normal motorcycle cleaner and a soft sponge. –
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
–
Empty the carburetor float chamber.
x(
p. 85)
Warning Danger of accidents Reduced braking due to wet or dirty brakes. – –
Clean or dry dirty or wet brakes by riding and braking gently.
After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate. –
Push back the protection covers on the handlebar instruments to allow water to evaporate.
–
After the motorcycle has cooled off, oil or grease all moving parts and bearings.
–
Clean the chain. (
–
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
p. 57)
Cleaning and polishing materials for metal, rubber and plastic ( –
Treat all painted parts with a mild paint polish. High-luster polish for paint (
–
p. 117)
p. 117)
To prevent electrical problems, treat electric contacts and switches with contact spray. Contact spray (
p. 117)
(EXC-F, EXC‑F SIX DAYS) – Lubricate the steering lock. Universal oil spray (
p. 118)
STORAGE
93
STORAGE 16
Storage 16.1
Warning Danger of poisoning Fuel is poisonous and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. –
Clean the motorcycle. (
p. 92)
–
Change the engine oil and oil filter, clean the oil screen.
–
Check the antifreeze and coolant level. (
–
Drain the fuel from the tank into a suitable container.
–
Empty the carburetor float chamber.
–
Check the tire air pressure. (
x(
p. 86)
p. 80)
x(
p. 85)
p. 75)
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Remove the battery. ( p. 75)
x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Recharge the battery. x ( p. 76) Guideline Storage temperature of battery without direct sunlight.
–
0… 35 °C (32… 95 °F)
The storage place should be dry and not subject to large temperature fluctuations.
Info KTM recommends jacking up the motorcycle. –
Jack up the motorcycle. (
–
Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
p. 37)
Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.
Putting into operation after storage 16.2
–
Remove the motorcycle from the work stand. (
(EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) – Install the battery. ( p. 76)
x
–
Fill up with fuel. (
–
Checks before putting into operation (
–
Make a test ride.
p. 30) p. 28)
p. 37)
TECHNICAL DATA - ENGINE
94
TECHNICAL DATA - ENGINE 17
Design
1-cylinder 4-stroke engine, water-cooled
Displacement
248.60 cm³ (15.1706 cu in)
Stroke
54.80 mm (2.1575 in)
Bore
76 mm (2.99 in)
Compression ratio
12.8:1
Idle speed
1,400… 1,500 rpm
Control
DOHC, four valves controlled via cam lever, drive via tooth-wheel chain
Valve diameter, intake
30.0 mm (1.181 in)
Valve diameter, exhaust
26.0 mm (1.024 in)
Valve clearance Exhaust at: 20 °C (68 °F)
0.12… 0.17 mm (0.0047… 0.0067 in)
Intake at: 20 °C (68 °F)
0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing
2 cylinder bearings
Conrod bearing
Needle bearing
Piston pin bearing
Bronze bush
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with two rotary pumps
Primary transmission
22:68
Clutch
Multidisc clutch in oil bath/hydraulically activated
Transmission ratio (EXC‑F, EXC‑F SIX DAYS, XCF-W) 1st gear
13:33
2nd gear
17:33
3rd gear
19:29
4th gear
23:28
5th gear
23:23
6th gear
26:22
Transmission ratio (SX‑F, 250 XC-F USA) 1st gear
13:32
2nd gear
15:30
3rd gear
17:28
4th gear
19:26
5th gear
21:25
6th gear
22:24
Generator (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F) Light coil and charging coil
12 V, 80 W
Generator (SX‑F) Light coil and charging coil
none
Ignition
Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan
Spark plug
NGK CR 9 EKB
Spark plug electrode gap
0.7 mm (0.028 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Starting aid (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
Electric starter/kickstarter
Starting aid (SX‑F)
Kickstarter
TECHNICAL DATA - ENGINE
95
Capacity- engine oil 17.1
Engine oil
1.10 l (1.16 qt.)
Engine oil (SAE 10W/50) (
1.2 l (1.3 qt.)
Coolant (
p. 116)
Capacity - coolant 17.2
Coolant
p. 116)
Coolant (mixed ready to use) (
p. 116)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
96
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 18
Loctite® 243™
Oil jet, conrod lubrication
M4
Oil jet for cam lever lubrication
M5
4 Nm (3 lbf ft)
Loctite® 243™
Screw, locking lever
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, freewheel hub
M5
7 Nm (5.2 lbf ft)
Loctite® 243™
Screw, ignition pulse generator
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, stator bracket (SX‑F)
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, oil filter cover
M5
6 Nm (4.4 lbf ft)
–
Screw, oil pump cover
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Oil jet, piston cooling
M6x0.75
4 Nm (3 lbf ft)
Loctite® 243™
Screw, cover plate of valve cover
M6
3 Nm (2.2 lbf ft)
Loctite® 243™
Screw, kickstarter stop
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, timing chain securing guide
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, exhaust flange
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, starter motor (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
M6
10 Nm (7.4 lbf ft)
–
Screw, generator cover
M6
10 Nm (7.4 lbf ft)
–
Screw, cable holder in generator cover
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch spring
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch slave cylinder
M6
10 Nm (7.4 lbf ft)
–
Locking screw for bearing
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, engine housing
M6
10 Nm (7.4 lbf ft)
–
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, timing chain tensioning rail
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, stator bracket (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
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)
–
Screw, cylinder head
M6
10 Nm (7.4 lbf ft)
–
Nut, camshaft bearing bridge
M7
15 Nm (11.1 lbf ft)
lubricated with engine oil
Screw, camshaft bearing bridge
M7
15 Nm (11.1 lbf ft)
lubricated with engine oil
Stud, camshaft bearing bridge
M7
Screw, kickstarter
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, timing chain guide rail
M8
10 Nm (7.4 lbf ft)
Loctite® 243™
Loctite® 243™
Plug, crankshaft location
M8
20 Nm (14.8 lbf ft)
–
Screw, unlocking of timing chain tensioner
M10x1
10 Nm (7.4 lbf ft)
–
Screw, engine sprocket
M10
60 Nm (44.3 lbf ft)
Loctite® 243™
Screw, cylinder head
M10
Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 40 Nm (29.5 lbf ft) Step 2 50 Nm (36.9 lbf ft)
lubricated with engine oil
Spark plug
M10
10… 12 Nm (7.4… 8.9 lbf ft)
–
Nut, rotor
M12x1
60 Nm (44.3 lbf ft)
–
Screw, camshaft gear
M12x1
80 Nm (59 lbf ft)
Loctite® 243™
Plug, oil pressure regulator valve
M12x1.5
20 Nm (14.8 lbf ft)
–
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
–
Plug for oil screen, short
M16x1.5
10 Nm (7.4 lbf ft)
lubricated with engine oil
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
97
Nut, inner clutch hub
M18x1.5
120 Nm (88.5 lbf ft)
Loctite® 243™
Nut, primary gear
M18LHx1.5
150 Nm (110.6 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)
–
TECHNICAL DATA - CARBURETOR
98
TECHNICAL DATA - CARBURETOR 19
EXC-F, EXC‑F SIX DAYS
19.1
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3900H
Needle position
3rd position from top
Idle mixture adjusting screw Open
1.25 turns
Pump membrane stop
2.15 mm (0.0846 in)
Main jet
168
Jet needle
OBDYS (OBETP)
Idling jet
42
Idle air jet
100
Cold start jet
65 (85)
Leakage nozzle
70
Slide stop
present
XCF‑W, 250 XC-F USA 19.2
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3900K
Needle position (250 XCF-W USA)
3rd position from top
Needle position (250 XCF-W ZA, 250 XC-F USA)
5th position from top
Idle mixture adjusting screw (250 XCF-W ZA, 250 XC-F USA) Open
1.0 turn
Idle mixture adjusting screw (250 XCF-W USA) Open
1.5 turns
Pump membrane stop
2.15 mm (0.0846 in)
Main jet
168
Jet needle (250 XCF-W USA)
OBEKT
Jet needle (250 XCF-W ZA, 250 XC-F USA)
OBETP
Idling jet
42
Idle air jet
100
Cold start jet
85
Leakage nozzle
50
SX‑F 19.3
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3925I
Needle position
4th position from top
Idle mixture adjusting screw Open
1.25 turns
Pump membrane stop
2.15 mm (0.0846 in)
Main jet
175
Jet needle
OBEKP
Idling jet
40
Idle air jet
100
Cold start jet
85
Leakage nozzle
50
TECHNICAL DATA - CHASSIS
99
TECHNICAL DATA - CHASSIS 20
Frame
Central tube frame made of chrome molybdenum steel tubing
Fork (EXC‑F, EXC‑F SIX DAYS, XCF-W)
WP Suspension 4860 MXMA PA
Fork (250 XC-F USA)
WP Suspension 4860 MXMA CC
Fork (250 SX-F EU)
WP Suspension 4860 MXMA CC
Fork (250 SX-F USA)
WP Suspension 4860 MXMA CC
Suspension travel Front
300 mm (11.81 in)
Rear
335 mm (13.19 in)
Fork offset (XCF‑W USA, XC‑F, SX‑F) Front marking
18 mm (0.71 in)
Rear marking
20 mm (0.79 in)
Fork offset (250 EXC-F SIX DAYS EU)
19 mm (0.75 in)
Fork offset (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
20 mm (0.79 in)
Shock absorber
WP Suspension PDS 5018 DCC
Brake system
Disc brakes, brake calipers on floating bearings
Diameter of brake discs Front
260 mm (10.24 in)
Rear
220 mm (8.66 in)
Wear limit of brake discs Front
2.5 mm (0.098 in)
Rear
3.5 mm (0.138 in)
Tire air pressure off road Front
1.0 bar (15 psi)
Rear
1.0 bar (15 psi)
Road tire pressure (EXC-F, EXC‑F SIX DAYS) Front
1.5 bar (22 psi)
Rear
2.0 bar (29 psi)
Final drive (EXC-F, EXC‑F SIX DAYS)
14:38 (13:50)
Final drive (XCF‑W)
13:52
Final drive (SX‑F, 250 XC-F USA)
13:48
Chain
5/8 x 1/4"
Rear sprockets available
38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle
63.5°
Wheelbase
1,475±10 mm (58.07±0.39 in)
Seat height unloaded
985 mm (38.78 in)
Ground clearance unloaded
380 mm (14.96 in)
Weight without fuel, approx. (EXC-F, EXC‑F SIX DAYS)
105.7 kg (233 lb.)
Weight without fuel, approx. (250 XCF-W ZA)
102.6 kg (226.2 lb.)
Weight without fuel, approx. (250 XCF-W USA, 250 XC-F USA)
101.6 kg (224 lb.)
Weight without fuel, approx. (SX‑F)
98 kg (216 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Maximum permissible overall weight
335 kg (739 lb.)
4Ah battery (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
YTX5L-BS
Battery voltage: 12 V Nominal capacity: 4 Ah maintenance-free
TECHNICAL DATA - CHASSIS
100
Lighting equipment 20.1
Headlight (EXC‑F, EXC‑F SIX DAYS, XCFW ZA)
BA20d
12 V 35/35 W
Parking light (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA)
W2,1x9,5d
12 V 5W
Indicator lights (EXC-F, EXC‑F SIX DAYS)
W2x4,6d
12 V 1.2 W
Flasher light (EXC-F, EXC‑F SIX DAYS)
BA15s
12 V 10 W
Brake/tail light (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA)
LED
License plate lamp (EXC-F, EXC‑F SIX DAYS)
W2,1x9,5d
12 V 5W
Validity
Front tire
Rear tire
(EXC-F, EXC‑F SIX DAYS)
90/90 - 21 M/C 54M M+S TT Metzeler MEC 6 DAYS EXTREME
120/90 - 18 M/C 65M M+S TT Metzeler MEC 6 DAYS EXTREME
(XCF‑W, 250 XC-F USA)
80/100 - 21 51M TT Bridgestone Bridgestone M59
100/100 - 18 64M TT Bridgestone Bridgestone M402
(SX‑F)
80/100 - 21 51M TT Bridgestone Bridgestone M59
100/90 - 19 62M TT Bridgestone Bridgestone M70
Tires 20.2
For further information, see the Service section under: http://www.ktm.com
Capacity - fuel 20.3
Total fuel tank capacity, approx. (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
9.2 l (2.43 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
p. 116)
Total fuel tank capacity, approx. (SX‑F)
8.0 l (2.11 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
p. 116)
Fuel reserve, approx. (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)
2 l (2 qt.)
TECHNICAL DATA - FORK
101
TECHNICAL DATA - FORK 21
EXC‑F, EXC‑F SIX DAYS, XCF-W 21.1
Fork part number
14.18.7E.04
Fork
WP Suspension 4860 MXMA PA
Compression damping Comfort
26 clicks
Standard
22 clicks
Sport
20 clicks
Rebound damping Comfort
24 clicks
Standard
22 clicks
Sport
22 clicks
Spring preload - Preload Adjuster Comfort
0 turn
Standard
1 turn
Sport
3 turns
Spring length with preload spacer(s)
510 mm (20.08 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 lb/in)
Fork length
940 mm (37.01 in)
Air chamber length
+0.79 110+20 −30 mm (4.33−1.18 in)
FORK OIL
Fork oil (SAE 5) (
p. 116)
250 XC-F USA 21.2
Fork part number
14.18.7E.28
Fork
WP Suspension 4860 MXMA CC
Compression damping Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Rebound damping Comfort
22 clicks
Standard
21 clicks
Sport
21 clicks
Spring length with preload spacer(s)
492 mm (19.37 in)
Spring rate Weight of rider: 65… 75 kg (143… 165 lb.)
4.2 N/mm (24 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)
4.4 N/mm (25.1 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)
4.6 N/mm (26.3 lb/in)
Fork length
940 mm (37.01 in)
Gas pressure
1.2 bar (17 psi)
Oil capacity / cartridge
195 ml (6.59 fl. oz.)
Fork oil (SAE 5) (
p. 116)
Oil capacity / fork tube without cartridge
365 ml (12.34 fl. oz.)
Fork oil (SAE 5) (
p. 116)
TECHNICAL DATA - FORK
102
250 SX-F EU 21.3
Fork part number
14.18.7E.03
Fork
WP Suspension 4860 MXMA CC
Compression damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Rebound damping Comfort
21 clicks
Standard
20 clicks
Sport
20 clicks
Spring length with preload spacer(s)
492 mm (19.37 in)
Spring rate Weight of rider: 65… 75 kg (143… 165 lb.)
4.2 N/mm (24 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)
4.4 N/mm (25.1 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)
4.6 N/mm (26.3 lb/in)
Fork length
940 mm (37.01 in)
Gas pressure
1.2 bar (17 psi)
Oil capacity / cartridge
195 ml (6.59 fl. oz.)
Fork oil (SAE 5) (
p. 116)
Oil capacity / fork tube without cartridge
360 ml (12.17 fl. oz.)
Fork oil (SAE 5) (
p. 116)
250 SX-F USA 21.4
Fork part number
14.18.7E.22
Fork
WP Suspension 4860 MXMA CC
Compression damping Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Rebound damping Comfort
22 clicks
Standard
22 clicks
Sport
20 clicks
Spring length with preload spacer(s)
492 mm (19.37 in)
Spring rate Weight of rider: 65… 75 kg (143… 165 lb.)
4.4 N/mm (25.1 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)
4.6 N/mm (26.3 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)
4.8 N/mm (27.4 lb/in)
Fork length
940 mm (37.01 in)
Gas pressure
1.2 bar (17 psi)
Oil capacity / cartridge
195 ml (6.59 fl. oz.)
Fork oil (SAE 5) (
p. 116)
Oil capacity / fork tube without cartridge
375 ml (12.68 fl. oz.)
Fork oil (SAE 5) (
p. 116)
TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER 22
EXC‑F, EXC‑F SIX DAYS, XCF-W
22.1
Shock absorber part number
12.18.7E.04
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Compression damping, high-speed Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Rebound damping Comfort
26 clicks
Standard
24 clicks
Sport
22 clicks
Spring preload
9 mm (0.35 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 psi)
Static sag
35 mm (1.38 in)
Riding sag
105 mm (4.13 in)
Fitted length
411 mm (16.18 in)
250 XC-F USA 22.2
Shock absorber part number
12.18.7E.28
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping, high-speed Comfort
1 turn
Standard
1 turn
Sport
3/4 turn
Rebound damping Comfort
25 clicks
Standard
25 clicks
Sport
23 clicks
Spring preload
5 mm (0.2 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 psi)
Static sag
33 mm (1.3 in)
Riding sag
112 mm (4.41 in)
Fitted length
411 mm (16.18 in)
103
TECHNICAL DATA - SHOCK ABSORBER 250 SX-F EU 22.3
Shock absorber part number
12.18.7E.03
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping, high-speed Comfort
1.5 turns
Standard
1.5 turns
Sport
1 turn
Rebound damping Comfort
24 clicks
Standard
22 clicks
Sport
21 clicks
Spring preload
6 mm (0.24 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 psi)
Static sag
33 mm (1.3 in)
Riding sag
105 mm (4.13 in)
Fitted length
411 mm (16.18 in)
250 SX-F USA 22.4
Shock absorber part number
12.18.7E.22
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping, high-speed Comfort
1 turn
Standard
1 turn
Sport
3/4 turn
Rebound damping Comfort
25 clicks
Standard
24 clicks
Sport
22 clicks
Spring preload
7 mm (0.28 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 psi)
Static sag
33 mm (1.3 in)
Riding sag
107 mm (4.21 in)
Fitted length
411 mm (16.18 in)
104
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
105
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 23
Spoke nipple, front wheel
M4,5
5 Nm (3.7 lbf ft)
–
Spoke nipple, rear wheel
M5
5 Nm (3.7 lbf ft)
–
Screw, spoiler on fuel tank (250 XCFW USA, 250 XC-F USA)
M5x12
1.5 Nm (1.11 lbf ft)
–
Remaining nuts, chassis
M6
15 Nm (11.1 lbf ft)
–
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
–
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
–
Screw, shock absorber adjusting ring
M6
5 Nm (3.7 lbf ft)
–
Screw, ball joint of push rod on footbrake cylinder
M6
10 Nm (7.4 lbf ft)
–
Nut, rear sprocket screw
M8
35 Nm (25.8 lbf ft)
Loctite® 243™
Nut, rim lock
M8
10 Nm (7.4 lbf ft)
–
Remaining nuts, chassis
M8
30 Nm (22.1 lbf ft)
–
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
–
Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, top triple clamp (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)
M8
17 Nm (12.5 lbf ft)
–
Screw, top triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
M8
20 Nm (14.8 lbf ft)
–
Screw, bottom triple clamp (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)
M8
12 Nm (8.9 lbf ft)
–
Screw, bottom triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
M8
15 Nm (11.1 lbf ft)
–
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
–
Screw, top steering stem (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
Screw, top steering stem (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
M8
20 Nm (14.8 lbf ft)
–
Screw, handlebar clamp (EXC‑F EU, EXC‑F AUS, XCF‑W, XC‑F, SX‑F)
M8
20 Nm (14.8 lbf ft)
–
Screw, handlebar clamp (250 EXCF SIX DAYS EU)
M8
16 Nm (11.8 lbf ft)
–
Screw, engine brace
M8
33 Nm (24.3 lbf ft)
–
Screw, subframe
M8
35 Nm (25.8 lbf ft)
Loctite® 243™
Screw, side stand fixing
M8
40 Nm (29.5 lbf ft)
Loctite® 243™
Engine carrying screw
M10
60 Nm (44.3 lbf ft)
–
Remaining nuts, chassis
M10
50 Nm (36.9 lbf ft)
–
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
–
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite® 243™
Nut, seat fixing
M12x1
20 Nm (14.8 lbf ft)
–
Screw, top shock absorber
M12
80 Nm (59 lbf ft)
Loctite® 243™
Screw, bottom shock absorber
M12
80 Nm (59 lbf ft)
Loctite® 243™
Nut, swingarm pivot
M16x1.5
100 Nm (73.8 lbf ft)
–
Screw-in nozzles, cooling system
M20x1.5
12 Nm (8.9 lbf ft)
Loctite® 243™
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
–
Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Screw, bottom steering head (XCF‑W USA, XC‑F, SX‑F)
M20x1.5
60 Nm (44.3 lbf ft)
Loctite® 243™
Screw, front wheel spindle
M24x1.5
45 Nm (33.2 lbf ft)
–
24.1
H2
EI/1
3 wh
2 br
1 pu L2 1 2 4
C D
BU/18
I
5 7 6 11 10 12 13 14 3 2 1
2.1
AT1/2
2 1
AM/3 AL/2
AR/3 AT/2
A6 B1 L1 2 AL1/2
1 H3
1 1
1 3
pu 2
3 G G2
ye H5
bl br
wh-gn wh 1
1 2
wh-gn
br 2
pu 1
CW/2
1 2 H1
2
2
wh
BG/3
5A
H9
ye-bl br
bl
4 3
AJ/3
H14
ye
DI/2
wh
br 3
br ye-re
CX/2
CE/4
ye-re
br
bl
N2
wh-re ye-re
bl
2
CA/4
3 4 3
AJ1/3
2
bl
br
wh-re
ye-re BK/4
BG1/3
bl ye
BO/2
S10
wh-gn
BV/2
br
BA2/1
1
wh
bl
S8
CR1/1
or pu
br
ye-re or
ye-bl
1
ye
bu br
bl
ye-bl
br
2
br
bl
ye re
BT/3
re-wh
bu
2
EH/1
br
BG/3
CR/1
2 t
CW1/2
gn
4 BF/1
3
re-bl
ye-bl BA/1
1
K1
CX1/2
1
AH2/2
gn
1 2 E6
re
2
ye
pu
ye-re
2
bu
1 2
bl
br
wh
AC/6
br
bl
bl
bl
2
H13
re
bl
1
K2
bu ye
br
BA1/1
re-bl gn
2
G
re
br-bl
2
ye-bl
3
1
re-wh
ye-re
5
br
1
6 4
br
ye-re
br
S7
br gr
v ye-re
wh
1
gn
3
bu
BC/6 BF1/1
bu-wh
DB/4 DA/4
S5
bu-wh
gr
CZ/3 CY/3
P1
S6
br
bl-wh
B3
CX/2 CW/2
bu
AH1/2
S2
H15
re
4
CX2/2
CW2/2
AK1/2
H18
2
BP/4
DG/4
H11
H4
3
CX3/2
CW3/2
H7
Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)
WIRING DIAGRAM 24
WIRING DIAGRAM
M
10 A
M1 AF/4
G1
BR/4
4
1
U
M
1 AK/2
S1
AH/2
br
br
2.2 2.1
BV/2
BS/2
600699-01
106
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
B3
Wheel speed sensor
E6
Thermoswitch (EXC-F SIX DAYS)
G1
Battery
G2
Generator
H1
Right rear flasher
H2
Left front flasher
H3
Left rear flasher
H4
Right front flasher
H5
Brake/tail light
H7
Parking light
H9
License plate lamp
H11
Low/high beam
H13
Horn
H14
Radiator fan (EXC-F SIX DAYS)
H15
Flasher indicator light
H18
High beam indicator light
K1
Starter relay with main fuse
K2
Flasher relay
L1
Pulse generator
L2
Ignition coil
M1
Starter motor
N2
Voltage regulator/rectifier
P1
Speedometer
S1
Rear brake light switch
S2
Front brake light switch
S5
Tripmaster switch (optional)
S6
Light switch
S7
Horn button, short circuit button
S8
Flasher switch
S10
Electric starter button
Cable colors bl
Black
bl-wh
Black-white
br
Brown
br-bl
Brown-black
bu
Blue
bu-wh
Blue-white
gn
Green
gr
Gray
or
Orange
pu
Violet
re
Red
re-bl
Red-black
re-wh
Red-white
wh
White
wh-gn
White-green
wh-re
White-red
ye
Yellow
ye-bl
Yellow-black
107
WIRING DIAGRAM ye-re
Yellow-red
108
WIRING DIAGRAM
109
24.2
1 2 wh
br pu 1 2
C D
L2
I
BU/18
A6
5 7 6 11 10 12 13 14 3 2 1 AT1/2
B1 2 1
AM/3 AL/2
AR/3 AT/2
AL1/2
1
L1
3 G
H3
bu 1
wh
ye H5
br
br 1
ye-bl bl pu 3 2
G2
wh-gn
br pu 1
wh wh-gn
CW/2
CX/2
1 2
2
BG/3
bl
1
1 2 H1
1
2
2
H9
br
wh CE/4
CA/4
2 1
br
bl
4 3
AJ/3
BO/2
3
pu ye
AJ1/3
br ye-re
BG1/3
bl ye
BS/2
wh-gn
ye-re
DI/2
2
wh
N2
bl
br
wh-re
ye-re
4 3
CR1/1
bl
ye-re
wh-re
bl
BA2/1
ye
or pu
BT/3
CR/1
ye-re
1
ye-re
BG/3
br
br
2 ye-bl
3
or
ye-bl
1
re-wh
2
br
AH2/2
4 3
CX1/2
gn
4
3
2
S11
re-bl
2 ye
K1
CW1/2
1
K2 S10
gn
ye-bl
S8
re
1 2
bu
2
ye
2
bl
1 H13
re
bl
bl
br
AC/6
re
bl
2
G
bu ye
1
BA1/1
re-bl gn
br
2
ye-bl
2
1
re-wh
br-bl
5
br
3
BF1/1
br
ye-re
ye-re
6 4
re
3
bu gn
BC/6
br
v ye-re
1
S7
bu-wh
br
wh
bu
BA/1
B3
S5
BF/1
AK1/2
DB/4 DA/4
4
AH1/2
CZ/3 CY/3
wh
1
CX2/2
CW2/2
CX/2 CW/2
P1
S6
bu-wh
br
DG/4
H15
3
BP/4
S2
H18
re
CX3/2
H11
H4
2
CW3/2
H7
H2
Wiring diagram (250 EXC-F AUS)
WIRING DIAGRAM
M
10 A
M1 AF/4
G1
2
BK/4
BR/4
2 1
1
U
BV/2
AK/2
S1
AH/2
bu
br
br
BS/2
BV/2
600698-01
110
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
B3
Wheel speed sensor
G1
Battery
G2
Generator
H1
Right rear flasher
H2
Left front flasher
H3
Left rear flasher
H4
Right front flasher
H5
Brake/tail light
H7
Parking light
H9
License plate lamp
H11
Low/high beam
H13
Horn
H15
Flasher indicator light
H18
High beam indicator light
K1
Starter relay with main fuse
K2
Flasher relay
L1
Pulse generator
L2
Ignition coil
M1
Starter motor
N2
Voltage regulator/rectifier
P1
Speedometer
S1
Rear brake light switch
S2
Front brake light switch
S5
Tripmaster switch (optional)
S6
Light switch
S7
Horn button, short circuit button
S8
Flasher switch
S10
Electric starter button
S11
Emergency OFF switch
Cable colors bl
Black
br
Brown
br-bl
Brown-black
bu
Blue
bu-wh
Blue-white
gn
Green
or
Orange
pu
Violet
re
Red
re-bl
Red-black
re-wh
Red-white
wh
White
wh-gn
White-green
wh-re
White-red
ye
Yellow
ye-bl
Yellow-black
ye-re
Yellow-red
111
24.3
H7
C D
L2
I
H5
5A N2
br
A6 B1 L1
ye-re
br wh-re
br
black
E6 K1
M1
wh
bl
ye-re wh-re
M
ye
bl br
br bl
wh
t
gn
re
ye-re br
br ye-re
ye bu
re-bl re-wh
wh br wh ye
P1
S12
bl
br
ye-bl
bl bl
bu-wh br ye-bl re-wh re-bl gn re bu ye bl
B3
re bu wh br
bl-wh
br
H11
Wiring diagram (XCF‑W, 250 XC-F USA)
WIRING DIAGRAM
S10
10 A
S6 G1
H14 M
br ye-re ye wh
ye-bl
3 G G2
U
v
br wh
S5
600700-01
112
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
B3
Wheel speed sensor
E6
Thermoswitch (XCF-W ZA)
G1
Battery
G2
Generator
H5
Brake/tail light (XCF-W ZA)
H7
Parking light (XCF-W ZA)
H11
Low beam (XCF-W ZA)
H14
Radiator fan (XCF-W ZA)
K1
Starter relay with main fuse
L1
Pulse generator
L2
Ignition coil
M1
Starter motor
N2
Voltage regulator/rectifier
P1
Speedometer
S5
Tripmaster switch (optional)
S6
Light switch
S10
Electric starter button
S12
Short circuit button
Cable colors bl
Black
bl-wh
Black-white
br
Brown
bu
Blue
bu-wh
Blue-white
gn
Green
re
Red
re-bl
Red-black
re-wh
Red-white
wh
White
wh-re
White-red
ye
Yellow
ye-bl
Yellow-black
ye-re
Yellow-red
113
600701-01
114
G
3 G2
S12
gn re-wh
re-bl
ye-bl
bl
re
br bu-wh
1 2 5 7 6
11 10
12 13 14
2
3
C D I
1
AM/3 AR/3
Wiring diagram (SX‑F)
B1
24.4
WIRING DIAGRAM
A6
L2
L1
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
G2
Generator
L1
Pulse generator
L2
Ignition coil
S12
Short circuit button
Cable colors bl
Black
br
Brown
bu-wh
Blue-white
gn
Green
re
Red
re-bl
Red-black
re-wh
Red-white
ye-bl
Yellow-black
115
SUBSTANCES
116
SUBSTANCES 25
Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1
Coolant Guideline – Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. KTM recommends Motorex® products. Mixture ratio Antifreeze: −25… −45 °C (−13… −49 °F)
50 % Anti-corrosion/antifreeze 50 % distilled water
Coolant (mixed ready to use) −40 °C (−40 °F)
Antifreeze Supplier Motorex® – Anti Freeze
Engine oil (SAE 10W/50) According to – JASO T903 MA ( –
SAE (
p. 119)
p. 119) (SAE 10W/50)
Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Cross Power 4T
Fork oil (SAE 5) According to – SAE ( p. 119) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Racing Fork Oil
Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)
AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES 26
Air filter cleaner Specification – KTM recommends Motorex® products. Supplier Motorex® – Twin Air Dirt Bio Remover
Chain cleaner Specification – KTM recommends Motorex® products. Supplier Motorex® – Chain Clean 611
Cleaning and polishing materials for metal, rubber and plastic Specification – KTM recommends Motorex® products. Supplier Motorex® – Protect & Shine 645
Contact spray Specification – KTM recommends Motorex® products. Supplier Motorex® – Accu Contact
High-luster polish for paint Specification – KTM recommends Motorex® products. Supplier Motorex® – Moto Polish
Long-life grease Specification – KTM recommends Motorex® products. Supplier Motorex® – Fett 2000
Motorcycle cleaner Specification – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900
Offroad chain spray Specification – KTM recommends Motorex® products. Supplier Motorex® – Chain Lube 622
117
AUXILIARY SUBSTANCES Oil for foam air filter Specification – KTM recommends Motorex® products. Supplier Motorex® – Twin Air Liquid Power
Universal oil spray Specification – KTM recommends Motorex® products. Supplier Motorex® – Joker 440 Universal
118
STANDARDS
119
STANDARDS 27
JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle and ATV engines.With most motorcycles and ATVs, 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 according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
120
INDEX
A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 62
Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Compression damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Air filter box lid installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Compression damping, low-speed shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 38
Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 B Basic chassis setting checking with rider's weight . . . . . . . . . . . . . . . . . . . . 37 Battery installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Brake discs checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Brake fluid front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 65 rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Brake fluid level of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 65 of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 69 Brake linings front brake, changing front brake, checking front brake, installing front brake, removing of rear brake, removing rear brake, changing . rear brake, checking . rear brake, installing .
. . . .
. . . . . .. .. ..
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
67 66 67 66 70 71 70 70
C Carburetor adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 emptying the float chamber . . . . . . . . . . . . . . . . . . . . 85 idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Chain cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Chain guide adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-62 Chain tension adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Chain wear checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Clutch changing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Compression damping, high-speed shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 37
Coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Coolant level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 D Dust boots cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
E Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil adding . changing draining refilling .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
89 86 86 89
Engine oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F Filler cap closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Filling up Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Flasher switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 68 checking free travel . . . . . . . . . . . . . . . . . . . . . . . . . 68 Fork checking basic setting . . . . . . . . . . . . . . . . . . . . . . . . 43 Fork legs bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Fork offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Fork protector installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INDEX
121
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Putting into operation advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 26 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Checks before putting into operation . . . . . . . . . . . . . . 28
Fuel tank installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuse installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 G Gas Bowden cable route checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . adjusting free travel . . . . . . . . . . . . . . . . . . . . . . . . . checking free travel . . . . . . . . . . . . . . . . . . . . . . . . .
12 64 65 64
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 K Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lower triple clamp fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51 M Main silencer installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motorcycle cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
O Oil filter changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Oil screen cleaning
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Oil screens cleaning
R Rear sprocket / engine sprocket checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Rear wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Rebound damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 39 Riding sag adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 S Seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Service schedule EXC‑F, EXC‑F SIX DAYS, XCF-W . . . . . . . . . . . . . . . 32-33 rider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 XC‑F, SX‑F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Shock absorber installing . . . . . . . removing . . . . . . . riding sag, checking static sag, checking
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Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Speedometer adjusting . . . . . . . . . . . . Function description . . . . Setting kilometers or miles Setting the clock . . . . . .
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Spoke tension checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Spring preload fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 41 Start number plate installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Starting
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steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 14 OWNER'S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering head bearing greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
P
Steering head bearing play adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Play in gas Bowden cable adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INDEX Storage
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T Technical data carburetor . . . . . chassis . . . . . . . engine . . . . . . . fork . . . . . . . . . shock absorber . . tightening torques, tightening torques,
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Tire air pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-91 Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 V View of vehicle left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 W Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-115 Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OWNER'S MANUAL 2010 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF-W ZA 250 SX-F EU 250 SX-F USA Art. no. 3211465en
TABLE OF CONTENTS TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................ 5 IMPORTANT INFORMATION ................................................ 6 VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example) ................. 8 View of the vehicle from the right rear (example) ................ 9 LOCATION OF SERIAL NUMBERS ...................................... 10 Chassis number............................................................. 10 Type label..................................................................... 10 Key number (EXC-F, EXC‑F SIX DAYS)............................. 10 Engine number.............................................................. 10 Fork part number........................................................... 10 Shock absorber part number........................................... 11 CONTROLS ....................................................................... 12 Clutch lever .................................................................. 12 Hand brake lever ........................................................... 12 Short circuit button (XCF‑W, SX‑F) .................................. 12 Short circuit button (EXC-F, EXC‑F SIX DAYS).................. 12 Emergency OFF switch (EXC‑F AUS) ............................... 12 Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W)......................................................................... 13 Electric starter button (EXC‑F AUS)................................. 13 Light switch (EXC-F, EXC‑F SIX DAYS) ............................ 13 Horn button (EXC-F, EXC‑F SIX DAYS)............................. 13 Turn signal switch (EXC-F, EXC‑F SIX DAYS).................... 13 Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) ...... 14 CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) ...................... 15 Speedometer................................................................. 15 Speedometer activation and test ..................................... 15 Tripmaster switch .......................................................... 15 Setting kilometers or miles ............................................. 15 Setting the clock ........................................................... 16 Adjusting the speedometer functions............................... 16 Querying the lap time .................................................... 17 SPEED display mode (speed).......................................... 17 Display mode SPEED/H (service hours)............................ 17 Display mode SPEED/CLK (clock) ................................... 18 Display mode SPEED/LAP (lap time) ............................... 18 Display mode SPEED/ODO (odometer) ............................. 18 Display mode SPEED/TR1 (trip master 1) ........................ 18 Display mode SPEED/TR2 (trip master 2) ........................ 19 Disply mode SPEED/A1 (average speed 1) ....................... 19 Display mode SPEED/A2 (average speed 2)...................... 19 Display mode SPEED/S1 (stop watch 1) .......................... 20 Display mode SPEED/S2 (stop watch 2) .......................... 20 CONTROLS ....................................................................... 22 Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF-W)....................... 22 Fuel tap (SX‑F).............................................................. 22 Opening filler cap .......................................................... 22 Closing filler cap ........................................................... 23 Choke (EXC-F EU, EXC‑F SIX DAYS)................................ 23 Choke (XCF‑W, SX‑F, EXC‑F AUS) ................................... 23 Shift lever..................................................................... 23 Foot brake lever............................................................. 24 Kick starter ................................................................... 24 Side stand (EXC‑F, EXC‑F SIX DAYS, XCF-W) ................... 24 Plug-in stand (SX‑F) ...................................................... 24 Steering lock (EXC-F, EXC‑F SIX DAYS) ........................... 25 Locking the steering (EXC-F, EXC‑F SIX DAYS)................. 25 Unlocking the steering (EXC-F, EXC‑F SIX DAYS).............. 25 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 26 Advice on first use ......................................................... 26
2 Running-in the engine ................................................... Preparing vehicle for arduous riding conditions................. Preparing for riding on dry sand ...................................... Preparing for riding on wet sand...................................... Preparing for riding on wet and muddy surfaces................ Preparing for rides at high temperature and slow speed ..... Preparing for rides at low temperatures or in snow ............ RIDING INSTRUCTIONS .................................................... Checks before putting into operation ............................... Starting ........................................................................ Starting up ................................................................... Shifting, riding .............................................................. Braking ........................................................................ Stopping, parking .......................................................... Refueling...................................................................... SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)........ Important maintenance work to be carried out by an authorized KTM workshop .............................................. Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. SERVICE SCHEDULE (SX‑F)............................................... Important maintenance work to be carried out by an authorized KTM workshop .............................................. Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. SERVICE SCHEDULE FOR RIDER....................................... Important checks and maintenance work to be carried out by the rider ............................................................. MAINTENANCE WORK ON CHASSIS AND ENGINE.............. Jacking up the motorcycle .............................................. Removing the motorcycle from the work stand.................. Checking the basic suspension setting with the rider's weight .......................................................................... Compression damping of shock absorber.......................... Adjusting high-speed compression damping of the shock absorber ....................................................................... Adjusting the low-speed compression damping of the shock absorber .............................................................. Adjusting the rebound damping of the shock absorber....... Measuring rear wheel sag unloaded ................................. Checking the static sag of the shock absorber .................. Checking the riding sag of the shock absorber .................. Adjusting the spring preload of the shock absorber ...... Adjusting the riding sag ............................................. Removing the shock absorber ..................................... Installing the shock absorber ..................................... Checking basic setting of fork ......................................... Adjusting the compression damping of the fork ................ Adjusting the rebound damping of the fork....................... Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... Bleeding fork legs.......................................................... Cleaning the dust boots of the fork legs ........................... Loosening the fork protector ........................................... Positioning the fork protection ........................................ Checking steering head bearing play................................ Adjusting play of steering head bearing (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) .................................................. Adjusting the play of the steering head bearing (SX‑F, 250 EXC-F SIX DAYS EU) .............................................. Removing the fork legs................................................... Installing the fork legs ............................................... Removing the fork protector .......................................
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27 27 27 28 29 30 30 31 31 31 32 32 32 33 33 35 35 36 37 37 38 39 39 40 40 40 40 40 40 41 42 42 43 43 43 44 45 45 45 45 46 47 48 48 48 48 49 49 50 50 51 52
TABLE OF CONTENTS
3
Installing the fork protector ....................................... Removing the front fender .............................................. Installing the front fender............................................... Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... Removing the start number plate (SX‑F) .......................... Installing the start number plate (SX‑F) ........................... Handlebar position ........................................................ Adjusting handlebar position ...................................... Checking throttle cable route .......................................... Checking the play in the throttle cable............................. Adjusting the play in the throttle cable ....................... Checking for chain dirt accumulation .............................. Cleaning the chain......................................................... Checking the chain tension ............................................ Checking chain tension when fitting rear wheel ................ Checking the rear sprocket/engine sprocket for wear ......... Checking chain wear ...................................................... Adjusting chain tension.................................................. Adjusting chain tension - after checking .......................... Adjusting chain tension - fitting rear wheel ...................... Adjusting the chain guide (EXC‑F, EXC‑F SIX DAYS, XCF-W)......................................................................... Adjusting the chain guide (SX‑F) ................................ Checking brake discs ..................................................... Checking free travel of hand brake lever........................... Adjusting basic position of hand brake lever (XCF‑W, SX‑F)............................................................................ Adjusting free travel of hand brake lever (EXC-F, EXC‑F SIX DAYS)............................................... Checking the brake fluid level of the front brake ............... Topping up the front brake fluid ................................. Checking the front brake linings...................................... Changing the front brake linings ................................. Checking free travel of foot brake lever ............................ Adjusting basic position of footbrake lever ................... Checking rear brake fluid level........................................ Adding brake fluid to the rear brake circuit ................. Checking rear brake linings ............................................ Changing the rear brake linings .................................. Removing front wheel ................................................ Installing the front wheel ........................................... Removing the rear wheel ........................................... Installing the rear wheel ............................................ Tire condition checking.................................................. Checking tire air pressure ............................................... Checking spoke tension.................................................. Removing the battery (EXC‑F, EXC‑F SIX DAYS, XCF-W)......................................................................... Installing the battery (EXC‑F, EXC‑F SIX DAYS, XCF-W)......................................................................... Recharging the battery (EXC‑F, EXC‑F SIX DAYS, XCF-W)......................................................................... Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W)........... Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W) ....... Adjusting the beam width of the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... Checking the headlight adjustment (EXC‑F, EXC‑F SIX DAYS, XCF-W) ............................................... Removing the seat .........................................................
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52 52 53 53 53 54 54 54 54 55 55 56 56 56 57 57 57 58 58 59 60 60 61 61 61 62 62 62 63 64 64 66 66 66 67 67 68 69 70 71 71 72 73 73 74 74 74 75 75 76 76 76
Mounting the seat ......................................................... 77 Dismounting the fuel tank ......................................... 77 Installing the fuel tank .............................................. 78 Cooling system .............................................................. 78 Checking the anti-freeze and coolant level ....................... 79 Checking the coolant level.............................................. 79 Draining the coolant .................................................. 80 Refilling coolant ....................................................... 80 Glass fiber yarn filling of main silencer ............................ 81 Removing main silencer ................................................. 81 Installing the main silencer ............................................ 81 Removing the air filter box lid......................................... 81 Installing the air filter box lid.......................................... 81 Removing the air filter ............................................... 82 Installing the air filter ............................................... 82 Cleaning air filter ...................................................... 82 Adjusting basic position of clutch lever............................ 83 Checking the fluid level of hydraulic clutch...................... 83 Changing the hydraulic clutch fluid ............................ 83 Checking the basic position of the shift lever.................... 84 Adjusting the basic position of the shift lever .............. 84 Carburetor - idle ............................................................ 85 Carburetor - adjusting idle ......................................... 85 Emptying the carburetor float chamber ....................... 86 Checking the engine oil level .......................................... 87 Changing the engine oil and oil filter, cleaning the oil screen ..................................................................... 87 Draining the engine oil .............................................. 87 Cleaning the oil screens ............................................ 88 Removing the oil filter ............................................... 89 Installing the oil filter ............................................... 89 Filling up with engine oil ........................................... 90 Adding engine oil .......................................................... 90 TROUBLESHOOTING......................................................... 91 CLEANING........................................................................ 93 Cleaning the motorcycle ................................................. 93 STORAGE ......................................................................... 94 Storage......................................................................... 94 Putting into operation after storage ................................. 94 TECHNICAL DATA - ENGINE .............................................. 95 Capacity - engine oil ...................................................... 96 Capacity - coolant.......................................................... 96 TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 97 TECHNICAL DATA - CARBURETOR..................................... 99 EXC-F, EXC‑F SIX DAYS ................................................. 99 XCF-W .......................................................................... 99 SX‑F............................................................................. 99 TECHNICAL DATA - CHASSIS .......................................... 100 Lighting equipment ..................................................... 100 Tires .......................................................................... 101 Capacity - fuel............................................................. 101 TECHNICAL DATA - FORK................................................ 102 EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 102 SX‑F EU ..................................................................... 102 SX‑F USA ................................................................... 103 TECHNICAL DATA - SHOCK ABSORBER ........................... 104 EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 104 SX‑F........................................................................... 104 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS ........................................................................ 105
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TABLE OF CONTENTS WIRING DIAGRAM .......................................................... Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)................. Wiring diagram (EXC‑F AUS) ........................................ Wiring diagram (XCF-W) ............................................... Wiring diagram (SX‑F) .................................................. SUBSTANCES................................................................. AUXILIARY SUBSTANCES................................................ STANDARDS................................................................... INDEX ............................................................................
4 106 106 110 112 114 116 117 119 120
MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following. 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).
All work marked with this symbol requires specialist knowledge and technical 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 in the following. Specific name
Identifies a specific name.
Name®
Identifies a protected name.
Brand™
Identifies a brand in merchandise traffic.
5
IMPORTANT INFORMATION
6
Use definition (EXC-F, EXC‑F SIX DAYS) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the use predominantly in motocross.
Use definition (XCF‑W, SX‑F) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info The motorcycle must be used only on secluded property remote from public road traffic.
Maintenance A prerequisite for trouble free operation and avoiding premature wear is that the engine and suspension are maintained and adjusted as described in this manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of components. Using a motorcycle in difficult conditions such as on sand or very wet and muddy ground 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. Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. Observing these rules will vastly increase the service life of 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; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.
Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise you. You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com
Work rules Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring compressor (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Following repairs or servicing, the vehicle must be checked for roadworthiness.
IMPORTANT INFORMATION
7
Transport Note Danger of damage The parked vehicle can roll away or fall over. –
Always place the vehicle on a firm and even surface.
Note Fire hazard Some vehicle components become very hot when the vehicle is operated. –
Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.
–
Switch off the engine.
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
–
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
Notes/warnings Pay close attention to the notes/warnings.
Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, 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 injury if the appropriate measures are not taken.
Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual –
It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
–
The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
VIEW OF VEHICLE
8
View of the vehicle from the left front (example) 3.1
600874-10
1
Hand brake lever
2
Filler cap
3
Clutch lever
4
Fuel tap
5
Shift lever
6
Air filter box lid
7
Chain guide
VIEW OF VEHICLE
9
View of the vehicle from the right rear (example) 3.2
600873-10
1
Rubber band for the side stand
2
Shock absorber, compression adjustment
3
Chassis number
4
Fork protector
5
Shock absorber, rebound adjustment
6
Level viewer, rear brake fluid
7
Level viewer, engine oil
8
Kickstarter
LOCATION OF SERIAL NUMBERS Chassis number 4.1
The chassis number is stamped on the steering head on the right.
500127-10
Type label 4.2
The type label is fixed to the front of the steering head.
500128-10
Key number (EXC-F, EXC‑F SIX DAYS) 4.3
The key number is stamped on the key strap.
500125-10
Engine number 4.4
The engine number is stamped on the left side of the engine under the engine sprocket.
600661-12
Fork part number 4.5
The fork part number is stamped on the inner side of the fork stub.
500082-10
10
LOCATION OF SERIAL NUMBERS
11
Shock absorber part number 4.6
The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.
500129-10
CONTROLS
12
Clutch lever 5.1
The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.
600659-10
Hand brake lever 5.2
Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake.
400196-10
Short circuit button (XCF‑W, SX‑F) 5.3
The short circuit button is fitted on the left side of the handlebar. Possible states • Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started. • Short circuit button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
500132-10
Short circuit button (EXC-F, EXC‑F SIX DAYS) 5.4
The short circuit button is fitted on the left side of the handlebar. Possible states • Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started. • Short circuit button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
500134-10
Emergency OFF switch (EXC‑F AUS) 5.5
The emergency OFF switch is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. Ignition on – In this position, the ignition circuit is closed, and the engine can be started.
500131-10
CONTROLS
13
Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W) 5.6
The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button
in basic position pressed – In this position, the electric starter is actuated.
400198-10
Electric starter button (EXC‑F AUS) 5.7
The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button
in basic position pressed – In this position, the electric starter is actuated.
500131-11
Light switch (EXC-F, EXC‑F SIX DAYS) 5.8
The light switch is fitted on the left side of the handlebar. Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned to the left. In this position, the high beam and the tail light are switched on.
500134-12
Horn button (EXC-F, EXC‑F SIX DAYS) 5.9
The horn button is fitted on the left side of the handlebar. Possible states • Horn button • Horn button
in neutral position pressed – The horn is operated in this position.
500134-11
Turn signal switch (EXC-F, EXC‑F SIX DAYS) 5.10
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 turned to the left. Turn signal light, right, on – Turn signal switch turned to the right.
500145-10
CONTROLS
14
Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) 5.11
Possible states High beam indicator lamp lights up blue – High beam is switched on. Turn signal indicator lamp flashes green – Turn signal light is switched on.
500147-01
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
15
Speedometer 6.1
–
Press the key
–
Press the button
to control different functions.
–
Press the button
to control different functions.
to change the display mode or change to one of the setup menus.
Info In its condition at delivery, the display mode SPEED/H andSPEED/ODO is activated. 400312-01
Speedometer activation and test 6.2
Activating the speedometer: The speedometer is activated when one of the keys is pressed or a signal is received from the wheel speed sensor. Display test For the function test of the display, all display segments light up briefly.
400313-01
WS (wheel size) After the display function test, the wheel size WS is displayed briefly.
Info 2205 mm corresponds to the size of the 21" front wheel with a series production tire. The display then changes to the last selected mode. 400314-01
Tripmaster switch 6.3
(Option: Tripmaster switch) You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info The trip master is an optional accessory.
Setting kilometers or miles 6.4
Info If you change the unit of measure, the ODO value is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed. Condition The motorcycle is stationary. –
Press the button display.
briefly and repeatedly until H appears at the bottom right of the
–
Press the button
for 3 - 5 seconds.
The Setup menu opens and the active functions are displayed. –
400329-01
Press the button
repeatedly until the Km/h/Mph display flashes.
Adjusting Km/h – Press the button
.
Adjusting Mph – Press the button
.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) –
Press the button
16
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
Info If no button is 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.
Setting the clock 6.5
Condition The motorcycle is stationary. –
Press the button the display.
briefly and repeatedly until CLK appears at the bottom right of
–
Press the button
for 3 - 5 seconds.
The hour display flashes. –
Set the hour display with the button
–
Press the button
–
You can set the following segments in the same way as the hours by pressing the button and the button .
and/or button
.
briefly.
The next segment of the display flashes and can be set. 400330-01
Info The seconds can only be set to zero. –
Press the button
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
Info If no button is 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.
Adjusting the speedometer functions 6.6
Info Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. –
Press the button display.
briefly and repeatedly until H appears at the bottom right of the
–
Press the button
for 3 - 5 seconds.
The Setup menu opens and the active functions are displayed. –
Switch to the function you require by briefly pressing the button
.
The selected function flashes. Activating a function – Press the button 400318-01
.
The icon remains in the display and the display changes to the next function. Deactivating a function – Press the button
.
The icon disappears from the display and the display changes to the next function. –
Activate or deactivate all functions accordingly.
–
Press the button
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
17
Info If no button is 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.
Querying the lap time 6.7
Info This function can be called only if lap times are measured. Condition The motorcycle is stationary. –
Press the button the display.
briefly and repeatedly until LAP appears at the bottom right of
–
Press the button
briefly.
–
Laps 1-10 can be displayed by pressing the button
–
The
–
Press the button
LAP 1 appears on the left side of the display. .
button has no function briefly.
Next display mode
400321-01
Info If an impulse is received from the wheel speed sensor, the left side of the display changes back to the SPEED mode.
SPEED display mode (speed) 6.8
–
Press the button the display.
briefly and repeatedly until SPEED appears on the left side of
The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph.
Info Making the setting according to the country. When an impulse comes from the front wheel, the left side of the speedometer display changes to the SPEED mode and the current speed is shown.
400317-02
Display mode SPEED/H (service hours) 6.9
Condition • The motorcycle is stationary –
Press the button display.
briefly and repeatedly until H appears at the bottom right of the
In display mode H, the service hours of the engine are displayed. The service hour counter stores the total traveling time.
Info 400316-01
The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals. If the speedometer is in H display mode at the start of the journey, it automatically changes to the ODO display mode. 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
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
18
Display mode SPEED/CLK (clock) 6.10
–
Press the button the display.
briefly and repeatedly until CLK appears at the bottom right of
The time is displayed in CLK display mode.
400319-01
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 clock.
Press the button briefly.
Next display mode
Display mode SPEED/LAP (lap time) 6.11
–
Press the button the display.
briefly and repeatedly until LAP appears at the bottom right of
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
Info If the lap time continues after you press the button already occupied. Lap 10 must be timed with the button .
, 9 memory locations are
400320-01
Press the button
.
Starts or stops the clock.
Press the button
.
Stops the current lap time and saves it, and the stop watch starts the next lap.
Press the button for 3 - 5 seconds.
The stop watch and the lap time are reset.
Press the button briefly.
Next display mode
Display mode SPEED/ODO (odometer) 6.12
–
Press the button the display.
briefly and repeatedly until ODO appears at the bottom right of
In ODO display mode, the total number of kilometers ridden is displayed.
400317-01
Press the button
.
No function
Press the button
.
No function
Press the button for 3 - 5 seconds.
–
Press the button briefly.
Next display mode
Display mode SPEED/TR1 (trip master 1) 6.13
–
Press the button display.
briefly and repeatedly until TR1 appears at the top right of the
TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refuelling stops. TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info 400323-01
If 999.9 is exceeded, the values of TR1, A1 and S1 are automaticallt reset to 0.0. Press the button
.
No function
Press the button
.
No function
Press the button for 3 - 5 seconds.
Displays of TR1, A1 and S1 are reset to 0,0.
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) Press the button briefly.
19
Next display mode
Display mode SPEED/TR2 (trip master 2) 6.14
–
Press the button display.
briefly and repeatedly until TR2 appears at the top right of the
TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button practical function when riding using the road book.
. A very
Info The TR2 value can also be corrected manually during the journey with the button and the button . If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
400324-01
Press the button
.
Increases value of TR2.
Press the button
.
Reduces value of TR2.
Press the button for 3 - 5 seconds.
Deletes value of TR2.
Press the button briefly.
Next display mode
Disply mode SPEED/A1 (average speed 1) 6.15
–
Press the button display.
briefly and repeatedly until A1 appears at the top right of the
A1 (average speed 1) shows the average speed calculated using TR1 (trip master 1) and S1 (stop watch 1). The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.
400325-01
Press the button
.
No function
Press the button
.
No function
Press the button for 3 - 5 seconds.
Displays of TR1, A1 and S1 are reset to 0,0.
Press the button briefly.
Next display mode
Display mode SPEED/A2 (average speed 2) 6.16
–
Press the button display.
briefly and repeatedly until A2 appears at the top right of the
A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.
Info The displayed value can differ from the actual average speed if S2 was not timed after the ride. 400326-01
Press the button
.
No function
Press the button
.
No function
Press the button for 3 - 5 seconds.
–
Press the button briefly.
Next display mode
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
20
Display mode SPEED/S1 (stop watch 1) 6.17
–
briefly and repeatedly until S1 appears at the top right of the
Press the button 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. The calculation of this value starts with the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.
400327-01
Press the button
.
No function
Press the button
.
No function
Press the button for 3 - 5 seconds.
Displays of TR1, A1 and S1 are reset to 0,0.
Press the button briefly.
Next display mode
Display mode SPEED/S2 (stop watch 2) 6.18
–
briefly and repeatedly until S2 appears at the top right of the
Press the button display.
S2 (stop watch 2) is a manual stop watch. If S2 is running in the background, the S2 display flashes in the speedometer display.
400328-01
Press the button
.
Starts or stops S2.
Press the button
.
No function
Press the button for 3 - 5 seconds.
Displays of S2 and A2 are reset to 0.0.
Press the button briefly.
Next display mode
Table of functions Display
Press the button
.
Press the button
.
Press the button 5 seconds.
for 3 -
Press the button briefly.
Display mode SPEED/H (service hours)
No function
No function
The display changes to the Setup menu of the speedometer functions.
Next display mode
Display mode SPEED/CLK (clock)
No function
No function
The display changes to the Setup menu of the clock.
Next display mode
Display mode SPEED/LAP (lap time)
Starts or stops the clock.
Stops the current lap time and saves it, and the stop watch starts the next lap.
The stop watch and the lap time are reset.
Next display mode
Display mode SPEED/ODO (odometer)
No function
No function
–
Next display mode
Display mode SPEED/TR1 (trip master 1)
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
Display mode SPEED/TR2 (trip master 2)
Increases value of TR2.
Reduces value of TR2.
Deletes value of TR2.
Next display mode
Disply mode SPEED/A1 (average speed 1)
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
Display mode SPEED/A2 (average speed 2)
No function
No function
–
Next display mode
Display mode SPEED/S1 (stop watch 1)
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
Display mode SPEED/S2 (stop watch 2)
Starts or stops S2.
No function
Displays of S2 and A2 are reset to 0.0.
Next display mode
Table of conditions and activability Display Display mode SPEED/H (service hours)
The motorcycle is stationary •
Menu can be activated
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)
21
Table of conditions and activability Display
The motorcycle is stationary
Menu can be activated
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)
•
Disply mode SPEED/A1 (average speed 1)
•
Display mode SPEED/A2 (average speed 2)
•
Display mode SPEED/S1 (stop watch 1)
•
Display mode SPEED/S2 (stop watch 2)
•
CONTROLS
22
Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF-W) 7.1
The fuel tap is on the left side of the fuel tank. Using tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. • Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve. • Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.
500137-10
Fuel tap (SX‑F) 7.2
The fuel tap is on the left side of the fuel tank. Using tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. • Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.
500178-10
Opening filler cap 7.3
–
400199-10
Press release button , turn filler cap counterclockwise and lift it upwards and remove.
CONTROLS
23
Closing filler cap 7.4
–
Replace the filler cap and turn clockwise until the release button locks in place.
Info Route the fuel tank breather hose without kinking.
400199-11
Choke (EXC-F EU, EXC‑F SIX DAYS) 7.5
The choke lever is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info If the engine is warm, the choke function must be deactivated.
500136-10
Possible states • Choke function activated – The choke lever is pulled to the stop. • Choke function deactivated – The choke lever is pushed back to the stop.
Choke (XCF‑W, SX‑F, EXC‑F AUS) 7.6
Choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info If the engine is warm, the choke function must be deactivated.
600660-10
Possible states • Choke function activated – The choke lever is pulled out to the stop. • Choke function deactivated – The choke lever is pushed in to the stop.
Shift lever 7.7
Shift lever is mounted on the left side of the engine.
600661-13
The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.
600661-10
CONTROLS
24
Foot brake lever 7.8
Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake.
600664-10
Kick starter 7.9
The kick starter is fitted on the right of the engine. The engine can be started with either the kick starter or the electric starter. The upper part of the kick starter can be swung out.
Info Before riding, swing the upper part of the kick starter inwards towards the engine.
600664-11
Side stand (EXC‑F, EXC‑F SIX DAYS, XCF-W) 7.10
Note Danger of damage The parked vehicle can roll away or fall over. –
Always place the vehicle on a firm and even surface.
Note Material damage Damage and destruction of components by excessive load. – 500140-10
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
To park the motorcycle, press the side stand to the ground with your foot and lean the motorcycle on it. When you are riding, the side stand must be folded up and secured with the rubber band .
600665-10
Plug-in stand (SX‑F) 7.11
Note Danger of damage The parked vehicle can roll away or fall over. –
Always place the vehicle on a firm and even surface.
To park the motorcycle, insert plug-in stand into the left side of the wheel spindle.
Info 400203-10
Remove the plug-in stand before starting on a trip.
CONTROLS
25
Steering lock (EXC-F, EXC‑F SIX DAYS) 7.12
Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.
500126-10
Locking the steering (EXC-F, EXC‑F SIX DAYS) 7.13
Note Danger of damage The parked vehicle can roll away or fall over. –
Always place the vehicle on a firm and even surface. –
Park the vehicle.
–
Turn the handlebar as far as possible 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. 400732-01
Unlocking the steering (EXC-F, EXC‑F SIX DAYS) 7.14
–
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 Never leave the key in the steering lock.
400731-01
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
26
Advice on first use 8.1
Danger Danger of accidents Danger arising from the rider's judgement being impaired. –
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning Risk of injury Missing or poor protective clothing present an increased safety risk. –
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be undamaged and meet legal requirements.
Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels. –
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning Danger of accidents Critical handling characteristic due to inappropriate riding style. –
Adapt your riding speed to the road conditoins and your riding ability.
Warning Danger of accidents Accident risk caused by presence of a passenger. –
Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning Danger of accidents Failure of brake system. –
If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake lever if you do not want to brake.
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 your motorcycle, remember that others may feel disturbed by excessive noise. –
Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
–
Before your first trip, read the entire operating instructions carefully.
–
Get to know the controls.
–
Adjust the basic position of clutch lever. (
p. 83)
(XCF‑W, SX‑F) – adjust the basic position of hand brake lever. (
p. 62)
(EXC-F, EXC‑F SIX DAYS) – Adjust the free travel of the hand brake lever. (
p. 62)
–
Adjust the basic position of the footbrake lever.
–
Adjust the basic position of the shift lever.
–
Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
x(
x(
p. 66)
p. 84)
Info Offroad, you should be accompanied by another person on another machine so that you can help each other. –
Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
–
Do not make any offroad trips that over-stress your ability and experience.
–
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION (EXC‑F, EXC‑F SIX DAYS, XCF-W) – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.
Info Motorcycles react sensitively to any changes of weight distribution. (SX‑F) – Do not transport luggage. –
Do not exceed the overall maximum permitted weight and the axle loads. Guideline
–
Maximum permissible overall weight
335 kg (739 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Check the spoke tension. (
p. 73)
Info The spoke tension must be checked after half an hour of operation. –
Run the engine in.
Running-in the engine 8.2
–
During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline Maximum engine speed During the first 3 service hours
7,000 rpm
Maximum engine performance
–
During the first 3 service hours
≤ 50 %
During the next 12 service hours
≤ 75 %
Avoid fully opening the throttle!
Preparing vehicle for arduous riding conditions 8.3
–
Using a motorcycle in arduous 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.
Arduous riding conditions are: – Riding on dry sand. (
p. 27)
–
Riding on wet sand. (
–
Riding on wet and muddy surfaces. (
–
Rides at high temperature and slow speed. (
–
Rides at low temperatures or in snow. (
p. 28) p. 29) p. 30)
p. 30)
Preparing for riding on dry sand 8.4
–
Check the radiator cap. Value on radiator cap »
1.8 bar (26 psi)
If the displayed value does not correspond to specifications:
Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – 600872-10
– –
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Change the radiator cap.
Seal the air filter box.
x
27
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
28
Tip Seal the air filter box on the edges against dirt. –
Clean the air filter.
x(
p. 82)
Info Check the air filter approx. every 30 minutes. –
Fit a dust protection device on the air filter. Dust protection device for air filter (59006019000)
Info See the KTM PowerParts fitting instructions.
600869-01
–
Fit a sand screen device on the air filter. Sand protection device for air filter (59006022000)
Info See the KTM PowerParts fitting instructions. –
Adjust the carburetor jetting and settings.
Info
600871-01
Your authorized KTM workshop has the recommended carburetor tuning settings. –
Clean the chain. Chain cleaner (
–
p. 117)
Fit the steel sprocket.
Tip Do not grease the chain.
600868-01
–
Clean radiator fins.
–
Straighten bent radiator fins carefully.
–
Check the radiator cap.
Preparing for riding on wet sand 8.5
Value on radiator cap »
1.8 bar (26 psi)
If the displayed value does not correspond to specifications:
Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – 600872-10
– –
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Change the radiator cap.
Seal the air filter box.
x
Tip Seal the air filter box on the edges against dirt. –
Clean the air filter.
x(
p. 82)
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
29
Info Check the air filter approx. every 30 minutes. –
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 settings.
Info
600870-01
Your authorized KTM workshop has the recommended carburetor tuning settings. –
Clean the chain. Chain cleaner (
–
p. 117)
Fit the steel sprocket.
Tip Do not grease the chain.
600868-01
–
Clean radiator fins.
–
Straighten bent radiator fins carefully.
Preparing for riding on wet and muddy surfaces 8.6
–
Seal the air filter box.
x
Tip Seal the air filter box along the edges to prevent the ingress of dirt. –
Clean the air filter.
x(
p. 82)
Info Check the air filter approx. every 30 minutes. –
Fit a waterproofing device on the air filter. Waterproofing device for air filter (59006021000)
Info See the KTM PowerParts fitting instructions. –
Info
600870-01
Your authorized KTM workshop has the recommended carburetor tuning settings. –
600868-01
Adjust the carburetor jetting and settings.
Fit the steel sprocket.
–
Clean the motorcycle. (
–
Straighten bent radiator fins carefully.
p. 93)
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
30
Preparing for rides at high temperature and slow speed 8.7
–
Check the radiator cap. Value on radiator cap »
1.8 bar (26 psi)
If the displayed value does not correspond to specifications:
Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – 600872-10
– –
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Change the radiator cap.
Seal the air filter box.
x
Tip Seal the air filter box on the edges against dirt. –
Clean the air filter.
x(
p. 82)
Info Check the air filter approx. every 30 minutes. –
Adjust the secondary drive to the road conditions.
Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive. –
Clean the chain. Chain cleaner (
600868-01
p. 117)
–
Clean radiator fins.
–
Straighten bent radiator fins carefully.
–
Check the coolant level. (
p. 79)
Preparing for rides at low temperatures or in snow 8.8
–
Seal the air filter box.
x
Tip Seal the air filter box on the edges against dirt. –
Clean the air filter.
x(
p. 82)
Info Check the air filter approx. every 30 minutes. –
Fit a waterproofing device on the air filter. Waterproofing device for air filter (59006021000)
Info See the KTM PowerParts fitting instructions. – 600870-01
Adjust the carburetor jetting and settings.
Info Your authorized KTM workshop has the recommended carburetor tuning settings.
RIDING INSTRUCTIONS
31
Checks before putting into operation 9.1
Info Make sure that the motorcycle is in a perfect technical condition before use.
Info In the interests of riding safety, make a habit of making a general check before you ride. –
Check the engine oil level. (
–
Check the chain tension. (
–
Check for chain dirt accumulation. (
–
Check the tire condition. (
–
Check the tire air pressure. (
–
Check the brake fluid level of the front brake. (
–
Check the rear brake fluid level. (
p. 87) p. 57) p. 56)
p. 72) p. 73) p. 62)
p. 66)
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check the brake system function.
–
Check the coolant level. (
–
Check the settings of all controls and ensure that they can be operated smoothly.
–
Check the functioning of the electrical equipment.
p. 64) p. 67)
p. 79)
Starting 9.2
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 effective exhaust extraction system.
Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. –
Always warm up the engine at low engine speeds.
Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again. Engine has been out of use for more than 1 week – Empty the carburetor float chamber. (
x
p. 86)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn handle of the fuel tap to the ON position. (Figure 500137-10
p. 22)
Fuel can flow from the fuel tank to the carburetor. (SX‑F) – Turn handle of the fuel tap to the ON position. (Figure 500178-10 Fuel can flow from the fuel tank to the carburetor. 400733-01
–
Remove the motorcycle from the stand.
–
Shift transmission to neutral.
(EXC‑F AUS) – Turn the emergency OFF switch to the position The engine is cold (XCF‑W, SX‑F, EXC‑F AUS) – Pull choke lever out as far as possible. (EXC-F EU, EXC‑F SIX DAYS) – Pull the choke lever to the stop.
.
p. 22)
RIDING INSTRUCTIONS
32 –
Press the electric starter button or press the kickstarter robustly through its full range.
Info Do not open the throttle.
Starting up 9.3
Info If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber band. –
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
Shifting, riding 9.4
Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –
Do not change into a low gear at high engine speed. The engine overspeeds and the rear wheel can block.
Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. –
When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
–
If the choke function was activated, deactivate it after the engine has warmed up.
–
When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces vehicle speed but lowers fuel consumption considerably.
–
Always open the throttle only as much as the engine 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 stationary for a long time. Guideline ≥ 2 min
–
Avoid frequent and prolonged slipping of the clutch. This causes heat build-up in the engine oil, the engine and the cooling system.
–
Ride at lower engine speeds instead of high revs and a slipping clutch.
Braking 9.5
Warning Danger of accidents If you brake too hard, the wheels can lock. –
Adapt your braking to the traffic situation and the road conditions.
Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. –
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
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.
–
On sandy, wet or slippery surfaces, use the rear brake.
–
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
–
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.
RIDING INSTRUCTIONS
33
Stopping, parking 9.6
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.
Warning Danger of burns Some vehicle components get very hot when the vehicle is in use. –
Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.
Note Danger of damage The parked vehicle can roll away or fall over. –
Always place the vehicle on a firm and even surface.
Note Fire hazard Some vehicle components become very hot when the vehicle is operated. –
Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.
Note Material damage Damage and destruction of components by excessive load. –
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
–
Brake the motorcycle.
–
Shift transmission to neutral.
(XCF‑W, SX‑F) – Press and hold the short circuit button
while the engine is idling until the engine stops.
(EXC-F, EXC‑F SIX DAYS) – Press and hold the short circuit button
while the engine is idling until the engine stops.
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
–
Park the motorcycle on firm ground.
Refueling 9.7
Danger 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 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 immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning Environmental hazard Improper handling of fuel is a danger to the environment. –
Do not allow fuel to get into the ground water, the ground, or the sewage system. –
Switch off engine.
–
Open the filler cap. (
p. 22)
RIDING INSTRUCTIONS
34 –
Fill the fuel tank with fuel up to measurement . Guideline Measurement of
35 mm (1.38 in)
A
Total fuel tank capacity, approx. (EXC‑F, EXC‑F SIX DAYS, XCF-W)
9.2 l (2.43 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 116)
400382-10
Total fuel tank capacity, approx. (SX‑F)
8.0 l (2.11 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 116)
–
Close the filler cap. (
p. 23)
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)
35
Important maintenance work to be carried out by an authorized KTM workshop 10.1
Engine
Change the engine oil and oil filter, clean the oil screen.
x(
p. 87)
S3N
S20A
•
•
Replace the spark plug.
• •
•
Check the engine mounting screws for tightness.
•
•
Clean the spark plug connectors and check for tightness.
•
•
Check that the screws in the shift lever and the kickstarter are tight.
•
•
Check the valve clearance.
Carburetor
Attachments
x
Check the carburetor connection boots for cracks and leakage.
•
Check the vent hoses for damage and routing without sharp bends.
•
•
Check the idle.
•
•
Check the cooling system for leakage.
•
•
•
•
Check the anti-freeze and coolant level. (
p. 79)
Check the exhaust system for leakage and looseness.
•
Check the throttle cables for damage, smooth operation and routing without sharp bends.
•
•
Check the fluid level of the hydraulic clutch. (
•
•
•
•
Clean the air filter.
x(
p. 83)
p. 82)
Check the cables for damage and routing without sharp bends.
•
Check the functioning of the electrical equipment.
•
Check the headlight setting. Brakes
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the screws and guide bolts of the rake system for tightness.
•
•
Check the shock absorber and fork for leakage and functioning.
•
•
Check the brake discs. (
p. 64) p. 67)
p. 61)
Check the brake fluid level of the front brake. ( Check the rear brake fluid level. (
p. 62)
p. 66)
Check the brake lines for damage and leakage. Check the free travel of the hand brake lever. ( Check the free travel of the foot brake lever. (
p. 61) p. 66)
Check the brake system function.
Clean the dust boots of the fork legs. ( Bleed fork legs. (
x
p. 48)
•
p. 48)
•
Check the frame and swingarm for damage.
•
Check the swingarm bearing.
•
Check the steering head bearing play. ( Wheels
• •
Check the front brake linings. ( Check the rear brake linings. (
Chassis
•
•
Check all screws to see if they are tight.
•
•
Check the spoke tension. (
•
•
p. 49)
p. 73)
Check the wheel hubs for damage. Check the rim run-out. Check the tire condition. (
p. 72)
Check the tire air pressure. ( Check the chain wear. (
p. 73)
p. 58)
Check the chain tension. ( Clean the chain. (
p. 57)
p. 56)
• •
•
•
•
•
•
•
•
•
•
•
•
Check the wheel bearing for play.
•
•
Clean and grease the adjusting screws of the chain adjuster.
•
•
S3N: once after three operating hours S20A: every 20 service hours / after every race S30A: every 30 service hours
S30A
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)
36
Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 10.2
Competition use S10A
S20A
Hobby use
S40A
S80A
Perform a fork service. (EXC‑F, EXC‑F SIX DAYS, XCF-W)
•
•
Perform a shock absorber service. (EXC‑F, EXC‑F SIX DAYS, XCF-W)
•
•
x
x Grease the steering head bearing. x
S20A
S40A
S60A
•
S10N
J1A
S80A •
•
• •
Treat electric contacts with contact spray.
•
Change the hydraulic clutch fluid. ( p. 83)
•
x
•
Change the front brake fluid.
x Change the rear brake fluid. x Check the clutch discs for wear. x Check the clutch. x Check the cylinder and piston for wear. x Check the camshafts. x Check the valve spring seat. x Check the valves. x Change the valves. x Check wear of valve guides. x Change the valve springs. x Check the timing-chain tensioner function. x Check the crankshaft run-out at the bearing pin. x Change the conrod bearing. x Change the crankshaft main bearing. x Fully check the transmission. x Check the shift mechanism. x Check the spring length of the oil pressure regulator valve. x Change the glass fiber yarn filling of the main silencer. x Change the foot brake cylinder seals. x Check/adjust the carburetor components. x
•
•
S10A: every 10 service hours S20A: every 20 service hours / after every race S40A: every 40 service hours S60A: every 60 service hours S80A: every 80 service hours S10N: once after 10 operating hours J1A: annually
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
SERVICE SCHEDULE (SX‑F)
37
Important maintenance work to be carried out by an authorized KTM workshop 11.1
Engine
Change the engine oil and oil filter, clean the oil screen.
x(
p. 87)
S3N
S10A
S30A
•
•
•
Replace the spark plug.
• •
•
•
Check the engine mounting screws for tightness.
•
•
•
Clean the spark plug connectors and check for tightness.
•
•
•
Check that the screws in the shift lever and the kickstarter are tight.
•
•
•
•
•
Check the valve clearance.
Carburetor
Attachments
x
Check the carburetor connection boots for cracks and leakage. Check the vent hoses for damage and routing without sharp bends.
•
•
•
Check the idle.
•
•
•
Check the cooling system for leakage.
•
•
•
•
•
•
•
•
Check the anti-freeze and coolant level. (
p. 79)
Check the exhaust system for leakage and looseness. Check the throttle cables for damage, smooth operation and routing without sharp bends.
•
•
•
Check the fluid level of the hydraulic clutch. (
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the brake system function.
•
•
•
Check the screws and guide bolts of the brake system for tightness.
•
•
•
Check the shock absorber and fork for leakage and functioning.
•
•
•
•
•
•
•
Check the frame and swingarm for damage.
•
•
Check the swingarm bearing.
•
•
•
•
•
Check all screws to see if they are tight.
•
•
•
Check the spoke tension. (
•
•
•
Clean the air filter.
x(
p. 83)
p. 82)
Check the cables for damage and routing without sharp bends. Brakes
Check the front brake linings. (
p. 64)
Check the rear brake linings. ( Check the brake discs. (
p. 67)
p. 61)
Check the brake fluid level of the front brake. ( Check the rear brake fluid level. (
p. 62)
p. 66)
Check the brake lines for damage and leakage. Check the free travel of the hand brake lever. ( Check the free travel of the foot brake lever. (
Chassis
Clean the dust boots of the fork legs. ( Bleed fork legs. (
x
p. 48)
p. 48)
Check the steering head bearing play. ( Wheels
p. 61) p. 66)
p. 49)
p. 73)
Check the wheel hubs for damage.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the wheel bearing for play.
•
•
•
Clean and grease the adjusting screws of the chain adjuster.
•
•
•
Check the rim run-out. Check the tire condition. (
p. 72)
Check the tire air pressure. ( Check the chain wear. ( Check the chain tension. ( Clean the chain. (
p. 73)
p. 58) p. 57)
p. 56)
S3N: Once after 3 service hours - corresponds to about 21 liters of fuel (5.55 US gal) S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)
SERVICE SCHEDULE (SX‑F)
38
Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 11.2
S10A
S20N
S20A
S30A
x x Perform a shock absorber service. (SX‑F) x Grease the steering head bearing. x Treat electric contacts with contact spray. Change the hydraulic clutch fluid. x ( p. 83) Change the front brake fluid. x Change the rear brake fluid. x Check the clutch discs for wear. x Check the clutch. x Check the cylinder and piston for wear. x Check the camshafts. x Check the valve spring seat. x Check the valves. x Change the valves. x Check wear of valve guides. Change the valve springs. x Check the timing-chain tensioner function. x Check the crankshaft run-out at the bearing pin. x Change the conrod bearing. x Change the crankshaft main bearing. x Fully check the transmission. x Check the shift mechanism. x
•
Conduct a minor fork service. (SX‑F)
•
•
•
•
J1A
•
• • • • • •
•
•
•
•
•
•
•
•
•
•
•
•
• • •
•
•
•
•
•
•
•
• •
x
x •
• •
x
Check/adjust the carburetor components.
• •
Check the spring length of the oil pressure regulator valve. Change the foot brake cylinder seals.
S80A
•
Conduct a major fork service. (SX‑F)
Change the glass fiber yarn filling of the main silencer.
S40A
x
S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S20N: Once after 20 service hours - corresponds to about 140 liters of fuel (37 US gal) S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal) S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal) S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal) S80A: Every 80 service hours - corresponds to about 560 liters of fuel (148 US gal) J1A: annually
•
•
•
•
•
•
•
•
•
•
•
•
•
•
SERVICE SCHEDULE FOR RIDER
39
Important checks and maintenance work to be carried out by the rider 12.1
NB1A Check the engine oil level. (
p. 87)
•
Check the brake fluid level of the front brake. ( Check the rear brake fluid level. ( Check the front brake linings. (
p. 62)
p. 66)
•
p. 64)
Check the rear brake linings. (
• •
p. 67)
•
Check and adjust the cables.
•
Bleed fork legs. (
•
p. 48)
Clean the dust boots of the fork legs. ( Clean the chain. (
p. 48)
•
Check the chain tension. ( Check the chain wear. (
p. 57)
•
p. 58)
•
Check rear sprocket/engine sprocket for wear. ( Clean the air filter.
•
p. 56)
x(
Check the coolant level. (
p. 73)
•
p. 72)
•
p. 79)
Empty the carburetor float chamber.
• •
p. 82)
Check the tire air pressure. ( Check the tire condition. (
p. 57)
•
x(
p. 86)
•
Check all controls for smooth operation.
•
Check braking.
•
Check all screws, nuts and hose clamps regularly for tightness.
•
NB1A: Depending on conditions of use according to requirements.
MAINTENANCE WORK ON CHASSIS AND ENGINE
40
Jacking up the motorcycle 13.1
Note Danger of damage The parked vehicle can roll away or fall over. – –
Always place the vehicle on a firm and even surface.
Jack up the motorcycle underneath the engine. The wheels should no longer touch the ground. Work stand (54829055000)
600697-01
–
Secure the motorcycle against falling over.
Removing the motorcycle from the work stand 13.2
Note Danger of damage The parked vehicle can roll away or fall over. –
Always place the vehicle on a firm and even surface.
–
Remove the motorcycle from the work stand.
–
Remove the work stand.
Checking the basic suspension setting with the rider's weight 13.3
Info When adjusting the basic suspension setting, first adjust the shock absorber and then the fork. –
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of the suspension components must match your body weight.
–
As delivered, KTM off-road motorcycles are adjusted for a standard rider weight (with full protective clothing). Guideline Standard rider weight
75… 85 kg (165… 187 lb.)
–
If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accordingly.
–
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.
Compression damping of shock absorber 13.4
The shock absorber can regulate compression damping separately in the low-speed and high-speed ranges (Dual Compression Control). The terms low-speed and high-speed refers to the movement of the shock absorber during compression and not to the riding speed of the motorcycle. Changes in the settings in the low-speed range have an impact on the high-speed range and vice versa.
Adjusting high-speed compression damping of the shock absorber 13.5
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. –
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Info The high-speed setting can be seen during the fast compression of the shock absorber.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
41
Turn adjusting screw all the way clockwise with a ring wrench.
Info Do not loosen nut ! –
Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline (EXC‑F, EXC‑F SIX DAYS, XCF-W) Compression damping, high-speed
600667-10
Comfort
2 turns
Standard
1.5 turns
Sport
1.25 turns
(SX‑F) Compression damping, high-speed Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
Adjusting the low-speed compression damping of the shock absorber 13.6
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. –
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. –
Turn adjusting screw clockwise with a screwdriver to the last click.
Info Do not loosen nut ! –
Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (EXC‑F, EXC‑F SIX DAYS, XCF-W)
600667-11
Compression damping, low-speed Comfort
22 clicks
Standard
20 clicks
Sport
15 clicks
(SX‑F) Compression damping, low-speed Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE
42
Adjusting the rebound damping of the shock absorber 13.7
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. –
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) –
Turn adjusting screw clockwise with a screwdriver to the last click.
Info Do not loosen nut ! –
Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (EXC‑F, EXC‑F SIX DAYS, XCF-W) Rebound damping
400210-10
Comfort
26 clicks
Standard
24 clicks
Sport
22 clicks
(SX‑F) Rebound damping Comfort
24 clicks
Standard
22 clicks
Sport
22 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
Measuring rear wheel sag unloaded 13.8
A 0
400220-10
–
Jack up the motorcycle. (
–
Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover.
–
Make a note of the value as measurement .
–
Remove the motorcycle from the work stand. (
p. 40)
p. 40)
MAINTENANCE WORK ON CHASSIS AND ENGINE
43
Checking the static sag of the shock absorber 13.9
A 0
–
Measure distance of rear wheel unloaded. (
–
Ask someone to help you by holding the motorcycle upright.
–
Measure the distance between the rear axle and the fixed point again.
–
Make a note of the value as measurement .
p. 42)
Info The static sag is the difference between measurements and . –
Check the static sag. (EXC‑F, EXC‑F SIX DAYS, XCF-W) Static sag
35 mm (1.38 in)
(SX‑F) Static sag
B 0
»
33 mm (1.3 in)
If the static sag is less or more than the specified value: –
Adjust the spring preload of the shock absorber.
x(
p. 43)
400221-10
Checking the riding sag of the shock absorber 13.10
0 A
–
Measure distance of rear wheel unloaded. (
–
With the help of a second person to steady the motorcycle, the rider wearing a full set of protective clothing sits on the motorcycle in the normal seating position (with feet on the footrests). Then depress and release the rear of the motorcycle repeatedly so that the rear suspension is returned to the normal operating position.
–
The other person now measures the distance between the rear axle and the fixed point again.
–
Make a note of the value as measurement .
p. 42)
Info The riding sag is the difference between measurements and . –
Check the riding sag. (EXC‑F, EXC‑F SIX DAYS, XCF-W)
C
Riding sag
105 mm (4.13 in)
(SX‑F) Riding sag »
If the riding sag differs from the specified measurement: –
400222-10
Adjust the riding sag.
Adjusting the spring preload of the shock absorber 13.11
105 mm (4.13 in)
x(
p. 44)
x
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. –
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. –
Remove shock absorber.
–
After removing the shock absorber, clean it thoroughly.
x(
p. 45)
MAINTENANCE WORK ON CHASSIS AND ENGINE 2 1
44
–
Loosen screw .
–
Turn adjusting ring until the spring is no longer under tension. Combination wrench (50329080000)
A
Hook wrench (T106S) –
Measure the overall spring length when not under tension.
–
Tighten the spring by turning adjusting ring to measurement . Guideline (EXC‑F, EXC‑F SIX DAYS, XCF-W) Spring preload
8 mm (0.31 in)
(SX‑F) Spring preload
6 mm (0.24 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
400216-10
Screw, shock absorber adjusting ring –
Install the shock absorber.
x(
p. 45)
Adjusting the riding sag –
x Remove shock absorber. x (
–
After removing the shock absorber, clean it thoroughly.
–
Choose and mount a suitable spring.
13.12
p. 45)
Guideline (EXC‑F, EXC‑F SIX DAYS, XCF-W) 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)
(SX‑F) 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)
Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. –
Install the shock absorber.
–
Check the static sag of the shock absorber. (
p. 43)
–
Check the riding sag of the shock absorber. (
p. 43)
–
Adjust the rebound damping of the shock absorber. (
x(
p. 45)
p. 42)
M6
5 Nm (3.7 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the shock absorber
45
x
13.13
–
Jack up the motorcycle. (
–
Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position.
–
Remove screw , push splash protector to the side, and remove the shock absorber.
–
Push splash protector to the side and position the shock absorber. Mount and tighten screw .
p. 40)
600668-10
Installing the shock absorber 13.14
x Guideline Screw, top shock absorber –
M12
80 Nm (59 lbf ft)
Loctite® 243™
M12
80 Nm (59 lbf ft)
Loctite® 243™
Mount and tighten screw . Guideline Screw, bottom shock absorber
600668-11
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 dissolve the Teflon coating, thereby drastically reducing the service life. –
Remove the motorcycle from the work stand. (
p. 40)
Checking basic setting of fork 13.15
Info For various reasons, no exact riding sag can be determined for the forks. –
As with the shock absorber, smaller weight differences can be compensated by the spring preload.
–
However, if your fork is often overloaded (hits the bump stops on compression), it is recommended to fit stiffer springs to avoid damage to the fork and frame.
400189-01
Adjusting the compression damping of the fork 13.16
Info The hydraulic compression damping determines the fork suspension behavior.
MAINTENANCE WORK ON CHASSIS AND ENGINE
46
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove protection covers . –
Turn adjusting screws clockwise all the way.
Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – 100020-10
Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Comfort
26 clicks
Standard
22 clicks
Sport
18 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. –
Mount protection covers .
(SX‑F) – Turn adjusting screws clockwise all the way.
Info Adjusting screws are located at the top 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 (SX‑F EU)
600669-10
Compression damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
(SX‑F USA) Compression damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
Adjusting the rebound damping of the fork 13.17
Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn adjusting screws clockwise all the way.
Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – 600670-10
Turn back counterclockwise by the number of clicks corresponding to the fork type.
MAINTENANCE WORK ON CHASSIS AND ENGINE
47
Guideline Rebound damping Comfort
24 clicks
Standard
20 clicks
Sport
20 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. (SX‑F) – Remove protection covers . –
Turn adjusting screws clockwise all the way. Guideline (SX‑F EU) Rebound damping
100020-10
Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
(SX‑F USA) Rebound damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Info Adjusting screws are located at 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.
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. –
Mount protection covers .
Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.18
–
Turn the adjusting screws counterclockwise all the way.
Info Make the same adjustment on both fork legs. –
Turn back clockwise by the number of turns corresponding to the fork type. Guideline Spring preload - Preload Adjuster
600671-01
Comfort
0 turn
Standard
2 turns
Sport
4 turns
Info Turn clockwise to increase spring preload; turn counterclockwise to reduce spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload.
MAINTENANCE WORK ON CHASSIS AND ENGINE
48
Bleeding fork legs 13.19
–
Jack up the motorcycle. (
–
Remove bleeder screws briefly.
p. 40)
Any excess pressure escapes from the interior of the fork. –
Mount and tighten bleeder screws.
–
Remove the motorcycle from the work stand. (
–
Jack up the motorcycle. (
–
Loosen the fork protector. (
–
Push dust boots of both fork legs downwards.
p. 40)
100021-10
Cleaning the dust boots of the fork legs 13.20
p. 40) p. 48)
Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, there is an ingress of dirt inside the boots. If this dirt is not removed, it may cause the oil seals to leak.
Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
600691-10
– –
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray (
p. 118)
–
Press the dust boots back into their normal position.
–
Remove excess oil.
–
Position the fork protection. (
–
Remove the motorcycle from the work stand. (
–
Remove screws and remove the clamp.
–
Remove screws on the left fork leg. Push the fork protector downwards.
–
Remove the screws on the right fork leg. Push the fork protector downwards.
–
Position the fork protection on the left fork leg. Mount and tighten screws .
p. 48) p. 40)
Loosening the fork protector 13.21
600875-11
Positioning the fork protection 13.22
Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Position the wiring harness.
600875-10
–
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)
MAINTENANCE WORK ON CHASSIS AND ENGINE
49
Checking steering head bearing play 13.23
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 driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. –
Jack up the motorcycle. (
–
Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.
p. 40)
No play should be noticeable in the steering head bearing. »
If there is noticeable play present: (SX‑F, 250 EXC-F SIX DAYS EU) – Adjust the play of the steering head bearing.
400387-10
(EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Adjust play of the steering head bearing. –
x(
x(
p. 50)
p. 49)
Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. »
If click positions are noticeable: (SX‑F, 250 EXC-F SIX DAYS EU) – Adjust the play of the steering head bearing. (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Adjust play of the steering head bearing. –
–
Adjusting play of steering head bearing 13.24
x(
x(
p. 50)
p. 49)
Check the steering head bearing and replace if required.
Remove the motorcycle from the work stand. (
p. 40)
x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA) –
Jack up the motorcycle. (
–
Loosen screws and .
–
p. 40)
Loosen and retighten screw . Guideline Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
–
Fully tighten screw . Guideline Screw, top triple clamp
100022-10
–
M8
20 Nm (14.8 lbf ft)
M8
20 Nm (14.8 lbf ft)
Tighten screw . Guideline Screw, top steering stem
–
Check the steering head bearing play. (
p. 49)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play of the steering head bearing 13.25
–
50
x (SX‑F, 250 EXC-F SIX DAYS EU)
Jack up the motorcycle. (
p. 40)
(250 EXC-F SIX DAYS EU) – Loosen screws . Remove screw . –
Loosen and retighten screw . Guideline Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
–
Fully tighten screws .
800022-10
Guideline Screw, top triple clamp –
M8
17 Nm (12.5 lbf ft)
Mount and tighten screw . Guideline Screw, top steering stem
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
(SX‑F) – Loosen screws . Remove screw . –
Loosen and retighten screw . Guideline Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
–
Fully tighten screws .
600876-10
Guideline Screw, top triple clamp –
M8
17 Nm (12.5 lbf ft)
Mount and tighten screw . Guideline Screw, top steering stem
M8
–
Check the steering head bearing play. (
–
Remove front wheel.
–
Remove screws and take off the clamp.
17 Nm (12.5 lbf ft) p. 49)
Removing the fork legs 13.26
x(
p. 69)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove cable clip . –
Remove screws and take off the brake caliper.
–
Hang the brake caliper and the brake line loosely to the side.
100802-10
(EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Loosen screws . Remove the fork leg on the left. –
100804-10
Loosen screws . Remove the fork leg on the right.
Loctite® 243™
MAINTENANCE WORK ON CHASSIS AND ENGINE
51
(250 EXC-F SIX DAYS EU) – Loosen screws . Remove the fork leg on the left. –
Loosen screws . Remove the fork leg on the right.
100803-10
(SX‑F) – Loosen screws . Remove the fork leg on the left. –
Loosen screws . Remove the fork leg on the right.
600877-10
Installing the fork legs 13.27
x –
Position the fork legs.
Info The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp. Position bleeder screws toward the front.
100021-10
(EXC‑F EU, EXC‑F AUS, XCF‑W ZA) – Fully tighten screws . Guideline Screw, top triple clamp –
M8
20 Nm (14.8 lbf ft)
M8
15 Nm (11.1 lbf ft)
M8
17 Nm (12.5 lbf ft)
M8
12 Nm (8.9 lbf ft)
M8
17 Nm (12.5 lbf ft)
Fully tighten screws . Guideline Screw, bottom triple clamp
100804-11
(250 EXC-F SIX DAYS EU) – Fully tighten screws . Guideline Screw, top triple clamp –
Fully tighten screws . Guideline Screw, bottom triple clamp
100803-11
(SX‑F) – Fully tighten screws . Guideline Screw, top triple clamp –
600877-11
Fully tighten screws .
MAINTENANCE WORK ON CHASSIS AND ENGINE
52
Guideline Screw, bottom triple clamp –
M8
12 Nm (8.9 lbf ft)
Position the brake caliper and mount and tighten screws . Guideline Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Mount cable clip . – 100802-11
Removing the fork protector 13.28
Position the wiring harness.
–
Position the brake line. Put the clamp on and mount and tighten screws .
–
Install the front wheel.
–
Remove the fork legs. (
–
Remove screws on the left fork leg. Remove the fork protector upwards.
–
Remove the screws on the right fork leg. Remove the fork protector upwards.
–
Position the fork protection on the left fork leg. Mount and tighten screws .
x(
p. 70)
x p. 50)
600878-10
Installing the fork protector 13.29
x Guideline Remaining screws, chassis –
M6
10 Nm (7.4 lbf ft)
Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis
–
Install the fork legs.
x(
M6 p. 51)
600878-10
Removing the front fender 13.30
600692-10
–
Remove screws . Remove the front fender.
–
Make sure the spacers remain in place.
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
53
Installing the front fender 13.31
–
Ensure that the spacers are mounted in the fender.
–
Position the front fender. Mount and tighten screws . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Info Make sure the holding lugs engage in the start number plate or headlight mask. 600692-10
Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.32
–
Switch off all electrical equipment.
–
Remove screw and take off clamp.
–
Loosen the rubber band . Push up the headlight mask and swing it forwards.
–
Pull out the electric plug connector and remove the headlight mask with the headlight.
600703-10
600702-10
Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.33
–
Connect the electric plug connector .
–
Position the headlight mask and fix it with the rubber band .
600702-11
Info Ensure that the retaining lugs engage in the fender.
600703-11
–
Position the brake line and wiring harness. Put the clamp on, mount and tighten screw .
–
Check the headlight adjustment. (
p. 76)
MAINTENANCE WORK ON CHASSIS AND ENGINE
54
Removing the start number plate (SX‑F) 13.34
–
Remove screw and take off clamp.
–
Remove screw with the spacer. Remove the start number plate.
500101-10
Installing the start number plate (SX‑F) 13.35
–
Position the start number plate. Mount and tighten screw with the spacer. Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Info Take care with the contact of the holding lug at the fender. –
Position the brake line and wiring harness. Put the clamp on, mount and tighten screw .
500101-11
Handlebar position 13.36
On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes
15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of from the center.
0 A
B 0
A 0
B 0
Distance between holes
3.5 mm (0.138 in)
The handlebar supports can be mounted in 4 different positions.
400223-11
Adjusting handlebar position 13.37
x
Warning Danger of accidents Handlebar breakage. –
If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handlebar.
0 1 2 0
0 1 2 0
400223-10
–
Remove the four screws . Remove the handlebar clamps. Remove the handlebar and lay it to one side.
Info Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. –
Remove the two screws . Remove the handlebar support.
–
Place the handlebar support in the required position. Fit and tighten the two screws . Guideline Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Info Position the left and right handlebar supports evenly.
0 2
Loctite® 243™
MAINTENANCE WORK ON CHASSIS AND ENGINE –
55
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.
Checking throttle cable route 13.38
–
The two throttle cables must run parallel behind the handlebar down to the frame. They must be routed directly to the right of the frame above the tank bracket towards the carburetor.
–
Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable.
600672-10
Checking the play in the throttle cable 13.39
Play in throttle cable »
3… 5 mm (0.12… 0.2 in)
If the throttle cable play does not meet specifications: –
Adjust the play in the throttle cable.
x(
p. 56)
Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
400192-10
–
–
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 effective exhaust extraction system.
Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. »
If the idle speed changes: –
Adjust the play in the throttle cable.
x(
p. 56)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play in the throttle cable 13.40
56
x –
Dismount the fuel tank.
x(
p. 77)
–
Check throttle cable route. (
p. 55)
–
Move the handlebar to the straight-ahead position.
–
Push back bellows .
–
Loosen nut . Turn adjusting screw in as far as possible.
–
Loosen nut . Turn adjusting screw so that there is play in the gas throttle cable at the throttle grip. Guideline Play in throttle cable
600673-10
3… 5 mm (0.12… 0.2 in)
–
Tighten nut .
–
Press and hold the throttle grip in the closed setting. Turn adjusting screw out until there is no play in the throttle cable .
–
Tighten nut .
–
Push bellows on. Check the throttle grip for smooth operation.
–
Install the fuel tank.
–
Check the play in the throttle cable. (
–
Check the chain for coarse dirt accumulation.
p. 78)
x(
p. 55)
Checking for chain dirt accumulation 13.41
»
If the chain is very dirty: –
Clean the chain. (
p. 56)
400678-01
Cleaning the chain 13.42
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 grease on the brake discs. –
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
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 The service life of the chain depends largely on its maintenance. –
Clean the chain regularly and then treat with chain spray. Chain cleaner (
p. 117)
Off-road chain spray (
400725-01
p. 117)
MAINTENANCE WORK ON CHASSIS AND ENGINE
57
Checking the chain tension 13.43
Warning Danger of accidents Danger caused by incorrect chain tension. –
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary. –
Jack up the motorcycle. (
–
Push the chain up at the rear edge of the chain guide to measure the chain tension .
p. 40)
Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension 400213-10
»
If the chain tension does not meet specifications: –
–
8… 10 mm (0.31… 0.39 in)
Adjusting chain tension - after checking. (
Remove the motorcycle from the work stand. (
p. 59)
p. 40)
Checking chain tension when fitting rear wheel 13.44
Warning Danger of accidents Danger caused by incorrect chain tension. –
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary. –
Make sure that the chain adjusters are fitted correctly on the adjusting screws.
–
Push the chain up at the rear edge of the chain guide to measure the chain tension .
Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension
400213-10
»
8… 10 mm (0.31… 0.39 in)
If the chain tension does not meet specifications: –
Adjust the chain tension when fitting rear wheel. (
p. 60)
Checking the rear sprocket/engine sprocket for wear 13.45
–
Check rear sprocket/engine sprocket for wear. »
If the rear sprocket / engine sprocket are worn: –
Replace the rear sprocket/engine sprocket.
Info When fitting the split link, always make sure that the closed side of the locking clip faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be replaced together. 400227-01
–
Check the chain guide for tightness and wear.
MAINTENANCE WORK ON CHASSIS AND ENGINE
58
Checking chain wear 13.46
–
Jack up the motorcycle. (
–
Shift transmission to neutral.
–
Pull on the upper part of the chain with the specified weight .
p. 40)
Guideline
0 A
Weight of chain wear measurement –
10… 15 kg (22… 33 lb.)
Measure the distance of 18 chain links in the lower chain section.
Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance at the longest chain section »
1 2 3
If the distance is greater than the specified measurement: –
B 0
272 mm (10.71 in)
Replace the chain.
Info When you replace the chain, you should also replace rear sprocket and engine sprocket. New chains wear out faster on old, worn sprockets.
16 17 18
400226-10
–
Remove the motorcycle from the work stand. (
p. 40)
Adjusting chain tension 13.47
Warning Danger of accidents Danger caused by incorrect chain tension. –
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary. –
Jack up the motorcycle. (
–
Push the chain up at the rear edge of the chain guide to measure the chain tension .
p. 40)
Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.
400213-10
MAINTENANCE WORK ON CHASSIS AND ENGINE –
59
Loosen nut .
–
Loosen nuts .
–
Adjust the chain tension by turning the adjusting screws left and right. Guideline Chain tension
8… 10 mm (0.31… 0.39 in)
Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. –
Tighten nuts .
–
Make sure that chain adjusters are fitted correctly on adjusting screws .
–
Tighten nut . Guideline Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. Chain adjusters can be turned by 180°.
400225-10
–
Remove the motorcycle from the work stand. (
–
Loosen nut .
p. 40)
Adjusting chain tension - after checking 13.48
–
Loosen nuts .
–
Adjust the chain tension by turning the adjusting screws left and right. Guideline Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. –
Tighten nuts .
–
Make sure that the chain adjusters are fitted correctly on the adjusting screws .
–
Tighten nut . Guideline Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info 400225-13
The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°.
MAINTENANCE WORK ON CHASSIS AND ENGINE
60
Adjusting chain tension - fitting rear wheel 13.49
–
Loosen nuts .
–
Adjust the chain tension by turning the adjusting screws left and right. Guideline Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. –
Tighten nuts .
400225-11
Adjusting the chain guide 13.50
x (EXC‑F, EXC‑F SIX DAYS, XCF-W) –
Remove screws and . Take off the chain guide.
Condition Number of teeth: ≤ 44 teeth – –
Insert nut in hole . Position the chain guide. Mount and tighten screws and . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Condition Number of teeth: ≥ 45 teeth – –
Insert nut in hole . Position the chain guide. Mount and tighten screws and . Guideline Remaining screws, chassis
400252-10
M6
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain guide 13.51
61
x (SX‑F) –
Loosen screw . Remove screw . Push the chain guide down.
Condition Number of teeth: ≤ 44 teeth –
Insert collar sleeve in hole . Position the chain guide.
–
Mount and tighten screw . Tighten screw . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Condition Number of teeth: ≥ 45 teeth –
Insert collar sleeve in hole . Position the chain guide.
–
Mount and tighten screw . Tighten screw . Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
400224-10
Checking brake discs 13.52
Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). –
Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) –
Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement .
Info
A
Wear reduces the thickness of the brake disc around the area used by the brake linings. Brake discs - wear limit
400257-10
»
2.5 mm (0.098 in)
Rear
3.5 mm (0.138 in)
If the brake disc thickness is less than the specified value: –
–
Front
Change the brake disc.
Check the front and rear brake discs for damage, cracking and deformation. »
If the brake disc shows signs of damage, cracking or deformation: –
Change the brake disc.
Checking free travel of hand brake lever 13.53
Warning Danger of accidents Brake system failure. –
If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications.
MAINTENANCE WORK ON CHASSIS AND ENGINE
62
(XCF‑W, SX‑F) – Push the hand brake lever forwards and check free travel . Free travel of hand brake lever »
≥ 3 mm (≥ 0.12 in)
If the free travel does not meet specifications: –
adjust the basic position of hand brake lever. (
p. 62)
400196-11
(EXC-F, EXC‑F SIX DAYS) – Push the hand brake to the handlebar and check free travel . Free travel of hand brake lever »
≥ 3 mm (≥ 0.12 in)
If the free travel does not meet specifications: –
Adjust the free travel of the hand brake lever. (
p. 62)
400196-13
Adjusting basic position of hand brake lever (XCF‑W, SX‑F) 13.54
–
Check the free travel of the hand brake lever. (
–
Adjust the basic setting of the hand brake lever to your hand size by turning adjusting screw .
p. 61)
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 adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!
400196-12
Adjusting free travel of hand brake lever (EXC-F, EXC‑F SIX DAYS) 13.55
–
Check the free travel of the hand brake lever. (
–
Adjust the free travel of the hand brake lever with adjusting screw .
p. 61)
Info
400196-12
Turn the adjustment screw clockwise to reduce free travel. The pressure point moves away from the handlebar. Turn the adjustment screw counterclockwise to increase free travel. The pressure point moves towards the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!
Checking the brake fluid level of the front brake 13.56
Warning Danger of accidents Failure of the brake system. –
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out 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 brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
MAINTENANCE WORK ON CHASSIS AND ENGINE
63
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Check the brake fluid level in viewer . »
If the brake fluid is below the MIN mark: –
Top up the brake fluid of the front brake.
x(
p. 63)
400231-10
Topping up the front brake fluid 13.57
x
Warning Danger of accidents Failure of the brake system. –
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning Skin irritation Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking effect caused by old brake fluid. –
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
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 user 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. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! –
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Add brake fluid to level . Guideline Measurement of Brake fluid DOT 4 / DOT 5.1 (
100395-10
–
5 mm (0.2 in) p. 116)
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt brake fluid immediately with water.
MAINTENANCE WORK ON CHASSIS AND ENGINE
64
Checking the front brake linings 13.58
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.) –
Check the brake linings for minimum thickness . Minimum thickness »
If the minimum thickness is less than specified: –
–
≥ 1 mm (≥ 0.04 in)
Change the front brake linings.
x(
p. 64)
Check the brake linings for damage and cracking. »
If damage or cracking is visible: –
Change the front brake linings.
x(
p. 64)
100394-10
Changing the front brake linings 13.59
x
Warning Danger of accident Brake system failure. –
Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning Skin irritation Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking effect caused by old brake fluid. –
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
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 necessary.
Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. –
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer 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 user 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. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!
MAINTENANCE WORK ON CHASSIS AND ENGINE –
65
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir, using suction to remove it if it does.
Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
100395-10
–
Remove locking split pins , withdraw bolt , and take out the brake linings.
–
Clean the brake caliper and brake caliper support.
–
Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly.
–
Fit the brake linings, insert the bolt, and mount the locking split pins.
–
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point.
–
Correct the brake fluid quantity to level .
100396-10
0
7 0
06
0
100397-01
7 100398-10
Guideline Measurement of
06
Brake fluid DOT 4 / DOT 5.1 ( –
5 mm (0.2 in) p. 116)
Position the cover with the membrane. Mount and tighten the screws.
Info 100399-10
Clean up overflowed or spilt brake fluid immediately with water.
MAINTENANCE WORK ON CHASSIS AND ENGINE
66
Checking free travel of foot brake lever 13.60
Warning Danger of accidents Brake system failure. –
If there is no free travel on the foot brake 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. –
Disconnect spring .
–
Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel . Guideline Free travel at foot brake lever »
If the free travel does not meet specifications: –
600704-10
–
Adjusting basic position of footbrake lever 13.61
3… 5 mm (0.12… 0.2 in)
Adjust the basic position of the footbrake lever.
x(
p. 66)
Reconnect spring .
x
Warning Danger of accidents Brake system failure. –
If there is no free travel on the foot brake 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. –
Disconnect spring .
–
Loosen nut and with push rod , turn it back until you have maximum free travel.
–
To adjust the basic position of the foot brake lever individually, lossen nut and turn screw accordingly.
Info The range of adjustment is limited. 600705-10
–
Turn push rod accordingly until you have free travel . If necessary, adjust the basic position of the footbrake lever. Guideline Free travel at foot brake lever
–
3… 5 mm (0.12… 0.2 in)
Hold screw and tighten nut . Guideline Remaining nuts, chassis
–
M8
30 Nm (22.1 lbf ft)
M6
15 Nm (11.1 lbf ft)
Hold push rod and tighten nut . Guideline Remaining nuts, chassis
–
Reconnect spring .
Checking rear brake fluid level 13.62
Warning Danger of accidents Failure of the brake system. –
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out 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 brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
Stand the vehicle upright.
–
Check the brake fluid level in the sight glass . »
67
If there is an air bubble in the sight glass visible: –
Add brake fluid to the rear brake circuit.
x(
p. 67)
400234-10
Adding brake fluid to the rear brake circuit 13.63
x
Warning Danger of accidents Failure of the brake system. –
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning Skin irritation Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking effect caused by old brake fluid. –
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
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 user 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. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! –
Stand the vehicle upright.
–
Remove screw cap with membrane and the O-ring.
–
Add brake fluid up to level . Brake fluid DOT 4 / DOT 5.1 (
–
p. 116)
Mount the screw cap with the membrane and the O-ring.
Info 400233-10
Clean up overflowed or spilt brake fluid immediately with water.
Checking rear brake linings 13.64
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.)
MAINTENANCE WORK ON CHASSIS AND ENGINE –
Check the brake linings for minimum thickness . ≥ 1 mm (≥ 0.04 in)
Minimum thickness »
If the minimum thickness is less than specified: –
–
68
Change the rear brake linings.
x(
p. 68)
Check the brake linings for damage and cracking. »
If damage or cracking is visible: –
Change the rear brake linings.
x(
p. 68)
400238-10
Changing the rear brake linings 13.65
x
Warning Danger of accident Brake system failure. –
Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning Skin irritation Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning Danger of accidents Reduced braking effect caused by old brake fluid. –
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
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 necessary.
Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. –
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer 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 user 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. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! –
Stand the vehicle upright.
–
Remove screw cap with membrane and the O-ring.
–
Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. 100807-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
69
–
Remove locking split pins , withdraw bolt , and take out the brake linings.
–
Clean the brake caliper and brake caliper support.
–
Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly.
–
Fit the brake linings, insert the bolt, and mount the locking split pins.
–
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point.
–
Correct the brake fluid quantity to marking .
100808-10
100407-10
100408-01
Brake fluid DOT 4 / DOT 5.1 ( –
p. 116)
Mount screw cap with membrane and the O-ring.
Info Clean up overflowed or spilt brake fluid immediately with water.
400233-10
Removing front wheel 13.66
x –
Jack up the motorcycle. (
–
Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.
p. 40)
Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
100809-01
500084-10
–
Remove screw .
–
Loosen screw .
MAINTENANCE WORK ON CHASSIS AND ENGINE –
70
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.
Info Do not operate 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 damaged.
500085-10
–
Remove spacers .
500086-10
Installing the front wheel 13.67
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 necessary. –
Clean and grease shaft seal rings and bearing surface of the spacers. Long-life grease (
p. 117)
–
Insert the spacers.
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
–
Mount and tighten screw .
500086-11
Guideline Screw, front wheel spindle –
500084-11
M24x1.5
45 Nm (33.2 lbf ft)
Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.
–
Remove the motorcycle from the work stand. (
–
Pull the front wheel brake and push down hard on the fork several times to align the fork legs.
–
Fully tighten screws .
p. 40)
Guideline Screw, fork stub
M8
15 Nm (11.1 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 13.68
71
x –
Jack up the motorcycle. (
–
Press the brake caliper by hand on to the brake disc in order to press back the brake piston.
p. 40)
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 spindle. Take the rear wheel out of the swingarm.
Info Do not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged. 400258-10
–
Remove spacers .
400260-11
Installing the rear wheel 13.69
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 necessary. –
Clean and grease shaft seal rings and bearing surface of the spacers. Long-life grease (
p. 117)
–
Insert the spacers.
–
Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
–
Put the chain on.
400260-10
400259-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
72
–
Position the chain adjuster . Mount nut , but do not tighten it yet.
–
Check chain tension when fitting rear wheel. (
–
Make sure that the chain adjusters are fitted correctly on the adjusting screws .
–
Tighten nut .
p. 57)
Guideline Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°. –
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point.
–
Remove the motorcycle from the work stand. (
p. 40)
400225-12
Tire condition checking 13.70
Info Only mount tires approved or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be mounted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces. –
Examine the front and rear tires for cuts, foreign bodies and other damage. »
If you find cuts, foreign bodies or other damage on a tire: –
–
Change the tires.
Check the depth of the tread.
Info Note local national regulations concerning the minimum tread depth. Minimum tread depth
400602-10
»
If the tread depth is less than the minimum allowable depth: –
–
≥ 2 mm (≥ 0.08 in)
Change the tires.
Check the age of the tires.
Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires be changed after five years at the latest, regardless of the actual state of wear. »
If a tire is more than 5 years old: –
Change the tires.
MAINTENANCE WORK ON CHASSIS AND ENGINE
73
Checking tire air pressure 13.71
Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. –
Remove the dust cap.
–
Check tire air pressure when tires are cold. Tire air pressure off road Front
1.0 bar (15 psi)
Rear
1.0 bar (15 psi)
Road tire pressure (EXC-F, EXC‑F SIX DAYS) 400695-01
»
1.5 bar (22 psi)
Rear
2.0 bar (29 psi)
If the tire pressure does not meet specifications: –
–
Front
Correct the tire air pressure.
Fit the dust cap.
Checking spoke tension 13.72
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 more loose spokes in a short time. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. –
Tap each spoke with a screwdriver.
Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note. »
400694-01
If the spoke tension varies: –
–
Correct the spoke tension.
x
Check the spoke torque. Guideline Spoke nipple, front wheel
M4.5
5… 6 Nm (3.7… 4.4 lbf ft)
Spoke nipple, rear wheel
M5
5… 6 Nm (3.7… 4.4 lbf ft)
Torque wrench with various accessories in set (58429094000)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the battery 13.73
74
x (EXC‑F, EXC‑F SIX DAYS, XCF-W)
Warning Risk of injury Battery acid and battery gases cause serious cauterization. –
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor. –
Switch off all power consumers and switch off the engine.
–
Remove the seat. (
–
Disconnect the negative (minus) cable of the battery.
–
Pull back the plus pole cover and disconnect the positive (plus) cable of the battery.
–
Hang the rubber band out to the bottom.
–
Lift the battery up.
p. 76)
500069-10
Installing the battery 13.74
x (EXC‑F, EXC‑F SIX DAYS, XCF-W) –
Place the battery in the battery holder. 4Ah battery (YTX5L-BS) (
–
p. 100)
Reconnect the rubber band .
–
Attach the plus cable and replace the plus pole cover .
–
Attach the minus cable .
–
Mount the seat. (
p. 77)
500069-11
Recharging the battery 13.75
x (EXC‑F, EXC‑F SIX DAYS, XCF-W)
Warning Risk of injury Battery acid and battery gases cause serious cauterization. –
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor.
Warning Environmental hazard Battery parts and acid are harmful to the environment. –
Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE
75
Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity. If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately. If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery. The battery is maintenance-free, i.e., the acid level does not have to be checked. –
Switch off all power consumers and switch off the engine.
–
Remove the seat. (
–
Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics.
–
Connect the battery charger to the battery. Switch on the battery charger.
p. 76)
Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery.
Info Never remove the lid . Charge the battery with at most 10% of the capacity specified on the battery .
400240-10
–
Switch off the charger after charging. Disconnect the battery. Guideline The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use
–
Mount the seat. (
3 months
p. 77)
Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.76
–
Switch off all power consumers and switch off the engine.
–
Remove the air filter box lid. (
–
Remove the protection cover .
p. 81)
Info The fuse is located in the starter relay under the filter box cover. –
Remove the fuse .
400270-10
Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.77
Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. –
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
76
Refit the fuse. Fuse (58011109110)
Info A reserve fuse is located in the starter relay. Replace a burned-out fuse only by an equivalent fuse. If the new fuse burns out, contact an authorized KTM workshop. 400273-10
–
Replace the protection cover.
–
Install the air filter box lid. (
p. 81)
Adjusting the beam width of the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.78
–
Check the headlight adjustment. (
–
Loosen screw .
–
Adjust the light range by swiveling the headlight.
p. 76)
Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking the headlight adjustment).
Info If you have a payload, you may have to correct the headlight beam width.
301251-10
–
Tighten screw .
Checking the headlight adjustment (EXC‑F, EXC‑F SIX DAYS, XCF-W) 13.79
A 0
–
On a light-colored wall behind a horizontal area, make a mark as high as the center of the headlight.
–
Make a second mark at distance of under the first mark. Guideline
0 B
Distance –
5 cm (2 in)
Stand the motorcycle upright in front of the wall at distance . The driver, in full protective clothing, should now sit on the motorcycle in a normal sitting position (feet on the footrests). Guideline
400726-10
Distance –
5 m (16 ft)
Switch on low beam. Check the headlight adjustment. The border between light and dark must be exactly at the lower mark when the motorcycle is operational and complete with rider. »
If the boundary between light and dark does not meet specifications: –
Adjust the beam width of the headlight. (
p. 76)
Removing the seat 13.80
–
500080-10
Remove screw . Lift up the seat at the rear, pull it back and then remove from above.
MAINTENANCE WORK ON CHASSIS AND ENGINE
77
Mounting the seat 13.81
–
Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward.
–
Make sure that the seat is correctly locked in.
–
Mount and tighten the screw of the seat fixing. Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
600674-01
Dismounting the fuel tank 13.82
x
Danger 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 and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. –
Remove the seat. (
p. 76)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
–
Pull off the fuel hose.
Info Remaining fuel may flow out of the fuel hose. 600678-10
–
Remove screws with the collar sleeve.
(EXC-F, EXC‑F SIX DAYS) – Hang the horn and horn bracket to one side. –
Remove screw with the collar sleeve.
–
Remove the tube from the fuel tank vent line.
–
Pull both spoilers to the side of the radiator bracket and take the fuel tank away upward.
600675-11
600677-10
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 13.83
78
x
Danger 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 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 immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. –
Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
–
Make sure that no cables are trapped or damaged.
–
Mount the fuel tank vent hose.
–
Mount and tighten screw with the collar sleeve.
600676-01
Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
(EXC-F, EXC‑F SIX DAYS) – Position the horn with the horn bracket.
600675-10
–
Mount and tighten screws with the collar sleeve. Guideline Remaining screws, chassis
–
Connect the fuel hose.
–
Mount the seat. (
M6
10 Nm (7.4 lbf ft)
p. 77)
600678-11
Cooling system 13.84
The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. 120 °C (248 °F) Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 600679-10
(XCF-W, 250 EXC-F SIX DAYS EU) The radiator fan provides extra cooling. It is controlled by a thermoswitch.
MAINTENANCE WORK ON CHASSIS AND ENGINE
79
Checking the anti-freeze and coolant level 13.85
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 the engine 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 contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition Engine is cold. –
Stand the motorcycle upright on a horizontal surface.
–
Remove radiator cap.
–
Check the anti-freeze of the coolant. −25… −45 °C (−13… −49 °F) »
If the anti-freeze of the coolant does not meet specifications: –
–
Correct the anti-freeze of the coolant.
Check the coolant level in the radiator.
400243-10
Coolant level above radiator fins. »
10 mm (0.39 in)
If the level of the coolant does not meet specifications: –
Correct the coolant level. Alternative 1 Coolant (
p. 116)
Alternative 2 Coolant (mixed ready to use) ( –
p. 116)
Refit the radiator cap.
Checking the coolant level 13.86
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 the engine 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 contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition The engine is cold. –
Stand the motorcycle upright on a horizontal surface.
–
Remove radiator cap.
–
Check the coolant level in the radiator. Coolant level above the radiator fins. »
If the coolant level does not meet specifications: –
Correct the coolant level. Alternative 1
400243-10
10 mm (0.39 in)
Coolant (
p. 116)
MAINTENANCE WORK ON CHASSIS AND ENGINE
80
Alternative 2 Coolant (mixed ready to use) ( –
Draining the coolant 13.87
p. 116)
Mount the radiator cap.
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 the engine 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 contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition The engine is cold. –
Stand the vehicle upright.
–
Place a suitable container under the water pump cover.
–
Remove screw . Remove radiator cap .
–
Completely drain the coolant.
–
Mount screw with a new seal and tighten it. Guideline Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
600679-11
Refilling coolant 13.88
x
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 contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. –
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. 116)
Coolant (mixed ready to use) ( p. 116)
600680-10
–
Refit the radiator cap.
–
Make a short test ride.
–
Check the coolant level. (
p. 79)
MAINTENANCE WORK ON CHASSIS AND ENGINE
81
Glass fiber yarn filling of main silencer 13.89
The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes.
Removing main silencer 13.90
Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –
Allow the exhaust system to cool down. Do not touch hot components. –
Disconnect spring .
–
Remove screws and take off main silencer.
–
Mount the main silencer. Mount and tighten screws .
600681-11
Installing the main silencer 13.91
Guideline Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
Reconnect spring .
–
Pull off the air filter box lid in area to the side and remove to the front.
–
Insert the air filter box lid into the rear area and clip it into the front area .
600681-10
Removing the air filter box lid 13.92
600682-10
Installing the air filter box lid 13.93
600682-11
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 13.94
82
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 since dust and dirt can get into the engine and result in increased wear.
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. –
Remove the air filter box lid. (
–
Detach air filter holder at the bottom and swing it to one side. Remove the air filter with the air filter support.
–
Remove the air filter from the air filter support.
–
Mount the clean air filter onto the air filter support.
–
Apply grease to the section of the air filter.
p. 81)
500107-10
Installing the air filter 13.95
x Long-life grease (
p. 117)
301262-10
–
Put in both parts together, position them and fix them with air filter holder .
Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. –
Install the air filter box lid. (
p. 81)
500107-10
Cleaning air filter 13.96
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 gasoline since these substances attack the foam. –
Remove the air filter.
–
Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner (
x(
p. 82)
p. 117)
Info Only squeeze the air filter when drying it out, never wring it out.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
83
Oil the dry air filter with a high/quality filter oil. Oil for foam air filter (
p. 117)
–
Clean the air filter box.
–
Check carburetor connection boot for damage and tightness.
–
Install the air filter.
x(
p. 82)
Adjusting basic position of clutch lever 13.97
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw .
Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!
500133-11
Checking the fluid level of hydraulic clutch 13.98
Warning Skin irritation Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! –
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Check the fluid level. Fluid level under top level of container »
If the level of the fluid does not meet specifications: –
400339-10
Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 (
–
4 mm (0.16 in)
p. 116)
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt fluid immediately with water.
Changing the hydraulic clutch fluid 13.99
x
Warning Skin irritation Brake fluid can cause skin irritation on contact. –
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE
84
Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! –
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws .
–
Remove cover with membrane .
–
Fill bleeding syringe with the appropriate hydraulic fluid.
400339-10
Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 (
p. 116)
–
On the slave cylinder, remove bleeder screw and mount bleeding syringe .
–
Inject the liquid into the system until it escapes from bore hole of the master cylinder without bubbles.
–
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
–
Remove the bleeding syringe. Mount and tighten screws bleeder screw.
–
Correct the fluid level of the hydraulic clutch.
600683-10
Guideline Fluid level under top level of container 400340-10
–
4 mm (0.16 in)
Position the cover with the membrane. Mount and tighten the screws.
Info Clean up overflowed or spilt fluid immediately with water.
Checking the basic position of the shift lever 13.100
–
Sit on the vehicle (facing the direction of travel) and measure the gap between the top of the boot and shift lever . Gap between the shift lever and the top of the boot »
A 0
10… 20 mm (0.39… 0.79 in)
If the distance does not meet the specifications: –
Adjust the basic position of the shift lever.
400692-10
Adjusting the basic position of the shift lever 13.101
–
100805-10
x
Remove screw and remove shift lever .
x(
p. 84)
MAINTENANCE WORK ON CHASSIS AND ENGINE
85
–
Clean gear teeth of the shift lever and shift shaft.
–
Mount the shift lever on the shift shaft in the required position and engage the gearing.
–
Mount and tighten the screw. Guideline Screw, shift lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Info
100806-10
The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
Carburetor - idle 13.102
The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.
Info The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.
600684-10
Carburetor - adjusting idle 13.103
The idle speed is adjusted with the adjustment screw . The idle mixture is adjusted with the idle mixture adjustment screw .
x –
Screw in the idle adjusting screw until it stops and then to the prescribed basic setting. Guideline Idle mixture adjusting screw (EXC‑F, EXC‑F SIX DAYS, SX‑F) Open
1.25 turns
Idle mixture adjusting screw (XCF-W) Open
1.0 turn
Adjustment tool for mixture control screw (77329034000)
600684-10
–
Run the engine until warm. Guideline Warm-up time
≥ 5 min
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 effective exhaust extraction system.
Adjust the idle speed with adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in to the stop. (XCF‑W, SX‑F, EXC‑F AUS) ( p. 23) Choke function deactivated – The choke lever is pushed back to the stop. (EXCF EU, EXC‑F SIX DAYS) ( p. 23) Idle speed
1,400… 1,500 rpm
–
Turn the idle adjusting screw slowly until the idle speed begins to fall.
–
Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
86
Adjust to the point between these two positions with the highest idle speed.
Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motorcyclist will set the mixture about ¼ of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle adjusting screw to the end without any change of engine speed, you have to mount a smaller idling jet. The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet. After changing the idling jet, start from the beginning with the adjusting steps. –
Adjust the idle speed with adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in to the stop. (XCF‑W, SX‑F, EXC‑F AUS) ( p. 23) Choke function deactivated – The choke lever is pushed back to the stop. (EXCF EU, EXC‑F SIX DAYS) ( p. 23) Idle speed
1,400… 1,500 rpm
Info Following extreme air temperature or altitude changes, adjust the idle speed again.
Emptying the carburetor float chamber 13.104
x
Danger 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 and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Warning Environmental hazard Improper handling of fuel is a danger to the environment. –
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info Carry out this work with a cold engine. (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn handle of the fuel tap to the OFF position. (Figure 500137-10
p. 22)
(SX‑F) – Turn handle of the fuel tap to the OFF position. (Figure 500178-10
p. 22)
No more fuel flows from the tank to the carburetor.
MAINTENANCE WORK ON CHASSIS AND ENGINE –
Guide the hose coming down behind the engine into a suitable container.
Info Water in the float chamber results in malfunctioning. –
Undo screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber.
–
Tighten screw .
–
Stand the motorcycle upright on a horizontal surface.
600684-11
Checking the engine oil level 13.105
Condition The engine is cold. –
Check the engine oil level. The engine oil level is at the bottom edge of level viewer . »
If the engine oil level is below the specified level: –
600685-11
Add engine oil. (
p. 90)
Condition The engine is warm. –
Check the engine oil level. The engine oil level is at the top edge of level viewer . »
If the engine oil level is below the specified level: –
Add engine oil. (
p. 90)
Changing the engine oil and oil filter, cleaning the oil screen 13.106
– – – – –
x Drain the engine oil. x ( p. 87) Clean the oil screens. x ( p. 88) Remove the oil filter. x ( p. 89) Install the oil filter. x ( p. 89) Fill up with engine oil. x ( p. 90)
301489-10
Draining the engine oil 13.107
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 substances cause environmental damage. –
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info Drain the engine oil only when the engine is warm. –
Stand the motorcycle on its side stand on a horizontal surface.
87
MAINTENANCE WORK ON CHASSIS AND ENGINE
88
–
Place a suitable container under the engine.
–
Remove oil drain plug .
–
Completely drain the engine oil.
–
Thoroughly clean the oil drain plug with the magnet.
–
Clean the sealing area on the engine.
–
Mount and tighten oil drain plug with the seal ring. Guideline Oil drain plug with magnet
600686-10
Cleaning the oil screens 13.108
M12x1.5
20 Nm (14.8 lbf ft)
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 substances cause environmental damage. –
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. –
Place a suitable container under the engine.
–
Remove plug with oil screen and the O-rings.
600693-10
–
Remove plug with oil screen and the O-rings.
–
Drain the remaining engine oil.
–
Thoroughly clean parts and sealing area.
600694-10
–
Position oil screen with the O-rings.
–
Mount and tighten plug with the O-ring. Guideline Plug for oil screen, long
M20x1.5
15 Nm (11.1 lbf ft)
600695-10
–
Position the oil screen with the O-rings.
–
Mount and tighten plug with the O-ring. Guideline Plug for oil screen, short
600696-10
M16x1.5
10 Nm (7.4 lbf ft)
lubricated with engine oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 13.109
89
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 substances cause environmental damage. –
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. –
Place a suitable container under the engine.
–
Remove screws . Remove oil filter cover with the O-ring.
–
Pull the oil filter insert out of the oil filter casing.
600687-10
Circlip pliers reverse (51012011000) –
Completely drain the engine oil.
–
Thoroughly clean parts and sealing surface.
–
Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil.
–
Fill oil filter with engine oil and place it in the oil filter container.
–
Lubricate O-ring of the oil filter cover.
–
Mount oil filter cover .
–
Mount and tighten screws .
600688-10
Installing the oil filter 13.110
x
600689-10
Guideline Screw, oil filter cover –
600687-11
Stand the motorcycle up.
M5
6 Nm (4.4 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with engine oil 13.111
90
x
Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –
Remove screw connection on the clutch cover and fill up with engine oil. Engine oil
–
1.10 l (1.16 qt.)
Engine oil (SAE 10W/50) (
p. 116)
Mount and tighten screw cap .
Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – 600690-10
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 effective exhaust extraction system.
–
Start the engine and check that it is oil-tight.
–
Check the engine oil level. (
p. 87)
Adding engine oil 13.112
Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –
Remove screw cap from the clutch cover and fill up with engine oil. Engine oil (SAE 10W/50) (
–
p. 116)
Mount and tighten screw cap .
Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – 600690-10
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 effective exhaust extraction system.
–
Start the engine and check that it is oil-tight.
–
Check the engine oil level. (
p. 87)
TROUBLESHOOTING
91
Faults
Possible cause
Action
The engine cannot be cranked (electric starter) (EXC‑F, EXC‑F SIX DAYS, XCF-W)
Operating error
–
Go through the steps of starting the engine. ( p. 31)
Battery discharged
–
Recharge the battery.
–
Check the charging voltage.
–
x ( p. 74) x Check the stall current. x Check the generator. x
–
Remove the fuse. (
p. 75) p. 75)
– Fuse blown
Engine turns but does not start
Engine has no idle
–
Replace the fuse. (
Starter relay defective
–
Check the starter relay.
Starter motor defective
–
Operating error
–
Go through the steps of starting the engine. ( p. 31)
Motorcycle was out of use for a long time and there is old fuel in the float chamber
–
Empty the carburetor float chamber. ( p. 86)
Fuel feed interrupted
–
Check the fuel tank breather.
–
Clean the fuel tap.
–
Check/adjust the carburetor components.
Engine flooded
–
Clean and dry the spark plug or replace if necessary.
Spark plug oily or wet
–
Clean and dry the spark plug or replace if necessary.
Electrode distance (plug gap) of spark plug too wide
–
Adjust the plug gap.
Defect in ignition system
–
Check the ignition system.
Short-circuit cable in wiring harness frayed, short-circuit button or emergency OFF switch defective
–
Check the wiring harness. (visual check)
–
Check the electrical system.
Plug connector of CDI control device, pulse generator or ignition coil oxidized.
–
Clean the plug connector and treat it with contact spray.
Water in carburetor or jets blocked
–
Check/adjust the carburetor components.
Idling jet blocked
–
Check/adjust the carburetor components.
Adjusting screws on carburetor distorted
–
Carburetor - adjust the idle speed. ( p. 85)
Spark plug defective
–
Change spark plug.
Ignition system defective
–
Check the ignition coil.
–
Check the CDI controller.
–
Check the spark plug connector.
x x
x
x x
– Carburetor running over because float needle dirty or worn.
–
Check/adjust the carburetor components.
Loose carburetor jets
–
Ignition system defective
–
–
x Check/adjust the carburetor components. x Check the ignition coil. x Check the CDI controller. x Check the spark plug connector. x Check the ignition pulse generator. x Check the generator. x
–
Check the fuel tank breather.
–
Clean the fuel tap.
–
Check/adjust the carburetor components.
– – Fuel feed interrupted
x
x
x Check the ignition pulse generator. x Check the generator. x
–
Engine has a lack of power
x
Guideline Spark plug electrode gap 0.7 mm (0.028 in)
– Engine does not speed up
x Check the starter motor. x
x
TROUBLESHOOTING
92
Faults
Possible cause
Action
Engine has a lack of power
Air filter severly contaminated
–
Clean the air filter.
Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer
–
Check exhaust system for damage.
–
Change glass fiber yarn filling of main silencer.
Valve clearance too little
–
Ignition system defective
–
Adjust the valve clearance.
–
x Check the ignition coil. x Check the CDI controller. x
–
Check the spark plug connector.
– Lack of fuel
p. 82)
x
– Engine stalls or pops back into the carburetor
x(
x Check the ignition pulse generator. x Check the generator. x
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Turn handle of the fuel tap to the ON position. (Figure 500137-10 p. 22) (SX‑F) – Turn handle of the fuel tap to the ON position. (Figure 500178-10 p. 22)
Engine overheats
–
Refuel. (
The intake system has an air leak
–
Check rubber sleeves and carburetor for tightness.
Coolant level low in cooling system
–
Check the cooling system for leaks.
–
Check the coolant level. (
Insufficient airflow
–
Switch off engine when stationary.
Radiator fins very dirty
–
Clean radiator fins.
Foam formation in cooling system
–
Drain the coolant.
–
Refill the coolant.
Bent radiator hose
–
Change the radiator hose.
Thermostat defective
–
Check the thermostat.
p. 33)
x( x(
p. 79)
p. 80) p. 80)
x
x
Guideline Opening temperature: 70 °C (158 °F) Defect in radiator fan system (XCF-W, 250 EXC-F SIX DAYS EU)
–
Check the radiator fan fuse.
–
Check the radiator fan.
– High oil consumption
x Check the thermostat. x
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. (
Engine oil too thin (low viscosity)
–
Change the engine oil and oil filter, clean the oil screen. ( p. 87)
p. 87)
x
Piston or cylinder is worn
–
Piston/cylinder - determine the mounting clearance
x
Battery discharged
The battery does not charge
–
Undesired power consumer
–
The battery in the speedometer is empty.
–
Change the battery in the speedometer.
– Speedometer values deleted (time, stop watch, lap times)
Check the charging voltage.
x Check the charging current. x Check the generator. x Check the stall current. x
–
CLEANING
93
Cleaning the motorcycle 15.1
Note Material damage Damage and destruction of components by high-pressure cleaning equipment. –
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
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 If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunlight on the motorcycle during cleaning. –
Close off the exhaust system to prevent water from entering.
–
First remove coarse dirt particles with a gentle water spray.
–
Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft brush. Motorcycle cleaner (
p. 117)
Info Use warm water containing normal motorcycle cleaner and a soft sponge. –
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
–
Empty the carburetor float chamber.
x(
p. 86)
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 cleaning, take a short ride until the engine reaches operating temperature.
Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate. –
Push back the protective covers from the handlebar armatures to allow any water that may have entered there to evaporate.
–
After the motorcycle has cooled off, oil or grease all moving parts and bearings.
–
Clean the chain. (
–
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
p. 56)
Cleaning and polishing materials for metal, rubber and plastic ( –
Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Cleaning and polishing materials for metal, rubber and plastic (
–
p. 117)
p. 117)
To prevent electrical problems, treat electric contacts and switches with contact spray. Contact spray (
p. 117)
(EXC-F, EXC‑F SIX DAYS) – Lubricate the steering lock. Universal oil spray (
p. 118)
STORAGE
94
Storage 16.1
Warning Danger of poisoning Fuel is poisonous and a health hazard. –
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. –
Clean the motorcycle. (
–
Change the engine oil and oil filter, clean the oil screen.
–
Check the anti-freeze and coolant level. (
–
Drain the fuel from the tank into a suitable container.
–
Empty the carburetor float chamber.
–
Check the tire air pressure. (
p. 73)
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Remove the battery. (
p. 74)
p. 93)
x (EXC‑F, EXC‑F SIX DAYS, XCF-W) – Recharge the battery. x (
x(
x(
p. 87)
p. 79) p. 86)
p. 74)
Guideline Storage temperature of battery without direct sunlight. –
0… 35 °C (32… 95 °F)
The storage place should be dry and not subject to large temperature fluctuations.
Info KTM recommends jacking up the motorcycle. –
Jack up the motorcycle. (
–
Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
p. 40)
Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.
Putting into operation after storage 16.2
–
Remove the motorcycle from the work stand. (
(EXC‑F, EXC‑F SIX DAYS, XCF-W) – Install the battery. (
x
–
Refuel. (
p. 74)
p. 33)
–
Check before putting into operation. (
–
Take a test ride.
p. 31)
p. 40)
TECHNICAL DATA - ENGINE
95
Design
1-cylinder 4-stroke engine, water-cooled
Displacement
248.60 cm³ (15.1706 cu in)
Stroke
54.80 mm (2.1575 in)
Bore
76 mm (2.99 in)
Compression ratio
12.8:1
Idle speed
1,400… 1,500 rpm
Control
DOHC, four valves controlled via cam lever, drive via tooth-wheel chain
Valve diameter, intake
30.0 mm (1.181 in)
Valve diameter, exhaust
26.0 mm (1.024 in)
Valve clearance Exhaust at: 20 °C (68 °F)
0.12… 0.17 mm (0.0047… 0.0067 in)
Intake at: 20 °C (68 °F)
0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing
2 cylinder bearings
Conrod bearing
Needle bearing
Piston pin bearing
Bronze bush
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with two rotary pumps
Primary transmission
22:68
Clutch
Multidisc clutch in oil bath/hydraulically activated
Transmission ratio (EXC‑F, EXC‑F SIX DAYS, XCF-W) 1st gear
13:33
2nd gear
17:33
3rd gear
19:29
4th gear
23:28
5th gear
23:23
6th gear
26:22
Transmission ratio (SX‑F) 1st gear
13:32
2nd gear
15:30
3rd gear
17:28
4th gear
19:26
5th gear
21:25
6th gear
22:24
Generator (EXC‑F, EXC‑F SIX DAYS, XCF-W) Light coil and charging coil
12 V, 80 W
Generator (SX‑F) Light coil and charging coil
none
Ignition
Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan
Spark plug
NGK CR 9 EKB
Spark plug electrode gap
0.7 mm (0.028 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Starting aid (EXC‑F, EXC‑F SIX DAYS, XCF-W)
Electric starter/kickstarter
Starting aid (SX‑F)
Kickstarter
TECHNICAL DATA - ENGINE
96
Capacity - engine oil 17.1
Engine oil
1.10 l (1.16 qt.)
Engine oil (SAE 10W/50) (
1.2 l (1.3 qt.)
Coolant (
p. 116)
Capacity - coolant 17.2
Coolant
p. 116)
Coolant (mixed ready to use) (
p. 116)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
97 Loctite® 243™
Oil jet, conrod lubrication
M4
Oil jet for cam lever lubrication
M5
4 Nm (3 lbf ft)
Loctite® 243™
Screw, freewheel hub
M5
7 Nm (5.2 lbf ft)
Loctite® 243™
Screw, ignition pulse generator
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, locking lever
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, oil filter cover
M5
6 Nm (4.4 lbf ft)
–
Screw, oil pump cover
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, stator bracket (SX‑F)
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Locking screw for bearing
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, cable holder in generator cover
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch slave cylinder
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch spring
M6
10 Nm (7.4 lbf ft)
–
Screw, cover plate of valve cover
M6
3 Nm (2.2 lbf ft)
Loctite® 243™
Screw, cylinder head
M6
10 Nm (7.4 lbf ft)
–
Screw, engine housing
M6
10 Nm (7.4 lbf ft)
–
Screw, exhaust flange
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, generator cover
M6
10 Nm (7.4 lbf ft)
–
Screw, kickstarter stop
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, starter motor (EXC‑F, EXC‑F SIX DAYS, XCF-W)
M6
10 Nm (7.4 lbf ft)
–
Screw, stator bracket (EXC‑F, EXC‑F SIX DAYS, XCF-W)
M6
8 Nm (5.9 lbf ft)
Loctite® 243™
Screw, timing chain securing guide
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, timing chain tensioning rail
M6
10 Nm (7.4 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
M7
15 Nm (11.1 lbf ft)
lubricated with engine oil
Stud, camshaft bearing bridge
M7
Plug, crankshaft location
M8
20 Nm (14.8 lbf ft)
–
Screw, kickstarter
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, timing chain guide rail
M8
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, cylinder head
M10
Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 40 Nm (29.5 lbf ft) Step 2 50 Nm (36.9 lbf ft)
lubricated with engine oil
Screw, engine sprocket
M10
60 Nm (44.3 lbf ft)
Loctite® 243™
Spark plug
M10
10… 12 Nm (7.4… 8.9 lbf ft)
–
Screw, unlocking of timing chain tensioner
M10x1
10 Nm (7.4 lbf ft)
–
Nut, rotor
M12x1
60 Nm (44.3 lbf ft)
–
Screw, camshaft gear
M12x1
80 Nm (59 lbf ft)
Loctite® 243™
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
–
Plug, oil pressure regulator valve
M12x1.5
20 Nm (14.8 lbf ft)
–
Plug for oil screen, short
M16x1.5
10 Nm (7.4 lbf ft)
lubricated with engine oil
Loctite® 243™
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
98
Nut, inner clutch hub
M18x1.5
120 Nm (88.5 lbf ft)
Loctite® 243™
Nut, primary gear
M18LHx1.5
150 Nm (110.6 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)
–
TECHNICAL DATA - CARBURETOR
99
EXC-F, EXC‑F SIX DAYS 19.1
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3900H
Needle position
3rd position from top
Idle mixture adjusting screw Open
1.25 turns
Pump diaphragm stop
2.15 mm (0.0846 in)
Main jet
168
Jet needle
OBDYS (OBETP)
Idling jet
42
Idle air jet
100
Cold start jet
65 (85)
Leakage nozzle
70
Slide stop
present
XCF-W 19.2
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3900K
Needle position
5th position from top
Idle mixture adjusting screw Open
1.0 turn
Pump membrane stop
2.15 mm (0.0846 in)
Main jet
168
Jet needle
OBETP
Idling jet
42
Idle air jet
100
Cold start jet
85
Leakage nozzle
50
SX‑F 19.3
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3925I
Needle position
4th position from top
Idle mixture adjusting screw Open
1.25 turns
Pump membrane stop
2.15 mm (0.0846 in)
Main jet
175
Jet needle
OBEKP
Idling jet
40
Idle air jet
100
Cold start jet
85
Leakage nozzle
50
TECHNICAL DATA - CHASSIS
100
Frame
Central tube frame made of chrome molybdenum steel tubing
Fork (EXC‑F, EXC‑F SIX DAYS, XCF-W)
WP Suspension Up Side Down 4860 MXMA PA
Fork (SX‑F)
WP Suspension Up Side Down 4860 MXMA CC
Suspension travel Front
300 mm (11.81 in)
Rear
335 mm (13.19 in)
Fork offset (SX‑F)
18 mm (0.71 in)
Fork offset (250 EXC-F SIX DAYS EU)
19 mm (0.75 in)
Fork offset (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
22 mm (0.87 in)
Shock absorber (EXC‑F, EXC‑F SIX DAYS, XCF-W)
WP Suspension PDS 5018 DCC
Brake system
Disc brakes, brake calipers on floating bearings
Brake discs - diameter Front
260 mm (10.24 in)
Rear
220 mm (8.66 in)
Brake discs - wear limit Front
2.5 mm (0.098 in)
Rear
3.5 mm (0.138 in)
Tire air pressure off road Front
1.0 bar (15 psi)
Rear
1.0 bar (15 psi)
Road tire pressure (EXC-F, EXC‑F SIX DAYS) Front
1.5 bar (22 psi)
Rear
2.0 bar (29 psi)
Final drive (EXC-F, EXC‑F SIX DAYS)
14:38 (13:50)
Final drive (XCF-W)
13:52
Final drive (SX‑F)
13:48
Chain
5/8 x 1/4"
Rear sprockets available
38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle
63.5°
Wheelbase
1,475±10 mm (58.07±0.39 in)
Seat height unloaded
985 mm (38.78 in)
Ground clearance unloaded
380 mm (14.96 in)
Weight without fuel, approx. (EXC-F, EXC‑F SIX DAYS)
105.7 kg (233 lb.)
Weight without fuel, approx. (XCF-W)
102.6 kg (226.2 lb.)
Weight without fuel, approx. (SX‑F)
98 kg (216 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Maximum permissible overall weight
335 kg (739 lb.)
4Ah battery (EXC‑F, EXC‑F SIX DAYS, XCF-W)
YTX5L-BS
Battery voltage: 12 V Nominal capacity: 4 Ah maintenance-free
Headlight (EXC‑F, EXC‑F SIX DAYS, XCFW)
S2 / socket BA20d
12 V 35/35 W
Parking light (EXC‑F, EXC‑F SIX DAYS, XCF-W)
W5W / socket W2.1x9.5d
12 V 5W
Indicator lamps (EXC-F, EXC‑F SIX DAYS)
W2.3W / socket W2x4.6d
12 V 2.3 W
Turn signal (EXC-F, EXC‑F SIX DAYS)
R10W / socket BA15s
12 V 10 W
Brake/tail light (EXC‑F, EXC‑F SIX DAYS, XCF-W)
LED
Lighting equipment 20.1
TECHNICAL DATA - CHASSIS License plate lamp (EXC-F, EXC‑F SIX DAYS)
101
W5W / socket W2.1x9.5d
12 V 5W
Validity
Front tire
Rear tire
(EXC-F, EXC‑F SIX DAYS)
90/90 - 21 M/C 54M M+S TT Metzeler MEC 6 DAYS EXTREME
120/90 - 18 M/C 65M M+S TT Metzeler MEC 6 DAYS EXTREME
(XCF-W)
80/100 - 21 51M TT Bridgestone Bridgestone M59
100/100 - 18 64M TT Bridgestone Bridgestone M402
(SX‑F)
80/100 - 21 51M TT Bridgestone Bridgestone M59
100/90 - 19 62M TT Bridgestone Bridgestone M70
Tires 20.2
Additional information is available in the Service section under: http://www.ktm.com
Capacity - fuel 20.3
Total fuel tank capacity, approx. (EXC‑F, EXC‑F SIX DAYS, XCF-W)
9.2 l (2.43 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
p. 116)
Total fuel tank capacity, approx. (SX‑F)
8.0 l (2.11 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
p. 116)
Fuel reserve, approx. (EXC‑F, EXC‑F SIX DAYS, XCF-W)
2 l (2 qt.)
TECHNICAL DATA - FORK
102
EXC‑F, EXC‑F SIX DAYS, XCF-W 21.1
Fork part number
14.18.7J.04
Fork
WP Suspension Up Side Down 4860 MXMA PA
Compression damping Comfort
26 clicks
Standard
22 clicks
Sport
18 clicks
Rebound damping Comfort
24 clicks
Standard
20 clicks
Sport
20 clicks
Spring preload - Preload Adjuster Comfort
0 turn
Standard
2 turns
Sport
4 turns
Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.)
510 mm (20.08 in)
Weight of rider: 75… 85 kg (165… 187 lb.)
513 mm (20.2 in)
Weight of rider: 85… 95 kg (187… 209 lb.)
510 mm (20.08 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 lb/in)
Fork length
940 mm (37.01 in)
Air chamber length
+0.79 110+20 −30 mm (4.33−1.18 in)
Fork oil per fork leg
635 ml (21.47 fl. oz.)
Fork oil (SAE 5) (
p. 116)
SX‑F EU 21.2
Fork part number
14.18.7J.03
Fork
WP Suspension Up Side Down 4860 MXMA CC
Compression damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Rebound damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Spring length with preload spacer(s)
492 mm (19.37 in)
Spring rate Weight of rider: 65… 75 kg (143… 165 lb.)
4.2 N/mm (24 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)
4.4 N/mm (25.1 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)
4.6 N/mm (26.3 lb/in)
Fork length
940 mm (37.01 in)
Gas pressure
1.2 bar (17 psi)
Oil capacity per cartridge
195 ml (6.59 fl. oz.)
Fork oil (SAE 5) (
p. 116)
Oil capacity fork leg without cartridge
360 ml (12.17 fl. oz.)
Fork oil (SAE 5) (
p. 116)
TECHNICAL DATA - FORK
103
SX‑F USA 21.3
Fork part number
14.18.7J.22
Fork
WP Suspension Up Side Down 4860 MXMA CC
Compression damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Rebound damping Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Spring length with preload spacer(s)
492 mm (19.37 in)
Spring rate Weight of rider: 65… 75 kg (143… 165 lb.)
4.4 N/mm (25.1 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)
4.6 N/mm (26.3 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)
4.8 N/mm (27.4 lb/in)
Fork length
940 mm (37.01 in)
Gas pressure
1.2 bar (17 psi)
Oil capacity per cartridge
195 ml (6.59 fl. oz.)
Fork oil (SAE 5) (
p. 116)
Oil capacity fork leg without cartridge
375 ml (12.68 fl. oz.)
Fork oil (SAE 5) (
p. 116)
TECHNICAL DATA - SHOCK ABSORBER EXC‑F, EXC‑F SIX DAYS, XCF-W 22.1
Shock absorber part number
12.18.7J.04
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed Comfort
22 clicks
Standard
20 clicks
Sport
15 clicks
Compression damping, high-speed Comfort
2 turns
Standard
1.5 turns
Sport
1.25 turns
Rebound damping Comfort
26 clicks
Standard
24 clicks
Sport
22 clicks
Spring preload
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 psi)
Static sag
35 mm (1.38 in)
Riding sag
105 mm (4.13 in)
Fitted length
411 mm (16.18 in)
SX‑F 22.2
Shock absorber part number
12.18.7J.03
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Compression damping, high-speed Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Rebound damping Comfort
24 clicks
Standard
22 clicks
Sport
22 clicks
Spring preload
6 mm (0.24 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 psi)
Static sag
33 mm (1.3 in)
Riding sag
105 mm (4.13 in)
Fitted length
411 mm (16.18 in)
104
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS
105
Spoke nipple, front wheel
M4.5
5… 6 Nm (3.7… 4.4 lbf ft)
–
Spoke nipple, rear wheel
M5
5… 6 Nm (3.7… 4.4 lbf ft)
–
Remaining nuts, chassis
M6
15 Nm (11.1 lbf ft)
–
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
Screw, ball joint of push rod on footbrake cylinder
M6
10 Nm (7.4 lbf ft)
–
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
–
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
–
Screw, shock absorber adjusting ring
M6
5 Nm (3.7 lbf ft)
–
Nut, rear sprocket screw
M8
35 Nm (25.8 lbf ft)
Loctite® 243™
Nut, rim lock
M8
10 Nm (7.4 lbf ft)
–
Remaining nuts, chassis
M8
30 Nm (22.1 lbf ft)
–
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
–
Screw, bottom triple clamp (SX‑F, 250 EXC-F SIX DAYS EU)
M8
12 Nm (8.9 lbf ft)
–
Screw, bottom triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
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 fixing
M8
40 Nm (29.5 lbf ft)
Loctite® 243™
Screw, subframe
M8
35 Nm (25.8 lbf ft)
Loctite® 243™
Screw, top steering stem (SX‑F, 250 EXC-F SIX DAYS EU)
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
Screw, top steering stem (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
M8
20 Nm (14.8 lbf ft)
–
Screw, top triple clamp (SX‑F, 250 EXC-F SIX DAYS EU)
M8
17 Nm (12.5 lbf ft)
–
Screw, top triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)
M8
20 Nm (14.8 lbf ft)
–
Engine attachment bolt
M10
60 Nm (44.3 lbf ft)
–
Remaining nuts, chassis
M10
50 Nm (36.9 lbf ft)
–
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
–
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite® 243™
Screw, bottom shock absorber
M12
80 Nm (59 lbf ft)
Loctite® 243™
Screw, top shock absorber
M12
80 Nm (59 lbf ft)
Loctite® 243™
Nut, seat fixing
M12x1
20 Nm (14.8 lbf ft)
–
Nut, swingarm pivot
M16x1.5
100 Nm (73.8 lbf ft)
–
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
–
Screw, bottom steering head (SX‑F)
M20x1.5
60 Nm (44.3 lbf ft)
Loctite® 243™
Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Screw-in nozzles, cooling system
M20x1.5
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, front wheel spindle
M24x1.5
45 Nm (33.2 lbf ft)
–
24.1
H2
EI/1
3 wh 2.1
2 br
1 pu 1
L2 2 4 5 7 6 11 10 12 13 14
BU/18
C D I 3 2 1 2 1
AM/3 AL/2
AR/3 AT/2
A6 B1 L1 AL1/2
1
3
br 1
bl 3
pu 2
G G2
ye H5
bl br
1 2
wh-gn wh-gn
wh
br 2
pu 1
CW/2
1 2 H1
2
1
wh
2
5A CE/4
CA/4
4 3
AT1/2
BG/3
H14
ye
AJ/3
3
br ye-re
CX/2
1
AJ1/3
ye-re
H9
ye-bl
H3
1 1
wh
br BG1/3
ye
bl
1 N2
br ye-bl
ye re
bl
br
wh-re
ye-re
br
br
bl
BA2/1
or pu
ye-bl
ye-re or
ye-re
wh-re
bl
4 3
br
bl wh-gn
br
bl
br bl
wh
S10
DI/2
2
wh
bu
2
EH/1
br
BK/4
CR1/1
bl
ye
BO/2
3
re-wh
bu br
BV/2
2
CR/1
2 t
CW1/2
gn
4
1
K1
CX1/2
1 BF/1
1
re-bl
ye-bl BA/1
2
gn
1 2 E6
re
2
BT/3
bu
1 BG/3
br
2
3
ye
pu
ye-re
bl
1
S8
bl
bl
2
AH2/2
bl
1
H13
re 2
bu ye
br
K2
re
2
BA1/1
ye-bl
br-bl
2
G
re-bl gn
ye-re
3
1
br
ye-re
5
re-wh
v ye-re
1
6 4
gn
AC/6
br
br
S7
br gr
wh
1
3
bu
BC/6 BF1/1
bu-wh
DB/4 DA/4
S5
bu-wh
gr
B3
CZ/3 CY/3
P1
S6
br
bl-wh
AK1/2
CX/2 CW/2
bu
AH1/2
H15
re
4
CX2/2
CW2/2
S2
H18
2
BP/4
DG/4
H11
H4
3
CX3/2
CW3/2
H7
Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)
WIRING DIAGRAM
M
10 A
M1 AF/4
G1
2
BR/4
4
U
M
AK/2
S1
AH/2
br
br
2.2 2.1
BV/2
BS/2
600699-01
106
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
B3
Wheel speed sensor
E6
Thermoswitch (EXC-F SIX DAYS)
G1
Battery
G2
Generator
H1
Right rear turn signal
H2
Left front turn signal
H3
Left rear turn signal
H4
Right front turn signal
H5
Brake/tail light
H7
Parking light
H9
License plate lamp
H11
Low/high beam
H13
Horn
H14
Radiator fan (EXC-F SIX DAYS)
H15
Turn signal indicator light
H18
High beam indicator light
K1
Starter relay with main fuse
K2
Turn signal relay
L1
Pulse generator
L2
Ignition coil
M1
Starter motor
N2
Voltage regulator/rectifier
P1
Speedometer
S1
Rear brake light switch
S2
Front brake light switch
S5
Tripmaster switch (optional)
S6
Light switch
S7
Horn button, short circuit button
S8
Turn signal switch
S10
Electric starter button
Cable colors bl
Black
bl-wh
Black-white
br
Brown
br-bl
Brown-black
bu
Blue
bu-wh
Blue-white
gn
Green
gr
Gray
or
Orange
pu
Violet
re
Red
re-bl
Red-black
re-wh
Red-white
wh
White
wh-gn
White-green
wh-re
White-red
ye
Yellow
ye-bl
Yellow-black
107
WIRING DIAGRAM ye-re
Yellow-red
108
WIRING DIAGRAM
109
24.2
CE/4
CW3/2
3 wh
2 br
1 pu S1
1 2 5 7
BU/18
6 11 10 12 13 14 3 2 1
S1 S1 AT1/2
1
AM/3 AL/2
AR/3 AT/2
1
CR/1
3
bu 1
ye-bl
CR1/1
S1
G S1
H5
bl br
bl br 1
br bl 3
pu 2
1 2
wh wh-gn
AL1/2
br 2
pu 1
H9
wh
H1
bl
br
1 2
CX/2
1
CW/2
BO/2
1
2
2
wh CE/4
CA/4
2 1
DI/2
2 H3
2
4 3
BG/3
BS/2
ye
AJ/3
br ye-re
3
ye-re
AJ1/3
N2
4 2
BG1/3
ye
pu
wh-gn
3 4 3
wh
2
ye
BR/4
wh-re ye-re
bl
BF/1
re-bl
S11
re-wh
ye-re
ye-bl
1
bl
BT/3
br
BG/3
wh-re
BK/4
br
1 ye-re
2
bl
3
or pu
S10
gn
br
ye-re or
ye-bl
S8
re
2
ye
2
br
br
M1
CX1/2
gn
4
1
bu
ye-bl
2
bl
2 ye
K1
CW1/2
1
AH2/2
bl
1 2 K2
re
wh-gn
re
AC/6
bu ye
ye H13
re
ye-bl
1
2
BA1/1
re-wh
br
G
re-bl gn
br-bl
1 2
br
3
5
br
ye-re
BF1/1
br
ye-re
1
S7
bu-wh
v ye-re
bl
br
6 4
bu gn
BC/6
BA/1
bl
2
wh
1
3
wh
S6
BF/1
DB/4 DA/4
P1
S5
bu-wh
br
B3
CZ/3 CY/3
CX/2
1
CW/2
bu
AH1/2
CE/4
H15
2
3
CX2/2
CW2/2
AK1/2
H18
re
4
BP/4
DG/4
CE/4
CE/4
2
CX3/2
CE/4
Wiring diagram (EXC‑F AUS)
WIRING DIAGRAM
M
110
600878-01
10 A
AF/4 G1
BA/1
1
1
U
BV/2
AK/2 S1
AH/2
bu
br
br
2.2 2.1
BS/2
BV/2
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
B3
Wheel speed sensor
G1
Battery
G2
Generator
H1
Right rear turn signal
H2
Left front turn signal
H3
Left rear turn signal
H4
Right front turn signal
H5
Brake/tail light
H7
Parking light
H9
License plate lamp
H11
Low/high beam
H13
Horn
H15
Turn signal indicator light
H18
High beam indicator light
K1
Starter relay with main fuse
K2
Turn signal relay
L1
Pulse generator
L2
Ignition coil
M1
Starter motor
N2
Voltage regulator/rectifier
P1
Speedometer
S1
Rear brake light switch
S2
Front brake light switch
S5
Tripmaster switch (optional)
S6
Light switch
S7
Horn button, short circuit button
S8
Turn signal switch
S10
Electric starter button
S11
Emergency OFF switch
Cable colors bl
Black
br
Brown
br-bl
Brown-black
bu
Blue
bu-wh
Blue-white
gn
Green
or
Orange
pu
Violet
re
Red
re-bl
Red-black
re-wh
Red-white
wh
White
wh-gn
White-green
wh-re
White-red
ye
Yellow
ye-bl
Yellow-black
ye-re
Yellow-red
111
24.3
H7
Wiring diagram (XCF-W)
L2
C D I A6 B1
3
L1
5A
M
br ye-re ye wh
ye-bl
G G2
N2
ye-re
br wh-re
M1
br wh H5
br
br
black
E6 K1
wh
bl
ye-re wh-re
M
ye
bl br
br bl
wh ye
t
gn
H14
re
re-bl re-wh
wh br wh ye-re br
br ye-re
ye bu
br
ye-bl
P1
S6
bl
B3
bl bl
bu-wh br ye-bl re-wh re-bl gn re bu ye bl
H11
re bu wh br
bl-wh
br
WIRING DIAGRAM
S12 S10
10 A G1
U
v S5
600700-01
112
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
B3
Wheel speed sensor
E6
Thermoswitch (XCF-W ZA)
G1
Battery
G2
Generator
H5
Brake/tail light (XCF-W ZA)
H7
Parking light (XCF-W ZA)
H11
Low beam (XCF-W ZA)
H14
Radiator fan (XCF-W ZA)
K1
Starter relay with main fuse
L1
Pulse generator
L2
Ignition coil
M1
Starter motor
N2
Voltage regulator/rectifier
P1
Speedometer
S5
Tripmaster switch (optional)
S6
Light switch
S10
Electric starter button
S12
Short circuit button
Cable colors bl
Black
bl-wh
Black-white
br
Brown
bu
Blue
bu-wh
Blue-white
gn
Green
re
Red
re-bl
Red-black
re-wh
Red-white
wh
White
wh-re
White-red
ye
Yellow
ye-bl
Yellow-black
ye-re
Yellow-red
113
600701-01
114
G S12
3
G2
gn re-wh
re-bl
ye-bl
bl
re
br bu-wh 1 2 5 7 6
11 10
12 13 14
2
3
C D I
1
AM/3 AR/3
Wiring diagram (SX‑F)
B1
24.4
WIRING DIAGRAM
A6
L2
L1
WIRING DIAGRAM Components A6
CDI controller
B1
Throttle position sensor
G2
Generator
L1
Pulse generator
L2
Ignition coil
S12
Short circuit button
Cable colors bl
Black
br
Brown
bu-wh
Blue-white
gn
Green
re
Red
re-bl
Red-black
re-wh
Red-white
ye-bl
Yellow-black
115
SUBSTANCES
116
Brake fluid DOT 4 / DOT 5.1 according to – DOT Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1
Coolant Guideline – Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends Motorex® products. Mixture ratio Antifreeze protection: −25… −45 °C (−13… −49 °F)
50 % corrosion inhibitor/antifreeze 50 % distilled water
Coolant (mixed ready to use) −40 °C (−40 °F)
Antifreeze Supplier Motorex® – Anti Freeze
Engine oil (SAE 10W/50) according to – JASO T903 MA ( –
SAE (
p. 119)
p. 119) (SAE 10W/50)
Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Cross Power 4T
Fork oil (SAE 5) according to – SAE ( p. 119) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Racing Fork Oil
Super unleaded (ROZ 95 / RON 95 / PON 91) according to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)
AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Twin Air Dirt Bio Remover
Chain cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chain Clean 611
Cleaning and polishing materials for metal, rubber and plastic Guideline – KTM recommends Motorex® products. Supplier Motorex® – Protect & Shine 645
Contact spray Guideline – KTM recommends Motorex® products. Supplier Motorex® – Accu Contact
Long-life grease Guideline – KTM recommends Motorex® products. Supplier Motorex® – Fett 2000
Motorcycle cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900
Off-road chain spray Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chain Lube 622
Oil for foam air filter Guideline – KTM recommends Motorex® products. Supplier Motorex® – Twin Air Liquid Bio Power
117
AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex® products. Supplier Motorex® – Joker 440 Universal
118
STANDARDS
119
JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground 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 according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
120
INDEX
A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Air filter box lid installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Anti-freeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Arduous riding conditions . . . . . . . . . . . . . . . . . . . . . . . . . dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . high temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . low temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . slow speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 27 30 30 29 30 30 28 29
B Basic position, shift lever adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Basic suspension setting checking with rider's weight . . . . . . . . . . . . . . . . . . . . 40 Battery installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Brake discs checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Brake fluid front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 63 rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Brake fluid level front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 62 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 66 Brake linings front brake, changing . front brake, checking . rear brake, changing . . rear brake, checking . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
64 64 68 67
C Carburetor adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 emptying the float chamber . . . . . . . . . . . . . . . . . . . . 86 idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Clutch fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 83 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 83 Compression damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Compression damping, high-speed shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 40 Compression damping, low-speed shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 41 Coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Coolant level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 E Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil adding . changing draining refilling .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
90 87 87 90
Engine oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F Filler cap closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Filling up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 66 checking free travel . . . . . . . . . . . . . . . . . . . . . . . . . 66 Fork basic setting, checking
. . . . . . . . . . . . . . . . . . . . . . . 45
Chain guide adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61
Fork legs bleeding . . . . . . . dust boots, cleaning installing . . . . . . . removing . . . . . . .
Chain tension adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fork protector installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chain wear checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chain cleaning
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48 48 51 50
INDEX
121
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Putting into operation advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 26 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 checks before putting into operation . . . . . . . . . . . . . . 31
Fuel tank installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuse installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . .
12 62 62 61
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Headlight beam width, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 76 Headlight adjustment checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Headlight mask with headlight installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 K Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Kick starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 M Main silencer installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motorcycle cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
O Oil filter changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Oil screen cleaning Oil screens cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 14 Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 P Play in throttle cable adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
R Rear sprocket / engine sprocket checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Rear wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Rebound damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 42 Riding sag adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 S Seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Service schedule EXC‑F, EXC‑F SIX DAYS, XCF-W . . . . . . . . . . . . . . . 35-36 rider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SX‑F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-38 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 basic position, checking . . . . . . . . . . . . . . . . . . . . . . 84 Shock absorber installing . . . . . . . removing . . . . . . . riding sag, checking static sag, checking
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45 45 43 43
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Speedometer adjusting . . . . . . . . . . . . clock, setting . . . . . . . . . function description . . . . setting kilometers or miles
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16 16 15 15
Spoke tension checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Spring preload fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 43 Start number plate installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Steering head bearing play adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-50 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INDEX
122
T Technical data carburetor . . . . . . . . . . chassis . . . . . . . . . . . . chassis tightening torques engine . . . . . . . . . . . . engine tightening torques fork . . . . . . . . . . . . . . shock absorber . . . . . . .
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. . . . . 99 . 100-101 . . . . 105 . . . 95-96 . . . 97-98 . 102-103 . . . . 104
Throttle cable route checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Tire pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Transport . . . . . Troubleshooting . Turn signal switch Type label . . . . .
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.... 7 . 91-92 . . . 13 . . . 10
U Use definition
................................. 6
V View of vehicle left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 W Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-115 Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPAIRMANUAL2005-2010 250 SX-F, EXC-F, EXC-F SIX DAYS XCF-W, XC-F, SXS-F REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION
ART.NR.: 3.206.063-E
MANUAL DE REPARACIÓN
1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS 13 14 15 16
I M P O R T A N T I N F O R M A T I O N /U P D A T I N G
INSTRUCTIONS
To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: 1,3,7,9,13,52,53,115,125-143,154-161,163,174-189
Remove page (s))
Replace by page (s)
5-5 to 5-6
5-5 to 5-6
10-1
10-1
10-10 to 10-12
10-10 to 10-27
11-1
11-1
12-1
Insert page (s)
after page
11-12 to 11-19
11-11
12-11 to 12-26
12-10
12-1
KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder. – Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder. – Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page at the beginning of the manual. – Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 For example: All pages with a page number that begins with the digit 3, must be put under the index heading “Chapter 3“. – Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.
EXPLANATION - UPDATING 3.206.027-E Repair Manual 250 SX-F
Basic version Model year 2005/06 (Engine number with first digit "5" and "6")
5/2005
3.206.052-E Updating of Rep.Manual 3.206.027-E
10/2007
3.206.063-E Updating of Rep.Manual 3.206.027-E
6/2009
Model year 2007/08 (Engine number with first digit "7" and "8")
Model year 2009/10 (Engine number with first digit "9" and "0")
Modification / Updating: Technical Details, Technical Specifications, Tightening torques, Periodic Maintenance Schedule
Edition: 6/2009
INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work.
WARNING
STRICT COMPLIANCE WITH THESE INSTRUCTIONS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB. !
CAUTION
IS
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC ! „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications, colors, materials, services offered and rendered, and the like so as to adapt them to local conditions without previous announcement and without giving reasons, or to cancel any of the above items without substituting them with others. It shall be acceptable to stop manufacturing a certain model without previous announcement. In the event of such modifications, please ask your local KTM dealer for information. KTM Sportmotorcycle AG 5230 Mattighofen, Austria All design and assembly modification rights reserved. C by KTM SPORTMOTORCYCLE AG, AUSTRIA
All rights reserved
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349. NOTE to table: – Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.063-E). You will find the number on the cover page or in the left margin on each right page of the manual. – Enter the corresponding page number in the repair manual (e.g.: 5-7) in column 2. – Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible. – Enter the correct text in column 4. Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual
Page
Current text
Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman
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2-1
GENERAL INFORMATION INDEX
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
BLEEDING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 CHANGING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 ADJUSTING THE THROTTLE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 SPECIAL TOOLS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2
2-2
2
Bleeding the cooling system The cooling liquid can be drained by removing the screw 1 on the water pump cover. To bleed the cooling system add approx. 1 liter of cooling liquid and remove the bleeder screw 2. Do not replace the bleeder screw until cooling liquid starts to leak out of the hole without bubbles. Now add cooling liquid until it reaches a level of approx. 10 mm above the radiator fins. Take a short ride and check the cooling liquid level again.
1 Changing the oil filter
3
– Place a vessel under the engine to catch the used oil. Remove the 2 screws 3 and take off the oil filter cover.
3
Art.-No. 3.206.063-E
4
– Lay the motorcycle down and fill the oil filter case about half full with engine oil. Fill the oil filter up with oil and insert the oil filter in the case. – Grease the O-ring in the oil filter cover and mount the cover 5. Mount the screws and tighten to 6 Nm.
5
Repair manual KTM 250 -F
– Use circlip pliers to pull the oil filter insert 4 out of the case. – Clean the oil filter cover, the sealing area on the O-ring and the engine case. Check the O-ring in the oil filter cover for damage and replace if necessary.
– Put the motorcycle in an upright position again.
6
– Remove the screw cap 6 from the clutch cover and add 1.1 liters of fully synthetic engine oil (Motorex Power Synt 4T 10W/50). – Start the engine and check all screw connections and the oil filter cover for leaks. – Finally, check the engine oil level and correct if necessary.
2-3 Oil circuit
8 bk 7 9 6
5
bn bl bm 4
2 1
3
Oil circuit The oil pump 1 draws the engine oil from the transmission oil sump through the long oil screen 2 and conveys it to the oil filter 3, where any contamination is filtered out. The cleansed engine oil is pumped past the bypass valve 4 through the hole in the crankshaft 5 to the conrod bearing 6 and sprayed onto the piston 8 from below through a jet 7. Two other oil ducts lead into the cylinder head. One duct supplies the hydraulic chain tensioner 9, the other duct leads to the camshaft bearing bridge bk, where the camshaft bearings and the cam lever are supplied with oil (via spraying nozzles). The second oil pump bl draws the engine oil out of the crankcase through the short oil screen bm and uses it to grease the transmission gears bn.
2-4
1 2
Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove bolts 1 and cover together with the rubber boot 2. The oil level in the horizontal-standing master cylinder should be 4 mm (0,157 in) below the upper edge. If necessary add SAE 10 biodegradable hydraulic oil (Motorex Kupplungs-Fluid 75). ONLY USE FLUID 75)
! SAE 10
CAUTION
!
BIODEGRADABLE HYDRAULIC OIL (MOTOREX KUPPLUNGSTO REFILL THE MASTER CYLINDER. NEVER USE BRAKE FLUID!
Bleeding of the hydraulic clutch – For bleeding, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove screws 1 and take off cover together with rubber bellows 2. – At the slave cylinder of the clutch, remove the bleeder nipple. At its place, mount the bleeder syringe 3 which is filled with biodegradable hydraulic oil (Motorex Kupplungs-Fluid 75).
3
Art.-No. 3.206.063-E
– Refill oil, until oil is discharged from the bore A of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. !
!
COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT. FOR FILLING OF THE MASTER CYLINDER, USE SAE 10 BIODEGRADABLE HYDRAULIC OIL (MOTOREX KUPPLUNGSFLUID 75) ONLY. NEVER USE BRAKE FLUID NOR MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.
A
5
Repair manual KTM 250 -F
CAUTION
HAVING
Adjusting the throttle cables
6 4
The throttle grip should always provide for a backlash of 3-5 mm. Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. To adjust the throttle cables, dismount the seat and the tank together with spoilers. Slide back the protection cover 4. Loosen the counter nut 5 and turn the adjusting screw 6 accordingly. Turning the adjusting screw counterclockwise will reduce the backlash, turning the adjusting screw clockwise will increase the backlash. Tighten the counter nut and check whether the throttle grip can be actuated smoothly. Mount tank and seat. – After a short, careful test ride, check engine oil and coolant level once more.
2-5
SPECIAL TOOLS – ENGINE 250 -F
2
4
3
1
6 5
7
8
9
bl
bk bn
bo
bp
bm
br
bq
35
30 25 20 15 12
5
10
bt
ck
cl
bs
2-6
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
SPECIAL TOOLS – ENGINE 250 -F
FIG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
PART NO. 560.12.001.000 770.29.002.000 770.29.003.000 503.29.050.000 600.29.073.000 770.29.026.000 590.29.034.000 580.12.009.000 600.29.015.000 584.29.037.037 510.12.012.000 510.12.011.000 590.29.019.000 770.29.041.000 590.29.033.000 503.29.003.000 590.29.041.000 770.29.035.000 770.29.018.000 770.29.018.050 770.29.036.000
DESCRIPTION Universal engine work stand Engine holder for engine work stand Engine holder for engine work stand Bleeding syringe for hydraulic clutch Spark plug wrench 16 mm Limit plug gauge 5 mm Wrench for mixture regulating screw Magneto extractor Piston ring mounting tool Mounting tool for inner rings of crankshaft bearings Chain sprocket holder Circlip pliers Valve spring mounter Valve spring mounter Puller for camshaft bearings Clutch holder Feeler gauge for valve clearance Protection cover for camshaft Pressing tool for valve guides Reamers for valve guides Tool for piston pin lock ring.
3-1
REMOVING AND REFITTING ENGINE INDEX
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
DISMOUNTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 MOUNTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3
3-2 Dismounting the engine – Thoroughly clean the motorcycle and jack up on a suitable assembly stand. Make sure it cannot tip over. – Remove the seat and tank with the spoiler. – Remove the frame protector on both sides. NOTE: you do not need to take the screws on the outside of the swing arm pivot all the way out. Just loosen and pull them out with the bushing. – Open the chain and remove.
– Dismount the foot brake cylinder 1; you do not need to loosen the line to the rear wheel brake. – Detach the return spring on the foot brake lever.
1 – Remove the upper shock absorber screw 2. – Loosen the nut on the swing arm pivot, knock out the swing arm pivot with a suitable driver and completely remove the swing arm, shock absorber and rear wheel from the motorcycle.
Art.-No. 3.206.063-E
2
– Detach the exhaust springs 3 on the cylinder head and between the manifold pipe and main silencer with a suitable tool.
Repair manual KTM 250 -F
3 3 – Remove the fixing screw 4 on the manifold pipes together with the washer and rubber sleeve.
4
3-3 – Pull the manifold pipe forward and remove from the motorcycle.
– Open the drain plug on the water pump and allow the cooling liquid to drain into a suitable vessel. – Loosen the hose clamp 1 and pull the radiator hoses off of the engine.
1 1 1 – Disconnect the spark plug connector 2.
3
– Unscrew the chain securing guide 3 on the clutch slave cylinder and tilt up.
2
4
– Unscrew the clutch slave cylinder 4 and let it hang down on the side. NOTE: do not actuate the clutch lever as long as the clutch slave cylinder is dismounted.
3-4 – Disconnect the generator potentiometer connector 2.
connector
1
and
the
throttle
1 2 – Unscrew the hot start control 3 from the carburetor. – Remove both upper engine braces 4.
4 3 Art.-No. 3.206.063-E
– Carefully disconnect the engine vent 5 and remove from the motorcycle together with the hose. NOTE: only pull the connection upwards, otherwise it can easily break.
5
Repair manual KTM 250 -F
– Loosen the carburetor connection boots 6.
6
6 – Dismount the carburetor towards the right and let it hang down. ! DO
CAUTION
!
NOT PLACE THE CARBURETOR IN THE AIR FILTER BOX SINCE THE AIR FILTER WILL ABSORB ANY LEAKING FUEL.
3-5 – Loosen the chain guide 1 and tilt upwards.
1
– Remove the front 2 and lower 3 engine fixing screws and lift the engine out of the frame from the left side.
2
! MAKE
3
CAUTION
SURE THE MOTORCYCLE CANNOT TIP OVER.
!
3-6 Mounting the engine – Lift the engine into the frame from the left, position and screw in the lower 1 and the front 2 engine fixing screws but do not tighten them yet.
2
1 – Mount the chain guide 3 and tighten the screw.
3
Art.-No. 3.206.063-E
– Place the carburetor into the boots.
Repair manual KTM 250 -F
– Tighten the carburetor connection boots 4.
4
4
3-7 – Mount the engine vent 1.
1
– Mount both upper engine braces 2 but do not tighten the screws yet. NOTE: the hose the engine vent should run between the two engine braces.
2
– Screw the hot start control 3 into the carburetor.
3 – Connect the generator connector 4 and throttle potentiometer connector 5. Attach the wiring harnesses with cable clips.
4 5 6
– Mount the clutch slave cylinder 6, screw in both front screws (M6x20) and tighten to 10 Nm.
– Position the chain securing guide 7, mount the M6x25 screw and tighten to 10 Nm. Tighten the screw on the chain roller.
7 8
– Connect the spark plug connector 8.
3-8 – Connect the radiator hoses to the engine and tighten the hose clamp 1.
1 1 1 – Attach the manifold pipe to the front of the motorcycle and slide into the main silencer.
Art.-No. 3.206.063-E
– Mount the fixing screw 2 for the manifold pipe with washers 3 and the rubber sleeve 4.
2 3
4
3
2 – Attach the exhaust springs 5.
Repair manual KTM 250 -F
5
5 6
– Position the rear wheel with the swing arm and shock absorber in the frame. – Insert the swing arm pivot and tighten the nut. – Tighten the upper shock absorber screw 6 to 70 Nm. – Tighten the nut on the swing arm pivot to 100 Nm. – Tighten the nuts on the two engine braces to 33 Nm. – Tighten the front and lower engine fixing screws to 60 Nm.
3-9 – Mount the foot brake cylinder 1, apply Loctite 243 to the screws and tighten to 10 Nm. – Apply Loctite 243 to the ball joint of the pushrod and tighten to 10 Nm. – Attach the return spring for the foot brake lever. – Mount the chain and chain joint.
1
!
CAUTION
!
WHEN
YOU MOUNT THE CHAIN JOINT, MAKE SURE THE CLOSED SIDE OF THE GUIDE POINTS IN THE RUNNING DIRECTION.
– To adjust the chain tensioning: see Owner's Manual. – Mount both sides of the frame protector. – To fill and bleed the cooling system: see Chapter 2 – Mount the seat and tank with the spoiler and take the motorcycle off the assembly stand.
4-1
DISASSEMBLING THE ENGINE INDEX
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 MOVING THE ENGINE INTO THE TDC POSITION . . . . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 REMOVING THE CYLINDER HEAD AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 REMOVING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 DISMANTLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 REMOVING THE CHAIN DRIVE AND PRIMARY GEAR . . . . . . . . . . . . . . . . . . . . . .4-9 DISMANTLING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 SEPARATING THE CASING HALVES, REMOVING THE CRANKSHAFT AND TRANSMISSION SHAFTS . . .4-12
4
4-2 Preparatory work – Thoroughly clean the outside of the engine and screw onto the engine work stand 560.12.001.000 with both engine holders 770.29.002.000 and 770.29.003.000. – Unscrew the shift lever, drain the oil and remove the oil filter cover. Discard the O-ring in the oil filter cover and the seal ring on the oil drain plug.
– Use suitable pliers (circlip pliers 510.12.011.000) to pull out the oil filter and discard. – Unscrew the spark plug.
Art.-No. 3.206.063-E
– Dismount the ignition cover 1.
1 – Unscrew the pulse generator 2, pull the rubber duct out of the recess and remove the pulse generator.
Repair manual KTM 250 -F
2
3 – Remove the plug 3 and pull out the oil screen. Discard the seal rings on the plug and on the oil screen.
4-3 – Remove the valve cover.
Moving the engine into the TDC position – Turn the crankshaft until the two marks 1 on the camshaft gears are aligned and precisely above the dividing line 2 between the two camshaft bearing bridges.
1 2 – Unscrew the engine locking screw 3, remove the seal ring and screw the engine locking screw back in (tightening torque 20 Nm).
3
4-4 Removing the camshafts – Open the plug on the chain tensioner 1 and pull out the chain tensioner 2. – Discard the sealing washer on the plug and the O-ring 3 on the chain tensioner.
1
3 2 – Loosen all of the screws and nuts on the upper camshaft bearing bridge 4 and carefully remove the camshaft bearing bridge.
4
NOTE: the screws on the timing chain guide rail 5 have distance bushings 6, be careful not to lose them.
Art.-No. 3.206.063-E
5
6
Repair manual KTM 250 -F
– Turn the exhaust camshaft up along the timing chain and towards the intake camshaft; take the timing chain off the camshaft gear.
– Also remove the intake camshaft; let the timing chain fall into the timing chain compartment.
4-5 Removing the cylinder head and piston
1
– Remove the lower camshaft bearing bridge 1, remove the dowels.
– Take the shims out of the spring retainers and mark their mounted positions. NOTE: you will only need to check the valve clearance after assembling; if valves or other parts in the valve control or replaced, the valve clearance will need to be readjusted.
– Remove the screws from the chain guide 2, the cylinder head 3 and the cylinder base 4.
2
3 3
4 – Pull the timing chain guide 5 out of the timing chain compartment.
5
– Loosen the cylinder head crews crosswise and remove together with the washers.
4-6 – Lift off the cylinder head, paying attention to the chain tensioning rail. – Discard the cylinder head gasket, remove the dowels.
– Lift off the cylinder, paying attention to the chain tensioning rail. – Discard the cylinder base gasket, remove the dowels.
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
– Carefully remove the piston pin retainer from the groove. NOTE: for easier demounting/mounting, remove the piston pin retainer opposite the timing chain compartment. – Carefully push the piston pin out of the piston; remove the piston.
4-7 – Loosen the rotor nut and remove together with the detent edged lock washer. – Screw the special tool 580.12.009.000 on the rotor, hold with a wrench and pull the rotor off the crankshaft by turning in the ejector screw. Remove the special tool from the rotor again.
Removing the clutch cover – Remove the water pump cover 1.
1
– Use a suitable wrench (510.12.011.000) to remove the lock ring 2; pull the water pump wheel off the shaft and take the needle roller out of the cross bore.
2
– Remove all of the screws from the big clutch cover as well as both of the upper screws and the lower right screw on the outer clutch cover. – Remove the dowels and discard the gasket.
4-8 Dismantling the clutch – Pull out the pushrod. – Loosen the screws on the pressure cap crosswise and remove together with the washers and springs. – Remove the pressure cap.
– Take the clutch disks out of the outer clutch hub.
Art.-No. 3.206.063-E
– Remove the pressure piece 1 and bend up the lock washer on the driving nut.
1
Repair manual KTM 250 -F
– Hold the driver with the special tool 503.29.003.000 and unscrew the driving nut (A/F 27). – Remove the driving nut together with the lock washer.
– Remove the driver together with the stop disk under the driver. NOTE: the stop disk usually adheres to the driver.
4-9 – Remove the outer clutch hub with the needle bearing and inner ring.
Removing the chain drive and primary gear – Push the timing chain towards the rear sprocket 1 and pull the rear sprocket off the timing train idler shaft.
1 – Pull the timing train idler shaft 2 out of the bearing seat together with the stop disk and remove the woodruff key 3. – Slip off the timing chain.
3
2
NOTE: mark the running direction if you plan to use the timing chain again. – Remove the timing chain tensioning rail and the chain securing guide.
– Loosen the nut on the primary pinion (A/F 27, LH thread) and remove together with the detent edged lock washer. – Remove the primary gear. NOTE: if you cannot remove the primary gear by hand, use a suitable extractor with a protector for the crankshaft. – Remove the crankshaft locking screw.
4-10 Dismantling the shift mechanism – Push back the shift rail 1 and pull out the shift shaft 2 together with the stop disk underneath.
2 1 – Remove the screw on the shift lock 3, push back the locking lever 4 and pull off the shift lock; let go of the locking lever.
5
– Remove the locking lever. – Detach the kickstarter spring 5 and pull the kickstarter shaft all the way out, being careful not to lose the washer and spring underneath.
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
6
3 4
NOTE: slightly turn the kickstarter shaft in a counterclockwise direction while you pull it out. – Remove the lock ring and washer from the starter idler 6; pull off the kickstarter idler.
4-11 Removing the oil pumps – Remove the oil pump gear and the oil pump idler. – Pull the needle roller 1 out of the oil pump shaft 2. – Remove the screws and remove the pump cover from the pressure pump 3.
2 1 3
– Pull out the oil pump shaft and remove the needle roller.
4
– Take both pressure pump rotors 4 out of the engine case.
4 – Remove the screws and lift the pump cover off the suction pump 5, discarding the O-ring.
5
– Remove both suction pump rotors 6 out of the engine case, do not lose the needle roller for the inner rotor. NOTE: the pressure pump rotors are narrower than the suction pump rotors.
6 6
4-12 Separating the casing halves, removing the crankshaft and transmission shafts – Turn the engine over and remove all of the casing screws as well as both nuts on the engine work stand holders.
1
– Lift off the left casing half; if necessary, gently tap on the shaft with a plastic hammer. !
CAUTION
!
DO
NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY THE HOUSING HALVES APART SINCE THIS WILL DAMAGE THE SEALING AREAS.
– Pull the bushing 1 and O-ring for the countershaft out of the countershaft shaft seal ring, discarding the O-ring. NOTE: the main shaft has a stop disk which usually adheres to the bearing; be careful not to lose it.
Art.-No. 3.206.063-E
– Lift the crankshaft out of the bearing.
– First pull out the upper springs 2 in the shift rails and then pull out the shift rails 3.
Repair manual KTM 250 -F
2 3 4 5
2 3 4
– Tilt the shift forks 4 aside and pull out the shift drum 5; remove the shift forks. If the lower springs do not stick to the shift rails, remove them with a suitable tool.
4 – Move the engine case into the upright position and hold both transmission shafts with one hand while you press the shafts out of the bearing seats from behind with your other hand. Make sure the engine case cannot fall off the mounting rack.
5-1
SERVICING INDIVIDUAL COMPONENTS
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
INDEX
LEFT CASING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 RIGHT CASING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 MEASURING THE OUTSIDE DIMENSION OF THE CRANKSHAFT WEBS . . . . . . . . . .5-6 CRANKSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 AXIAL CLEARANCE OF THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 MEASURING THE PISTON AND CYLINDER, MOUNTING CLEARANCE . . . . . . . . . . .5-7 PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 CHECKING THE OIL PUMPS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 CAMSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 AUTOMATIC DECOMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 CAMSHAFT BEARING BRIDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 TIMING TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 PRE-MOUNTING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 PRE-MOUNTING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 GENERAL INFORMATION ON SERVICING THE TRANSMISSION . . . . . . . . . . . . . .5-21 ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5
IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING Read through the following section before commencing work. Then determine the assembly sequence so that the engine housing halves only need to be heated up once before replacing the bearings. Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is best used as a base. Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx. 150° C. After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must be replaced.
5-2 Left casing half
3
2
Remove all shaft seal rings and the bearing fixing screws, heat the casing half in the oven to approx. 150° C. – Roller bearing for the crankshaft 1 Press in the roller bearing from the outside with a suitable driver. Press in a new roller bearing from the inside up to the stop.
1
4 6
– Grooved ball bearing for the main shaft 2 Press in a grooved ball bearing from the outside with a suitable driver. Press in a new grooved ball bearing from the inside up to the stop. – Grooved ball bearing for the countershaft 3 Press in the grooved ball bearing with a suitable driver from the outside. Press in a new bearing from the inside up to the stop. – Needle bearing for the shift shaft 4 Press in the needle bearing from the outside. Press in a new needle bearing from the inside until flush. – Shaft seal ring for the crankshaft 5 – Press in a new shaft seal ring from the outside (open side on the inside)until flush.
5 7
– Shaft seal ring for the countershaft 6 Press in a new shaft seal ring from the outside (open side on the inside) until flush.
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
– Shaft seal ring for the shift shaft 7 Press in a new shaft seal ring from the outside (open side on the inside) until flush. – When the casing half has cooled, check the bearings for a tight fit. – Make sure there are no score marks or seizing marks on the oil pump housing. – Blow compressed air through all oil ducts and make sure they are not clogged.
5-3
3
2
Right casing half Remove the shaft seal ring and the bearing fixing screws, heat the casing half in the oven to approx. 150° C. – Roller bearing for the crankshaft 1 Press in the roller bearing from the outside with a suitable driver. Press in a new roller bearing from the inside up to the stop.
A 1
4
– Grooved ball bearing for the main shaft 2 Press in the grooved ball bearing from the outside with a suitable driver. Press in a new grooved ball bearing from the inside up to the stop. – Grooved ball bearing for the countershaft 3 Press in the grooved ball bearing from the outside with a suitable driver. Press in a new grooved ball bearing from the inside up to the stop. – Grooved ball bearing for the shift drum 4 Press in the grooved ball bearing from the outside with a suitable driver. Press in a new grooved ball bearing from the inside up to the stop.
5
– Needle bearing for the shift shaft 5 Press in the needle bearing from the outside. Press in a new needle bearing from the inside until flush. – Needle bearing for the timing train idler shaft 6 Pull the Needle bearing out of the casing half with a bearing extractor. Press in a new bearing up to the stop. – Shaft seal ring for the crankshaft 7 Press in a new shaft seal ring (open side on the inside) until flush. – When the casing half has cooled, check the bearings for a tight fit.
6
– Apply Loctite 243 to the bearing fixing screws and tighten to 10 Nm.
B 7 – Make sure there are no score marks or seizing marks on the oil pump housing. – Make sure the oil ducts are not clogged. NOTE: remove the jets and the bypass valve to clean the oil ducts and check whether they are clogged. – Apply Loctite 243 to the oil jet 70 A and tighten to 3 Nm. – Apply Loctite 243 to the oil jet 150 B and tighten by hand.
5-4 Bypass valve – Check the valve piston, sealing seat and pressure spring for damage.
1
Minimum length of the pressure spring 1: 23.5 mm NOTE: if the length of the pressure spring is less than 23.5 mm, the opening pressure of the bypass valve will be reduced. This will lead to a drop in the oil pressure and consequently to increased wear.
Clutch cover – Pry the shaft seal ring out of the kickstarter shaft 2, press in a new shaft seal ring (open side on the inside) up to the stop. – Pry the shaft seal ring 3 out of the water pump. – Press the grooved ball bearing 4 out of the timing train idler shaft from the outside to the inside. Press in a new grooved ball bearing from the inside to the outside up to the stop.
2
3
– Press a new shaft seal ring into the water pump (open side on the outside) until flush. – Pry the shaft seal ring out of the crankshaft 5, press in a new shaft seal ring (open side on the inside) up to the stop.
Art.-No. 3.206.063-E
– Blow compressed air through the oil duct 6 and make sure it is not clogged.
4 5
Repair manual KTM 250 -F
6
5-5
A B
Crankshaft If replacing the conrod bearing, make sure the crank pin is in the right position. The holes in the crankshaft web A must align with the holes in the crank pin B. !
CAUTION
!
IF
YOU PRESS IN THE CRANK PIN IN THE WRONG POSITION, THE CONROD BEARING WILL NOT BE SUPPLIED WITH ENGINE OIL, WHICH WILL RESULT IN DAMAGE TO THE BEARINGS.
If you will continue to use the crankshaft, check the crankshaft journal for runout. Place the crankshaft on a roller stand or similar support and use a dial gauge to check the crankshaft journal for runout. Crankshaft journal runout: max. 0.15 mm Check the conrod bearing for radial and axial clearance. Radial clearance: max. 0.03 mm Axial clearance: 0.2 - 0.4 mm
5-6 Measuring the outside dimension of the crankshaft webs – Measure the outside dimension of the crankshaft webs using a sliding gauge, as illustrated. Outside dimension of the crankshaft webs = 53.75 mm ± 0.10 mm
Crankshaft bearings – Fix the crankshaft in the vise with protective jaws. – Heat the special tool 584.29.037.037 on a hotplate to approx. 150° C and immediately slip onto the inner ring. Firmly press the special tool together to obtain a good heat transfer and pull the inner ring off the crankshaft. – To mount the new inner ring, heat the special tool to approx. 150° C again, clamp around a new inner ring and immediately slip onto the crankshaft journal. – Make sure the new inner ring fits flush. – After replacing the inner ring, measure the axial clearance of the crankshaft. !
CAUTION
!
NEVER
Art.-No. 3.206.063-E
CLAMP THE CRANKSHAFT INTO A VISE WITH THE CRANKSHAFT JOURNAL AND TRY TO STRIKE THE INNER BEARING RING. THE CRANKSHAFT WEB WILL BE PRESSED TOGETHER AND RENDER THE CRANKSHAFT USELESS.
Axial clearance of the crankshaft – Insert the crankshaft in the right casing half and mount the left casing half. – Mount the casing screws around the crankcase and tighten. – Mount the dial gauge support on the engine case and measure the axial clearance of the crankshaft. Axial clearance: 0.2 - 0.4 mm – Correct the axial clearance if the measured value does not correspond to the setpoint value. – To correct, remove the crankshaft and pull the inner ring off the crankshaft on the ignition side using the special tool. Add or remove compensating disks.
Repair manual KTM 250 -F
NOTE: Add compensating disks if the axial clearance is too large. Remove compensating disks if the axial clearance is too small. Only add compensating disks on the ignition side.
5-7 Nikasil cylinder coating
1
Nikasil is the brand name for a cylinder coating process developed by the Mahle piston company. The name is derived from the two materials used in the process - one layer of nickel in which the exceptionally hard silicon carbite is embedded. The major advantages of the Nikasil coating include its outstanding heat dissipation and the improved power output, the insignificant wear and low weight of the cylinder. It is inexpensive to repair (replace) a worn coating if the cylinder barrel is not damaged.
Measuring the piston and cylinder, establishing the mounting clearance of the piston – To establish the wear to the cylinder, use a micrometer to measure the cylinder in the middle of the bearing surface. – Measure the diameter of the cylinder in the X and the Y axis to detect any ovality.
x y
Cylinder diameter
Size I: 76.000 - 76.012 mm Size II: 76.013 - 76.025 mm
NOTE: mark the cylinder size 1 on the side of the cylinder, the piston size 2 on the piston head.
2
– The piston is measured at the piston skirt across the piston pin, as illustrated. Piston diameter
Size I: 75.960 - 75.970 mm Size II: 75.971 - 74.980 mm
– The piston mounting clearance is the difference between the smallest cylinder diameter and the piston diameter. Piston mounting clearance
Size I: 0.030 - 0.052 mm Size II: 0.032 - 0.055 mm Wear limit: 0.070 mm
5-8 Piston – Replace the piston if oil consumption is high or the piston skirt is excessively grooved. – If the piston is to be remounted: 1. Check the piston bearing surface for damage 2. Piston ring grooves: the piston rings must move freely in the groove. Use old piston rings or sandpaper (400 grit) to clean the piston ring grooves. 3. Check the piston rings for damage and end gap. 4. Replace piston pins that are badly discolored or have visible running marks. Place the piston pin in the conrod and check for clearance.
Piston ring end gap
A
– Insert the piston ring in the cylinder and align with the piston (approx. 10 mm under the upper edge of the cylinder). – Use a feeler gauge A to measure the end gap. Compression ring : max. 0.80 mm Oil scraper ring : max. 1.00 mm If the end gap is larger than indicated above, check the cylinder for wear. If the cylinder wear is within the tolerance limits, replace the piston ring.
Art.-No. 3.206.063-E
Checking the oil pumps for wear
B
– Insert the inner and outer rotors in the engine case with the marks facing the case. The marks should no longer be visible when mounted. – Use a feeler gauge B to measure the wear: Outer rotor - oil pump housing: max. 0.20 mm
Outer rotor - inner rotor: max. 0.20 mm
Repair manual KTM 250 -F
B
5-9
bl 2 bk 1 7 6
9 1 5
3
6 8
4
3
3
4
7 1
3 1
Lubricating system – Replace the O-rings and sealing washer 1 each time you change the oil filter. – Replace the oil filter 2 each time you change the oil. – Check whether the O-rings 3 are brittle and replace if necessary; always replace the O-rings when you repair the engine. – Clean the oil screens 4 with compressed air and petroleum; replace if damaged. – Thoroughly clean the magnet on the oil drain plug 5 each time you change the oil filter. – Check the oil pump rotors 6 (see pages 5-8). Thoroughly clean the oil pump rotors before remounting. – Check the inside of the oil pump covers 7 for seizing marks and replace if necessary; replace the O-ring 8. – Place the oil pump shaft 9 on an even surface and check for eccentricity. – Check whether the toothing on the oil pump wheel bk and oil pump idler bl is worn. The recess for the needle roller should not be worn.
5-10 Camshaft bearing – Clamp the camshaft in a vise with protective aluminum jaws. Position one of the cams so that the camshaft cannot be turned. – Loosen the camshaft gear (A/F 21) and remove the screw.
– Pull off the camshaft gear using the extractor 590.29.033.000 and pressure tool 770.29.035.000.
Art.-No. 3.206.063-E
– Knock out the positioning pin 1.
B 1
2
NOTE: There is a hole B in the camshaft across from the positioning pin. The positioning pin can be knocked out through this hole with a suitable driver.
Repair manual KTM 250 -F
– Pull off the camshaft bearing using the extractor 590.29.033.000 and pressure tool 770.29.035.000.
– Slide on a new camshaft bearing; if necessary, knock on the inner ring with a suitable pipe. NOTE: the positioning ring 2 for the camshaft bearing must face up, as shown in the photo. If the camshaft bearing is mounted upside down, the camshaft will not fit in the cylinder head. – Knock in the positioning pin. – Slide on the camshaft gear, apply Loctite 243 to the screw and tighten to 80 Nm. NOTE: use the same procedure for both camshafts.
5-11 Camshafts – Check pivot points 1 and cams 2 for wear and damage. – Check the toothing of the camshaft gears 3 for wear and damage.
3
1
– Replace the camshaft bearings (see pages 5-10).
4 2 1
5 6 7
2 Automatic decompression
4
– Remove the camshaft gear and camshaft bearing (see pages 5-10). – Pull out the automatic decompression shaft 4.
– Use a driver to knock out the bearing bolts 5 through the hole in the cam. – Remove the automatic decompression spring 6 and automatic decompression weight 7.
5
– Check all parts for damage and wear. – Assemble in the reverse order. – Perform a function test. The spring should turn the automatic decompression shaft back to the stop, if not, increase the preload or replace.
5-12
2 2
Camshaft bearing bridges – Check both camshaft bearing bridges for wear, seizing marks and damage.
1
– Pull out the cam lever shafts 1; they are inserted loosely, and can easily be removed by tapping gently on the camshaft bearing bridge. NOTE: if remounting the cam lever, write down the installation position. – Check the cam lever shafts and cam lever 2 for wear, seizing marks and damage.
– Blow into the oil bore 3 with compressed air or a cleansing spray to make sure the oil jets 4 are not clogged. – If the oil jets ("50") were removed, apply Loctite 243 and tighten to 3 Nm.
3 4
4
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
– Install the cam lever according to the original installation position and slide into the cam lever shafts. NOTE: the cam levers must be arched up towards the camshaft (see photo). The cam levers will break if they are mounted upside down.
5-13 Timing chain tensioner !
1
CAUTION
!
IF
YOU DO NOT FOLLOW THESE INSTRUCTIONS, THE TIMING CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP, RESULTING IN ENGINE DAMAGE.
2
NOTE: – The timing chain tensioner 1 operates with spring force and with oil pressure. A stop system is used to ensure the right timing chain tension in the engine starting phase, even if the oil pressure is insufficient. The stop system prevents the piston 2 on the timing chain tensioner from being retracted. – In a dismounted state, the piston on the timing chain tensioner extends completely. – Fully depress the spring tensioner. This will require some effort since the oil must be squeezed out. If the timing chain tensioner is released it will extend completely again; it may not be mounted in this state, since the locking mechanism will not function. – Press down on the timing chain tensioner to ensure smooth operation.
– To prepare the timing chain tensioner for installation, place 2 spacing washers or similar implements with a thickness of 2 - 2.5 mm next to the piston of the timing chain tensioner. This will ensure that the piston cannot be completely retracted when the piston is pressed down. If you release the piston, the stop system will lock, the piston will protrude approx. 3 mm and stay in this position - this position is required for refitting!
– If you press the timing chain tensioner again and it extends no more than half way (preventing it from extending completely), the stop system will lock and the timing chain tensioner can no longer be pressed together - this position is necessary to ensure that the timing chain is adequately tensioned, even if the oil pressure is low.
5-14 Timing train Thoroughly clean all parts and check for wear. – Check the toothing of the control idler 1 for breakout and wear. – Check the timing chain tensioning rail 2 for seizing marks and damage. – Check the timing chain guide 3 for seizing marks and damage. – Check the timing chain clip 4 for seizing marks and damage. – Check the timing chain 5 for damage and wear; make sure the chain links operate smoothly.
5
NOTE: The smooth operation of the chain links can easily be checked by simply letting the timing chain hang down - the chain links should align in a row. Replace the timing chain if the chain links do not align in a row - they are no longer free-moving.
3
1
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
2 4
5-15
Cylinder head – Loosen the screws and remove the exhaust flange together with the gasket.
– Remove the shims from the valve spring retainers (if still mounted). – Dismount the valve keys using the special tools 590.29.019.000 and 770.29.041.000 and relieve the valve springs. NOTE: Used valves must be remounted in the same valve guide as before. We suggest that you place the valves in a carton in the position they were previously mounted in the cylinder head (see illustration).
5-16
2
1
– Remove the valve spring retainer 1 and valve springs 2 from the cylinder head. – Pull the valve stem sealing 3 off the valve guides and take out the spring washers 4. – Check the sealing areas of the spark plug thread and the valve seats for damage and cracks. Use a ruler and a feeler gauge to check the distortion of the sealing area to the cylinder. Distortion max. 0.10 mm.
3
– Check the valve guides using the limit plug gauge 770.29.026.000 5 (Ø 5.05 mm). If you can easily slide the limit plug gauge into the valve guide, it must be renewed and reamed in a special workshop.
4
– Valve seats may not be impacted. Sealing seat width: Inlet max. 1.50 mm; outlet max. 1.50 mm. Grind the valves if necessary.
5
– Check the valve disks for wear and runout. Runout at the valve disk max. 0.05 mm. The valve seat should not be impacted. The sealing area should be in the center of the valve seat. The valve stem is hard-plated, wear usually appears at the valve guide.
Art.-No. 3.206.063-E
– Check the valve springs for ruptures or wear (visual check), measure the length with a sliding gauge. Minimum length 38.5 mm. Replace the spring if it is shorter. – Always replace the valve stem seal if dismounting the valves. – Measure the thickness of the valve spring retainers, minimum thickness 0.9 mm. – Insert the valve spring retainers in the cylinder head. – Mount the valve stem seals on the valve guides and oil. – Thoroughly oil the valve stem and insert in the valve guides. NOTE: Make sure the valves are in the correct position when mounted. – Position the valve springs, insert the valve spring retainers in the valve springs. NOTE: mount the valve springs with the end with the larger diameter on the bottom.
Repair manual KTM 250 -F
– Pretension the valve springs with the special tool and mount the valve keys. NOTE: make sure the valve keys fit correctly, use a little grease to attach them to the valve. – Finally, tap on the valve spring retainer several times with a plastic hammer.
5-17
4
6
8 7 9
2 1 3
5 bk
Clutch – Check the pressure piece 1 for seizing marks and smooth operation. – Check the axial bearing 2 for damage. – Lay the pushrod 3 on an even surface and check for runout. – Check the length of the clutch springs 4; minimum length 37.0 mm (new 38.0 mm), replace all 5 springs if necessary. – Check the thickness of the lining disks (8 pieces) 5; minimum thickness 2.9 mm. The lining disks must be flat. – Clutch disks (7 pieces) 6; must be flat; check for mechanical damage. Replace the clutch disks if they have score-shaped breakout. – Check the driver 7 for seizing marks and damage. – Check the pressure cap mounting face 8 for damage. – Check the thrust face 9 of the outer clutch hub and the lining disks for wear. If the depressions are larger than 0.5 mm, replace the lining disks and the outer clutch hub. – Check the needle bearing bk for seizing marks and damage.
5-18
3 9
bl 8 7
bk
6 1 5
Art.-No. 3.206.063-E
2
4
Kickstarter
A B
– Remove all parts from the kickstarter shaft and clean. – Check the toothing on the kickstarter pinion 1 for wear and the clearance of the mounting. – Check the toothing of the kickstarter idler 2 for wear and the clearance of the mounting. – Check the ratchet surface and toothing of the kickstarter ratchet gear 3 for wear. – Check the pivot points and toothing of the kickstarter shaft 4 for wear and damage. Make sure the oil bore for the kickstarter pinion is not clogged.
Repair manual KTM 250 -F
Pre-mounting the kickstarter shaft – Clamp the kickstarter shaft in a vise with the toothed end facing up (use protective jaws). – Mount the stop disk 5 and kickstarter pinion with the lock toothing facing down. – Mount the stop disk 6 and circlip 7 with the sharp edge facing up. – Mount the kickstarter spring 8, inserting the inner end in the hole in the kickstarter shaft. – Mount the driving hub 9, pushing the recess over the end of kickstarter spring. – Unclamp the kickstarter shaft. – Slide the kickstarter ratchet gear on the kickstarter shaft so that mark A on the ratchet gear coincides with the hole B for the spring in the kickstarter shaft. – Mount the ratchet gear spring bk and stop disk bl on the kickstarter shaft.
5-19
6
D
8 9
C E
7
A 1 4 5 1 2 3 5
B 1 4
4
5-20 Shift mechanism – Check the shift forks 1 on the leaf A for wear. The forks have a thickness of 4.8 to 4.9 mm when new, the wear limit is 4.6 mm. – Check the shift grooves B on the shift drum 2 for wear. – Check the fit of the shift drum in the grooved ball bearing 3. – Check the grooved ball bearing 3 for smooth operation. – Check the shaft rollers 4 for pressure points and cracks. – Check the shift rails 5 for runout on an even surface. Check the shift rails for score marks and seizing marks. The shift forks must operate smoothly on the shift rails. – Check the shift rail 6 at the contact areas C for wear. Check the return surface D on the shift rail for wear (replace in case of severe indentation). – Check the guide bolt E for a tight fit and wear.
F
– Pre-mount the shift shaft and check the clearance F between the shift rail 6 and the shift quadrant. The clearance must lie between 0.40 - 0.80 mm.
Pre-mounting the shift shaft
Art.-No. 3.206.063-E
bk
– Clamp the short end of the shift shaft in a vise (use protective jaws). – Mount the shift rail 6 with the guide bolt facing down and attach the guide bolt to the shift quadrant. – Mount the pressure spring 7.
6
7
9 8
– Mount the stop disk bl.
bl
Repair manual KTM 250 -F
– Slide on the spring guide 8, slide the return spring 9 over the spring guide with the angled end up and lift the angled end over the dolly bolt bk (see illustration).
5-21
1
2 3 4
5
6 7 9 8 bk bl
General information on servicing the transmission Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gear wheels and check the following parts for wear and seizing marks: – Bearings – Pivot points on the main shaft and countershaft and pivot points on the idler gears – Shift dogs – Tooth faces on all gear wheels – Tooth profiles on the main shaft and countershaft as well as the corresponding gear wheels – Profiles of all sliding gears for smooth operation Carefully clean all parts, replace any damaged and 4+6 parts. Mount new circlips whenever you repair the transmission.
Assembling the main shaft – Clamp the main shaft in the vise with the toothed end facing down (use protective jaws). – Carefully oil all parts before mounting. – Mount the split needle bearing 1, mount the 5-speed idler gear 2 with the shift dogs facing up. – Mount the stop disk 3 (22x28,5x1mm) and circlip 4 with the sharp edge facing up. – Slip on the 3rd/4th gear sliding gear 5 with the small gear wheel on the bottom and mount the circlip 6. – Slip on the stop disk 7 and the split needle bearing 8. – Slip on the 6th gear sliding gear 9 with the recess facing up. – Slip on the 2nd gear fixed gear bk with the collar facing down and mount the stop disk bl (17.2x24x1mm). – Finally, check all of the gear wheels for smooth operation.
5-22
br
bs
bq
bp
bo bn
bm bl
7 6
9
5 4 3
2
Art.-No. 3.206.063-E
1
General information on servicing the transmission Clamp the main shaft or countershaft in the vise (use protective jaws). Remove the gears and check the following parts for wear and seizing marks: – Bearings – Pivot points on the main and countershaft and pivot points on idler gears – Shift dogs – Tooth faces on all gear wheels – Tooth profiles on the main shaft and countershaft as well as the corresponding gear wheels – Profiles of all sliding gears for smooth operation Carefully clean all parts, replace any damaged and 6+bn parts. Mount new circlips whenever you repair the transmission. Repair manual KTM 250 -F
bk
Assembling the countershaft – Clamp the countershaft in the vise with the toothed end facing down (use protective jaws). – Carefully oil all parts before mounting. – Mount the idler gear sleeve(25x28x9.7mm) 1 and the 2nd gear idler gear 2 on the countershaft with the recess for the shift dogs facing up. – Mount the thrust washer 3 (25x35x1mm) and the lock ring 4 with the sharp edge facing up. – Mount the 6th gear sliding gear 5 with the shift groove facing up. – Mount the lock ring 6 and the stop disk 7 (25.2x32x1mm). – Mount the 2 split needle bearings 9 + bl and the 4th gear idler gear 8 with the recess for the shift dogs facing down. – Mount the 3rd gear idler gear bk with the recess for the shift dogs facing up. – Mount the stop disk bm (25.2x32x1mm) and the lock ring bn. – Slip on the 5th gear sliding gear bo with the shift groove facing down and the stop disk bp (20x31.9x1mm). – Mount the needle bearing bq, 1st gear idler gear br with the recess facing down and the stop disk bs (17.2x30x1mm).
8
6-1
ASSEMBLING THE ENGINE
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
INDEX
INSTALLING THE TRANSMISSION SHAFTS AND CRANKSHAFT, ASSEMBLING THE CASING HALVES . . .6-2 MOUNTING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 MOUNTING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 MOUNTING THE PRIMARY PINION AND THE CHAIN DRIVE . . . . . . . . . . . . . . . . .6-7 MOUNTING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 MOUNTING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 MOUNTING THE PISTON AND CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .6-10 MOUNTING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 MOUNTING THE CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 CHECKING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 ASSEMBLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6
6-2 Installing the transmission shafts and crankshaft, assembling the casing halves – Place the right casing half on the engine work stand in an upright position. – Put the two transmission shafts together and insert in the casing half with one hand while you guide the transmission shafts into the bearings with the other hand. NOTE: the countershaft has a stop disk facing the bearing, the main shaft does not.
Art.-No. 3.206.063-E
– Lay the engine case down and insert the shift forks.
1
4
Repair manual KTM 250 -F
2
A
3 2
NOTE: – The smaller shift fork 1 is used for the main shaft, the larger forks (2 and 3) for the countershaft. – The "one-sided" shift fork 2 is inserted on the bottom, the "symmetrical" shift fork 3 on top. – The needle rollers on the shift forks must point towards the shift drum. – Mount the shift drum and allow the needle rollers on the shift forks to engage. NOTE: the shift drum has a groove A without "curves" around its edge; no shift fork can engage in this shift groove.
3
– Attach the lower springs to the shift rails 4 with grease and mount the shift rails; press down on the shift rails to check for smooth operation. – Insert the upper springs in the shift rails.
4 4
NOTE: – The conical ends of the springs point towards the outside. – The shorter shift rail is used for the single shift fork on the main shaft.
6-3 – Mount the crankshaft.
1
NOTE: the cone 1 for the rotor must face up.
– Degrease the entire sealing area and apply a thin coat of permanently elastic sealing compound (309 098). – Mount the dowels; do not forget the stop disk for the main shaft. – Mount the left casing half, gently tapping on the bearings with a plastic hammer if necessary. – Turn in the screws as illustrated and tighten to 10 Nm. ! DO
CAUTION
!
NOT PULL THE CASING HALVES TOGETHER BY TIGHTENING THE SCREWS.
NOTE: use the M6x45 screw to fasten the hose retaining clip *up to model 2007). – Unscrew the nuts on the engine work stand holder again.
M6x50
M6x50 M6x50
M6x40
M6x65 M6x50
M6x50
M6x50
M6x50
M6x50
M6x30 M6x50
3 2
M6x50 – Grease a new O-ring 2 for the countershaft and insert in the collar 3 of the bushing; mount the bushing with the collar facing down.
6-4 Mounting the oil pumps – Mount the oil pump shaft with the pressure pump rotors and the needle roller as illustrated. The marks 1 on both rotors must be opposite the needle roller.
1
Art.-No. 3.206.063-E
– Slide the preassembled oil pump shaft into the right engine case half. The marks should no longer be visible. – Fill the oil pump with engine oil.
Repair manual KTM 250 -F
– Mount the pressure pump cover. Apply Loctite 222 to the screws and tighten to 6 Nm. – Insert the needle roller 2 in the oil pump shaft and mount the oil pump gear 3. – Mount the stop disk 4 and lock washer 5, holding the oil pump shaft on the other side.
2
9 8
5
7 6
4 3
2
6 – Slide on the thrust washer 6 and oil pump idler 7, mount the thrust washer 8 and the lock ring 9. Check the wheels for easy action.
3
6-5 – Mount the suction pump rotors 1 with the marks facing the case. The marks should no longer be visible when mounted.
1
– Insert the needle roller 2 in the recess of the oil pump shaft and inner rotor. – Fill the oil pump with engine oil. – Insert a new O-ring 3 and mount the oil pump cover 4. Apply Loctite 222 to the screws and tighten to 6 Nm.
2 3
4 – Insert the preassembled kickstarter shaft in the seat of the engine case; slightly turn the kickstarter shaft in a clockwise direction until the kickstarter ratchet gear 5 stops behind the stop plate 6. Attach the kickstarter spring again.
5 6
6-6 Mounting the shift mechanism – Mount the locking lever 1 with the washer 2, bushing 3 and spring 4. Apply Loctite 243 to the screw and tighten to 6 Nm.
1
2 1
3
4
– Press the locking lever away from the shift drum and slip on the shift lock. NOTE: the flat surfaces on the shift lock are not symmetrical.
Art.-No. 3.206.063-E
– Apply Loctite 243 to the shift lock and tighten to 10 Nm.
Repair manual KTM 250 -F
– Mount the preassembled shift shaft in the case (do not forget the stop disk), press the shift rail back and allow to engage in the shift lock. – Mount the shift lever and shift through the gears while turning the main shaft; remove the shift lever again.
6-7 Mounting the primary pinion and the chain drive – Move the crankshaft into the TDC position and lock in place with the locking screw (20 Nm). – Mount the woodruff key (if previously removed). – Mount the primary gear, detent edged lock washer and nut (+ Loctite 243, A/F 27, LH thread). Tighten the nut to 150 Nm.
– Mount the timing chain tensioning rail 1 and the chain securing guide 2. Apply Loctite 243 to the screws and tighten to 10 Nm.
1
NOTE: – Make sure you only apply Loctite 243 to the screw thread otherwise the timing chain tensioning rail will block and can break. – The chain securing guide must rest against the stop A.
2
A – Slip on the timing chain. Pay attention to the running direction if using a used chain. – Place the stop disk 3 on the bearing 4 of the timing train idler shaft 5. – Position the timing train idler 6 on the bearing and align the marks M with the primary gear.
M 7 6 5
3 4
– Slide in the timing train idler shaft with the woodruff key 7.
7
6-8 Mounting the clutch – Slide the inner ring 1, needle bearing 2 and outer clutch hub on the main shaft.
2
NOTE: Turn the starter idler 3, oil pump gear 4 and outer clutch hub back and forth until the toothing engages.
3 1 4
– Slide on the stop disk and driver.
Art.-No. 3.206.063-E
– Apply Loctite 243 to the driving nut 5 and mount with a new lock washer 6. – Hold the driver with special tool 503.29.003.000 and tighten the driving nut to 120 Nm (A/F 27). – Turn down the lock washer the driving nut.
– Insert the pressure piece 7. – Thoroughly oil all lining disks. – Starting with lining disk 8, insert all 8 lining disks and all 7 clutch disks 9 in the outer clutch hub, ending with a lining disk on top.
Repair manual KTM 250 -F
7
9
6 5 2
1
8
6-9 – Mount the pressure cap and gradually tighten the screws with the washers and springs crosswise to 10 Nm.
Mounting the clutch cover – Mount a new gasket and the clutch cover (do not forget the dowels). – Turn in the screws as illustrated and tighten to 10 Nm.
M6x25+Cu
M6x25
M6x55
M6x35 M6x25
M6x55
M6x20
M6x35
M6x25 M6x25 – Insert the needle roller in the shaft, mount the water pump wheel and lock ring.
– Mount the water pump cover with a new gasket and tighten the screws to 10 Nm.
6-10 – Insert the woodruff key in the crankshaft groove. – Slip on the rotor. – Mount the spring washer and nut. Tighten the nut to 60 Nm.
Mounting the piston and cylinder head – Place the well-oiled piston on the cylinder and clamp the piston rings together with the piston ring compressor 600.29.015.000. – Gently tap on the piston ring compressor with a plastic hammer from above to make it fit flush against the cylinder. – Carefully tap the piston into the cylinder with the hammer handle, making sure the piston rings do not jam. !
CAUTION
!
IF THE PISTON RING COMPRESSOR PRESSES THE PISTON RINGS TOGETHER PROPERLY AND FLUSH AROUND THE ENTIRE CYLINDER, YOU WILL BE ABLE TO PUSH THE PISTON INTO THE CYLINDER BY TAPPING LIGHTLY WITH THE HAMMER HANDLE. EXCESSIVE FORCE USUALLY DAMAGES THE PISTON RINGS.
Art.-No. 3.206.063-E
– Mount a new cylinder base gasket and thrust bushing. – Slide the piston out of the bottom of the cylinder until you can push in the piston pin.
1
NOTE: – You should easily be able to push the piston pin into the conrod bearing. – The arrow mark 1 on the piston must point to the front, i.e. the exhaust side.
– Cover the engine case with a cloth or towel to prevent the piston pin lock ring from falling in while mounting. – Mount the piston pin lock ring (special tool 770.29.036.000).
Repair manual KTM 250 -F
NOTE: the gap must be on the top or bottom but not on the side.
– Attach a cable clip to the timing chain and pull it through the timing chain compartment. – Slide the cylinder onto the engine case.
6-11 – Attach thrust bushings to the cylinder and mount a new cylinder head gasket. – Pull the timing chain through the timing chain compartment with the cable clips and mount the cylinder head, being careful not to damage the chain tensioning rail.
– Turn in the well-oiled cylinder head screws and washers and tighten crosswise to 40 Nm in the first stage. – Tighten crosswise to 50 Nm in the second stage.
– Tighten the 3 screws to 10 Nm.
– Insert the guide rail with the nose 1 resting in the recess 2 in the securing guide.
3
1 1 2 – Align the hole in the guide rail with the hole in the cylinder head.
3
– Apply Loctite 243 to the thread of the bearing bolt 3, mount the bearing bolt with a new CU seal ring and tighten to 10 Nm.
6-12 – Place the shims in the spring retainers in accordance with their mounted position. NOTE: check the valve clearance after assembling; adjust the valve clearance if valves or other parts in the valve control were replaced.
1 1
1 1
– Mount the thrust bushings and pull the timing chain up. – Fold all 4 cam levers 1 up and mount the lower camshaft bearing bridge, positioning the timing chain over the nose 2. – Remove the cable clip from the timing chain.
2
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
– Oil the screws 3 on the lower camshaft bearing bridge, turn in and tighten to 18 Nm.
3
6-13 Mounting the camshafts – Place the intake camshaft in the bearing seat, mark 1 aligned with the dividing edge 2 between the camshaft bearing bridges, and run the chain over the camshaft gear such that the chain is tensioned on the intake side. NOTE: – The camshafts are differentiated by the automatic decompressor, which is mounted on the exhaust camshaft. – The lock ring on the camshaft ball bearing must engage in the groove in the camshaft bearing bridge.
– Run the timing chain over the rear sprocket of the exhaust camshaft and press the exhaust camshaft into the bearing seat. NOTE: – The lock ring on the camshaft ball bearing must engage in the groove in the camshaft bearing bridge. – If mark 3 on the exhaust camshaft is not positioned over the dividing edge 2 of the camshaft bearing bridge, lift the exhaust camshaft out again and turn it accordingly.
1
3 2
4 5
– Mount the upper camshaft bearing bridge 4 - do not forget the needle rollers required for centering. – Mount the timing chain guide rail 5 with the distance bushings. – Oil the screws and nuts on the camshaft bearing bridge and tighten to 18 Nm.
6-14 Mounting the chain tensioner
1
– Press the chain tensioner together up to the first notch and lock in this position. Slide into the hole in the cylinder heads together with a new O-ring. NOTE: – Check and lock the chain tensioner: see Chapter 5. – The piston 1 must protrude approx. 3 mm out of the chain tensioner.
– Mount the plug with a new seal ring and tighten to 25 Nm.
Art.-No. 3.206.063-E
– Press against the piston of the chain tensioner with a screwdriver to cause the mounting lock to yield and the piston to extend. The chain tensioner rail will be loaded and the timing chain tensioned. NOTE: if you press against the chain tensioner now it will lock. This makes sure that the timing chain is tensioned when you start the engine and not enough oil pressure has been built up yet. !
CAUTION
!
IF
THE CHAIN TENSIONER IS NOT LOCKED AND RELIEVED AFTER ASSEMBLY AS DESCRIBED IN CHAPTER 5, THE TIMING CHAIN WILL SKIP WHEN THE ENGINE IS STARTED, RESULTING IN ENGINE DAMAGE.
Checking the valve clearance – Use the feeler gauge 590.29.041.000 to measure the valve clearance:
Repair manual KTM 250 -F
Intake valves 0.10 - 0.20 mm Exhaust valves 0.12 - 0.22 mm – Write down any deviations from the specified valve clearance, remove the camshafts and measure the thickness of the installed shims. If the measured valve clearance is too small, use thinner shims; if the valve clearance is too large, install thicker shims. Shims are available in thicknesses of 1.72 to 2.60 mm in graduations of 0.04 mm. – Check the valve clearance again after assembly and correct again if necessary. – Unscrew the engine locking screw, remount with the CU-seal ring and tighten to 20 Nm.
6-15 Assembling the engine – Mount the valve cover with a new gasket and tighten the screws.
– Place the oil screen 1 on a pin wrench approx. 300 mm long. Insert the pin wrench through the opening in the bore of the opposite engine case wall and slide the oil screen all the way into the engine case. Pull out the pin wrench, mount the plug with a new gasket and tighten to 15 Nm.
1
!
CAUTION
!
THE
SCREEN IS MOUNTED SLANTING DOWNWARDS. IF MOUNTED INCORRECTLY IT WILL LOSE ITS FILTERING EFFECT AND LEAD TO EXCESSIVE ENGINE WEAR.
– Push in the pushrod. – Mount the pulse generator 2, apply Loctite 243 to the screws and tighten to 6 Nm. Press the cable guide into the recess in the case.
2
– Mount the ignition cover with dowels and a new gasket. – Tighten the screws to 10 Nm. NOTE: longer screws (M6x35 instead of M6x30) are used at the dowel positions. – Fill the oil filter case approx. 1/3 full with engine oil, slide in the filter and mount the cover with a new O-ring. Tighten the screws to 6 Nm. – Screw in the spark plug and tighten to 12 Nm.
– Mount the oil drain plug with a new seal ring and tighten to 20 Nm. – Mount the shift lever, apply Loctite 243 to the screw and tighten to 10 Nm.
7-1
ELECTRICAL
Art.-No. 3.206.063-E
INDEX
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 CHECKING THE STATOR AND PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . .7-3 REPLACING THE STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 MAIN FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 CHECKING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 CHECKING THE START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 DISMOUNTING AND MOUNTING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 CHECKING THE CHARGING VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 CHECKING FOR LOSS OF CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 ENGINE CHARACTERISTIC (250 EXC-F EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 MEASURING WITH THE PEAK VOLTAGE ADAPTER STATIC IGNITION VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 STATIC GENERATOR VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Repair manual KTM 250 -F
THROTTLE VALVE SENSOR ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
7
7-2 CDI unit Check the cables and socket connections to the CDI unit. The CDI unit can only be tested on an ignition test bench. !
CAUTION
NEVER
!
TEST THE CDI UNIT WITH A CONVENTIONAL MEASURING DEVICE. SENSITIVE ELECTRONIC COMPONENTS COULD BE DESTROYED.
HIGHLY
Checking the ignition coil – Disconnect the ignition coil and remove the spark plug connector. – Use an ohmmeter to take the following measurements: NOTE: the following measurements only correspond to the setpoint values at a coil temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint value. Measurement Primary coil Secondary coil
Cable colors Resistance blue/white - ground 0.30 Ω ± 0.05 Ω blue/white - ignition wire 6.30 kΩ ± 1.25 kΩ
Ignition system troubleshooting
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
Check the emergency OFF switch before you test the ignition system. Check whether there is an ignition spark upon starting, proceeding as follows: – Pull off the spark plug connector. – Disconnect the spark plug connector from the ignition wire – Hold the loose end of the ignition wire approx. 5 mm from the ground. – A strong spark should be visible when the kickstarter is actuated. – If a spark is visible, mount the spark plug connector again. – Unscrew the spark plug and insert in the spark plug connector. – Hold the spark plug against the ground. A strong spark should be visible when the kickstarter is actuated. If not, the spark plug connector or spark plug is defective. If – – –
no spark is visible during the first test, check the following parts: Emergency OFF switch Cable tree parts belonging to the emergency OFF switch. Test with a peak voltage adapter
If – – – – – –
the ignition is being supplied with voltage but no spark is visible, check: The ground connection from the CDI unit and ignition coil The cable from the CDI unit to the ignition coil The pulse generator The stator The ignition coil The short-circuit button
NOTE: the CDI unit cannot be tested with simple devices. It can only be tested on an ignition test bench.
7-3 Ignition system General information The measurements described below will only detect serious defects. Short circuits in the coil that lead to a weak ignition spark or poor generator capacity can be established with the peak voltage adapter 584.29.042.000. In case of a defect, check the cable and the plug and socket connections in the ignition system first. Always pay attention to the right measuring range when measuring.
Checking the stator and pulse generator Use an ohmmeter to take the following measurements: IGNITION
MEASURE pulse generator charging coil
4K-3A
1
stator pulse generator charging coil
4K-3B
stator
CABLE COLOURS
RESISTANCE
red – green
100 Ω ± 20 Ω
ground – red
∞Ω
ground – yellow
0,74 Ω ± 0,15 Ω
black/red– red/white
26 Ω ± 5,2 Ω
ground – black/red
∞Ω
red – green
100 Ω ± 20 Ω
ground – red
∞Ω
ground – yellow
0,65 Ω ± 0,15 Ω
white – yellow
0,16 Ω ± 0,03 Ω
black/red– red/white
15 Ω ± 3 Ω
ground – black/red
∞Ω
NOTE: the measurements must be performed at a temperature of 20° C, otherwise the readings will deviate significantly.
Replacing the stator – – – – – –
Remove the screw and the retaining bracket. Remove the 2 screws 1 and take the stator out of the ignition cover. Place a new stator in the ignition cover. Degrease the thread of all 3 screws and apply Loctite 243. Mount the screws and tighten (tightening torques see chapter 10). Run the wiring harness stress free and fix with the retaining bracket. Don't forget the cable socket.
Main fuse
2
– The main fuse (10 amperes) is located under the filter box cover in the starter engine relay. – The main fuse 2 is visible after you remove the filter box cover and protection cover.
!
CAUTION
!
NEVER
USE A STRONGER FUSE OR A REPAIRED FUSE. IMPROPER USE CAN DESTROY THE ENTIRE ELECTRIC SYSTEM
– The spare fuse is located under the protection cover 3.
3
7-4 Checking the starter – Disconnect the negative terminal from the battery and remove the starter. – Connect the negative terminal from a 12V battery to the starter case and briefly connect the positive terminal from the battery to connector 1 on the starter (use thick cables). – The starter should start to turn when the electric circuit is closed. – If not, replace the starter.
1
Checking the start relay
2
– – – – –
4
3
– Connect the starter relay to a 12 V battery as illustrated. – Use an ohmmeter to check the continuity between terminals A and B.
A Art.-No. 3.206.063-E
Remove the seat and the filter box cover. Disconnect the negative terminal from the battery. Remove the starter relay from the support. Pull the connector 2 from the starter relay. Disconnect cables 3 and 4 from the starter relay and remove the starter relay.
Setpoint value: 0 Ω OK Setpoint value: ∞ Ω defective NOTE: you should hear a click when you switch the starter relay.
0Ω
The starter relay is mounted in the reverse order, paying attention to the following points:
B
– Replace any damaged or defective parts.
Dismounting and mounting the battery – Remove the seat. – First disconnect the negative terminal, then the positive terminal from the battery. – Remove the filter box cover, detach the rubber strap 5 and remove the battery.
Repair manual KTM 250 -F
The battery is mounted in the reverse order, paying attention to the following points:
5
– Replace any damaged or defective parts. – Connect the positive terminal then the negative terminal to the battery.
Charging the battery !
CAUTION
!
– DO – TO – – –
NOT REMOVE THE LOCKING STRIPS. LOAD, CONNECT THE BATTERY TO THE BATTERY CHARGER BEFORE YOU SWITCH ON THE BATTERY CHARGER. IF YOU ARE CHARGING THE BATTERY IN A CLOSED ROOM, MAKE SURE IT IS WELL VENTILATED. THE BATTERY PRODUCES EXPLOSIVE GASSES WHILE CHARGING. IF THE BATTERY IS CHARGED TOO LONG OR AT AN EXCESSIVE VOLTAGE, ACID WILL LEAK THROUGH THE SAFETY VALVES AND THE BATTERY WILL LOSE CAPACITY. QUICK CHARGES WITH HIGH VOLTAGE WILL IMPAIR THE SERVICE LIFE OF YOUR BATTERY.
– Connect KTM battery charger no. 584.29.074.000. The battery charger can also be used to test the offload voltage, the battery's startability and the generator capacity. This battery charger cannot be overcharged. – If it is not used for longer periods of time, recharge the battery every 3 months.
7-5 Checking the charging voltage NOTE: the following figures only apply to fully charged batteries (charging condition at least 90 %). – Connect a voltmeter to both battery terminals. – Start the engine. – Rev the engine up to 5000 rpm and read the voltage. 14.5 V
Setpoint value: 14.0 – 15.0 V If the measured value deviates significantly from the setpoint value: – Check the socket connectors from the stator to the voltage regulator and from the voltage regulator to the wiring harness. – Check the stator. – Replace the voltage regulator.
Checking for loss of current Check for loss of current before you check the voltage regulator. – Disconnect the ground wire from the battery. – Connect an ammeter between the ground wire and the negative terminal on the battery. 0.0 mA
Setpoint value: max. 0.2 mA – If this value is higher than specified, look for the power consumers.
Engine characteristic (250 EXC-F)
B
– Two ignition curves (performance and soft) are stored in the CDI unit. The performance ignition curve is activated in the condition at delivery. – Remove the seat and tank to change the ignition curve:
A
B
A Performance (higher engine performance)
socket connector connected
B Soft (better driveability)
socket connector disconnected
7-6 Measuring with the peak voltage adapter 584.29.042.000: static ignition values Measuring conditions: – cold engine – seat and tank removed – all plug and socket connectors and the ground connection in a non-corroding condition, plugs tightly connected – depress the kickstarter forcefully at least 5 times for each measurement
Connecting the peak voltage adapter and setting the multimeter The peak voltage adapter is equipped with 4 cables: 2 red and 2 black. One red and one black cable have a measuring tip which - to measure is applied to the electric terminals of the components. The two other cables have plugs that are plugged into the respective sockets on the multimeter. The red plug is plugged into the socket on the multimeter marked with a +, V or a red circle 1. The black plug must be plugged into the socket marked with a -, Com or a black circle 2. Turn the multimeter on and switch to the range for voltage measurements - DCV. Depending on the measurement, some multimeters must be set to the level of voltage to be measured 3. !
CAUTION
!
THE PEAK VOLTAGE ADAPTER IS NOT SUITABLE TO MEASURE SECONDARY VOLTAGES (THE HIGH-VOLTAGE SIDE OF THE IGNITION COIL). THE MEASURING RANGE IS BETWEEN 0 AND APPROX. 500 VOLTS.
3 1
Art.-No. 3.206.063-E
2
WARNING
TO
PREVENT AN ELECTRIC SHOCK, DO NOT TOUCH METAL PARTS OR THE ENDS OF THE CONNECTING CABLE WITH YOUR BARE HANDS DURING OR IMMEDIATELY AFTER MEASURING.
Check the pulse generator (pick up) for an output signal - two-pole plug 4 with green and red cables:
5
– Apply the red measuring tip of the peak voltage adapter 584.29.042.000 to the green cable and the black measuring tip to the red cable, disconnect plug 4 to disconnect the CDI unit. Multimeter display: 4.5 volts +/- 0.5 volt – Same measurement with CDI unit connected. Multimeter display: 3 volts +/- 0.5 volt
Repair manual KTM 250 -F
4
Check the generator charging coil for ignition capacitor charge - twopole plug 5 with black/red and red/white cables: – Apply the red measuring tip of the peak voltage adapter to the black/red cable and the black measuring tip to the red/white cable, disconnect plug 5 to disconnect the CDI unit. Multimeter display: 30 volts +/- 5 volts
6
S
– Same measurement with CDI unit connected Multimeter display: 200 volts +/- 10 volts Check the primary voltage output 6 for ignition coil control for output voltage (blue/white cable): – Apply the red measuring tip R of the peak voltage adapter to the black/white cable (ground) and the black measuring tip S to the blue/white cable, CDI unit and ignition coil 7 connected.
R
Multimeter display: 200 volts +/- 10 volts
7
7-7 Measuring with the peak voltage adapter 584.29.042.000: static generator values Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded (if installed) and light switch turned off – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement
Check the generator output 6 for voltage between the following cable colors:
2 S 1
– between yellow and brown (ground), connector 1 disconnected Multimeter display: 15 volts +/- 1 volt – take the same measurement with connector 1 connected Multimeter display: 12 volts +/- 1 volt – between white and brown (ground), connector 2 disconnected Multimeter display: 19 volts +/- 1 volt – take the same measurement with connector 2 connected Multimeter display: 14 volts +/- 1 volt NOTE: The black measuring lead S of the peak voltage adapter must be applied to the ground.
8-1
FUEL SYSTEM
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
INDEX
DISMOUNTING AND INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . .8-3 DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 CHOKE KNOB AND HOT START SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . .8-11 CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . . . . . . . . .8-12 CARBURETOR ADJUSTING IDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
8
8-2
CARBURATOR - KEIHIN FCR-MX 39
Art.-No. 3.206.063-E
550 mm
630 mm 550 mm
Repair manual KTM 250 -F
630 mm
400 mm
8-3 Dismounting and mounting the carburetor NOTE: clean the motorcycle thoroughly before you start to work on the carburetor.
1
– Remove the seat and tank with the spoilers. – Remove the carburetor cover 1.
– Loosen the 2 nuts 2 and disconnect both throttle cables from the carburetor.
2
– Loosen the 2 hose clamps 3 and 4.
2
3 – Loosen the socket connection on the throttle sensor. – Unscrew the hot start control 5.
4 5 – Pull the carburetor out of the connection boot and remove from the left side.
– To mount the carburetor, insert in the connection boot and attach with the hose clamps. Make sure the carburetor is mounted vertically. – Attach/Adjust both throttle cables and check the throttle grip for smooth operation. – Connect the throttle sensor connector, screw in the hot start control. – Run the carburetor vent hoses through the retainer on the rear of the engine. – Start the engine and check whether the carburetor functions properly. Turn the handlebar all the way to the left and right; the engine speed should not change. If it does, check whether the throttle cables are installed correctly.
8-4 Disassembling the carburetor NOTE: Before you start disassembling the carburetor, you should look for a clean workplace. It should offer you enough space to lay out all individual components of the carburetor in perfect order. – Dismount the carburetor and remove any coarse dirt.
1
– Loosen both screws 1 and remove all of the vent hoses from the carburetor.
1
– Remove both screws 2 and remove the slide cover and gasket from the carburetor.
Art.-No. 3.206.063-E
2
2
– Remove screw 3 and pull the jet needle out of the throttle slide. – Remove screw 4.
3
4
Repair manual KTM 250 -F
5
– Pull the throttle slide arm up and take the throttle slide roller 5 and the slide shim out of the carburetor.
8-5 – Turn the carburetor around, remove the 3 screws and remove the cover of the accelerator pump. NOTE: When dismounting the cover, watch out for the spring and the sealing rings as they may get lost easily. – Remove the 2 sealing rings, the spring and the diaphragm from the pump housing.
– Remove the screws on the float chamber and remove the housing.
2
– Pull out the float hinge pin 1 and remove the float together with the float needle valve. – Remove the main jet 2.
1 7 4 5
6 3
– Remove the screw 3 and use pliers to carefully extract the seat of the float needle valve from the carburetor. – Screw out the idling jet 4, the starting jet 5 and the needle jet 6. – Turn in the mixture control screw 7 down to the stop, count the number of turns and write it down. – Turn out the mixture control screw and dismount it together with the spring, the washer, and the O-ring. NOTE: The spring, the washer, and the O-ring will usually remain in the bore. These parts can be removed with the help of compressed air.
8-6 – Remove screws 1 and the throttle sensor 2.
1 2
NOTE: the throttle sensor should only be dismounted if defective. If the screws 1 are loosened, the throttle sensor must be adjusted again.
1 – Remove screw 3 and pull the connecting piece out of the carburetor.
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
3 4 5
6
– Remove the 2 screws and take the intake trumpet together with the O-ring 4 off the carburetor. – Unscrew the idle-air jet 5 and the main air jet 6. – Thoroughly clean all jets and other parts and blow compressed air through them. – Clean the carburetor housing and blow compressed air through all the ducts in the carburetor. – Check all gaskets for damage and, if necessary, replace them.
8-7 Checking the choke knob and hot start slide
1
Choke knob: The choke knob must be easy to actuate . The piston 1 of the choke knob must not have any pronounced score marks or deposits. Hot start slide: The hot start slide must be easily actuated. The piston on the hot start slide may not have any scores or deposits.
Checking the accelerator pump Check the membranes for cracking or brittleness. Check gaskets for damage. Check if the bores 2 are unobstructed.
2 2
Checking the jet needle Check the jet needle for bending and wear.
Checking the float needle valve Check the sealing surface of the needle valve for notches. There must not be any dirt between the valve seat and the float needle.
Checking the throttle valve
3
4
The rollers 3 at the throttle valve must be easy to turn and must not have any flat spots. Check the throttle valve paddles 4 for damage.
8-8 Assembling the carburetor
3 1
– Mount the idle-air jet 1 and the main air jet 2. – Place the O-ring 3 in the groove and secure the intake trumpet to the carburetor by means of the 2 screws.
2 – Insert the fuel port in the carburetor and fix with screw 4. NOTE: In the mounted state, the connection piece must be easy to turn.
Art.-No. 3.206.063-E
4 – Mount the choke slide 5, the hot start knob 6 and actuate several times, checking for smooth operation. Also make sure the choke and the hot start knob lock into place.
5 6
Repair manual KTM 250 -F
7 8 9
bk
– Thread the spring, the washer and the O-ring onto the mixture control screw 7 and screw the mixture control screw in as far as it will go. – Now, unscrew the mixture control screw the number of turns written down during disassembly. NOTE: See the Technical Specifications for the basic carburetor setting. – Mount idling jet 8, starting jet 9 and needle jet together with main jet bk.
– Insert the needle valve seat bl in the bore and fix with screw bm.
bm bl
8-9 – Position the float and the float needle valve and mount the float hinge pin 1. – Check the float level (see page 8-14).
1 – Mount the float chamber and the gasket, position the bracket for the adjustment screw 2 and fix the float chamber with the screws 3. NOTE: When positioning the float chamber, make sure that the push rod 4 of the accelerator pump slides into the bore.
2 3
4 5
– Place the membrane 5 with the labeling facing upwards and the spring into the pump housing. – Place the O-ring 6 into the groove. Secure the sealing ring 7 with some grease in the cover and fasten the cover by means of 3 screws.
7 6 – Mount the throttle valve sensor such that the flat spot at the carburetor engages the groove of the throttle valve sensor and secure it by means of the screw.
9
8
– Pull up the throttle slide arm, push the throttle slide together with roll 8 and the slide shim into the carburetor so that the rolls 9 engage in the throttle slide (see illustration). – Check the throttle slide for smooth operation.
8-10 – Apply Loctite 243 to the screw 1 and tighten. – Mount the jet needle and fix with the screw 2.
2
1 – Position the slide cover with the gasket and fasten with the 2 screws 3.
3
3
Art.-No. 3.206.063-E
– Fix the vent hoses on the float chamber with the 2 screws 4.
Repair manual KTM 250 -F
4
4
8-11 Adjusting the position of the throttle valve sensor
1
2
1
NOTE: Before checking the position of the throttle valve sensor, you have to adjust the idle speed correctly. – Disengage the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve resistance. – Now, multiply this value by 0.15. This yields the adjustment value for the throttle valve sensor.
EXAMPLE: Throttle valve sensor resistance (bl/s) = 5 kΩ Throttle valve sensor resistance (ge/s) = 5 kΩ x 0.15 = 750 Ω ± 50 Ω
bl bl
ge ge s bl = blue ge = yellow s = black
s
– Connect the multimeter (measuring range Ω x100) to the yellow (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve sensor resistance with the throttle grip closed. According to the above example, this value should be 750 Ω ± 50 Ω. – If the value measured does not correspond to the desired value, loosen the 2 screws 1 and turn the throttle valve sensor 2 until the instrument displays the desired value. – Secure the throttle valve sensor in this position by fastening the screws and check the value once more. – Connect the throttle valve sensor to the wiring harness.
8-12 Checking the throttle valve sensor NOTE: The following measurement must be taken at a component temperature of approx. 20°C. – Open the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor. Resistance of throttle valve sensor: 4 - 6 kΩ
bl bl
ge ge
– Now, connect the multimeter to the yellow (+) and the black (-) cable of the throttle valve sensor. – As you open the throttle grip slowly, the resistance must change evenly. Resistance of throttle valve sensor: 0-5 kΩ ±1 kΩ (while opening the throttle grip)
s bl = blue ge = yellow s = black
s Dismounting and installing the throttle valve sensor
Art.-No. 3.206.063-E
1
1 2
Repair manual KTM 250 -F
– Disconnect the plug-and-socket connection of the throttle valve sensor and remove the screws 1. – Take the throttle valve sensor off the carburetor.
– When mounting the throttle valve sensor, make sure that the flat spot at the throttle valve pin engages the groove on the throttle valve sensor. – Mount the 2 screws, however, do not yet tighten them fully and adjust the position of the throttle valve sensor. Secure the 2 screws with Loctite 243.
8-13 CARBURETOR – Adjust idling Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.
1
2
3
The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2. The adjusting wheel is used to adjust the basic setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system. Clockwise turning reduces the fuel quantity (lean mixture), counterclockwise turning increases the fuel quantity (rich mixture). TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS: 1. Turn in mixture control screw 2 up to the stop, and turn it back out to the basic position (see technical date-engine) 2. Warm up the engine 3. Use the adjusting wheel 1 to set the normal idle speed (1400 1500 rpm). 4. Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease. Memorize this position, and turn mixture control screw slowly counterclockwise until the idling speed decreases again. Adjust the point of the highest idling speed between these two positions. If, in the course of this procedure, the speed undergoes a relatively high increase, reduce the idle speed to a normal level and repeat the procedure specified in 4. Serious competitive racers will choose a setting approx. 1/4 turn (clockwise) leaner than this ideal value because their engine will heat up more when used in competitions. NOTE: If you fail to obtain a satisfying result by following the procedure described above, an incorrectly dimensioned idling nozzle may be the cause. If: a) the mixture control screw has been screwed in up to the stop without causing any change in rotational speed, a smaller idling jet has to be installed; b) the engine dies when the mixture control screw is still open by 2 turns, a larger idling jet needs to be selected. Naturally, in cases of jet changes, you have to start your adjusting work from the beginning. 5. Then, use the adjusting wheel to set the desired idle speed. 6. In cases of greater changes in the outside temperature and extremely different altitudes, the idling speed should be readjusted. Basic information on carburetor wear As a result of engine vibrations, the throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause the carburetor to malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 200 hours.
Adjusting the mixture control screw Introduce the special tool 590.29.034.000 on the mixture control screw 2 at the carburetor bottom. Press the tool slightly upward and turn the adjusting wheel 3 until the tool engages the slot of the mixture control screw. Now, you can go about adjusting the screw. Marks were provided on the adjusting wheel, making it easier to keep track of the turns.
8-14 Checking the float level (float height) For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it. In this position, the edge of the float should be parallel with the float chamber sealing surface (see illustration). If the float height does not correspond to the desired value, check the float needle valve and, if necessary, replace it. If the float needle valve is o.k., you can adjust the float height by bending the float lever 1. Mount the float chamber, install the carburetor, and adjust the idle speed.
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
1
9-1
TROUBLE SHOOTING INDEX
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9
9-2 TROUBLE Engine doesn’t crank (E-starter).
CAUSE Blown fuse
REMEDY Dismount the left paneling and the filter box cover and replace the fuse in the starter relay.
Discharged battery.
Recharge the battery and investigate the causes for discharging; contact a KTM dealer.
Engine cranks but doesn’t start (E- Operating error starter).
Open fuel tap, tank fuel, actuate choke. Pay attention to starting information (see driving instructions).
Engine will not start (Kickstarter). The motorcycle has been out of operation for a longer period of time. Therefore old fuel has accumulated in the float chamber
The easily inflammable components of the new fuels evaporate during longer periods of standing still. When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start when the float chamber is filled with new fuel.
Fuel supply interrupted
Close fuel tap, loosen fuel hose at carburetor, lead into a basin and open fuel tap – if fuel leaks out, the carburetor may need cleaning – if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
Flooded engine
Clean and dry the spark plug or exchange it, respectively
Sooty or wet spark plug
Clean and dry the spark plug or exchange it, respectively
Electrode gap too large
Adjust spark plug electrode gap to 0.6 mm
Art.-No. 3.206.063-E
Spark plug connector or spark plug Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate starter, a strong spark faulty must be produced at the spark plug – If no spark is created replace the spark plug. – If the new spark plug doesn't produce a spark either, disconnect the spark plug connector from the ignition cable, hold it a distance of approx. 5 mm from ground and start. – If a spark now occurs, replace spark plug cap – If no spark is produced, control ignition system Short circuit cable scored in wiring Dismount the fuel tank, disconnect the black/yellow cable harness, short circuit button faulty from the cable of the short-circuit button, respectively, and check the ignition spark. If a spark is generated, look for the problem in the shortcircuit circuit. The plug connection of the CDI-unit, Remove the seat and the fuel tank. Clean the plug connection the pulse generator or the ignition and treat it with contact spray coil has oxydized
Repair manual KTM 250 -F
Engine fails to idle
Water in carburetor or jets blocked
Dismount and clean the carburetor
Glogged idling jet
Disassemble the carburetor and clean the jets
Incorrect adjustment of adjusting Have the carburetor adjusted screws on carburetor Defective spark plug
Replace the spark plug
Defective ignition system
Have the ignition system checked
9-3 TROUBLE Engine does not rev up
CAUSE REMEDY Carburetor fuel level too high because float Dismount carburetor and check if worn out needle valve is dirty or worn out Loose carburetor jets
Tighten jets
Electronic ignition timing faulty
Have ignition system checked
Engine will not reach full power Fuel supply partially interrupted or Clean and check fuel system as well as carburetor carburetor dirty Float leaks
Replace the float
Air filter very dirty
Clean or replace air filter
Exhaust system is not tight, deformed, or Check if exhaust is damaged, replace glasfiber yarn in the silencer does not contain enough exhaust silencer glassfiber yarn Valve gap too small
Adjust valve gap
Electronic ignition timing faulty
Have ignition system checked
Engine stops or splutters in Insuffient fuel carburetor Engine takes air out of control
Clean and check fuel system and carburettor
Engine gets too hot
Insufficient cooling liquid
Refill cooling liquid (see maintenace work), check cooling system for leaks
Not enough air stream
Drive on briskly
Cooling system has not been bled
Bleed cooling system
Radiators very dirty
Clean radiators with water jet
Foam formation in cooling system
Replace cooling liquid, use antifreeze liquid with brand name
Bent cooling hose
Shorten or replace cooling hose
Hose of engine ventilation is bent
Dislocate i.e. replace non-buckling vetilation hose
Engine oil level too high
Check engine oil level and, if necessary, correct it
Motor oil too thin (viscosity)
Use thicker engine oil; see chapter “Engine oil“
High oil consumption
The battery is discharged
Check rubber sleeve and carburetor for tight fit
The battery isn’t charged by the generator Remove seat and fuel tank and check voltage regulator because connections; voltage regulator and generator should be checked by a KTM dealer.
10-1
TECHNICAL SPECIFICATIONS
Art.-No. 3.206.063-E
INDEX
ENGINE 250 SX-F MODEL 2005-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 ENGINE 250 SXS-F MODEL 2006-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 CHASSIS 250 SX-F MODEL 2005-06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 CHASSIS 250 SXS-F MODEL 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 CHASSIS 250 SX-F/SXS-F MODEL 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 ENGINE 250 XC-F, XCF-W, EXC-F MODEL 2007 . . . . . . . . . . . . . . . . . . . . . . .11-5 CHASSIS 250 XC-F, XCF-W, EXC-F MODEL 2007 . . . . . . . . . . . . . . . . . . . . . .11-6 ENGINE 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2008 . . . . . . . . . . . . . . . . . . .11-7 CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2008 . . . . . . . . . . . . . . . . . .11-8 ENGINE 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2009 . . . . . . . . . . . . . . . . . . .11-9 CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2009 . . . . . . . . . . . . . . . . .11-12 ENGINE 250 SX-F, XCF-W, EXC-F MODEL 2010 . . . . . . . . . . . . . . . . . . . . . .11-18 CHASSIS 250 SX-F, XCF-W, EXC-F MODEL 2010 . . . . . . . . . . . . . . . . . . . . .11-20 MOUNTING CLEARANCES, WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-25
Repair manual KTM 250 -F
TIGHTENING TORQUES ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-26 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-27
10
10-2
TECHNICAL DATA – ENGINE 250 SX-F 2005/06/07, SXS-F 2006/07
Design
Liquid-cooled single cylinder 4-stroke engine
Displacement
249.51 ccm
Bore/Stroke
76 / 55 mm
Ratio
12.8 : 1
Fuel
unleaded fuel with at least RON 95
Valve timing
4 valves controlled by finger levers and 2 camshafts,
Art.-No. 3.206.063-E
driven by a pair of spur gears and a tooth-type chain Camshaft
05
Valve diameter Intake
30.9 mm
Valve diameter Exhaust
26.5 mm
Valve clearence cold Intake
0.10 - 0.20 mm
Valve clearence cold Exhaust
0.12 - 0.22 mm
Crank shaft bearing
2 cylinder roller bearings
Connecting rod bearing
needle bearing
Top end bearing
bronze bushing
Piston
alluminium alloy forged
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
pressure circulation lubrication with 2 rotor pumps
Engine oil
full synthetic oil (Motorex Power Synt 4T 10W/50)
Quantity of engine oil
1.1 liters
Primary drive
22:68
Transmission claw shifted
6-speed
1st gear
13:32
2nd gear
15:30
3rd gear
17:28
4th gear
19:26
5th gear
21:25
6th gear
22:24
Ignition system
contactless DC-CDI ignition with digital advanced system by KOKUSAN
Generator
no generator
Spark plug
NGK CR 9 EBK
Cooling system
liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
Cooling liquid
1.2 liters, 50% antifreeze, 50% destilled water, at least -25° (-13° F)
Repair manual KTM 250 -F
BASIC CARBURATOR SETTING 250 SX-F 2005/06 Type
Keihin FCR-MX 39
Main jet
168
Jet needle
OBETP
Idling jet
40
Main air jet
200
Idling air jet
100
Needle position
5th from top
Starting jet
85
Mixture control screw open
1,25
Slide
15
Performance restrictor
–
Stop pump membrane
858 / 2,15 mm
Leak jet
-
Hot start device
2,5 mm
250 SXS-F 2006
250 SX-F 2007
250 SXS-F 2007
180
175
180
50
10-3
TECHNICAL DATA – CHASSIS 250 SX-F 2005/06, SXS-F 2006
Frame
Central tube chrome-moly-steel frame
Fork
4860 MA/PA
Wheel travel front/rear
300/335 mm
Rear suspension
WP Progressive Damping System shock absorber, aluminium swing arm
Front brake
Disk brake with carbon-steel brake disc Ø 260 mm, brake caliper floated
Rear brake
Disk brake with carbon-steel brake disc Ø 220 mm, brake caliper floated
Brake disc
Wear limit max. 2,5 mm front and 3,5 mm rear
Front tires Air pressure offroad
80/100 - 21“ 1,0 bar
Rear tires Air pressure offroad
100/90 - 19“ 1,0 bar
Fuel tank capacity
7 liters
Final drive ratio
13:48 Z
Chain
X-ring 5/8 x 1/4 "
Steering head angle
63,5°
Wheel base
1481 ± 10 mm
Seat height, unloaded
925 mm
Ground clearance, unloaded
380 mm
STANDARD-ADJUSTMENT – FORK 250 SX-F 2005
250 SX-F 2006
250 SXS-F 2006
WP 4860 MA/PA
WP 4860 MA/PA
WP 4860 MA/PA
14.18.7A.03
14.18.7B.03
14.18.7B.15
Compression adjuster
22
20
22
Rebound adjuster
20
18
24
Spring
4,4 N/mm
Spring preload
5 mm
5,5 mm
Air chamber length
100 mm
-
Fork oil
SAE 5
STANDARD-ADJUSTMENT – SHOCK ABSORBER
Compression adjuster
250 SX-F 2005
250 SX-F 2006
250 SXS-F 2006
WP PDS 5018 DCC
WP PDS 5018 DCC
WP PDS 5018 DCC
12.18.7A.03
12.18.7B.03
12.18.7B.11
15 LS (low speed) 2 HS (high speed)
Rebound adjuster
22
Spring
80/250
Spring preload
5 mm
12 LS (low speed) 2,5 HS (high speed)
2 HS (high speed) 25
76/250
84-250
10-4
TECHNICAL DATA – CHASSIS 250 SX-F/SXS-F 2007 Central tube chrome-moly-steel frame
Fork
WP 4860 CC MA
Wheel travel front/rear
300/335 mm
Rear suspension
WP PDS shock absorber 5018 DCC, aluminium swing arm
Front brake
Disk brake with carbon-steel brake disc Ø 260 mm, brake caliper floated
Rear brake
Disk brake with carbon-steel brake disc Ø 220 mm, brake caliper floated
Brake disc
Wear limit max. 2.5 mm front and 3.5 mm (SXS-F: 3,8 mm) rear
Front tires Air pressure offroad
80/100-21“ 1.0 bar
Rear tires Air pressure offroad
110/90-19“ 1.0 bar
Fuel tank capacity
8 liters (2.1 US gall.)
Final drive ratio
13:48
Chain
5/8 x 1/4“
Available final sprockets
38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle
63.5°
Wheel base
1475 ± 10 mm
Seat height, unloaded
925 mm
Ground clearance, unloaded
380 mm
Weight (without fuel)
approx . 98.2 kg
Art.-No. 3.206.063-E
Frame
STANDARD-ADJUSTMENT – FORK 250 SX-F
Repair manual KTM 250 -F
WP 4860 CC MA 14.18.7C.03 Compression adjuster
15
Rebound adjuster
20
Spring
4,4 N/mm
Oil capacity without CC
385 ml
Oil capacity CC
195 ml
Gas pressure
1,2 bar
Fork oil
SAE 5
STANDARD-ADJUSTMENT – SHOCK ABSORBER 250 SX-F
250 SXS-F WP 4860 CC MA 14.18.7C.15
250 SXS-F
WP PDS 5018 DCC 12.18.7C.03
WP PDS 5018 DCC 12.18.7C.011
15 LS (low speed)
12 LS (low speed)
1 HS (high speed)
24 HS (high speed)
Rebound adjuster
25
20
Spring
63-250
69-250
Spring preload
5 mm
4 mm
Compression adjuster
10-5
TECHNICAL DATA – ENGINE 250 XC-F, XCF-W, EXC-F 2007 ENGINE
250 XC-F
250 XCF-W, EXC-F
Design
Liquid-cooled single cylinder 4-stroke engine
Displacement
249.51 ccm
Bore/Stroke
76 / 55 mm
Ratio
12.8 : 1
Fuel
unleaded fuel with at least RON 95 (USA = Premium PON 91)
Valve timing
4 valves controlled by finger levers and 2 camshafts, driven by a pair of spur gears and a tooth-type chain
Camshaft
Intake: 770.36.009.100 / Exhaust: 770.36.110.100
Valve diameter Intake
30.9 mm
Valve diameter Exhaust
26.5 mm
Valve clearence cold Intake
0.10 - 0.20 mm (0.004 - 0.008 in)
Valve clearence cold Exhaust 0.12 - 0.22 mm (0.005 - 0.009 in) Crank shaft bearing
2 cylinder roller bearings
Connecting rod bearing
needle bearing
Top end bearing
bronze bushing
Piston
alluminium alloy forged
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
pressure circulation lubrication with 2 rotor pumps
Engine oil
full synthetic oil (Motorex Power Synt 4T 10W/50)
Quantity of engine oil
1.1 liters
Primary drive
22:68
Clutch
multiple disc clutch in oil bath, hydraulically operated (brake fluid DOT 5.1)
Transmission claw shifted
6-speed
6-speed
1st gear
13:32
13:33
2nd gear
15:30
17:33
3rd gear
17:28
19:29
4th gear
19:26
23:28
5th gear
21:25
23:23
6th gear
22:24
26:22
Ignition system
contactless DC-CDI ignition with digital advanced system by KOKUSAN
Generator
12 V 150 W
Spark plug
NGK CR 9 EBK
Cooling system
liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
Cooling liquid
1.2 liters, 50% antifreeze, 50% destilled water, at least -25° (-13° F)
Starting equipment
kick - electric starter
BASIC CARBURATOR SETTING Type Main jet Jet needle Idling jet Main air jet Idling air jet Needle position Starting jet Mixture control screw open Slide Performance restrictor Stop pump membrane Leak jet
250 XCF-W ZA Keihin FCR-MX 3900G 168 OBETP 42 200 100 5th from top 85 1,25 15 – 858 / 2,15 mm 70
250 XC-F, XCF-W USA Keihin FCR-MX 3900G 168 OBEKT 40 200 100 3rd from top 85 0,75 15 – 858 / 2,15 mm 70
250 EXC-F EU, AUS Keihin FCR-MX 3900G 168 OBEKT 40 200 100 2nd from top 85 0,75 15 Slide stop 858 / 2,15 mm 70
250 EXC-F SIXDAYS Keihin FCR-MX 3900G 172 OBETP 42 200 100 5th from top 85 1,25 15 – 858 / 2,15 mm 70
10-6
TECHNICAL DATA – CHASSIS 250 250 XC-F, XCF-W, EXC-F 2007
Frame
Central tube chrome-moly-steel frame
Fork
WP Suspension – 4860 MXMA / MXMA + PA
Wheel travel front/rear
300/335 mm
Rear suspension
WP Suspension – 5018 PDS MCC / DCC, aluminium swing arm
Front brake
Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
Disk brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake disc
Wear limit max. 2,5 mm front and 3,5 mm rear
Front tires
XC-F, XCF-W: 80/100-21“
Air pressure offroad Air pressure road
1,0 bar 1,5 bar
Rear tires
XC-F, XCF-W: 100/100-18“
Air pressure offroad Air pressure road
1,0 bar 2,0 bar
Fuel tank capacity
C-F, XCF-W, EXC-F AUS: 8,5 Liter
EXC-F EU: 7 Liter
Final drive ratio
XC-F: 13:48
EXC-F: 14:38
Chain
5/8 x 1/4“
EXC-F: 90/90-21“
EXC-F: 120/90-18“
XCF-W: 13:52
Art.-No. 3.206.063-E
Available final sprockets 38, 40, 42, 45, 48, 49, 50, 51, 52 Bulbs (EXC)
headlight parking light brake - rear light flasher light
12V 12V 12V 12V
Battery
maintenance-free battery 12V 4Ah
Steering head angle
63.5°
Wheel base
1475 ± 10 mm
Seat height, unloaded
925 mm
35/35W (socket BA20D) 5W (socket W2, 1x9,5d) 21/5W (socket BaY15d) 10W (socket Ba15s)
Ground clearance, unloaded 380 mm Weight (without fuel)
approx. 107 kg (235.4 lbs)
Repair manual KTM 250 -F
STANDARD ADJUSTMENT – FORK 250 XCF-W 250 EXC-F
250 XC-F 250 EXC-F SIXDAYS
WP 4860 MXMA 14187C04
WP 4860 MXMA + PA 14187C28
Compression adjuster
20
18
Rebound adjuster
20
20
Spring
4.2 N/mm
4.4 N/mm
Spring preload
–
2 turns
Air chamber length
110 mm
110 mm
Fork oil
SAE 5
SAE 5
STANDARD ADJUSTMENT – SHOCK ABSORBER 250 XCF-W 250 EXC-F
250 XC-F 250 EXC-F SIXDAYS
Compression adjuster
WP 5018 PDS MCC 12187C04 15
WP 5018 PDS DCC 12187C28 15 LS (low speed) 1.0 HS (high speed)
Rebound adjuster
25
24
Spring
76/250
76/250
Spring preload
5 mm
5 mm
10-7
TECHNICAL DATA – ENGINE 250 SX-F, XC-F, XCF-W, EXC-F 2008 ENGINE
250 SX-F, XC-F
250 XCF-W, EXC-F
Design
Liquid-cooled single cylinder 4-stroke engine
Displacement
249.51 ccm
Bore/Stroke
76 / 55 mm
Ratio
12.8 : 1
Fuel
unleaded fuel with at least RON 95 (USA = Premium PON 91)
Valve timing
4 valves controlled by finger levers and 2 camshafts, driven by a pair of spur gears and a tooth-type chain
Valve diameter Intake
30.9 mm
Valve diameter Exhaust
26.5 mm
Valve clearence cold Intake
0.10 - 0.15 mm
Valve clearence cold Exhaust 0.12 - 0.17 mm Crank shaft bearing
2 cylinder roller bearings
Connecting rod bearing
needle bearing
Top end bearing
bronze bushing
Piston
alluminium alloy forged
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
pressure circulation lubrication with 2 rotor pumps
Engine oil
full synthetic oil (Motorex Power Synt 4T 10W/50)
Quantity of engine oil
1.1 liters
Primary drive
22:68
Clutch
multiple disc clutch in oil bath, hydraulically operated (brake fluid DOT 5.1)
Transmission claw shifted
6-speed
6-speed
1st gear
13:32
13:33
2nd gear
15:30
17:33
3rd gear
17:28
19:29
4th gear
19:26
23:28
5th gear
21:25
23:23
6th gear
22:24
26:22
Ignition system
contactless DC-CDI ignition with digital advanced system by KOKUSAN
Generator
12 V 80 W at 5000 rpm, SX-F without generator
Spark plug
NGK CR 9 EBK
Cooling system
liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
Cooling liquid
1.2 liters, 50% antifreeze, 50% destilled water, at least -25° (-13° F)
Starting equipment
Kick-and Electric starter; SX-F kickstarter only
BASIC CARBURATOR SETTING 250 SX-F
250 XC-F/XCF-W ZA 250 XCF-W USA
250 EXC-F EU, AUS 250 EXC-F Six Days
Type Keihin FCR-MX
3925F
3900K
3900K
3900H
3900K
Main jet
175
168
168
168
172
Jet needle
OBETP
OBETP
OBEKT
OBDYS
OBETP
Idling jet
40
40
42
42
42
Main air jet
200
200
200
200
200
Idling air jet
100
100
100
100
100
Needle position
4th from top 4th from top
3rd from top
3rd from top
5th from top
Starting jet
85
85
85
65
85
Mixture control screw open
1
1
1,5
1,25
1,25
Slide
15
15
15
15
15
Performance restrictor
–
–
–
Slide stop
–
Leak jet
–
–
50
70
70
Hot start device
2.5 mm
–
–
–
–
10-8
TECHNICAL DATA – CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F 2008 Frame
Central tube chrome-moly-steel frame
Fork
WP Suspension – 4860 MXMA CC / MXMA + PA
Wheel travel front/rear
300/335 mm
Rear suspension
WP Suspension – 5018 PDS DCC, aluminium swing arm
Front brake
Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Rear brake
Disk brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Brake disc
Wear limit max. 2,5 mm front and 3,5 mm rear
Front tires
SX-F, XC-F, XCF-W 80/100-21“
Air pressure offroad Air pressure road
1.0 bar 1.5 bar
Rear tires
SX-F 100/90-19“
Air pressure offroad Air pressure road
1.0 bar 2.0 bar
Fuel tank capacity
250 SX-F: 7.2 liters 250 XC-F, XCF-W, EXC-F: 9.2 liters, 2 liters Reserve
Final drive ratio
250 SX-F, XC-F 13:48
Chain
5/8 x 1/4“
EXC-F, EXC-F Six Days 90/90-21“
XC-F, XCF-W 100/100-18“
EXC-F, EXC-F Six Days 120/90-18“
250 XCF-W, EXC-F Six Days 13:52
250 EXC-F 14:38 (13:52)
Art.-No. 3.206.063-E
Available final sprockets 38, 40, 42, 45, 48, 49, 50, 51, 52 Bulbs (250 XCF-W ZA, 250 EXC-F, Six Days)
headlight parking light brake - rear light flasher light
Battery
maintenance-free battery 12V 4Ah
Steering head angle
63.5°
Wheel base
1475 ± 10 mm
Seat height, unloaded
925 mm (36.5 in)
12V 12V 12V 12V
35/35W (socket BA20D) 5W (socket W2, 1x9,5d) 21/5W (socket BaY15d) 10W (socket Ba15s)
Ground clearance, unloaded 380 mm
Repair manual KTM 250 -F
Weight (without fuel)
SX-F: 96.5 kg XC-F: 104.2 kg XCF-W USA: 105.2 kg XCF-W ZA, EXC-F, EXC-F Six Days: 107.2 kg
10-9 STANDARD ADJUSTMENT – FORK 250 SX-F
250 XC-F
250 XCF-W, EXC-F
250 EXC-F Six Days
WP 4860 MXMA CC 14.18.7D.03
WP 4860 MXMA CC 14.18.7D.28
WP 4860 MXMA PA 14.18.7D.04
WP 4860 MXMA PA 14.18.7D.34
Compression adjuster
14
20
22
24
Rebound adjuster
21
21
20
22
Spring
4.4 N/mm
4.4 N/mm
4.2 N/mm
4.4 N/mm
Spring preload
–
–
2 turns
2 turns
Air chamber length
–
–
110 mm
110 mm
Fork oil
SAE 5
SAE 5
SAE 5
SAE 5
250 XC-F
250 XCF-W, EXC-F
250 EXC-F Six Days
WP 5018 PDS DCC 12.18.7D.03 14 LS (low speed) 1.0 HS (high speed)
WP 5018 PDS DCC 12.18.7D.28 15 LS (low speed) 1.0 HS (high speed)
WP 5018 PDS DCC 12.18.7D.04 15 LS (low speed) 1.5 HS (high speed)
WP 5018 PDS DCC 12.18.7D.34 15 LS (low speed) 1.5 HS (high speed)
Rebound adjuster
23
23
24
22
Spring
66/250
66/250
69/250
69/250
Spring preload
5 mm
5 mm
6 mm
8 mm
STANDARD ADJUSTMENT – SHOCK ABSORBER 250 SX-F
Compression adjuster
10-10
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
TECHNICAL DATA – ENGINE 250 SX-F, XC-F, XCF-W, EXC-F 2009
10-11
10-12
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
TECHNICAL DATA – CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F 2009
10-13
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
10-14
10-15
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
10-16
10-17
10-18
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
TECHNICAL DATA – ENGINE 250 SX-F, XCF-W, EXC-F 2010
10-19
10-20
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
TECHNICAL DATA – CHASSIS 250 SX-F, XCF-W, EXC-F 2010
10-21
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
10-22
10-23
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
10-24
10-25
ASSEMBLY CLEARANCE, WEAR LIMIT Crankshaft
axial clearance run out of crank stud crankshaft webs - measure outer dimension
Conrod bearing Cylinder Piston
Valves
radial clearance
max. 0.03 mm 0.2 - 0.4 mm
bore diameter size I
76.000 - 76.012 mm
bore diameter size II
76.013 - 76.025 mm
diameter size I
75.960 - 75.970 mm
diameter size II
75.971 - 75.980 mm
assembly clearance size I
0.030 - 0.052 mm
assembly clearance size II
0.032 - 0.055 mm
compression ring
Oil pumps
Bypass valve Clutch Transmission shafts
0.070 mm max. 0.80 mm
oil scraper ring
max. 1.00 mm
seat sealing intake
max. 1.50 mm
seat sealing exhaust
max. 1.50 mm
spring washer Valve springs
max 0.15 mm 53.75 mm ± 0.10 mm
axial clearance
wear limit Piston ring end gap
0.2 - 0.4 mm
minimum length
0.90 mm 38.50 mm
clearance outer rotor - housing
max. 0.20 mm
clearance outer rotor - inner rotor
max. 0.20 mm
axial clearance
0.12 mm
minimum spring length
23.5 mm
length of springs
min. 37.0 mm (new 38.0 mm)
wear limit
min. 2.90 mm
axial clearance
0.1 - 0.4 mm
eccentricity
0.06 mm
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
10-26
TIGHTENING TORQUES - ENGINE
10-27
TIGHTENING TORQUES - CHASSIS
11-1
PERIODIC MAINTENANCE SCHEDULE INDEX
MODEL 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 MODEL 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4 MODEL 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
MODEL 2008 250 SX-F, XC-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8 250 XCF-W, EXC-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 MODEL 2009 250 SX-F, XC-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 250 XCF-W, EXC-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14 MODEL 2010 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-16 250 XCF-W, EXC-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18
11
11-2
PERIODIC MAINTENANCE SCHEDULE 2005 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Change engine oil, oil filter
ENGINE CARBURETOR
every 10 hours or 70 l fuel z
z
z
Check and adjust valve clearance
z
z
Check engine mounting bolts for tightness
z
z
Clean the spark-plug connector and check for a tight fit
z
z
Check the screws on the kick starter and shift lever for a tight fit
z
z
Clean oil screen and drain plug magnet
ADD-ON PARTS
1st service after 3 hours or 20 l fuel z
Replace spark plug (after 30 hours)
z
Check carburetor connection boot for cracks and leaks Check idle speed setting
z
z
Check vent hoses for damage or bends
z
z
Check cooling system for leaks, check quantity of antifreeze
z
z z
Check exhaust system for leaks and fitment Check cables for damage, smooth operation and bends, adjust and lubricate
z
z
Check fluid level of the clutch master cylinder
z
z z
Clean air filter and filter box
z
WHEELS
CHASSIS
BRAKES
Check electric wires for damage and bends Check brake fluid level, lining thickness, brake discs
z
z
Check brake lines for damage and leaks
z
z
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
z
z
Check the screws and guide bolts on the brake system for a tight fit
z
z
Check shock absorber and fork for leaks and function
z
z
Clean fork dust bellows
z
Bleed fork legs
z
Check swing arm bearings
z
Check/adjust steering head bearings
z
z
Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber)
z
z
Check/adjust steering head bearings
z
z
Check tires and air pressure
z
z
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
z
z
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
z
z
Check clearance of wheel bearings
z
z
IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER
Complete maintenance of fork
at least once a year z
every 2 years z
Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements
z
Clean and adjust carburetor
z
Treat electric contacts and switches with contact spray
z
Change hydraulic clutch fluid
z
Change brake fluid
z
IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
11-3
PERIODIC MAINTENANCE SCHEDULE 2005 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start Check oil level
z
Check brake fluid level
z
Check brake pads for wear
z
After every cleaning
For crosscountry use
at least once a year
z
Lubricate and adjust cables and nipples Bleed fork legs regularly
z
Remove and clean fork dust bellows regularly
z z
Clean and lubricate chain, check tension and adjust if necessary
z z
Clean air filter and filter box Check tires for pressure and wear
z
Check cooling fluid level
z
Check fuel lines for leaks
z z
Drain and clean float chamber Check all control elements for smooth operation
z
Check brake performance
z
z
z
Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent
z z
Art.-No. 3.206.063-E
Check tightness of screws, nuts and hose clamps regularly
RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP)
A 100 liter fuel consumption is equivalent to approx. 15 operating hours
every 10 hours 70 liter
Check the clutch disks for wear
z
Check the length of the clutch springs
Repair manual KTM 250 -F
every 20 hours 140 liter z
every 40 hours 270 liter z z
every 60 hours 400 liter z z
every 80 hours 540 liter z z
Check the clutch drive for indentations
z
z
Check the outer clutch hub for indentations
z
z
Check the cylinder and piston for wear
z
z
Check the groove on the piston pin retainer for wear (visual check)
z
z
Check the camshaft for wear (visual check)
z
z
Check the spring cap for wear
z
z
Check the eccentricity of the valve disk
z
z
Check the valve guides for wear
z
z z
Replace the valves Replace the valve springs
z
z
Check the function of the chain tensioner
z
z
Check the eccentricity of the crankshaft journal
z
z
Replace the conrod bearings
z
z
Check piston pin bearing
z
z z
Replace the crankshaft main bearings z
Check the entire transmission including the roller and bearings for wear
z
z
Check the length of the bypass valve spring
z
Replace the glass-fiber yarn filling in the silencer
z
z
z
z
z
Replace the sealing cup for the foot brake cylinder
z
z
z
z
z
Replace the throttle slide, jet needle and main jet holder (every 200 hours) NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
11-4
PERIODIC MAINTENANCE SCHEDULE 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Change engine oil, oil filter
ENGINE CARBURETOR
every 10 hours or 70 l fuel z
z
z
Check and adjust valve clearance
z
z
Check engine mounting bolts for tightness
z
z
Clean the spark-plug connector and check for a tight fit
z
z
Check the screws on the kick starter and shift lever for a tight fit
z
z
Clean oil screen and drain plug magnet
ADD-ON PARTS
1st service after 3 hours or 20 l fuel z
Replace spark plug (after 30 hours)
z
Check carburetor connection boot for cracks and leaks Check idle speed setting
z
z
Check vent hoses for damage or bends
z
z
Check cooling system for leaks, check quantity of antifreeze
z
z z
Check exhaust system for leaks and fitment Check cables for damage, smooth operation and bends, adjust and lubricate
z
z
Check fluid level of the clutch master cylinder
z
z z
Clean air filter and filter box
z
WHEELS
CHASSIS
BRAKES
Check electric wires for damage and bends Check brake fluid level, lining thickness, brake discs
z
z
Check brake lines for damage and leaks
z
z
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
z
z
Check the screws and guide bolts on the brake system for a tight fit
z
z
Check shock absorber and fork for leaks and function
z
z
Clean fork dust bellows
z
Bleed fork legs
z z
Check swing arm bearings Check/adjust steering head bearings
z
z
Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber)
z
z
Check/adjust steering head bearings
z
z
Check tires and air pressure
z
z
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
z
z
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
z
z
Check clearance of wheel bearings
z
z
IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER
Complete maintenance of fork
at least once a year z
every 2 years z
Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements
z
Clean and adjust carburetor
z
Treat electric contacts and switches with contact spray
z
Change hydraulic clutch fluid
z
Change brake fluid
z
IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
11-5
PERIODIC MAINTENANCE SCHEDULE 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start Check oil level
z
Check brake fluid level
z
Check brake pads for wear
z
After every cleaning
For crosscountry use
at least once a year
z
Lubricate and adjust cables and nipples Bleed fork legs regularly
z
Remove and clean fork dust bellows regularly
z z
Clean and lubricate chain, check tension and adjust if necessary
z z
Clean air filter and filter box Check tires for pressure and wear
z
Check cooling fluid level
z
Check fuel lines for leaks
z z
Drain and clean float chamber Check all control elements for smooth operation
z
Check brake performance
z
z
z
Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent
z z
Art.-No. 3.206.063-E
Check tightness of screws, nuts and hose clamps regularly RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP)
A 100 liter fuel consumption is equivalent to approx. 15 operating hours
every 10 hours 70 liter
Check the clutch disks for wear
z
Check the length of the clutch springs
Repair manual KTM 250 -F
every 20 hours 140 liter z
every 40 hours 270 liter z z
every 60 hours 400 liter z z
every 80 hours 540 liter z z
Check the clutch drive for indentations
z
z
Check the outer clutch hub for indentations
z
z
Check the cylinder and piston for wear
z
z
Check the groove on the piston pin retainer for wear (visual check)
z
z
Check the camshaft for wear (visual check)
z
z
Check the spring cap for wear
z
z
Check the eccentricity of the valve disk
z
z
Check the valve guides for wear
z
z z
Replace the valves Replace the valve springs
z
z
Check the function of the chain tensioner
z
z
Check the eccentricity of the crankshaft journal
z
z
Replace the conrod bearings
z
z
Check piston pin bearing
z
z z
Replace the crankshaft main bearings z
Check the entire transmission including the roller and bearings for wear
z
z
Check the length of the bypass valve spring
z
Replace the glass-fiber yarn filling in the silencer
z
z
z
z
z
Replace the sealing cup for the foot brake cylinder
z
z
z
z
z
Replace the throttle slide, jet needle and main jet holder (every 200 hours) NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
11-6
PERIODIC MAINTENANCE SCHEDULE 2007
CARBURETOR
ENGINE
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
1st service after 3 hours or 20 l fuel
every 20 hours or 140 l fuel or 1 race z
Change engine oil, oil filter
z
Clean oil screen and drain plug magnet
z
z
Check and adjust valve clearance
z
z
Check engine mounting bolts for tightness
z
z
Clean the spark-plug connector and check for a tight fit
z
z
Check the screws on the kick starter and shift lever for a tight fit
z
z
Replace spark plug (after 30 hours)
z
Check carburetor connection boot for cracks and leaks Check idle speed setting
z
z
Check vent hoses for damage or bends
z
z
Check cooling system for leaks, check quantity of antifreeze
z
z z
WHEELS
CHASSIS
BRAKES
ADD-ON PARTS
Check exhaust system for leaks and fitment Check cables for damage, smooth operation and bends, adjust and lubricate
z
z
Check fluid level of the clutch master cylinder
z
z
Clean air filter and filter box
z
Check electric wires for damage and bends
z
Check headlamp setting
z
Check function of electric systems (low high beam, brake light, indicator lamps, speedometer illumination, horn, emergency OFF switch or button
z
z
Check brake fluid level, lining thickness, brake discs
z
z
Check brake lines for damage and leaks
z
z
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
z
z
Check the screws and guide bolts on the brake system for a tight fit
z
z
Check shock absorber and fork for leaks and function
z
z
Clean fork dust bellows
z
Bleed fork legs
z
Check swing arm bearings
z
Check/adjust steering head bearings
z
z
Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber)
z
z
Check/adjust steering head bearings
z
z
Check tires and air pressure
z
z
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
z
z
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
z
z
Check clearance of wheel bearings
z
z
ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER
Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Treat battery connections with contact grease Treat electric contacts and switches with contact spray Change hydraulic clutch fluid Change brake fluid Clean Sparkarrestor (XC-W USA)
at least once a year z
every 2 years z
z z z z z z z
Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
11-7
PERIODIC MAINTENANCE SCHEDULE 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start
Art.-No. 3.206.063-E
For crosscountry use
at least once a year
z z z z z
Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly
Repair manual KTM 250 -F
After every cleaning
z z z z z
z z z z z z z
z
z z z z
IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx. 15 operating hours
COMPETITIVE every 10 hours every 20 hours every 40 hours every 80 hours RACING 70 liter 140 liter 270 liter 540 liter HOBBY-USE every 20 hours every 40 hours 140 liter 270 liter z z
Check the clutch disks for wear Check the length of the clutch springs Check the clutch drive for indentations Check the outer clutch hub for indentations Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check) Check the camshaft for wear (visual check) Check the spring cap for wear Check the eccentricity of the valve disk Check the valve guides for wear Replace the valves Replace the valve springs Check the function of the timing chain tensioner Check the eccentricity of the crankshaft journal Replace the conrod bearings Check piston pin bearing Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear Check the length of the bypass valve spring Replace the glass-fiber yarn filling in the silencer Replace the sealing cup for the foot brake cylinder Replace the throttle slide, jet needle and main jet holder (every 200 hours)
––– z z z z z z z z z z z z z z z
z
z z
z z z z
every 80 hours 540 liter z z z z z z z z z z z z z z z z z z z z z
NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
11-8
PERIODIC MAINTENANCE SCHEDULE 2008 250 SX-F/XC-F
CARBURETOR
ENGINE
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
1st service after 3 hours or 20 l fuel
every 20 hours or 140 l fuel or 1 race z
Change engine oil, oil filter
z
Clean oil screen and drain plug magnet
z
z
Check and adjust valve clearance
z
z
Check engine mounting bolts for tightness
z
z
Clean the spark-plug connector and check for a tight fit
z
z
Check the screws on the kick starter and shift lever for a tight fit
z
z
Replace spark plug (after 30 hours)
z
Check carburetor connection boot for cracks and leaks Check idle speed setting
z
z
Check vent hoses for damage or bends
z
z
Check cooling system for leaks, check quantity of antifreeze
z
z z
WHEELS
CHASSIS
BRAKES
ADD-ON PARTS
Check exhaust system for leaks and fitment Check cables for damage, smooth operation and bends, adjust and lubricate
z
z
Check fluid level of the clutch master cylinder
z
z
Clean air filter and filter box
z
Check electric wires for damage and bends
z
Check headlamp setting
z
Check function of electric systems (low high beam, brake light, indicator lamps, speedometer illumination, horn, emergency OFF switch or button
z
z
Check brake fluid level, lining thickness, brake discs
z
z
Check brake lines for damage and leaks
z
z
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
z
z
Check the screws and guide bolts on the brake system for a tight fit
z
z
Check shock absorber and fork for leaks and function
z
z
Clean fork dust bellows
z
Bleed fork legs
z z
Check swing arm bearings Check/adjust steering head bearings
z
z
Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber)
z
z
Check/adjust steering head bearings
z
z
Check tires and air pressure
z
z
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
z
z
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
z
z
Check clearance of wheel bearings
z
z
250 SX-F/XC-F
ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER
Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Treat battery connections with contact grease Treat electric contacts and switches with contact spray Change hydraulic clutch fluid Change brake fluid Clean Sparkarrestor (XC-F USA)
at least once a year z
every 2 years z
z z z z z z z
Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
11-9
PERIODIC MAINTENANCE SCHEDULE 2008 250 SX-F/XC-F
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
Before each start Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly
After every cleaning
For crosscountry use
at least once a year
z z z z z z z z z z
z z z z z z z
z
z z z z
250 SX-F/XC-F
IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP)
A 100 liter fuel consumption is equivalent to approx. 15 operating hours
Check the clutch disks for wear Check the length of the clutch springs Check the clutch drive for indentations Check the outer clutch hub for indentations Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check) Check the camshaft for wear (visual check) Check the spring cap for wear Check the eccentricity of the valve disk Check the valve guides for wear Replace the valves Replace the valve springs Check the function of the chain tensioner Check the eccentricity of the crankshaft journal Replace the conrod bearings Check piston pin bearing Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear Check the length of the bypass valve spring Replace the glass-fiber yarn filling in the silencer Replace the sealing cup for the foot brake cylinder Check the throttle slide, jet needle and main jet holder (every 50 hours)
every 10 hours 70 liter
every 20 hours 140 liter z z z z
every 40 hours 270 liter z z z z z z z z z z
every 60 hours 400 liter z z z z
z z z z z
z
z z
z z z z
z z
NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
every 80 hours 540 liter z z z z z z z z z z z z z z z z z z z z z
11-10
PERIODIC MAINTENANCE SCHEDULE 2008 250 XCF-W/EXC-F
WHEELS
CHASSIS
BRAKES
ADD- ON PARTS
CARBURETOR
ENGINE
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Change engine oil, short and long oil filters Clean oil screen and drain plug magnet Check oil lines for damage or bends Replace spark plug (after 30 hours) Check and adjust valve clearance Check engine mounting bolts for tightness Clean the spark-plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Check carburetor connection boot for cracks and leaks Check idle speed setting Check vent hoses for damage or bends Check cooling system for leaks, check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage, smooth operation and bends adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems (low high beam, brake light, indicator lamps, speedometer illumination, horn, emergency OFF switch or button Check brake fluid level, lining thickness, brake discs Check brake lines for damage and leaks Check/function smooth operation and adjust free travel of handbrake/foot brake lever Check the screws and guide bolts on the brake system for a tight fit Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs Check swing arm bearings Check/adjust steering head bearings Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber) Check spoke tension and rim joint Check tires and air pressure Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension Lubricate chain, clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings
1st service after 3 hours or 20 l fuel z z z z z z z z z z
every 15 hours or 100 l fuel or 1 race z z z z z z z z z z z z
z
z
z
z z z z
z
z
z z z z z
z
z z z z z z z z z
z
z
z z z z z
z z z z z
250 XCF-W/EXC-F
ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER
Complete maintenance of fork
at least once a year z
every 2 years z
Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements
z
Clean and adjust carburetor
z
Treat electric contacts and switches with contact spray
z
Treat battery connections with contact grease
z
Change hydraulic clutch fluid
z
Change brake fluid
z
Clean Sparkarrestor (XCF-W USA)
z
Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
11-11
PERIODIC MAINTENANCE SCHEDULE 2008 250 XCF-W/EXC-F
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
Before each start Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly
After every cleaning
For crosscountry use
at least once a year
z z z z z z
z
z z z z
z z z z z z
z
z z z
250 XCF-W/EXC-F
z
IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) COMPETITIVE every 10 hours every 20 hours every 40 hours every 80 hours A 100 liter fuel consumption RACING 70 liter 140 liter 270 liter 540 liter is equivalent to approx. 15 operating hours HOBBY-USE every 20 hours every 40 hours ––– every 80 hours 140 liter 270 liter 540 liter z z z Check the clutch disks for wear z z z Check the length of the clutch springs z z Check the clutch drive for indentations z z Check the outer clutch hub for indentations z z Check the cylinder and piston for wear z z Check the groove on the piston pin retainer for wear (visual check) z z Check the camshaft for wear (visual check) z z Check the spring cap for wear z z Check the eccentricity of the valve disk z z Check the valve guides for wear z Replace the valves z z Replace the valve springs z z Check the function of the timing chain tensioner z z Check the eccentricity of the crankshaft journal z z Replace the conrod bearings z z Check piston pin bearing z Replace the crankshaft main bearings z z Check the entire transmission including the roller and bearings for wear z z Check the length of the bypass valve spring z z z z Replace the glass-fiber yarn filling in the silencer z z z Replace the sealing cup for the foot brake cylinder Check the throttle slide, jet needle and main jet holder (every 50 hours) NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
11-12
PERIODIC MAINTENANCE SCHEDULE SX-F, XC-F 2009
11-13
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
PERIODIC MAINTENANCE SCHEDULE SX-F, XC-F 2009
11-14
PERIODIC MAINTENANCE SCHEDULE XCF-W, EXC-F 2009
11-15
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
PERIODIC MAINTENANCE SCHEDULE XCF-W, EXC-F 2009
11-16
PERIODIC MAINTENANCE SCHEDULE SX-F 2010
11-17
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
PERIODIC MAINTENANCE SCHEDULE SX-F 2010
11-18
PERIODIC MAINTENANCE SCHEDULE XCF-W, EXC-F 2010
11-19
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
PERIODIC MAINTENANCE SCHEDULE XCF-W, EXC-F 2010
12-1
WIRING DIAGRAMS INDEX
MODEL 2005 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 250 EXC-F USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
MODEL 2006 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 250 EXC-F USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3 250 EXC-F EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4 MODEL 2007 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5 250 EXC-F EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4 250 XC-F, XCF-W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6 MODEL 2008 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7 250 XC-F, XCF-W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8 250 EXC-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 MODEL 2009 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11 250 XCF-W, XC-F USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 250 EXC-F AUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15 250 EXC-F EU, EXC-F SIX DAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-17 MODEL 2010 250 SX-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-19 250 XCF-W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21 250 EXC-F AUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-23 250 EXC-F EU, EXC-F SIX DAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-25
12
12-2
stop button
generator G
green
red-black
yellow-black
red-white
black
3
red
brown
I
C D
blue-white
pick up
ignition coil
CD I harness - 594.39.032.000 Repair manual KTM 250 -F
250 SX-F 2005/06
20.02.2005
Art.-No. 3.206.063-E
stop switch
start button
start relay
light switch
han dl e ba r sw itch (opti onal)
starter motor
battery
10 A
wh-re
ye-re
wh-re
ye-re
bu
ye
wh
re wh
regulator-rectifier
br
br ye-re br
U
ye
ye-re bl
wh
cooling fan
ye-bl
ye-re
speed sensor
br
bl br
multi-func.-digital-speedometer
br
black
M
rear light/brakelight
v
wh br
3 TPS
12-3
ignition coil
250 EXC-F USA 2005/06
wh
ye
gn
re ye
bu
bl ye
bl
bu
I
gn
re
D
re-wh
re-bl
ye-bl
C
bu-wh
br
bl-wh
wh
re-wh
re-bl
wh br br
headlight
ye-bl
wiring diagramm
pick up
G
generator
main h a r n ess
594.11.075.100
25.02.2005
start button
flasher switch
start relay starter motor
10 A
f lasher relay M
wh-re
bl
wh-re
br
ye-re
ye-bl bl
or
pu
ye-re
h orn
re
or
ye-bl
br
ye
re
wh
bu
gn
re
bu
multi-func.-digital-speedometer
bl
black
G
battery
ye-re
12-4
high/low beam switch horn switch stop button han dl e ba r sw itch (opti onal)
wh
regulator-rectifier
br
ye-re
br
br-bl
ye-re
U
ye
br ye-re
wh
cooling fan
bl
bl bl
pu ye
bl
wh-gn
flasher control lamp
bl br right rear flasher
bu br
front brake switch
ye wh-gn
rear light/brakelight
driving light lamp
v
ye-re
speed sensor
rear brake switch br
br
ye-re
br
ye-re
br
bl
gn-wh wh br
bl br right front flasher ye-bl
ye-bl br
ye
re-bl gn
re ye
bu
bl bl
ye
left rear flasher
I
bu
re
gn
ye-bl
re-wh
D
3 TPS
br pu
re-bl
br
C
br
bl-wh
wh
bu-wh
br
wh
pu
gn
re-wh
headlight
bu
ignition coil
pick up
G
generator
left front flasher
wiring diagramm
m a in h a r n e s s
594.11.075.150 Repair manual KTM 250 -F
Art.-No. 3.206.063-E
250 EXC-F 2006/07
05.03.2005
stop button
generator
yellow-black
3
green
red-black
bl ac k
red-white
G
red
brown
I
C D
blue-white
pick up
12-5
i gni ti o n c oi l
250 SX-F 2007
CDI harness - 594.39.032.000
08.04.2006
12-6
stop switch
start butt on
handle bar switch (optional)
start rel ay
light switch starter motor
batt ery
10 A
wh-re
ye-re
wh-re
ye-re
bu
ye
wh
re wh
regulator-rectifier
br
br ye-re
U
ye
br ye-re bl
wh
cooling fan
ye-bl
ye-re
speed sensor
br
bl br
multi-func.-digital-speedometer
br
black
M
rear light/brakelight
v
wh br
3 TPS
ignition coil
wiring diagramm Art.-No. 3.206.063-E
250 XC-F, XCF-W 2007
wh
ye
gn
re ye
bu
bl ye
bl
bu
I
gn
re
D
ye-bl
re-wh
re-bl
bu-wh
br
C
bl-wh
br
wh
re-wh
re-bl
wh br
pick up
G
generator
main harness 594.11.075.100 Repair manual KTM 250 -F
headlight
ye-bl
08.04.2006
stop button
generator
yellow-black
red-black
black
red-white
G
7
6
3
green red
brown blue-white 5
11 10
12 1 3 1 4
3
I
2
C D
1
2
1
C_AM/3 C_AR/3
throttle position sensor
12-7
i g n i t i on c o i l
250 SX-F 2008
CDI harness 594.39.032.100
pick up
12-8
stop switch
start button
battery
start relay
light switch
handle bar switch (optional)
starter motor
10 A
wh-re
ye-re
wh-re
ye-re ye
wh
re bu wh
regulator-rectifier
br
br ye-re
U
ye
br ye-re bl
wh
cooling fan
ye-bl
bl
ye-re
speed sensor
br
br
multi-func.-digital-speedometer
br
black
M
wh br
3 TPS
ignition coil
wiring diagramm Art.-No. 3.206.063-E
250 XC-F, XCF-W 2008
wh
ye
gn
re ye
bu
bl ye
bl
I
bu
gn
re-bl
re
D
ye-bl
re-wh
br
bu-wh
C
bl-wh
br
wh
re-wh
re-bl
wh br
pick up
G
generator
main harness 594.11.075.100 CDI harness 594.39.032.100
Repair manual KTM 250 -F
headlight
ye-bl
rear light/brakelight
v
battery
start relay high/low beam switch horn switch stop button
start button
flasher switch
handle bar switch (optional)
starter motor
10 A
M flasher relay C_AF/4
G
ye-re
wh-re
C_BK/4 C_BR/4
3 2 1
bl
4
ye-re
1
ye-bl
2
or
ye-re
3
bl
1
or
horn
re
2
pu
C _B T / 3
C_AH2/2
C _ BA 1 / 1
ye-bl
br
br -b l
2
br
cooling fan C _ B S/ 2
bl
ye-re ye
4 3
wh
2
2 1
ye-re
bl
2
ye-re
1
1
U
C_CE/4
ye-re
3
br
1
br
C_CA/4
regulator-rectifier ye-re
rear brake switch
br
br
2
ye
1
1
re
wh
wh
bu
gn
4 3
bu
re
5
2
br
C_DB/4
C_DA/4 C_CY/3
C_CZ/3 C_CX/2
C_CW/2
multi-func.-digital-speedometer
2
6 4
wh-re
C_BG/3
C_AC/6
3
br
C_BC/6
bl
black
4 3 C_BA2/1
C_BF1/1
speed sensor C _ B V/ 2
1
ye-re
C_BO/2
2
br
flasher control lamp
C _ A K/ 2 C_AH/2
br
C_CX/2
1 2
bl
C_CW/2
ye
bl
wh-gn
1 2
pu
rig h t re a r flas he r
2
br
wh-gn
2
1
wh
3
1 2
br ye-bl
right front flasher
C_BF/1
bl C_BA/1
C_CX2/2
C_CW2/2
wh-gn
C _ B S/ 2
y e -b l
C_BV/2
br pu
1 2
1
wh
2 1
C_AM/3
C_A L /2
C_AR/3
C_A T /2
3 TPS
ignition coil
pick up
wiri ng diagram
2 1
left rear flasher
G
generator
left front flasher
250 EXC-F 2008
br pu
C_CX1/2
C_ A T 1 / 2 C _A L 1 / 2
I
D
C C_CX3/2
C_CW3/2
2 1
2
C_CW1/2
1
C_CR1/1
2
gn
3
re ye
bu
6 11 10 12 13 14
bl
ye
7
bl
5
bu
ye-bl
re-wh
4
gn
gr
2
re-bl
br
1
re
bu-wh
bu-wh
br
2.1
ye
wh
C_CR/1
3
re-wh
C_ E I/ 1
re-bl
C_EH/1
br
licence plate lamp
wh
1
gn
4
C_DI/2
bu
1
bl-wh
C_BP/4
C_DG/4
headlight
2
br
gr
2.2 2.1
C_BU/18
12-9
rear light/ brake light
3
pu
C_BG/3
bl
C_AJ/3
1 C_AJ1/3
ye
1
br
2
C_AH1/2
C_AK1/2
br
C_BG1/3
bu
front brake switch
driving light lamp
v
main harness 594.11.075.150 CDI harness 780.39.032.000
12-10
Cable colours
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
bl: black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple
12-11 2009
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-12
12-13 2009
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-14
12-15 2009
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-16
12-17 2009
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-18
12-19 2010
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-20
12-21 2010
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-22
12-23 2010
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-24
12-25 2010
Repair manual KTM 250 -F
Art.-No. 3.206.063-E
12-26
SHOCK ABSORBER2005-2010 WP PDS 5018 MCC
WP PDS 5018 DCC, SXS
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Shock absorber
5018 PDS 2003 Introduction Exploded view Disassembly shock absorber Disassembly tube side Disassembly MCC Assembling MCC Assembling Tube side Disassembly piston-rod side Diassembly adaptor DU-bush Assembling adaptor DU-bush Assembling piston-rod side Assembling shock absorber Bleeding On pressure with nitrogen Mounting spring Adjustment
2 3 4 13 33 39 44 53 63 67 70 81 87 92 95 98 1
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Introduction General notice Pay attention to the following notes, when you are working with WP suspension products as described in this workshop manual: Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension. These tools with a unique “T” number (available at WP Suspension) protect you from damaging the parts. Always use aluminium protector-plates, when clamping our products or parts in the vice. Always replace damaged or worn parts.
Shock absorber 5018 PDS 2003
05/2002
Clean all parts before assembling. Caution: Many times it is necesarry to assemble parts with T131, T132 and T163. These parts must dry for at least four hours!!
We r k p l a a t s h a n d b o e k
2
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Exploded view
3
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassembly Shock absorber Take note of the rebound (REB) position. Fully closed is turning the adjustment screw (“+”) clockwise.
MCC MCC = Mono Compression Control
Shock absorber 5018 PDS 2003
05/2002
Take note of the compression (COM) position. Fully closed is turning the adjustment screw (“+”) clockwise.
DCC DCC = Dual Compression Control Take note of the compression Low-Speed position. We r k p l a a t s h a n d b o e k Fully closed is turning the adjustment screw clockwise.
4
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
DCC Take note of the compression High-Speed position. Fully closed is turning the hexagonal (size 17) screw clockwise.
Shock absorber 5018 PDS 2003
05/2002
Measure the length of the spring. Spring preload.
Unscrew the Allen bolt (size 4).
We r k p l a a t s h a n d b o e k
5
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Release the spring preload with open spanner T106.
Shock absorber 5018 PDS 2003
05/2002
Screw the screw retainer against the lock retainer.
Disassemble the spring retainer and springring.
We r k p l a a t s h a n d b o e k
6
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the washer.
Shock absorber 5018 PDS 2003
05/2002
Remove the spring. Pay attention to the assembling direction!!!
Remove the second washer.
We r k p l a a t s h a n d b o e k
7
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Spring with washers, spring retainer and springring.
We r k p l a a t s h a n d b o e k
8
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassemble the rubber cap.
Shock absorber 5018 PDS 2003
05/2002
Unscrew slowly the nitrogen plug (size 4) to release the pressure.
Nitrogen plug with O-ring.
We r k p l a a t s h a n d b o e k
9
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Tap the cap from the tube.
Shock absorber 5018 PDS 2003
05/2002
1. Place disassembling bush T1216 on the adaptor DU-bush.
2.
We r k p l a a t s h a n d b o e k
10
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Push the adaptor DU-bush downwards.
Shock absorber 5018 PDS 2003
05/2002
Disassemble the springring out of the tube.
Springring.
We r k p l a a t s h a n d b o e k
11
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Pull carefully but firmly the piston-rod “complete” out of the tube.
Push with depth-stop T107S the separation piston downwards.
We r k p l a a t s h a n d b o e k
12
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassembly tube-side Drain the oil out the tube.
Shock absorber 5018 PDS 2003
05/2002
Clamp the tube side in the vice.
Remove the springring out of the groove and slide it a little bit downwards.
We r k p l a a t s h a n d b o e k
13
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Slide the guiding bush downwards.
Shock absorber 5018 PDS 2003
05/2002
Remove the upper springring.
Remove the guiding bush. Pay attention to the assembling direction!!! We r k p l a a t s h a n d b o e k
14
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the springring.
Shock absorber 5018 PDS 2003
05/2002
Spring guiding bush with the two springrings.
We r k p l a a t s h a n d b o e k
15
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the screw-retainer of the tube.
Shock absorber 5018 PDS 2003
05/2002
Screw-retainer with the Allen bolt.
We r k p l a a t s h a n d b o e k
16
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Unscrew the screw-cap of the MCC (size 24) (DCC also size 24)
Shock absorber 5018 PDS 2003
05/2002
Remove the screw-cap.
Remove the washer inside the screwcap, or on top of the spring inside the bottom. We r k p l a a t s h a n d b o e k
17
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the spring.
Shock absorber 5018 PDS 2003
05/2002
Pull the damping holder “cpl” out of the bottom.
Srew-cap with adjustment needle, spring and the MCC damping holder “cpl”. We r k p l a a t s h a n d b o e k
18
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Heat the lock retainer.
Shock absorber 5018 PDS 2003
05/2002
Unscrew the lock retainer with open spanner T1233.
Screw the lock retainer of the bottom.
We r k p l a a t s h a n d b o e k
19
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Heat the bottom near the tube.
Shock absorber 5018 PDS 2003
05/2002
Use slide-spanner T146 with bush T1201.
Unscrew the tube.
We r k p l a a t s h a n d b o e k
20
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Screw the tube out of the bottom.
Shock absorber 5018 PDS 2003
05/2002
Screw the lock retainer of the tube.
Tube with lock retainer.
We r k p l a a t s h a n d b o e k
21
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassemble the O-ring out of the groove inside the bottom.
Shock absorber 5018 PDS 2003
05/2002
Place dis- / assembling tool T145S on top of the screw-cap
Place pin spanner T125S onto T145S.
We r k p l a a t s h a n d b o e k
22
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Heat the reservoir near the bottom.
Shock absorber 5018 PDS 2003
05/2002
Unscrew the screw-cap.
Turn the reservoir from the bottom.
We r k p l a a t s h a n d b o e k
23
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the O-ring.
Shock absorber 5018 PDS 2003
05/2002
Bottom “cpl” with both O-rings.
We r k p l a a t s h a n d b o e k
24
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Pay attention to the assembling direction!!! Push the separation piston out of the reservoir.
Shock absorber 5018 PDS 2003
05/2002
Separation piston.
Disassemble the O-ring.
We r k p l a a t s h a n d b o e k
25
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Separation piston, piston ring and O-ring.
We r k p l a a t s h a n d b o e k
26
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Clamp the bottom in the vice.
Shock absorber 5018 PDS 2003
05/2002
Use disassembling tool T120 for disassembling the adaptor bushes.
Tap the adaptor bush out of the heimjoint.
We r k p l a a t s h a n d b o e k
27
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the seal.
Shock absorber 5018 PDS 2003
05/2002
Disassemble the springring.
Tap the other adaptor bush out of the heim-joint.
We r k p l a a t s h a n d b o e k
28
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Use Dis- / assembling tool T1207S for disassembling the heim-joint.
Shock absorber 5018 PDS 2003
05/2002
Press the heim-joint out of the bottom at the side were the springring is removed.
Adaptor bushes, seals, springrings and heim-joint.
We r k p l a a t s h a n d b o e k
29
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Replace one springring.
Shock absorber 5018 PDS 2003
05/2002
Assemble the heim-joint with the bevelled edge into the direction of the bottom with assembling tool T1206.
Press the heim-joint into the bottom with support of the vice.
We r k p l a a t s h a n d b o e k
30
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Press with T1207(A) the heim-joint against the springring.
Shock absorber 5018 PDS 2003
05/2002
Assemble the springring into the groove.
Replace the seals.
We r k p l a a t s h a n d b o e k
31
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
1. Assemble the adaptor bushes with support of T1206.
Shock absorber 5018 PDS 2003
05/2002
2.
We r k p l a a t s h a n d b o e k
32
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassembly MCC There is a separated workshop manual for the DCC. ----------------------------------------------------Damping holder MCC.
Shock absorber 5018 PDS 2003
05/2002
Remove the disk. Pay attention to the assembling direction!!!
Clamp the damping holder with clamping block T1202S. Not too tight!
We r k p l a a t s h a n d b o e k
33
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Unscrew the nut (size 10).
Shock absorber 5018 PDS 2003
05/2002
Turn the nut of.
Remove the piston with check-valve.
We r k p l a a t s h a n d b o e k
34
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Piston with the check-valve side.
Shock absorber 5018 PDS 2003
05/2002
Compression side.
Damping holder with shims (setting).
We r k p l a a t s h a n d b o e k
35
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the shims of the damping holder. Pay attention to the assembling order and direction!!!
Shock absorber 5018 PDS 2003
05/2002
- Nut M6 - piston with check-valve - setting (shims) - damping holder - disk.
We r k p l a a t s h a n d b o e k
36
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the O-ring of the screw-cap.
Shock absorber 5018 PDS 2003
05/2002
Turn clockwise the adjustment needle out of the screw-cap.
Adjustment needle “complete”.
We r k p l a a t s h a n d b o e k
37
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
- Steel ball - spring - adjustment needle with O-ring - screw-cap - O-ring
We r k p l a a t s h a n d b o e k
38
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assembling MCC Assemble the spring and steel ball, and grease, also the O-ring, these with water proof grease T159.
Shock absorber 5018 PDS 2003
05/2002
Assemble the O-ring.
Assemble the needle.
We r k p l a a t s h a n d b o e k
39
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the needle fully open.
Shock absorber 5018 PDS 2003
05/2002
Replace the setting and piston with the check-valve
Wet the thread of the nut with Loctite 2701 (T132) and turn the nut on the holder. We r k p l a a t s h a n d b o e k
40
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Tighten the nut to a torque of 6Nm.
Shock absorber 5018 PDS 2003
05/2002
Replace the disk.
We r k p l a a t s h a n d b o e k
41
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assembling tube side Assemble the O-ring on the bottom.
Shock absorber 5018 PDS 2003
05/2002
Assemble the O-ring inside the bottom.
Grease the O-ring groove of the separation piston with O-ring grease T158. We r k p l a a t s h a n d b o e k
42
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the O-ring.
Shock absorber 5018 PDS 2003
05/2002
Grease the O-ring with T158.
Pay attention to the groove of the nitrogen reservoir.
We r k p l a a t s h a n d b o e k “groove”.
43
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
1. Assemble the separation piston and piston ring with the hollow surface into the reservoir at the groove side.
Shock absorber 5018 PDS 2003
05/2002
2.
Push the separation piston into the reservoir.
We r k p l a a t s h a n d b o e k
44
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Wet the thread of the bottom with T132.
Shock absorber 5018 PDS 2003
05/2002
Wet the thread of the reservoir with T132 on both sides.
Wet the thread of the screw-cap.
We r k p l a a t s h a n d b o e k
45
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the reservoir with screw-cap on the bottom.
Shock absorber 5018 PDS 2003
05/2002
Tighten the reservoir wit T125S and T145S.
Wet the thread inside the bottom with T132.
We r k p l a a t s h a n d b o e k
46
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the lock retainer as far as possible onto the tube.
Shock absorber 5018 PDS 2003
05/2002
Wet the thread of the tube with T132.
Turn the tube into the bottom.
We r k p l a a t s h a n d b o e k
47
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Tighten the tube with T146 and T1201.
Shock absorber 5018 PDS 2003
05/2002
Screw the lock retainer against the bottom and tighten it with T1233.
Turn the screw spring retainer onto the tube and...
We r k p l a a t s h a n d b o e k
48
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
...completely downwards.
Shock absorber 5018 PDS 2003
05/2002
Assemble the springring passed the groove of the tube.
Slide the spring guide onto the tube.
We r k p l a a t s h a n d b o e k
49
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the first springring into the groove.
Shock absorber 5018 PDS 2003
05/2002
Slide the guiding bush over the springring.
Assemble the second springring.
We r k p l a a t s h a n d b o e k
50
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Wet the O-ring of the piston MCC with T158.
Shock absorber 5018 PDS 2003
05/2002
Assemble the damping holder MCC “cpl” into the housing of the bottom.
Assemble the spring.
We r k p l a a t s h a n d b o e k
51
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Place the ring into the screw-cap.
Shock absorber 5018 PDS 2003
05/2002
Turn the screw-cap into the bottom.
Tighten the screw-cap.
We r k p l a a t s h a n d b o e k
52
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassembly piston-rod side
Shock absorber 5018 PDS 2003
05/2002
Clamp the piston-rod “cpl” in the vice.
Unscrew the nut (size 22)
We r k p l a a t s h a n d b o e k
53
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn off the nut.
Shock absorber 5018 PDS 2003
05/2002
Place a screwdriver on top of the pistonrod and lift the entire assembly onto the screwdriver.
- Rebound bush plane - compression setting 1 (shims) - piston 1 - rebound setting 1 (shims) - intermediate bush We r k p l a a t s h a n d b o e k - compression setting 2 (shims) - piston 2 - rebound setting 2 (shims) - piston-rod nut.
54
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the adaptor DU-bush.
Shock absorber 5018 PDS 2003
05/2002
Remove the cap.
Remove the bump rubber.
We r k p l a a t s h a n d b o e k
55
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Clamp the mounting-fork in the vice.
Shock absorber 5018 PDS 2003
05/2002
Unscrew the screw-cap of the rebound adjustment (size 15).
Turn the screw-cap out of the mountingfork.
We r k p l a a t s h a n d b o e k
56
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
1. Turn the rebound adjustment needle anti clockwise out of the mounting-fork.
Shock absorber 5018 PDS 2003
05/2002
2.
Rebound adjustment needle with the screw-cap.
We r k p l a a t s h a n d b o e k
57
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
1. Push the rubber plug out of the mounting-fork.
Shock absorber 5018 PDS 2003
05/2002
2.
Push with an pin (d2) on top of the pistonrod the rebound needle out of the pistonrod. We r k p l a a t s h a n d b o e k
58
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Take the rebound needle out.
Shock absorber 5018 PDS 2003
05/2002
Rebound needle.
Clamp the mounting-fork in the vice and unscrew the locking nut (size 24).
We r k p l a a t s h a n d b o e k
59
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Clamp the piston-rod in clamping block T1202S.
Shock absorber 5018 PDS 2003
05/2002
Heat de mounting-fork.
Unscrew the mounting-fork.
We r k p l a a t s h a n d b o e k
60
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the mounting-fork of the piston-rod.
Shock absorber 5018 PDS 2003
05/2002
Turn the nut of the piston-rod.
Push with een Allenkey (size 5) the rebound tube out of the piston-rod.
We r k p l a a t s h a n d b o e k
61
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Piston-rod and rebound tube “cpl”.
We r k p l a a t s h a n d b o e k
62
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Disassembly adaptor DU-bush Adaptor DU-bush.
Shock absorber 5018 PDS 2003
05/2002
1. Lift the rebound spring out of the adaptor.
2.
We r k p l a a t s h a n d b o e k
63
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Remove the steel washer. Pay attention to the back-up ring in the washer.
Shock absorber 5018 PDS 2003
05/2002
Remove the quad ring.
Remove the second back-up ring.
We r k p l a a t s h a n d b o e k
64
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Lift the dirt scraper out of the adaptor.
Shock absorber 5018 PDS 2003
05/2002
Disassemble the O-ring.
Dis- / assembling tool T1504, adaptor and support bush T1209.
We r k p l a a t s h a n d b o e k
65
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Press the DU-bush out of the adaptor.
We r k p l a a t s h a n d b o e k
66
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assembling adaptor DU-bush Press the DU-bush into the adaptor with T1504 and T1209.
Shock absorber 5018 PDS 2003
05/2002
Calibrate the DU-bush with the calibration thorn T1205. Important: wet the thorn with oil before the calibration.
Press the dirt scraper into the adaptor with assembling bush T1204.
We r k p l a a t s h a n d b o e k
67
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the first the back-up ring and then the quad ring into the adaptor.
Shock absorber 5018 PDS 2003
05/2002
Replace the steel disk with the back-up ring.
Assemble the rebound spring with support of T1209.
We r k p l a a t s h a n d b o e k
68
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the O-ring.
Shock absorber 5018 PDS 2003
05/2002
Grease the O-ring with T158.
We r k p l a a t s h a n d b o e k
69
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assembling piston-rod side Turn the lock nut on the piston-rod.
Shock absorber 5018 PDS 2003
05/2002
Grease the O-ring of the rebound tube with T158.
Assemble the tube into the piston-rod.
We r k p l a a t s h a n d b o e k
70
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Wet the thread of the piston-rod with T132.
Shock absorber 5018 PDS 2003
05/2002
Turn the mounting-fork on the pistonrod.
Tighten the mounting-fork.
We r k p l a a t s h a n d b o e k
71
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the lock nut against the mountingfork.
Shock absorber 5018 PDS 2003
05/2002
Tighten the nut.
1. Place assembling tool T1215 on top of the piston-rod.
We r k p l a a t s h a n d b o e k
72
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
2.
Shock absorber 5018 PDS 2003
05/2002
Assemble the bump rubber.
Replace the cap.
We r k p l a a t s h a n d b o e k
73
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Replace carefully the adaptor DU-bush.
Shock absorber 5018 PDS 2003
05/2002
Replace the entire damping package.
Pay attention to the first shim, this one must be centered on the ring.
We r k p l a a t s h a n d b o e k
74
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Grease the thread of the piston-rod with a little bit of T158.
Shock absorber 5018 PDS 2003
05/2002
Turn the nut on the piston-rod.
Turn the nut just so far so that the pistons can still be turned.
We r k p l a a t s h a n d b o e k
75
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Place the center sleeve T1214...
Shock absorber 5018 PDS 2003
05/2002
...over both pistons and adaptor DU-bush.
Place T107S through T1214, intermediate bush and piston rod.
We r k p l a a t s h a n d b o e k
76
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Tighten the piston-rod nut to a torque of 40Nm.
Shock absorber 5018 PDS 2003
05/2002
Check if you can lift the shim.
Grease the O-ring of the rebound needle with T158.
We r k p l a a t s h a n d b o e k
77
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the needle into the piston-rod.
Shock absorber 5018 PDS 2003
05/2002
Push the needle further.
Grease the O-ring and steel ball of the rebound adjustment needle with T159.
We r k p l a a t s h a n d b o e k
78
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Screw the adjustment needle into the mounting-fork.
Shock absorber 5018 PDS 2003
05/2002
Turn de rebound screw-cap into the mounting-fork.
Tighten the screw-cap.
We r k p l a a t s h a n d b o e k
79
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn the adjustment completely open.
Shock absorber 5018 PDS 2003
05/2002
Push the needle downwards.
Assemble the rubber plug.
We r k p l a a t s h a n d b o e k
80
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assembling shock absorber Turn the compression adjustment fully open. (DCC High and Low-speed)
Shock absorber 5018 PDS 2003
05/2002
Fill the tube with oil, just under the springring groove inside the tube.
Place plunger T1210S into the tube.
We r k p l a a t s h a n d b o e k
81
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Push the plunger downwards.
Shock absorber 5018 PDS 2003
05/2002
Push with T107S the separation piston in the reservoir as far as possible.
Slide the O-ring of T107S against the screw-cap.
We r k p l a a t s h a n d b o e k
82
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Push again with T1210S.
Shock absorber 5018 PDS 2003
05/2002
Push with T107S the separation piston...
...to the correct position, the O-ring of T107S must have a distance of about 10mm from the screw-cap. We r k p l a a t s h a n d b o e k
83
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Fill oil till 10mm under the groove.
Shock absorber 5018 PDS 2003
05/2002
Close the compression adjustment. (DCC Low-speed)
Push both pistons under the oil.
We r k p l a a t s h a n d b o e k
84
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Open the compression adjustment.
Shock absorber 5018 PDS 2003
05/2002
Push the adaptor DU-bush just under the O-ring groove.
We r k p l a a t s h a n d b o e k
85
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the springring.
Shock absorber 5018 PDS 2003
05/2002
Pull the piston-rod fully out.
Tap the cap into the tube.
We r k p l a a t s h a n d b o e k
86
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Bleeding Clamp “not too tight” the shock absorber in the vice like picture.
Shock absorber 5018 PDS 2003
05/2002
1. Unscrew the screw-cap and remove the entire MCC.
2.
We r k p l a a t s h a n d b o e k
87
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Turn adaptor T1502S of the air release bottle T144S into the MCC (DCC) housing of the bottom.
Shock absorber 5018 PDS 2003
05/2002
Ensure that there is sufficient oil in the bottle.
Hold the bottle up so that the oil wil flow into the shock absorber.
We r k p l a a t s h a n d b o e k
88
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Push the piston rod slowly completely inwards.
Shock absorber 5018 PDS 2003
05/2002
And out. Repeat those handlings several times.
Cant the shock absorber several times.
We r k p l a a t s h a n d b o e k
89
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Repeat all the handling till all air is out of the shock absorber.
Shock absorber 5018 PDS 2003
05/2002
Push the separation piston to the correct position.
Remove the adaptor.
We r k p l a a t s h a n d b o e k
90
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Assemble the MCC (DCC).
We r k p l a a t s h a n d b o e k
91
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
On pressure with nitrogen Turn the nitrogen plug with O-ring several turns into the screw-cap of the reservoir
Shock absorber 5018 PDS 2003
05/2002
Nitrogen charging device T170S.
We r k p l a a t s h a n d b o e k
92
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Place the shock absorber in T170S and open de tap for about 20 seconds.
Shock absorber 5018 PDS 2003
05/2002
Close the nitrogen plug.
Close the tap.
We r k p l a a t s h a n d b o e k
93
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003
05/2002
Assemble the rubber cap.
We r k p l a a t s h a n d b o e k
94
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assembling spring Assemble the washer.
Shock absorber 5018 PDS 2003
05/2002
Assemble the spring.
We r k p l a a t s h a n d b o e k
95
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Assemble the second washer.
Shock absorber 5018 PDS 2003
05/2002
Assemble the spring retainer.
Assemble the springring.
We r k p l a a t s h a n d b o e k
96
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Adjust the spring...
Shock absorber 5018 PDS 2003
05/2002
...to the correct preload.
Tighten the bolt to a torque of 5Nm.
We r k p l a a t s h a n d b o e k
97
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Adjustment Turn the mounting-fork to the correct position.
Shock absorber 5018 PDS 2003
05/2002
Compression position (MCC)!
Compression Low-speed position (DCC)!
We r k p l a a t s h a n d b o e k
98
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling
Compression High-Speed position (DCC)!
Shock absorber 5018 PDS 2003
05/2002
Rebound position!
We r k p l a a t s h a n d b o e k
99
REPAIRMANUAL2005-2010 WP SHOCK ABSORBER 5018 DCC 5018 SXS 5018 SMR REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION
ART.NO.: 3.211.208-E
MANUAL DE REPARACIÓN
1 SPECIAL TOOLS 2 GENERAL INFORMATION 3 DISASSEMBLING AND ASSEMBLING THE SHOCK ABSORBER 4 5 6 7 8 9 10 11 12 13 14 15 16
INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work.
WARNING
STRICT COMPLIANCE WITH THESE INSTRUCTIONS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB. !
CAUTION
IS
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC ! „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM/WP SPARE PARTS when replacing parts. The KTM high performance shock absorber is only able to meet user expectations if the maintenance work is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications, colors, materials, services offered and rendered, and the like so as to adapt them to local conditions without previous announcement and without giving reasons, or to cancel any of the above items without substituting them with others. It shall be acceptable to stop manufacturing a certain model without previous announcement. In the event of such modifications, please ask your local KTM dealer for information. KTM Sportmotorcycle AG 5230 Mattighofen, Austria All design and assembly modification rights reserved. C by KTM SPORTMOTORCYCLE AG, AUSTRIA
All rights reserved
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349. NOTE to table: – Enter the complete item no. for the repair manual in column 1 (e.g.: 3.211.208-E). You will find the number on the cover page or in the left margin on each right page of the manual. – Enter the corresponding page number in the repair manual (e.g.: 2-3) in column 2. – Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible. – Enter the correct text in column 4. Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual
Page
Current text
Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman
Company/work shop
1-1
SPECIAL TOOLS
Workshop Manual WP 5018 DCC with SXS/SMR
Art.Nr.: 3.211.208-E
INDEX
T 107S DEPTH STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 120 DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 125S PIN WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 132 LOCTITE 2701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 145S DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 146 DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 152 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 158 O-RING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 159 WATER-RESISTANT GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 170S1 NITROGEN FILLING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 625 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1201 BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1202S CLAMPING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1204 MOUNTING TOOL FOR DUST BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1205 CALIBRATION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1206 MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 1207S DISMOUNTING/MOUNTING TOOL (A+B) . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 1208 DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 1209 DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 1214 CENTERING BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 1215 MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 1216 DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 1218 ADJUSTING WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 1233 HOOK WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 1240S VACUUM FILLING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 14031 DISMOUNTING/MOUNTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1
1-2 T 107S Depth Stop
T 120 Dismounting/mounting tool
Art.Nr.: 3.211.208-E
T 125S Pin wrench
T 132
Workshop Manual WP 5018 DCC with SXS/SMR
Loctite 2701
T 145S Dismounting/mounting tool
1-3 T 146 Dismounting/mounting tool
T 152 Lubricant
T 158 O-Ring Grease
T 159 Water-resistant grease
T 170S1 Nitrogen Filling Device
1-4 T 625 Lubricant
T 1201 Bushing
Art.Nr.: 3.211.208-E
T 1202S Clamping Blocks
T 1204
Workshop Manual WP 5018 DCC with SXS/SMR
Mounting tool for dust boot
T 1205 Calibration pin
1-5 T 1206 Mounting tool
T 1207S Dismounting/mounting tool (A+B)
T 1208 Dismounting/mounting tool
T 1209 Dismounting/mounting tool
T 1214 Centering bushing
1-6 T 1215 Mounting tool
T 1216 Dismounting/mounting tool
Art.Nr.: 3.211.208-E
T 1218 Adjusting wrench
T 1233
Workshop Manual WP 5018 DCC with SXS/SMR
Hook Wrench
T 1240S Vacuum filling device
1-7 T 14031 Dismounting/mounting tool
2-1
GENERAL INFORMATION INDEX
EXPLODED VIEW PDS 5018 DCC 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 EXPLODED VIEW PDS 5018 DCC 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 EXPLODED VIEW PDS 5018 SXS/SMR 2005/2006 . . . . . . . . . . . . . . . . . . . . . . .2-6 EXPLODED VIEW PDS 5018 SXS 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 NOTE: UPDATED SETTING LISTS ARE AVAILABLE AT KTM-DEALER.NET.
Workshop Manual WP 5018 DCC with SXS/SMR
Art.Nr.: 3.211.208-E
ADJUSTING THE POSITION OF THE COMPRESSION AND REBOUND DAMPING . . .2-10 ADJUSTING THE SPRING PRELOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 RECOMMENDED PERIODIC MAINTENANCE INTERVALS PDS 5018 DCC 2006/07 . . . . . . . . . . . . . . . . . . . . . . . .SEE KTM-REPAIR MANUAL PDS 5018 SXS/SMR 2005-2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2
2-2 Exploded view PDS 5018 DCC 2006
8 2 5 4 3 bm bn bo bp bq bl bs bt # ck # cl
6
4 3
5 1 cp bl cq cr dq cs dr ct ek dk dl dr dm em eo dl en
jt
Reparatur-Kit Repair-Kit Parts with
#
ep eq
hk
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dp
gk
es et fk
gl
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ho gm
hn hp # hq # hp #
fm fl gn eq er # go fo fs gp gq fq
ik #
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js
hl
ht # il #
ip iq is jl
jk jr jp jo jm jq jn
Workshop Manual WP 5018 DCC with SXS/SMR
Art.No.: 3.211.208-E
2-3 Item 1 2 3 4 5 6 8 11 12 13 14 15 16 18 19 20 21 25 26 27 28 29 30 31 32 35 36 37 40 42 43 44 45 46 47 48 48 48 48 48 48 49 50 50 50 50 50 50 50 50 50 50 51 52 54 54 54 54 54 54 54
Description Upper shock absorber case DCC (dual compression control) Distance bushing 12x24 Seal ring D=25 Lock ring Bearing Bleeder screw O-ring 48x2 WP Caution (PDS KTM) Reservoir O-ring 41x5 Dividing piston Piston ring 3.9x1.5x156 Reservoir cap O-ring 5.28x1.78 Plug Rubber cap "Do not open" O-ring 52x2 Shim 16x8.2x0.6 Needle Screw cap Lock ring Pipe Circlip Spring guide Adjusting ring AH screw Spacer Spring Spring ring Spring retainer O-ring 66.27x3.53 Piston rod nut O-ring 44.17x1.78 Piston ring Spacer plate Shim 16x30x0.20 Shim 16x32x0.20 Shim 16x34x0.20 Shim 16x36x0.20 Shim 16x21x1 Piston 6+6x3.5/4.5 Spacer plate 16x21x0.30 Spacer plate 16x22x0.30 Shim 16x23x0.30 Shim 16x40x0.25 Shim 16x30x0.30 Shim 16x32x0.30 Shim 16x34x0.30 Shim 16x36x0.30 Shim 16x38x0.30 Shim 16x40x0.30 Holder D=16 M16x1 L=48 Spacer plate D=23 D=16 H3 Spacer plate 16x20x0.30 Shim 16x28x0.15 Shim 16x30x0.20 Shim 16x28x0.20 Shim 16x32x0.20 Shim 16x34x0.20 Shim 16x36x0.25
56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 57 58 60 61 62 63 64 65 66 70 71 72 73 74 75 76 79 80 81 85 86 87 88 90 91 92 93 94 95 96 97 98 99
Shim 16x34x0.15 Shim 16x34x0.20 Shim 16x36x0.20 Shim 16x38x0.20 Shim 16x40x0.20 Shim 16x42x0.20 Shim 16x44x0.20 Shim 16x28x0.25 Shim 16x30x0.25 Shim 16x32x0.25 Shim 16x34x0.25 Shim 16x36x0.25 Shim 16x38x0.25 Shim 16x44x0.25 Shim 16x40x0.25 Shim 16x42x0.25 Shim for rebound damping D=34; H=8 Piston 6+6x7/4.5 Vb 1.0 Piston rod Bushing M8x1 O-ring 7x1.5 Needle seat Pipe O-ring 8x2 Tube adapter Needle O-ring 2.2x1.6 Adaptor Steel washer 18.5x43.7x6 Rebound rubber Safety ring 22.55x1.5 Quad seal ring 18x2.62 O-ring 41x5 bush Dust boot Lock ring Cover Rubber buffer plug Nut Fork part Threaded bushing Rubber plug Steel ball Spring Reservoir cap O-ring 4x1.5 Adjusting screw Shock absorber oil Seal ring repair kit 5018 PDS
2-4 Exploded view PDS 5018 DCC 2007
2
jt #8
4 3 5 bm
js
64 5 3
Reparatur-Kit Repair-Kit Teile mit Parts with
#
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bt# ck # cl dl
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dm dp
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SIEHE SETTING LISTE SEE SETTING LIST
dq dr
jk
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jq jp jn
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fl fm SIEHE SETTING LISTE SEE SETTING LIST
ek
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SIEHE SETTING LISTE SEE SETTING LIST
SIEHE SETTING LISTE SEE SETTING LIST
dr en
hn hp# ik# ht#
eo em
fr
jr jo jm
Workshop Manual WP 5018 DCC with SXS/SMR
Art.No.: 3.211.208-E
2-5 Item 1 2 3 4 5 6 8 12 19 20 21 31 32 35 36 37 40 42 43 44 45 46 47 49 51 52 57 58 70 71 72 73 74 75 76 79 80 81 85 86 87 90 91 92 93 94 95 96 97 98 99
Description Upper shock absorber case DCC (dual compression control) Distance bushing Seal ring Lock ring Bearing Bleeder screw WP Caution (PDS KTM) O-ring Plug Rubber cap "Do not open" Circlip (not for SX) Spring guide (not for SX) Adjusting ring AH screw Spacer Spring Spring ring Spring retainer O-ring Piston rod nut O-ring Piston ring Piston Holder Spacer plate Shim for rebound damping Piston Needle O-ring Adaptor Steel washer Rebound rubber Safety ring Quad seal ring O-ring Bush Dust boot Lock ring Cover Rubber buffer plug Fork part Threaded bushing Rubber plug Steel ball Spring Reservoir cap O-ring Adjusting screw Shock absorber oil Seal ring repair kit 5018 PDS
2-6 Exploded view PDS 5018 SXS/SMR 2005/2006
2-7
Workshop Manual WP 5018 DCC with SXS/SMR
Art.No.: 3.211.208-E
Part list SXS/SMR 2006 Pos. Pieces 40 50 60 90 100 110 140 150 180 200 220 230 240 260 270 280 290 320 330 350 360 370 380 400 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830
Part description
Part number
Bump rubber Reservoir cap Rebound disc Piston 6+6x7/4,5 O-ring 44,17x1,78 Piston ring Piston rod nut Support disc Piston Piston rod nut Sleeve Tube Lock washer tube Circlip Spring guide Circlip DCC complete Wp Caution (PDS Ktm) Circlip Stainl.steel Bleed plug O-ring 5,28x1,78 Nitrogen plug Interm. ring screw spring ret. Interm. ring screw spring ret. Circlip Ball-steel Spring Mount.f.adapt. O-ring Reservoir cap Reb. Rubber plug Mount Adj.screw reb. Dust seal O-ring Adaptor Bush Backup ring Quad ring Backup ring Disc steel Rebound rubber Piston rod Needle guiding O-ring O-ring Nut Needle Tap piston rod Oil seal Adaptor bush O-ring Heim joint O-ring Lock washer Shock absorber housing Allen screw M5x30 Spring ret. (adjust) Separation piston O-ring Piston rin Reservoir Reservoir cap O-ring O-ring Spring ret.
5018.0480 5018.0473 5018.0483 5018.0197 5018.0099 5018.0135 5018.0496 5018.0477 5018.0476 5018.0470 5018.0469 5018.0467 5018.0241 5018.0133 5018.0081 5018.0133 5018.0213S6 5200.0041 5018.0126 5018.0095 4681.0893 3612.0151 5018.0114 5018.0114 5018.0273 4054.0603 4860.0028 5018.0105 5018.0222 5018.7039 5018.0297 5018.0502 5018.0434 5018.0082 5018.0103 5018.0435 4618.0119 5018.0102 5018.0101 5018.0102 5018.0113 5018.0107 5018.0471 5018.0482 4681.0339 4618.0018 5018.0481 5018.0478 5018.0472 4618.0003 4618.0007 4681.0016 5018.0005 5018.0097 5018.0168 5018.0468 5018.0327 5018.0474 4618.0002 4618.0014 4618.0015 5018.0479 5018.0236 4681.0016 5018.0352 5018.0319
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1
2-8 Exploded view PDS 5018 SXS 2007
2-9
Workshop Manual WP 5018 DCC with SXS/SMR
Art.No.: 3.211.208-E
Pos. 10 20 30 40 50 60 90 100 110 140 150 170 180 190 210 220 230 231 240 250 270 290 300 310 320 330 410
Part description Mount Adaptor Shock absorber housing Bump rubber Reservoir cap Rebound disc Piston O-ring Piston ring Support disc Adaptor Piston O-ring Piston ring Piston rod nut Spring ret. DCC complete HS DCC complete LS Circlip Stainl.steel Nitrogen plug Interm. ring screw spring ret. Spring ret. Circlip Needle O-ring O-ring O-ring
Part number 5018.0583S1 5018.0435S1 5018.0581S1 5018.0480 5018.0580 5018.0516 5018.0197 5018.0099 5018.0135 5018.0578 5018.0510 5018.0446 5018.0099 5018.0135 5018.0141 5018.0582S 5018.0586S1 5018.0590S 5018.0126 3612.0151 5018.0114 5018.0463 5018.0273 5018.0513 4681.1265 5018.0352 4681.0893
Pieces 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2-10 Adjusting the position of the compression and rebound damping Rebound damping: – Turn in the adjusting screw 1 in a clockwise direction all the way to the stop. – Turn back the respective number of clicks in a counterclockwise direction.
1
Compression damping, low speed: – Turn in the adjusting screw 2 in a clockwise direction all the way to the stop. – Turn back the respective number of clicks in a counterclockwise direction.
2 3
2
Compression damping, high speed: – Turn in the adjusting screw 3 in a clockwise direction all the way to the stop. – Turn back the respective number of clicks in a counterclockwise direction.
3
Adjusting the spring preload
4
NOTE: the spring preload is the difference between the unloaded and preloaded length of the spring. – Tighten the adjusting nut 4 with the special tool T106 until you have the prescribed spring preload. – Tighten the lock screw on the adjusting nut.
Recommended periodic maintenance and inspection
30 hours 200 liter
40 hours 260 liter
50 hours 325 liter
60 hours 400 liter
70 hours 455 liter
80 hours 520 liter
90 hours 600 liter
100 hours 665 liter
Check the bearing in the shock absorber top / replace if necessary Check the piston rod on scratches / leakage Check the static sag - before riding Check the spring Check the bump rubber Check the O-ring of the spring retainer / replace if necessary Complete maintenance of the shock absorber
20 hours 130 liter
A 100 liter fuel consumption is equivalent to approx. 15 operating hours
10 hours 65 liter
of the 5018 SXS/SMR Shock absorber
z
z
z
z z
z
z
z
z z
z
z
z
z z
z z z
z z z z
z z
3-1
DISASSEMBLING AND ASSEMBLING THE SHOCK ABSORBER
Workshop Manual WP 5018 DCC with SXS/SMR
Art.Nr.: 3.211.208-E
INDEX
DISASSEMBLING THE SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 DISASSEMBLING THE TUBE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 DISASSEMBLING ADAPTOR BUSHES AND HEIM JOINT . . . . . . . . . . . . . . . . . . . .3-9 DISASSEMBLING THE NITROGEN RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 ASSEMBLING THE NITROGEN RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 ASSEMBLING THE TUBE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 ASSEMBLING ADAPTOR BUSHES AND HEIM JOINT . . . . . . . . . . . . . . . . . . . . . .3-13 MOUNTING THE RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 INSPECTION OF THE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 MOUNTING THE PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 MOUNTING THE DCC MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 ASSEMBLING THE SHOCK ABSORBER BODY . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 FILLING THE SHOCK ABSORBER BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 DISASSEMBLING THE PISTON ROD (DOES NOT APPLY TO SXS/SMR) . . . . . . . . .3-17 DISASSEMBLING THE PISTON ROD (FOR SXS/SMR ONLY) . . . . . . . . . . . . . . . .3-19 INSPECTION OF THE PISTON ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 ASSEMBLING PISTON ROD SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 DISASSEMBLING ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 ASSEMBLING ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 CHECKING THE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 CONTINUING TO ASSEMBLE THE PISTON ROD (DOES NOT APPLY TO SXS/SMR) . .3-34 CONTINUING TO ASSEMBLE THE PISTON ROD (APPLIES TO SXS/SMR ONLY) . . .3-36 ASSEMBLING THE SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37 EVACUATING AND FILLING THE SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . .3-38 ON PRESSURE WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 ASSEMBLING THE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
3
3-2 Disassembling the shock absorber – Unscrew the Allen bolt 1 of the spring retainer (Size 5). – Place the shock absorber in the vice according to the picture.
1
– Screw the spring retainer 2 downwards.
3
– Push the spring retainer 3 downwards so that you are able to remove the springring 4.
2
Art.Nr.: 3.211.208-E
– Disassemble the spring ring.
4
– Remove the spring retainer 5.
Workshop Manual WP 5018 DCC with SXS/SMR
5
– Disassemble the O-ring out of spring retainer.
3-3 – Remove the washer.
– Remove the spring. – Remove the second washer 1.
1 – – – – –
4 2 1
Lock washer 5 Spring 4 Spring retainer 3 O-Ring 2 Washers 1
3 5 – Disassemble the rubber plug 6 “do not open” out of the screw cap of the nitrogen reservoir. NOTE: the SXS/SMR shock absorber does not have a rubber cap.
6 7
– Slowly loosen the nitrogen filling plug 7 (Size 4). This will cause the nitrogen pressure to build up. – Pay attention to the O-ring of the nitrogen filling plug.
3-4 – Unscrew the oil filling plug for about two turns. (size 5) This wil help you later by removing the piston rod “complete” out of the shock absorber!
– Tap the cap 1 from the tube.
1
Art.Nr.: 3.211.208-E
– Place disassembling bush T 1216 2 on the adaptor and push the adaptor downwards.
2
Workshop Manual WP 5018 DCC with SXS/SMR
– Disassemble the spring ring 3 out of the groove of the tube.
3 – Pull careful but firmly the piston rod “complete” out of the tube. NOTE: usually takes a great deal of effort
3-5 Disassembling the tube side – Drain the oil out of the tube.
– Clamp the tube side in the vice according to the picture.
– Remove the spring ring 1 out of the groove and slide it downwards. – Slide the guiding bush 2 downwards.
3
– Remove the upper spring ring 3.
2
– Remove the guiding bush. – Remove the springring. NOTE: does not apply to the 2007 SX/SXS models (no spring guide used).
1
– Turn the screw retainer 4 of the tube.
4
3-6 All models accept SXS 2007: – Clamp the tube side in the vice according to the picture.
1
– Unscrew the screw cap 1 of the DCC out of the shock absorber housing (size 24). NOTE: DDC = Dual Compression Control. – Remove the screw cap 1.
2 4 3
– Pull the DCC mechanism 2 out of the shock absorber housing.
5
SXS 2007: – Clamp the tube side in a vise as shown in the photo (use protective jaws). – Loosen and remove both compression controls with T 1218 3. NOTE: the LS compression control 4 is completely removed, the HS compression control 5 by individual parts (see photo below).
Art.Nr.: 3.211.208-E
Individual HS compression control parts: - HS compression control 5 - Cage 6 - Washers 7 - Spring 8 - Spring alignment 9 - Compression damping piston bk
bk 9 8 7 6 5 Workshop Manual WP 5018 DCC with SXS/SMR
– Turn the oil filling plug bl out of the shock absorber housing (AH, Größe 5).
bl
NOTE: since only assemblies are available for shock absorbers starting with the 2007 model, no further disassembly is necessary. – Remove the sticker bm.
bm
3-7 – Heat the shock absorber housing 1 near the tube.
1 – Unscrew the lock ring several turns with T 1233 2.
2
– Clean the tube with brake cleaner. – Heat the shock absorber housing near the tube. – Unscrew the tube out of the bottom with slide-spanner T 146 and bush T 1201.
– Screw the tube out of the shock absorber housing.
– SXS/SMR models only: tap sleeve 3 out of the pipe
3
3-8 – Remove the O-ring 1 inside the shock absorber housing out of the groove.
1
2
NOTE: only when you want to disassemble the screw cap of the nitrogen reservoir 2! – Heat the nitrogen reservoir near the screw cap.
Art.Nr.: 3.211.208-E
– Place T 145S 3 on the screw cap.
3
– Place T 125S 4 on T 145S and unscrew the nitrogen reservoir.
Workshop Manual WP 5018 DCC with SXS/SMR
– Remove the O-ring.
4
3-9 Disassembling adaptor bushes and heim joint
1
– Clamp the shock absorber housing in the vice. – Use Disassembling tool T 120 1 for disassembling the adaptor bushes.
– Tap the adaptor bush out of the heim joint.
– Remove the seal 2.
2 – Tap the other adaptor bush out of the shock absorber housing and remove the seal.
– Use dis- / assambling tool T 1207S (A+B) 3.
3
3-10 – Press the heim joint against the springring.
– Disassemble the springring 1.
1
Art.Nr.: 3.211.208-E
– Press the heim joint out of the shock absorber housing.
Workshop Manual WP 5018 DCC with SXS/SMR
– Disassemble the other spring ring 2.
2
– Individual parts of the heim joint.
3-11 Disassembling the nitrogen reservoir – Push the dividing piston 1 out of the reservoir 2.
2
1
– Remove the piston ring 3. – Remove the O-ring 4 out of the groove of the separation piston.
4 3 Assembling the nitrogen reservoir – Check the inner side of the nitrogen reservoir for scratches.
– Apply the groove of the separation. – Assemble the O-ring in the groove. – Apply the O-ring with T 158.
– Apply the running surface of the nitrogen reservoir with a little bit of T158. –
Assemble the separation piston.
NOTE: the reservoir has an identification groove that must be mounted facing the shock absorber housing. – Push the separation piston further into the nitrogen reservoir.
3-12 Assembling the tube side – Clean the thread of the nitrogen reservoir.
– Place the new O-ring 1 in the groove of the shock absorber housing.
1
Workshop Manual WP 5018 DCC with SXS/SMR
Art.Nr.: 3.211.208-E
– Assemble the O-ring 2 inside the groove of the shock absorber housing.
2
3
NOTE: the SXS/SMR shock absorber does not have the needle 3.
3-13 Assembling adaptor bushes and heim joint – Place the spring ring 1 in the shock absorber housing.
1
– Assemble the heim joint 2 with the bevelled edge into the direction of the shock absorber housing with assembling tool T 1206 3.
3 2 – Press the heim joint into the shock absorber housing.
– Press with T 1207(A) the heim joint 4 against the spring ring.
4 – Assemble the spring ring 5.
5
3-14 – Assemble both seals 1.
1 – Assemble one adaptor bush with support of T 1206 2 in the heim joint. – Press the other adaptor bush with support of the vice in the heim joint.
2 Mounting the reservoir Art.Nr.: 3.211.208-E
– Wet the thread of the shock absorber housing with T 132.
Workshop Manual WP 5018 DCC with SXS/SMR
– Screw the nitrogen reservoir on the shock absorber housing and tighten it with T 145S 3 and T 125S 4.
3
4
3-15 Inspection of the tube – Inspect the running surface of the tube. If necessarry polish the running surface with sandpaper 600.
– Measure the inner diameter at both ends and in the center of the pipe. The maximum diameter is: 50,12mm
Mounting the pipe – Screw the lock ring 1 as far as possible on the thread or the tube. – Wet the thread of the tube with T 132.
1 SXS/SMR shock absorber only: – Mount the sleeve 2.
2 – Screw the tube into the shock absorber housing. – Tighten the tube with T 146 and T 1201.
3-16 – Screw the lock ring 1 against the shock absorber housing and tighten it with T 1233.
1 Mounting the DCC mechanism
2
4
Art.Nr.: 3.211.208-E
3
All models accept SXS 2007: – Wet the O-ring 2 with T 158. – Place the DCC mechansm 3 in the shock absorber housing. – Turn the screw cap 4 in the the shock absorber housing. – Tighten the screw cap to a torque of 50 Nm.
SXS 2007: – Apply T 158 to the O-ring and mount the compression damping piston 5. – Slip on the spring alignment 6, see photo.
7
6
– Position the cage 7 on the HS compression control 8.
5
8
Workshop Manual WP 5018 DCC with SXS/SMR
– Position the spring 9 on the spring alignment, mount the HS compression control 8 with the cage, making sure it is correctly seated.
9
8 Assembling the shock absorber body – Screw the Allen bolt in the screw retainer bk and assemble the screw retainer on the tube.
bm
– Assemble the springring bl past the second groove.
bn bk
bl
– Assemble the guiding bush bm. – Assemble the spring ring bn in the upper groove of the tube. – Slide the guiding bush over the upper spring ring and place the second spring ring bl in the groove. NOTE: does not apply to the 2007 SX/SXS models (no spring guide used).
3-17 Filling the shock absorber body – Fill the tube till approximately 10 mm under the inner side spring ring groove of the tube. NOTE: only use the specified oil.
Disassembling the piston rod (also applies to SXS 2007 but not to SXS up to 2006/SMR)
1
2
– Untighten the piston rod nut 1 with spanner size 22 mm. – Remove the piston rod nut. – Remove the rebound setting 2.
– Remove the piston 3 (“piston 2”).
3
– Remove the compression setting 4.
4
– Untighten the piston rod tap 5 (Size 22).
5
6
– Screw the piston rod tap of the piston rod. – Remove the rebound setting 6.
– Remove the piston 7 (“piston 1”). – Remove the compression setting 8.
7
8
3-18 – Remove the rebound disc 1.
Workshop Manual WP 5018 DCC with SXS/SMR
Art.Nr.: 3.211.208-E
1
6
3
4 4 2 4
5
4 8 7 1
– – – – – – – –
Rebound disc 1 Piston 1 2 Piston 2 3 Settings 4 (rebound and compresion) Piston rod tap 5 Piston rod nut 6 Piston ring(s) 7 O-ring(s) 8
3-19 Disassembling the piston rod (for SXS up to 2006/SMR only) – Loosen the nut on the piston rod 1 with a 17 mm wrench.
1
2
– Remove the nut from the piston rod. – Remove the shims from the rebound 2. NOTE: the lower large shim is centered with a smaller shim
– Remove the piston ("piston 2") 3.
3
4
NOTE: the compression shims usually stick to the piston. – Remove the set of shims from the compression damping 4 together with the compression disk.
– Loosen and remove the adapter 5 (A/F 13).
5
– Loosen and remove the piston rod nut 6 (A/F 22).
6
– Remove the set of shims from the rebound 7. – Remove the piston ("piston 1") 8.
7
8
– Remove the set of shims from the compression 9. – Remove the rebound disk bk.
9
bk
3-20
7 254623
– – – – – – – – –
Piston rod nut A/F 17 1 Set of shims 2 (rebound and compression damping) Piston ("2") 3 Adapter 4 Piston rod nut A/F 22 5 Rebound disk 6 Piston ("1") 7 Piston ring 8 O-ring 9
98 216 2
Art.Nr.: 3.211.208-E
– Slide the adaptor bk from the piston rod.
bk
Workshop Manual WP 5018 DCC with SXS/SMR
– Remove the cap bl.
bl
– Remove the bump rubber bm.
bm
3-21 – Clamp the piston rod in the vice according to the picture.
– Unscrew the screw cap 1 of the rebound adjustment.
– Remove the screw cap 1.
1
– Turn anti clockwise the rebound adjustment screw 2 out of the mounting fork.
2
3-22 – Remove the rebound adjustment screw 1. – Pay attention to the steel balls 2 and spring 3.
1
– Parts of the rebound adjustment screw.
2
Art.Nr.: 3.211.208-E
3
2 – Push with a pin (size 2,5mm) the rebound adjustment needle 4 through the mounting fork out of the piston rod. – Pay attention to the rubber plug 5 of the mounting fork.
4 5
NOTE: further disassembly of the piston rod only applies to models for which individual parts are available (see exploded view).
Workshop Manual WP 5018 DCC with SXS/SMR
– Heat the top of piston rod according to the picture.
– Place Allen key (size 5) in the piston rod and unscrew the seat. NOTE: SXS/SMR with HH, A/F 13
3-23 – Remove the seat 1 - does not apply to SXS/SMR – Always assemble a new O-ring on the seat.
1
NOTE: since only assemblies are available for shock absorbers starting with the 2007 model, no further disassembly is necessary. – Heat the lock nut of the piston rod/mounting fork.
– Unscrew the lock nut, (Size 24)
– Clamp the piston rod in clamping block T 1202S.
– Heat the mounting fork.
3-24 – Untighten the mounting fork.
– Remove the mounting fork.
Art.Nr.: 3.211.208-E
– Brush the thread of the piston rod clean.
– Unscrew the lock nut.
Workshop Manual WP 5018 DCC with SXS/SMR
– Remove the lock nut.
3-25 – Disassemble the rebound adjustment tube - does not apply to SXS/SMR – Always assemble a new O-ring!
– Rebound adjustment tube. 1
1
Inspection of the piston rod – Replace the piston rod if you have inspect that the running surface of the.piston rod has scratches and or indentations. – Always replace also the bush of the adaptor.
– Place the V-blocks as far as possibble at the outside running surface of the piston rod! – Measure the diameter of the piston rod, rotate the piston rod 90° and measure the diameter again. – Repeat these measurements on several.places of the piston rod. The maximum diameter is: 17,98 mm The minimum diameter is: 17,94 mm
– Measure the straightness of the piston rod, rotate the piston rod 360°. The maximum travel is: 0,06 mm.
3-26 Assembling piston rod side – Clamp the piston rod in the clamping block T 1202S.
– Apply the new O-ring of the rebound adjustment tube 1 with T 158. NOTE: the shock absorber on SXS/SMR models does not have an adjusting pipe for the rebound damping.
1
Art.Nr.: 3.211.208-E
– Assemble the rebound adjustment tube in the piston rod.
Workshop Manual WP 5018 DCC with SXS/SMR
– Apply the O-ring of the reboundl adjustment needle 2 with T 158.
2 – Assemble the rebound adjustment needle in the piston rod.
3-27 – Screw the lock nut 1 on the piston rod. – Pay attention to the assembling direction! The rounded side 2 should face the center of the piston rod.
1
– Screw the lock nut fully on the thread of the piston rod.
– Wet the thread of the piston rod with T 132.
2
– Clamp the piston rod in T 1202S and screw the mounting fork on the piston rod – Tighten the mounting fork.
– Tighten the lock nut.
3 4
– Place the piston rod / mounting fork in the vice according to the picture. – Grease the O-ring 3 and steel balls 4 of the rebound needle with water proof grease T 159. – Assemble the rebound adjustment needle in the mounting fork.
3-28 – Screw the rebound adjustment needle in the mounting fork. – When you feel the clicks turn the rebound adjustment needle two turns further.
– Assemble the screw cap 1 of the rebound adjustment. – Tighten the screw cap.
1
Art.Nr.: 3.211.208-E
– Turn the rebound adjustment screw 2 anti clockwise fully open.
2
Workshop Manual WP 5018 DCC with SXS/SMR
– Push the rebound adjustment needle fully downwards.
– Apply the thread of the seat with T 132. – Grease the O-ring of the seat with T 158.
3-29 – Tighten the seat! (PDS 2006/07: AH 5 mm; SXS/SMR: A/F 13).
– Place assembling tool T 1215 1 on top of the piston rod.
1
– Assemble the bump rubber 2.
3 2
– Assemble the cap 3.
3-30 Disassembling adaptor NOTE: only applies to models for which individual parts are available (see exploded view).
1 2
– Lift the rebound rubber 1 out of the adaptor 2. – Remove the steel plate 3.
3 – Remove the back-up ring 4. – Remove the quad ring 5.
4
– Remove the second back-up ring.
5
Art.Nr.: 3.211.208-E
– Lift the dirt scraper 6 out of the adaptor. – Disassemble the O-ring 7 out of the groove of the adaptor.
6 7
Workshop Manual WP 5018 DCC with SXS/SMR
– Dis-/assembling tool T 1208 (up to model 2006) or T14031 (model 2007 on), adaptor and T 1209.
– Press the bush out of the adaptor.
3-31 Assembling adaptor – Press the bush into the adaptor with T 1208 (up to model 2006) or T14031 (model 2007 on) and T 1209. – Wet the calibration thorn with shock absorber oil! – Calibrate the bush with calibration thorn T 1205 with support of T 1209. – Press the calibration thorn completely through the bush.
– Press the dirt scraper with T 1204 into the adaptor.
– Assemble in correct order the back-up rings and quad ring!!! See disassembling.
– Assemble the steel plate 1.
1
– Assemble the rebound rubber 2. – Ensure that you can rotate the rebound rubber in the adaptor.
3-32 – Grease the groove of the adaptor with T 158.
1
– Assemble the O-ring 1. – Grease the inside lip of the dirt scraper 2 with T 625.
2 – Put special tool T 1215 onto the piston rod. – Slide carefully the adaptor 3 over the tool on the piston rod.
3
Art.Nr.: 3.211.208-E
Checking the parts – Inspect the surface of the rebound disc. – If necessarry polish the surface of the rebound disc with sandpaper 600 on a flat plate.
Workshop Manual WP 5018 DCC with SXS/SMR
– Always check the first shim that is assembled on the piston if it is not bended. If bended check the second shim and so on.
– Disassemble the piston ring and the O-ring of the piston. – Inspect the surface of the piston ring. – Replace the piston ring when you see through the surface a bronze color. Also replace the piston ring if the surface is feeling rough. The best way to do this is to compare it with a new one!
3-33 – Polish the surface of both sides of the pistons on a flat plate with sandpaper 600.
Pistons NOTE: – The "piston 1" and "piston 2" designations refer to assembling, i.e. the piston mounted on the piston rod first will be designated "piston 1". – Since pistons are mounted on the piston rod from above, "upper view" will refer to the side of the piston facing up after mounting before the respective set of shims is mounted.
1
3
2
–
1: Piston 1, upper view for PDS 5018 2006/07, not for SXS up to 2006/SMR
–
2: Piston 2, upper view for PDS 5018 2006/07, not for SXS up to 2006/SMR
–
3: Piston 1, lower view for PDS 5018 2006/07, not for SXS up to 2006/SMR
–
4: Piston 2, lower view for PDS 5018 2006/07, not for SXS up to 2006/SMR
4 –
5: Piston 1, upper view for PDS 5018 SXS up to 2006/SMR
–
6: Piston 2, upper view for PDS 5018 SXS up to 2006/SMR
–
7: Piston 1, lower view for PDS 5018 SXS up to 2006/SMR
–
8: Piston 2, lower view for PDS 5018 SXS up to 2006/SMR
5 6
7
8
3-34
2
Continuing to assemble the piston rod (also applies to SXS 2007 but not to SXS up to 2006/SMR) – Assemble the rebound disc 1. – Assemble the compression setting 2, mounting the shims with the smaller diameter first.
1
– Place the piston (“piston 1”) 3.
4
– Assemble the rebound setting 4, mounting the shims with the larger diameter first.
3
– Wet the thread of the piston rod with T 132. Art.Nr.: 3.211.208-E
5
NOTE: Screw the piston rod tap on the piston rod so far as that the piston can stil be rotate!
– Place the second compression setting 6, mounting the shims with the smaller diameter first.
6 Workshop Manual WP 5018 DCC with SXS/SMR
– Screw the piston rod tap 5 on the piston rod.
– Assemble the second piston (“piston 2”) 7.
7
– Assemble the second rebound setting 8, mounting the shims with the larger diameter first.
8
– Grease the thread of the piston rod tap with T 152.
3-35 – Screw the piston rod nut 1 with the collar downwards on the piston rod tap.
1
– Grease the O-ring 2 of the adaptor with T 158.
2 – Place center sleeve T 1214 3 over both pistons and push the adaptor 4 in the center sleeve.
4 3 – Tighten the piston rod nut to a torque of 40 Nm and remove the centering sleeve T 1214 again.
4
3-36 Continuing to assemble the piston rod (applies to SXS up to 2006/SMR only)
1
2
– Mount the rebound disk 1. – Mount the set of shims for the compression 2.
– Mount the piston ("piston 1") 3. – Mount the set of shims for the rebound damping 4.
Art.Nr.: 3.211.208-E
3
4
6 5
– Apply T 132 to the thread of the piston rod, screw on the nut (A/F 22) 5 and tighten to 40 Nm. – Apply T 132 to the thread of the adapter 6 and screw on.
Workshop Manual WP 5018 DCC with SXS/SMR
– Mount the set of shims for the compression damping 7 together with the compression damping disk.
7
8
– Mount the piston ("piston 2") 8.
– Mount the shims for the rebound damping 9.
9
bk
NOTE: the lower large shim is centered with a smaller shim. – Apply T 132 to the thread of the piston rod and screw on the piston rod nut. NOTE: mount the piston rod nut with the collar facing down. – Tighten the piston rod nut (A/F 17) bk to 25 Nm.
3-37 – Grease again the O-ring 1 of the adaptor with T 158.
1 – Assemble the rubber plug 2 into the mounting fork.
2
Assembling the shock absorber – Assemble the piston rod “complete” into the tube.
– Push the adaptor 3 beyond the springring groove of the tube.
3
3-38 – Assemble the spring ring 1 first with the closed side into the groove.
1
– Pull the piston rod “complete” fully out. – Tap the cap 2 with a plastic hammer in the tube.
2
Workshop Manual WP 5018 DCC with SXS/SMR
Art.Nr.: 3.211.208-E
Evacuating and filling the shock absorber
3
!
CAUTION
!
YOU START TO WORK WITH THE VACUUM/FILLING DEVICE, CAREFULLY READ THE INSTRUCTIONS PROVIDED IN CHAPTER 4 (OWNER'S MANUAL) TO AVOID MAKING ANY ERRORS WHEN FILLING THE SHOCK ABSORBER.
BEFORE
– Loosen all adjusting screws in a counterclockwise direction. – Screw the filling adapter 3 in the opening in the shock absorber, tighten by hand and attach to the connector on the vacuum filling device T 1240S.
3
– Hold the shock absorber as shown in the photo. The filling connection with the adapter must be in the highest position. DO
WARNING
NOT HOLD THE PISTON ROD SINCE IT WILL MOVE IN AND OUT DURING THE FILLING PROCESS.
3-39 1. Ventilation/filling process – Move the control levers into the positions shown in the photo.
5
6 4
1 2 3
3
NOTE: "External tank" control lever 1 to "Closed", "Damper" 2 to "Vacuum" and "Oil reservoir" 3 to "Vacuum". – Press the "On/Off" 4 switch to start the ventilation process. NOTE: – The pressure gauge 5 (bar) will drop below 0 bar (almost -1). – The vacuum gauge 6 (mbar) will drop to 4 mbar.
– As soon as the vacuum gauge 6 (mbar) reaches approx. 4 mbar, turn the "Oil reservoir" control lever 3 to "Equalize Pressure". NOTE: the pressure gauge 5 (bar) will rise to 0 bar.
– As soon as the pressure gauge 5 (bar) reaches 0 bar, turn the "Damper" control lever 2 to "Pressure".
2
NOTE: oil will be pumped into the shock absorber, the pressure gauge 5 (bar) will rise to approx. 3 bar; this value is preset (see Chapter 4).
– As soon as the pressure gauge 5 (bar) reaches approx. 3 bar, turn the "Damper" control lever 2 back to "Vacuum".
2
NOTE: the pressure gauge 5 (bar) will drop to 0 bar.
2. Ventilation/Filling process – As soon as the pressure gauge 5 (bar) reaches 0 bar, turn the "Oil reservoir" control lever 3 to "Vacuum".
3
NOTE: the vacuum gauge 6 (mbar) will drop to 8 mbar.
3
– As soon as the vacuum gauge 6 (mbar) reaches 8 mbar, turn the "Oil reservoir" control lever 3 to "Equalize Pressure". NOTE: the pressure gauge 5 (bar) will drop to 0 bar.
– As soon as the pressure gauge 5 (bar) reaches 0 bar, turn the "Damper" control lever 2 to "Pressure".
2
NOTE: oil will be pumped into the shock absorber, the pressure gauge 5 (bar) will rise to approx. 3 bar; this value is preset (see Chapter 5).
2
– As soon as the pressure gauge 5 (bar) reaches approx. 3 bar, turn the "Damper" control lever 2 to "Vacuum". NOTE: the pressure gauge 5 (bar) will drop to 0 bar. – As soon as the pressure gauge 5 (bar) reaches 0 bar, actuate the "On/Off" 4 switch. The shock absorber is filled.
3-40 – Adjust the O-ring 1 on the shaft of T 107S to 106mm.
1 – Push the separation piston with T 107S to the correct position, the O-ring must have a distance for about 10 mm from the screw cap.
Art.Nr.: 3.211.208-E
– Unscrew the adapter from the opening in the shock absorber.
– Screw the oil filling plug 2 in the shock absorber housing and tighten it.
Workshop Manual WP 5018 DCC with SXS/SMR
2
– Screw the nitrogen filling plug 3 with O-ring several turns in the screw cap of the nitrogen reservoir.
3
3-41 On pressure with nitrogen – Nitrogen charging device T 170S1. Adjust the nitrogen gas pressure to 10 - 11 bar.
– Place the shock absorber in the Nitrogen charging device and ensure that the Allen key is fitting in the nitrogen filling plug.
– Open the tap A for about 20 seconds.
A
– Close the nitrogen filling plug.
– Close the tap and pull the Allen key of the nitrogen charging device out of the nitrogen filling plug.
3-42 – Remove the shock absorber out of the nitrogen charging device.
– Place the rubber plug ‘do not open’.
Art.Nr.: 3.211.208-E
Assembling the spring – Place the washer 1. – Place the spring.
1 – Place the first washer 2.
Workshop Manual WP 5018 DCC with SXS/SMR
– Assemble the (new) O-ring 3 in the groove of the spring retainer 4.
2
3 4 – Place the spring retainer 4. – Place the spring ring 5 in the groove of the mounting fork.
4
5
3-43 – Adjust the spring to the correct spring preload as noticed before.
– Tighten the Allen bolt of the screw retainer to a torque of 5 Nm.
– Clean the nitrogen reservoir. – Assemble a new sticker.
– Set the shock absorber in the correct mounting position. NOTE: adjustments of the rebound and compression damping should be on the same side. – Move the rebound and compression damping adjustments in the right position.
FORKS2005-2010 WP 4860 MXMA/PA
WP 4860 MXMA CC
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
12_234
Frontfork
Frontfork 4860 MXMA 2003
05/2002
4860 MX Multi Adjuster 2003 Introduction Exploded view Disassembly forkleg Disassembly cartridge Disassembly compression holder Assembling compression holder Disassembly tap rebound Assembling tap rebound Assembling cartridge Assembling forkleg
1
2 3 4 17 21 24 27 31 34 37
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Introduction General notice: Pay attention to the following notes, when you are working with WP Suspension products as described in this workshop manual. Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension. These tools with a unique “T” number (available at WP Suspension) protect you from damaging the parts. Always use aluminium protector-plates, when clamping our products or parts in the vice. Always replace damaged or worn parts. Clean all parts before assembling.
Frontfork 4860 MXMA 2003
05/2002
Caution: Many times it is necesarry to assemble parts with T131, T132 and T163. These parts must dry for at least four hours!!
2
Workshop manual 4860 MXMA
Product Exploded View Disassembly & assembling
Frontfork 4860 MXMA 2003
05/2002
Exploded view
3
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Disassembly forkleg Note the rebound position by turning the knob to the right.
12_062
After removing the rubber cap. Note the compression position by turning the screw to the right.
05/2002
12_063
Frontfork 4860 MXMA 2003
Clamp the outer-tube in T1403S and unscrew the screw-cap PA with T103.
4
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards...
12_067
...and place open-end spanner (size 22) on the hydraulic stop.
05/2002
12_068
Frontfork 4860 MXMA 2003
Unscrew the screw-cap.
5
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove the screw-cap from the piston- rod.
12_070
Remove the preload spacers.
Frontfork 4860 MXMA 2003
05/2002
12_074
Pull the spring downwards and remove the spanner.
12_075
6
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove the spring.
12_076
Remove the adjustment tube with the O-ring.
Frontfork 4860 MXMA 2003
05/2002
12_089
7
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Drain the oil out the forkleg.
12_094
Clamp the axle-clamp in the vice so that the forkleg is at an angle of ±45 degrees.
Frontfork 4860 MXMA 2003
05/2002
12_095
Unscrew the compression holder out of the axle-clamp. (size 19) (when the cartridge is rotating with the holder, bend the piston- rod a little bit to the side)
12_096
8
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove holder compression. Caution: oil iscoming out the cartridge.
12_097
Disassemble the cartridge out the forkleg.
05/2002
12_098
Frontfork 4860 MXMA 2003
Disassemble the dust-wiper.
12_099
9
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Disassemble the circlip.
12_100
05/2002
Heat the outer-tube near the oilseal. (not too hot)
Frontfork 4860 MXMA 2003
Heat the outer-tube at this level..
10
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Pull with both hands the outer-tube from the inner-tube.
05/2002
Remove DU-bush inner-tube.
Frontfork 4860 MXMA 2003
1. Remove DU-bush.
11
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove DU-bush inner-tube.
Frontfork 4860 MXMA 2003
05/2002
Remove DU-bush outer-tube.
12
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove support ring.
12_105
Disassemble the oilseal. Pay attention to the assembling direction!!!
Frontfork 4860 MXMA 2003
05/2002
12_106
13
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove the circlip.
12_107
Remove the dust wiper.
Frontfork 4860 MXMA 2003
05/2002
12_108
14
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Heat the axle-clamp.
12_111
Use T1404S...
Frontfork 4860 MXMA 2003
05/2002
12_112
15
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
...and unscrew the inner-tube from the axle-clamp.
12_113
Remove the inner-tube.
Frontfork 4860 MXMA 2003
05/2002
12-114
Remove the O-ring out the groove of the axle-clamp.
12_115
16
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Disassembly cartridge 1. Clamp the tube with plug in the clamping-block (Tool T508S + T509).
12_116
2.
05/2002
12_117
Frontfork 4860 MXMA 2003
3.
12_118
17
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Unscrew the screw sleeve (size 22).
12_119
Turn the screw sleeve out of the tube.
Frontfork 4860 MXMA 2003
05/2002
12_120
Disassemble the piston-rod “complete”. Pay attention to the piston ring!!!
12_121
18
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Clamp the piston rod in T508S “not too tight” and unscrew the hydraulic stop from the piston-rod. 12_164
Remove the hydraulic stop.
Frontfork 4860 MXMA 2003
05/2002
12_165
19
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove the screw sleeve with spring retainer. 12_167
Disassemble the DU-bush with T507 and press it out the screw sleeve with support of the vice.
Frontfork 4860 MXMA 2003
05/2002
12_168
- Spring retainer - screw sleeve - DU-bush 12_169
20
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Disassembly holder compression Clamp the compression holder in the vice and unscrew the check-valve nut. (size 17) Version with a locking: remove the locking with a file.
12_124
Remove the check-valve nut.
Frontfork 4860 MXMA 2003
05/2002
12_125
Remove the check-valve spring. Pay attention to the assembling direction!!! 12_126
21
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove the check-valve shim.
12_127
Disassemble the compression piston with O-ring. Pay attention to the assembling direction!!!
Frontfork 4860 MXMA 2003
05/2002
12_128
Place a screwdriver on top of the holder and remove the entire shim packet.
12_129
22
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Disassemble the O-ring.
12_130
Remove the copper washer.
Frontfork 4860 MXMA 2003
05/2002
12_131
- Holder compression - copper washer - O-ring - shims compression - piston compression with Oring - shim check-valve - spring check-valve - nut check-valve
12_132
23
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assembling holder compression Replace copper washer.
12_133
Assemble the O-ring.
05/2002
12_134
Frontfork 4860 MXMA 2003
Replace the entire shim packet.
12_135
24
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Replace piston. Pay attention to the assembling direction!!! 12_136
Replace shim check-valve.
Frontfork 4860 MXMA 2003
05/2002
12_137
Replace spring check-valve. Pay attention to the assembling direction!!! 12_138
25
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Wetting the thread of the nut with T132 and tighten it...
12_140
...to a torque of 5Nm.
Frontfork 4860 MXMA 2003
05/2002
12_141
Check if the spring is correctly placed in the chamber of the nut.
12_142
26
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Disassembly tap rebound Clamp the piston-rod (at the level where the hydraulic stop is mounted) in T508S and unscrew the rebound tap. (Size 17) 12_143
Remove the rebound tap “complete”.
05/2002
12_144/ 145/146 posterize
Frontfork 4860 MXMA 2003
Remove the rebound spring.
12_147
27
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Pull the rebound needle with spring out of the tap rebound.
12_148
Check the O-ring.
Frontfork 4860 MXMA 2003
05/2002
12_149
Pay attention to the position of the triangular shims on the piston!!! Clamp the tap in the vice and unscrew the nut. (Size 10) Version with locking: Remove the locking with a file.
12_150
28
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove the nut. Pay attention to the assembling direction!!! 12_151
Place a screwdriver on top of the tap and remove the entire shim packet.
Frontfork 4860 MXMA 2003
05/2002
12_152
Remove piston rebound. Pay attention to the assembling direction!!! 12_153
29
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Remove check-valve shims.
12_154
Remove spring check-valve.
Frontfork 4860 MXMA 2003
05/2002
12_155
- Rebound adjustment needle with O-ring - spring - tap rebound - spring check-valve - shims check-valve - piston rebound - shims - nut M6x0.5
12_156
30
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assembling tap rebound Assemble the spring and shims checkvalve.
12_157
Assemble the piston rebound. Pay attention to the assembling direction!!!
Frontfork 4860 MXMA 2003
05/2002
12_158
Replace the shims. Pay attention to the position of the triangular shims on the piston!!! 12_159
31
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Wetting the thread of the nut with T132. Screw the nut on the tap...
12_160
...tighten the nut to a torque of 5 Nm.
Frontfork 4860 MXMA 2003
05/2002
12_161
Grease the O-ring of the adjustment needle with T158.
12_162
32
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Mount the needle with spring into the tap rebound.
Frontfork 4860 MXMA 2003
05/2002
12_163
33
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assembling cartridge Press with T507 the DU-bush into the screw sleeve.
12_171
Clamp the piston-rod in T508S. At the level where the hydraulic stop is mounted.
Frontfork 4860 MXMA 2003
05/2002
12_172
Wetting the thread with T131. And screw the tap in the piston-rod.
12_173
34
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Tighten the tap rebound.
12_174
Clamp the piston-rod “not too tight” in at the other side and replace the screw sleeve with spring retainer.
Frontfork 4860 MXMA 2003
05/2002
12_175
Screw the hydraulic stop “hand tight” to the end of the thread of the piston-rod.
12_176
35
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Clamp the tube with plug in the clamping block (T508S and T509) and assemble the piston-rod “cpl.” into the tube. Guide the piston ring!!!
12_177
Before assembling wet the thread of the screw sleeve with T131. Screw the screw sleeve into the tube.
05/2002
12_178
Frontfork 4860 MXMA 2003
Tighten the screw sleeve.
12_179
36
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assembling forkleg Replace a new O-ring in the groove of the axle-clamp.
12_180
Wetting the thread of the axle-clamp with T132.
Frontfork 4860 MXMA 2003
05/2002
12_181
Wetting the thread of the inner-tube with T132.
12_182
37
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assemble the inner-tube in the axleclamp.
12_183
Screw very tight the inner-tube with T503S / T1404S.
05/2002
12_184
Frontfork 4860 MXMA 2003
Apply the dust wiper with T511.
14_0007
38
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Place T1401 over the inner-tube and assemble the dust wiper.
14_0008
Replace the circlip.
Frontfork 4860 MXMA 2003
05/2002
14_0011
Apply the innerside of the oilseal with T511 and the outerside with frontfork oil.
14_0010
39
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assemble the oilseal. Pay attention to the assembling direction!!! 14_0012
Remove the tool and replace the support ring.
Frontfork 4860 MXMA 2003
05/2002
12_190
40
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Replace the DU-bush.
05/2002
Replace the tube.
Frontfork 4860 MXMA 2003
Replace the DU-bush.
41
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Replace the DU-bush on the inner-tube.
Frontfork 4860 MXMA 2003
05/2002
Slide carefully the outer-tube over the inner-tube.
42
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assemble with T1402S the DU-bush with the flat side- and...
12_194
...tap or push it into the outer-tube.
Frontfork 4860 MXMA 2003
05/2002
12_195
43
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Use the other side of T1402S...
12_196
...and tap the oilseal into the outer-tube.
Frontfork 4860 MXMA 2003
05/2002
12_197
Assemble the circlip into the groove of the outer-tube.
Important: Check this very carefully!!! 12_198
44
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assemble the dust wiper with T1402S.
12_199
Frontfork 4860 MXMA 2003
05/2002
Place the cartridge into the forkleg.
Apply the O-ring of the compression piston with frontfork oil.
12_202
45
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Assemble the cartridge in the center of the axle-clamp and tighten the holder compression to a torque of 25Nm. 12_203
Assemble the adjustment tube with the O-ring into the piston-rod.
Frontfork 4860 MXMA 2003
05/2002
12_204
46
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Keep the outer-tube down and the piston- rod a little bit extended (like picture), fill the forkleg with oil till the edge of the outer-tube, wait a few moments, you will see air bubbles rising up. The oil must stay above the 4 holes of the inner-tube, if necesarry fill some extra oil in the forkleg.
12_206
Move the piston-rod (keep the adjustment tube on his place) several times up and down till you feel that the cartridge is full with oil, (the damping is smooth over the entire stroke) mostly it is necesarry to fill some (not too much) extra oil in the forkleg. Now compress the piston-rod and outertube fully down, and fill the forkleg with oil till about 25mm under the 4 holes of the inner-tube. Move the piston-rod and the outer-tube at the same time several times up and down over the entire stroke.
Frontfork 4860 MXMA 2003
05/2002
12_208
Push the piston-rod and outer-tube fully down and adjust the oil level (airchamber) with T137S. 12_209
47
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Pull the piston-rod out and assemble the spring.
12_211
Pull the spring downwards and place open-end spanner 22 on the hydraulic stop.
Frontfork 4860 MXMA 2003
05/2002
12_212
Replace first the steel washer on the spring, then the preload spacer(s).
12_213
48
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Screw handtight the screw-cap on the piston-rod.
Frontfork 4860 MXMA 2003
05/2002
Screw down the screw-cap, till the hydr. stop is against the screw-cap and tighten it to a torque of 25Nm.
49
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Pull the spring downwards and remove the spanner.
05/2002
Tighten the screw-cap with T103.
Frontfork 4860 MXMA 2003
Position rebound!
50
Workshop manual 4860 MXMA
Product Exploded View Disassembly & Assembling
Position compression! And replace the rubber cap.
Frontfork 4860 MXMA 2003
05/2002
12_226
51
REPAIRMANUAL2005-2010 WP FORK 4860 MXMA CLOSED CARTRIDGE REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION
ART.NR.: 3.211.199-E
MANUAL DE REPARACIÓN
1 SPECIAL TOOLS 2 GENERAL INFORMATION 3 DISMOUNTING/MOUNTING THE FORK 4 DISASSEMBLING AND ASSEMBLING THE FORK 5 6 7 8 9 10 11 12 13 14 15 16
INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work.
WARNING
STRICT COMPLIANCE WITH THESE INSTRUCTIONS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB. !
CAUTION
IS
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC ! „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM/WP SPARE PARTS when replacing parts. The KTM high performance fork is only able to meet user expectations if the maintenance work is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications, colors, materials, services offered and rendered, and the like so as to adapt them to local conditions without previous announcement and without giving reasons, or to cancel any of the above items without substituting them with others. It shall be acceptable to stop manufacturing a certain model without previous announcement. In the event of such modifications, please ask your local KTM dealer for information. KTM Sportmotorcycle AG 5230 Mattighofen, Austria All design and assembly modification rights reserved. C by KTM SPORTMOTORCYCLE AG, AUSTRIA
All rights reserved
REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349. NOTE to table: – Enter the complete item no. for the repair manual in column 1 (e.g.: 3.211.199-E). You will find the number on the cover page or in the left margin on each right page of the manual. – Enter the corresponding page number in the repair manual (e.g.: 4-7) in column 2. – Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible. – Enter the correct text in column 4. Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual
Page
Current text
Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman
Company/work shop
1-1
SPECIAL TOOLS
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
INDEX
T 103 PIN SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 131 LOCTITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 132 LOCTITE 2701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 137S SQUEEZE BOTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 158 O-RING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 T 159 WATER PROOF GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 511 GREASE FOR SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 605 PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 1240S VACUUM FILLING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 1401 SEAL ASSEMBLING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 T 1402S ASSEMBLING TOOL SEAL AND DU-BUSH . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1403S CLAMPING-BLOCK 48/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 1404 PIN SPANNER INNER-TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 14.015S CLAMPING BLOCK 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 14.016S CLAMPING BLOCK 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 T 14.017 SPANNER 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 14.018 SPANNER SCREW-CAP MEMBRANE HOLDER . . . . . . . . . . . . . . . . . . . .1-5 T 14.019 CHARGING DEVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 14.020 SUPPORT TOOL DIS- / ASSEMBLING CLOSED CARTRIDGE . . . . . . . . . . .1-5 T 14.021 CALIBRATE MANDREL DU-BUSH 12 . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 T 14.022 DIS- / ASSEMBLING TOOL DU-BUSH 12 . . . . . . . . . . . . . . . . . . . . . . .1-6 T 14.023 THREADED BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 14.024 SUPPORT BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 14.025 ASSEMBLING TOOL OIL SEAL SCREW SLEEVE . . . . . . . . . . . . . . . . . . .1-6 T 14.029 MOUNTING BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 T 14.030 ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 T 14.033 ASSEMBLING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1
1-2 T 103 Pin spanner
T 131 Loctite 243
T 132 Art.No.: 3.211.199-E
Loctite 2701
T 137S
Repair manual WP Fork “Closed Cartridge”
Squeeze bottle
T 158 O-Ring grease
1-3 T 159 Water proof grease
T 511
Grease for seals
T 605 Pin
T 1240S Vacuum filling device
T 1401 Assembling tool for seal
1-4 T 1402S Assembling tool seal and DU-bush
T 1403S
Clamping-block 48/60
T 1404 Art.No.: 3.211.199-E
Pin spanner inner-tube
T 14.015S
Repair manual WP Fork “Closed Cartridge”
Clamping block 27
T 14.016S Clamping block 12
1-5 T 14.017 Spanner 50
T 14.018
Spanner screw-cap membrane holder
T 14.019 Charging device tool
T 14.020 Support tool dis-/assembling closed cartridge.
T 14.021 Calibrate mandrel DU-bush
1-6 T 14.022 Dis-/assembling tool DU-bush
T 14.023 Threaded bush
T 14.024 Art.No.: 3.211.199-E
Support bush
T 14.025
Repair manual WP Fork “Closed Cartridge”
Assembling tool oil seal screw sleeve
T 14.029 Mounting bush
1-7 T 14.030 Adaptor
T 14.033 Assembling tool
2-1
GENERAL INFORMATION
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
INDEX
EXPLODED VIEW SXS 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 PART LIST SXS 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 EXPLODED VIEW SXS 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 PART LIST SXS 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 EXPLODED VIEW SX 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 PART LIST SX 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 EXPLODED VIEW SXS 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 PART LIST SXS 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 ADJUSTING THE POSITION OF THE COMPRESSION AND REBOUND DAMPING . . .2-10 EXPLANATION OF THE SPRING PRELOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 BLEEDER SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 RECOMMENDED PERIODICAL MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . .2-12
2
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
2-2
Exploded view SXS 2005
2-3 Part list SXS 2005 Pos. 9 10 11 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 91 92 93 94 95 120 180
Part description Ball-steel d3 Inner-tube SXS’05 d48 L595 Ti Lock washer SB58 Lock nut M6x1 Cil.head screw Support ring d50xd57.6x1.5 Oil seal washer d4 Outer-tube 54/60 L577 Screw cap Tube d35xD 37.5 Screw sleeve M24.5x1 DU-bush d47xd49x20 DDL02 DU-bush d48xd52x12 DDL02 DU-bush d14xd12x10 DDL02 Rubber plug O-ring N.B.R. 24x2 O-ring N.B.R. 38x2 O-ring N.B.R. 261.5 O-ring N.B.R. 48x2 O-ring N.B.R. 17x2 O-ring N.B.R. 21x2 O-ring N.B.R. 46x2 Rubber cap O-ring N.B.R. 2x1.5 O-ring N.B.R. 6x1.2 O-ring N.B.R. 9.5x1.5 O-ring Viton 7x1.5 O-ring N.B.R. 4x1.5 Bush d10x3 Axle-clamp Ma brake KTM SXR “03 Axle-clamp MA ri KTM SXR “03 Oil seal d12xd22x9.5 Bolt with flange M 8x25 Holder adj. tube d4 L=18 Adj. screw 1.8 Retainer Ring d10.8 Needle bleed adj. Bolt M20x1 L33 Tap compression d2.5 ‘03 Check valve ring Piston rod tap rebound Spring rebound adj. C=4N/mm Shuttle valve spring C0.4 Lo=8 Lock washer d20 Rebound spring L33.5 d=13 c=11 Lock washer d30 Membrane CC Piston rod d12 M9x1 L405 Oil seal d48xd57.8x9.5 ‘03 Dust stripper d48 d58.4 x11.8 Spring d2.9 L6.5 Check valve spring th 0.7 Adj. Tube L=371 Adj. tube L=85 Hydr.stop d28 Guiding ring D44.2xs39.3 Ring D42.4x6.5 Ring D23.45x2.65 Support ring D37.5 Plug G1/8 Clamping disc Check valve holder L=7 Piston ring 5x1x68 Spacer 43x35x2.5 Spacer 43x35x5 Spacer 43x35x1.5 Contra nut M12x1 SLW17 Washer 32x42x2.5 Tube d23 L417 CC Piston rod d12 L117 Adaptor guiding bush Washer copper 20.5x26x1 Membrane holder cpl. Adj.screw M5 Spring d=3.9 C=1.1N/mm Lo=8mm Pin valve O-ring Viton 1.5 x 1 Piston rebound bleed 1.2 Piston compression
Art. No. 4054.0603. 4860.0439. 4860.0070. 4860.0441. 4860.0443. 4860.0013. 4860.0440. 4860.0244 4860.0284. 4860.0468. 4860.0470. 4860.0428. 4860.0429. 4860.0430. 1508.0017. 3548.0320. 4054.0037. 4054.0230. 4681.0016. 4681.0811. 4681.1499. 4860.0048. 4860.0141. 4860.0298. 4860.0299. 4860.0301. 5018.0157. 5018.0222. 4054.0497. 4860.0465. 4860.0466. 4860.0471. 5060.0113. 4860.0271. 4860.0272. 4860.0273. 4860.0277. 4860.0280. 4860.0282. 4860.0297. 4860.0450. 4860.0444. 4860.0382. 4860.0446. 4860.0447. 4860.0448. 4860.0281. 4860.0464. 4860.0347. 4860.0400. 4860.0490. 4860.0202. 4860.0269. 4860.0274. 4860.0286. 4860.0294. 4860.0295. 4860.0296. 4860.0304. 4860.0452. 4860.0453. 4860.0454. 4860.0455. 4860.0456. 4860.0457. 4860.0458. 4860.0459. 4860.0460. 4860.0461. 4860.0462. 4860.0463. 4860.0275. 4860.0476. 4860.0472. 4860.0473. 4860.0474. 4681.1351. 4860.0489. 4860.0047.
Pcs 2 1 1 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 1 1 1 1 2 2 2 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
2-4
Exploded view SXS 2006
2-5 Part list SXS 2006 Pos. 10 20 50 60 70 80 90 100 110 120 130 140 160 190 200 210 220 230 240 260 270 280 290 300 310 320 330 340 350 360 370 390 400 410 430 440 450 460 470 490 500 510 520 530 540 550 560 580 590 600 630 710 720 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 900 910 920 930 940 950 960 965 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 1080
Part description Dust stripper Oil seal Inner-tube Hydr.stop Support ring DU-bush DU-bush Lock washer Outer-tube Check valve ring O-ring Shuttle valve spring Piston rebound bleed Lock nut Needle bleed adj. O-ring Spring rebound adj. Piston rod Contra nut Ring Spring guide Rebound spring Tube Piston ring Ring Adaptor guiding bush Tube Support ring Guiding ring Cap Lock washer Tap compression O-Ring Shim Piston compression O-ring Check valve Check valve spring Check valve holder Clamping disc Membrane Fork oil Oil seal washer Bleeder screw O-ring Plug Spring Washer Spacer Adj.tube Rubber cap Axle-clamp O-ring Screw sleeve Oil seal O-ring DU-bush Membrane holder cpl. Bolt O-ring Spring O-ring O-ring Lock washer O-ring Needle bleed adj. Lock nut Piston rod O-Ring Screw cap Adj. screw Ball-steel Spring O-ring Rubber plug Oil seal washer Cil.head screw O-ring Bolt Adj. screw Ball-steel Spring O-ring Holder adj. tube Retainer ring O-ring O-ring Washer copper
Part number 4860.0400 4860.0347 4860.0550 4860.0521 4860.0013 4860.0429 4860.0428 4860.0070 4860.0539E 4860.0513 4860.0299 4860.0382 4860.0489 4054.0486 4860.0277 4860.0298 4860.0444 4860.0531 4860.0459 4860.0296 4860.0525 4860.0511 4860.0461 4860.0455 4860.0295 4860.0463 4860.0468 4860.0304 4860.0294 4860.0297 4860.0446 4860.0509 4860.0299 4054.0414 4860.0047 4681.1499 4860.0061 4860.0202 4860.0163 4860.0514 4860.0281 4860.0401 5018.0222 4860.0527 5018.0222 4860.0542 9141.0052 4860.0552 4860.0456 4860.0533 4860.0141 4860.0545 4860.0048 4860.0546 4860.0471 4681.1499 4860.0430 4860.0548 4860.0518 4860.0541 4860.0540 4681.0340 4054.0230 4860.0448 4860.0298 4860.0506 4860.0276 4860.0516 4860.0301 4860.0532 4860.0523 4054.0603 4860.0522 5018.0222 1508.0017 5018.0222 4860.0526 4014.0024 4860.0280 4860.0523 4054.0603 4860.0522 5018.0222 4860.0271 4860.0273 4860.0301 4681.0811 4860.0275
Pieces 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0,5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
2-6
Exploded view SX 2007
2-7 Part list SX 2007 Pos. 10 20 30 40 50 60 70 80 90 100 130 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 390 400 410 430 440 450 460 470 480 490 500 510 520 530 540 541 542 550 560 570 580 600 610 620 630
Part description Dust stripper Oil seal Support ring DU-bush DU-bush Lock washer Outer-tube Rebound support O-ring Shuttle valve spring Piston rebound Nut Needle for rebound adjustment O-ring Spring for rebound adjustment Piston rod Piston ring Ring Oil seal Screw sleeve Lock nut Spring guide Rebound spring Lock washer Support ring Guiding ring adapter Guiding ring Check valve ring Lock washer Control knob for compression Screw Tap compression O-ring Piston compression O-ring Check valve spring Check valve holder Clamping disc Membrane O-ring Screw O-ring Screw O-ring Screw Spring Spacer Spacer Spacer Adj.tube Bolt Rubber cap Inner-tube Piston rod Membrane holder cpl. DU-bush Check valve, complete
Part number 4860.0400 4860.0399 4860.0013 4860.0429 4860.0428 4860.0070 4860.0492E 4860.0576 4860.0299 3548.0377 4860.0575 4054.0486 4860.0277 4860.0298 4860.0444 4860.0464 4860.0455 4860.0296 4860.0471 4860.0546S 4860.0459 4860.0525 4860.0511 4860.0512 4860.0577 4860.0520 4860.0294 4860.0297 4860.0446 4860.0569 4860.0527 4860.0509 4860.0299 4860.0047 4681.1499 4860.0202 4860.0163 4860.0514 4860.0281 5018.0222 4860.0527 5018.0222 4860.0542 5018.0222 4860.0526 9141.0052 4860.0456 4860.0457 4860.0458 4860.0269 4860.0280 4860.0141 4860.0530S1 4860.0516S1 4860.0519S1 4860.0430 4860.0518S
Pieces 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
2-8
Exploded view Fork SXS 2007
2-9 Part list Fork SXS 2007 Pos. 10 20 30 40 50 60 70 80 90 100 130 160 170 180 190 200 210 220 230 240 245 250 260 270 310 320 335 360 370 400 410 420 430 440 450 460 470 480 490 500 505 510 520 530 540 541 542 550 560 570 580 580 600 610 612 615 620 630 640 850
Part description Dust stripper Oil seal Support ring DU-bush DU-bush Lock washer Outer-tube Piston rod tap rebound O-ring Shuttle valve spring Piston rebound bleed Lock nut Needle bleed adj. O-ring Piston rebound bleed Piston rod Piston ring Ring Oil seal Screw sleeve O-ring Contra nut Spring guide Rebound spring Ring Cap Tube Tap compression O-ring Piston compression O-ring Check valve Check valve spring Check valve holder Clamping disc Membrane Oil seal washer Cil.head screw O-ring Plug O-ring Oil seal washer Bleeder screw Spring Spacer 43x35x2.5 Spacer 43x35x5 Spacer 43x35x1.5 Adj.tube Bolt Rubber cap Inner-tube right Inner-tube left Screw cap Membrane holder cpl. O-ring Lock washer DU-bush Screw, O-ring, spring cpl. O-ring Fork oil
Part number 4860.0400 4860.0347 4860.0013 4860.0429 4860.0428 4860.0070 4860.0684 4860.0576 4860.0299 4860.0382 4860.0679 4054.0486 4860.0277 4860.0298 4860.0444 4860.0464 4860.0455 4860.0296 4860.0471 4860.0546S 4681.1499 4860.0459 4860.0525 4860.0578 4860.0294 4860.0297 4860.0468S 4860.0509 4860.0299 4860.0047 4681.1499 4860.0061 4860.0202 4860.0163 4860.0514 4860.0281 5018.0222 4860.0527 5018.0222 4860.0542 4014.0024 5018.0222 4860.0526 9141.0052 4860.0456 4860.0457 4860.0458 4860.0269 4860.0280S 4860.0141 4860.0676S1 4860.0675S1 4860.0516S1 4860.0605S1 4860.0340 4860.0448 4860.0430 4860.0518S 4860.0275 4860.0401
Pieces 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ? ? ? 1 1 1 1 1 1 1 1 1 1 1 1 0.4
2-10 Adjustments – Take notice of the position of the compression adjustment 1! – Count the amount of clicks by turning the adjustment screw clockwise till fully closed.
1
Art.No.: 3.211.199-E
– Remove the rubber cap out of the axleclamp.
– Take notice of the position of the rebound adjustment 2! – Count the amount of clicks by turning the adjustment screw clockwise till fully closed. – For the standard position see setting list.
2 Position of the compression and rebound adjustment – Set the rebound position 1, see KTM-Owners manual. – Assemble the rubber cap.
Repair manual WP Fork “Closed Cartridge”
– Set the compression position 2, see KTM-Owners manual.
2-11 Explanation of the spring preload
– Total spring length without the spacers, see chapter inspection of the spring!
– Spring length with spacers 1, see setting list.
1 A
– Spring with the spacers. 1.
1
– The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A -B = Spring preload
B
2-12 Air release screw – Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor!
– Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw.
1
Repair manual WP Fork “Closed Cartridge”
30 hours 200 liter
40 hours 260 liter
50 hours 325 liter
60 hours 400 liter
70 hours 455 liter
80 hours 520 liter
90 hours 600 liter
100 hours 665 liter
Clean dust scrapers (after 1 hour) Bleed fork legs regularly - after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork
20 hours 130 liter
A 100 liter fuel consumption is equivalent to approx. 15 operating hours
10 hours 65 liter
Art.No.: 3.211.199-E
Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork
z z z
z z
z z
z z z
z z
z z
z z
z z z
z z
z z
z
z
z
3-1
DISMOUNTING/MOUNTING THE FORK INDEX
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
DISMOUNTING THE FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 MOUNTING THE FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3
3-2 Dismounting the fork – Place your motorcycle on a stand.
– Notice the position of the front fork in the triple-clamps.
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual.
3-3 Mounting the fork – Clean the innerside of the triple-clamps with brake cleaner. – Slide both fork legs into the triple-clamps.
NOTE: Pay attention to the position of the fork legs. Standard riding height!
NOTE: The maximum riding height is the level of the second groove!
– Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! – Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! – Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!
– Tighten both bolts of the upper tripleclamp to a torque of 20 Nm.
4-1
DISASSEMBLING/ASSEMBLING THE FORK
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
INDEX
DISASSEMBLING THE CARTRIDGE OUT OF THE FRONT FORK LEG . . . . . . . . . . . . .4-2 INSPECTION OF THE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 DISASSEMBLING THE INNER-TUBE / OUTER-TUBE . . . . . . . . . . . . . . . . . . . . . . .4-6 INSPECTION OF THE OUTER-TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 INSPECTION OF THE DU-BUSHES, SUPPORT RING AND SEALS . . . . . . . . . . . . .4-12 INSPECTION OF THE INNER-TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 DISASSEMBLING THE CLOSED CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 RELEASE THE NITROGEN GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 INSPECTION OF THE PISTON ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 DISASSEMBLING THE MEMBRANE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 INSPECTION OF THE CHECK VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 DISASSEMBLING THE SCREW SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 DISASSEMBLING THE REBOUND ADJUSTMENT ADAPTOR . . . . . . . . . . . . . . . . .4-33 DISASSEMBLING THE TAP REBOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 INSPECTION OF THE REBOUND SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 DISASSEMBLING THE SCREW-CAP / MEMBRANE CC . . . . . . . . . . . . . . . . . . . .4-38 ASSEMBLING THE SCREW-CAP/MEMBRANE CC . . . . . . . . . . . . . . . . . . . . . . . .4-44 DISASSEMBLING THE TAP COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49 INSPECTION OF THE COMPRESSION SETTING . . . . . . . . . . . . . . . . . . . . . . . . .4-51 ASSEMBLING THE TAP COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51 ASSEMBLING THE HOLDER MEMBRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53 ASSEMBLING THE TAP REBOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56 ASSEMBLING THE REBOUND ADJUSTMENT ADAPTOR . . . . . . . . . . . . . . . . . . . .4-59 ASSEMBLING THE SCREW SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60 ASSEMBLING THE CLOSED CARTRIDGE (MODEL 2005) . . . . . . . . . . . . . . . . . . .4-62 ASSEMBLING THE CLOSED CARTRIDGE (STARTING WITH MODEL 2006) . . . . . .4-66 BLEEDING THE CLOSED CARTRIDGE (MODEL 2005) . . . . . . . . . . . . . . . . . . . . .4-69 BLEEDING THE CLOSED CARTRIDGE (STARTING WITH MODEL 2006) . . . . . . . . .4-71 ON PRESSURE WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74 ASSEMBLING THE INNER-TUBE / OUTER-TUBE . . . . . . . . . . . . . . . . . . . . . . . .4-76 ASSEMBLING THE CARTRIDGE IN THE FRONT FORK LEG . . . . . . . . . . . . . . . . . .4-82 FILLING OIL IN THE FRONT FORK LEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84
4
4-2 Disassembling the cartridge out of the front fork leg – Place clamping block T1403S in the vice.
– Clamp the outer-tube 1 of the front fork leg in the clamping block at the level of the lower triple-clamp.
1
Art.No.: 3.211.199-E
– Place T14.017 2 on the screw-cap of the front fork leg.
2
Repair manual WP Fork “Closed Cartridge”
– Loosen the screw-cap.
4-3 – Remove the front fork leg out of the vice and move the outer-tube downwards to the axle-clamp.
– Drain the oil out of the front fork leg. – Only for replacing the spring or changing the spring preload!
– Place the front fork leg in the vice according to the picture.
– Unscrew the rebound adjustment holder 1 out of the axle-clamp, (Size 19).
1
1
4-4 – Push the cartridge downwards and place T14.020 1 over the piston-rod, just below the contra nut. (art. no. 4860.0459) NOTE: Do this with help of a second person.
1 Art.No.: 3.211.199-E
– Screw the rebound adjustment holder from the nut, (Size 19 and 17)
Repair manual WP Fork “Closed Cartridge”
– Unscrew the rebound adjustment holder from the piston-rod. – Pay attention to the rebound adjustment tube 2, remove it when it comes out of the piston-rod!
2
4-5 – Push the cartridge downwards and remove T14.020 1.
– Remove the nut 2.
1
2
– Release the spring pressure on the cartridge slowly. – Remove the closed cartridge 3 complete.
3 – “The closed cartridge complete” SXS 2005/06.
– “The closed cartridge complete” SX 2007
4-6 – Remove the spring 1 with the spacer 2.
1
– Also remove the bushing on the lower end of the spring (2006 model).
2 Inspection of the spring NOTE: Only for replacing the spring or changing the spring preload! – It is necessary to place the front fork leg according to the picture for about 5 minutes. The amount of rest oil that stay left in the front fork leg is ± 10ml. – See the setting list for the correct amount of oil volume, this oil volume is minus the 10ml of rest oil. For example 385ml - 10ml = 375ml.
Model 2005: – The total length of the spring (without spacers) is 505mm +/- 3mm. Art.No.: 3.211.199-E
– Replace the spring when the total length is less then 495mm. model 2006 onwards: – The total length of the spring (without spacers) is 455mm +/- 3mm. – Replace the spring when the total length is less then 447mm. – Inspect the coils of the spring if they are not flat, incase they are, you have to replace the spring.
Disassembling the inner-tube / outer-tube
Repair manual WP Fork “Closed Cartridge”
– Place the front fork leg in the vice according to the picture.
– Remove the dust stripper carefully 3.
3
4-7 – Slide the dust stripper 1 downwards.
1 – Remove the lock washer with a screwdriver. NOTE: The lock washer is on one side chamfered to disassemble it easier!
– Heat the surface of the outer-tube near the oil seal to a temperature of ± 50°C.
– Remove the front fork leg out of the vice and pull with both hands the outer-tube from the inner-tube. 2 vom Innenrohr 3.
2
3
4-8 Inspection of the outer-tube – The outer-tube.
– Inspect the outside surface of the outer-tube if there isn’t any damage because of (for example) stones.
Art.No.: 3.211.199-E
– Inspect the inside running surface of the outer-tube on scratches. – Also inspect the anodized coating of the running surface.
– Micrometer 1 for measuring the oil seal and DU-bush chambers of the outer-tube.
Repair manual WP Fork “Closed Cartridge”
1
4-9 – Measure the chamber for the DU-bush. The maximum diameter is: 52.15 mm
– Measure the chamber for the oil seal. The maximum diameter is: 57.50 mm
– Micrometer for measuring the diameter of the running surface of the outer-tube.
– Place at the side of the screw cap the micrometer ± 300mm into the outer-tube. – Measure the diameter of the running surface and measure again after rotating the outertube 90°. The maximum diameter is: 49.20mm
4-10 – Place the inner-tube 1 in the vice according to the picture.
1
– Remove the DU-bush 2 from the inner-tube.
2
Art.No.: 3.211.199-E
3
– Remove the outer-tube DU-bush 3.
Repair manual WP Fork “Closed Cartridge”
4
– Remove the support ring 4.
4-11 – Remove the oil seal 1.
1
– Remove the lock ring. 2.
2 – Remove the dust stripper 3.
3 – – – – – –
6 5 4
1 2 3
Dust stripper 3 Lock ring 2 Oil seal 1 Support ring 4 DU-bush outer-tube 5 DU-bush inner-tube 6
4-12 Inspection of the DU-bushes, support ring and seals – Replace the DU-bush of the inner-tube if the surface is feeling rough. NOTE: The best way to do this is to compare it with a new one!
– Replace the DU-bush when you see through the surface a bronze color.
Art.No.: 3.211.199-E
– Replace the DU-bush of the outer-tube if the surface is feeling rough. NOTE: The best way to do this is to compare it with a new one!
Repair manual WP Fork “Closed Cartridge”
– Replace the DU-bush when you see through the surface a bronze color.
– Check if the support ring is not bended.
4-13 – Always replace the dust stripper and oil seal with every service! See periodic service interval!
– Unscrew both bolts out of the axle-clamp.
– Heat the axle-clamp. NOTE: the inner tube and axle clamp come as a unit for SX models starting in 2007 and do not need to be disassembled.
– Place T1404S 1 in the inner-tube with the pin (T605) 2 through the holes of the inner-tube.
1 1 2
2 – Loosen the inner-tube.
4-14 – Unscrew the inner-tube 1 from the axle-clamp 2.
2 1 – Take the axle-clamp out of the vice.
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
– Axle-clamp complete!
4-15 Inspection of the inner-tube – Inner-tube.
– Inspect the outside running surface of the inner-tube on scratches, wear and tear.
NOTE: When the scratches are sharp and they are not to deep, polish them with “Scotch Brite” hand pad.
– Micrometer for measuring the outside diameter of the inner-tube.
4-16 – Measure the outside diameter of the inner-tube, rotate the innertube 180° and measure again. Repeat these measurements on several places of the inner-tube. The maximum diameter is: 48.005mm
Art.No.: 3.211.199-E
The minimum diameter is: 47.950mm
Repair manual WP Fork “Closed Cartridge”
– Clock gauge for measuring the straightness of the inner-tube.
– Measure the straightness of the inner-tube. NOTE: – Place the V-blocks as far as possible at the sides of the running surface of the innertube according to the picture – Place the gauge clock in the middle of the inner-tube. – Rotate the inner-tube 360°. The maximum travel is: 0.06mm
4-17 – Take the spacer 1 out of the axle-clamp 2.
1
2
3
– Use air pressure to remove the O-ring 3 out of the groove of the axleclamp.
– Remove the hydraulic sleeve 4.
4
– Axle-clamp with components.
4-18 Disassembling the closed cartridge – The closed cartridge complete.
– Remove the rebound adjustment tube 1.
1
Art.No.: 3.211.199-E
– Clamp the reservoir of the cartridge in the vice according to the position of the picture.
– Hold the rebound adjusting screw 2 and loosen the screw 3.
Repair manual WP Fork “Closed Cartridge”
2
3
4-19 Release the nitrogen gas pressure
1
– Unscrew the Allen bolt 1 that is nearist to the compression adjustment screw, (Size 3). – Remove the Allen bolt 1 with the seal out of the screw-cap.
– Model 2005: Allen bolt 2 with the seal. – From model 2006 on: AH flat-head screw 3 with O-ring.
2 3 – Special tool T14.019 4.
4 5 – Remove the protecting cap 5 of the needle and stick the needle through the middle of the filling rubber plug. NOTE: you will hear that the nitrogen gas pressure is releasing the membrane.
4-20 – 2005: place T14.018 1 on the screw-cap.
1
– 2006: place T103 2 on the screw-cap.
2
Art.No.: 3.211.199-E
– Loosen the screw-cap of the membrane holder.
– Lift with a screw driver the screw-cap 3 of the membrane holder out of the reservoir.
3
Repair manual WP Fork “Closed Cartridge”
4
– Take the membrane holder 4 out of the reservoir.
– Drain the oil out of the cartridge.
4-21 – Clamp the closed cartridge in the vice according to the picture!
– Heat the screw sleeve 1.
1
– Loosen the screw sleeve, (Size 24)
– Unsrew the screw sleeve out of the tube.
– Pull the piston rod out of the tube.
4-22 – The complete piston rod with the rebound setting - pay attention to the piston ring 1!
1 – Remove the tube 2 (SXS) or guiding ring adapter 3 (SX). – Remove the support ring 4 and the lock ring 5 (SX only).
3 2 4 5
Art.No.: 3.211.199-E
– Tube d35xD37.5 with guiding ring 6.
6
Repair manual WP Fork “Closed Cartridge”
– Remove the guiding ring.
4-23 – Place clamping block T14.016 in the vice. NOTE: Place the piston rod 1 in the vice according to the picture. – Remove the piston ring 2.
2 1 – Loosen the tap rebound 3, (Size 17).
3
– Screw the tap rebound with needle and spring out of the piston rod.
– Remove the rebound spring 4.
4
4-24 – Remove the steel washer 1.
1
– Remove the screw sleeve 2.
2
Art.No.: 3.211.199-E
Inspection of the piston rod – Piston rod. – Replace the piston rod if you have inspect that the surface of the piston rod has scratches and or indentations. – Always replace also the DU-bush d12 of the screw sleeve.
– Use a clock gauge for measuring the straightness of the piston rod. – Measure the straightness of the piston rod, rotate the piston rod 360°.
Repair manual WP Fork “Closed Cartridge”
The maximum travel is: 0.12 mm
– Micrometer. – Measuring the outside diameter of the piston rod.
4-25 – Measure the diameter of the piston rod, rotate the piston rod 90° and measure the diameter again. – Repeat these measurements on several places of the piston rod. The maximum diameter is: 12.00 mm. The minimum diameter is: 11.92 mm.
– Place clamping block T14.015 1 in the vice.
1
– Screw the screw sleeve 2 handtight back into the tube.3.
2 3 – Clamp the tube in the clamping block at the level of the screw sleeve.
4-26 Disassembling the membrane holder – The membrane holder complete.
– Screw the plug 1 out of the membrane holder, (Size 4) - this plug is for factory production use!
1
NOTE: starting in 2007 SX forks have the filling screw in this position which should be removed; drain the oil into a suitable vessel.
Art.No.: 3.211.199-E
– Remove the plug.
– Remove the O-ring 2.
Repair manual WP Fork “Closed Cartridge”
2
– Remove the O-ring 3.
3
4-27 – Disassemble the spring ring 1. NOTE: – Pay attention in which groove 2 the springring is assembled! – By changing the position of the spring ring in the groove you will change the spring preload more or less with 1.5 mm! – The distance between each groove is 1.5 mm.
1 2
– Place the membrane holder in the vice according to the picture.
– The adjustment screw of the pressure release valve 3.
3
– Unscrew the adjustment screw with a correct fitting screwdriver. – Screw the adjustment screw out of the membrane holder 4.
4
4-28 – Turn the membrane holder up side down and remove the spring. 1.
1
– The check valve pin. 2.
2
NOTE: It is not possible to disassemble the check-valve pin out of the membrane holder!
Art.No.: 3.211.199-E
Check valve SX 2007: – Press against the check valve with a suitable screwdriver and lift out. Remove the check valve and the spring.
Inspection of the check valve spring
Repair manual WP Fork “Closed Cartridge”
– Check valve spring.
– The length of the spring must be 8.0 +/- 0.2 mm (up to model 2006) or 6.5 mm +/- 0.25 mm (2007). – Replace the check valve spring if the length is less then 7.8 mm /6.25 mm.
4-29 – Place the tube in the clamping block T14.015 at the level of the screw sleeve. Heat the membrane holder at the level of the spring ring groove. NOTE: the membrane holder and tube come as a unit for SX models starting in 2007 and do not need to be disassembled.
1
– Loosen the membrane holder with T14.017 1.
– Screw the membrane holder 2 off the tube 3.
2 3 – Remove the O-ring inside.
– The membrane holder with components.
4-30 Disassembling the screw sleeve – Turn the screw sleeve 1 out of the tube 2.
1 2 – Screw sleeve complete.
Art.No.: 3.211.199-E
– Remove the O-ring 3.
3
Repair manual WP Fork “Closed Cartridge”
– Remove the spring ring 4.
4 – Remove the check-valve ring 5.
5
4-31 – Screw the threaded bush T14.023 1 on the screw sleeve till about 0.5 mm just above the edge of the thread of the screw sleeve 2.
1 2 – Place the screw sleeve 2 with clamping block T14.015 3 in the vice.
2 3 – Heat the threaded bush to a temperature of approx. 50°C.
– Lift the oil seal 4 with a screw driver out of the screw sleeve.
4
– Pay attention to the assembling direction.
4
4-32 – This side of the oil seal is visible when the oil seal is assembled in the screw sleeve. NOTE: Always replace the oil seal! !
CAUTION
!
DO NOT MOUNT THE OIL GASKET YET FOR FORKS STARTING WITH THE MODEL. IT WILL BE MOUNTED DURING ASSEMBLY.
2006
– Remove the threaded bush 1.
1
Art.No.: 3.211.199-E
– Use T14.022 2 to press the DU-bush out of the screw sleeve 3.
2
3
Repair manual WP Fork “Closed Cartridge”
NOTE: always replace the DU-bush d12 4!
4
– The screw sleeve with components. – Inspect the surface of the check valve ring 5 on scratches, wear and tear.
5
4-33 Disassembling the rebound adjustment adaptor – The rebound adjustment adaptor complete.
1
– Remove the O-ring 1. – Remove the copper washer 2. NOTE: Always replace the copper washer.
2 – Turn the adjustment screw clockwise and remove the needle.3.
3
– Remove the O-ring 4 with a hobby knife out of the groove inside the rebound adjustment adaptor.
4
NOTE: Always replace the O-ring.
– The rebound adjustment adaptor with components.
4-34 Disassembling the tap rebound – The tap rebound complete.
– Pull the rebound adjustment needle 1 out of the tap rebound.
1
Art.No.: 3.211.199-E
– Needle 2 with spring 3.
3
2
– Take the O-ring 4 of the needle.
Repair manual WP Fork “Closed Cartridge”
4
– Place the tap rebound in the vice according to the picture.
4-35 – Pay attention to the position of the rebound triangular shims 1!
1 – Unscrew the lock nut.
– Remove the lock nut 2.
2
– Remove the bush 3 (does not apply to SX 2007).
3
– Place a screwdriver on top of the tap rebound.
4-36 – Slide the complete rebound setting 1 over the shaft of the screwdriver.
1
– Remove the check-valve spring 2.
2
Art.No.: 3.211.199-E
– Remove the O-ring 3 (does not apply to SX 2007).
3
Repair manual WP Fork “Closed Cartridge”
– The tap rebound with components.
4-37 – Rebound piston, setting side 1 shown!
1 – Rebound piston, Check-valve setting side shown!
Inspection of the rebound setting – Polish both sides of the rebound piston with sandpaper 600 on a flat plate.
– Check the first shim 2 of the rebound setting that is assembled on the rebound piston if it is not bended. – If bended check the second shim and so on. Inspect also the check valve shim(s). – Always replace bended shims!
2
4-38 Disassembling the screw-cap / membrane CC – Place the screw cap / membrane CC in the vice according to the picture. – Loosen the Allen bolt 1, (Size 3)
1
NOTE: from model 2006 on a Phillips flat-head screw M4 is used.
– Remove the Allen bolt.
– Take the seal 2 out of the screw-cap.
Art.No.: 3.211.199-E
2
– Allen bolt 3 with seal (2005).
Repair manual WP Fork “Closed Cartridge”
– Phillips flat-head screw M4 4 with O-ring (from model 2006 on).
3
4 – Remove the O-ring 5 out of the groove of the screw-cap.
5
4-39 Disassembling model 2005 – Place the screw-cap in the vice according to the picture.
– Loosen the tap compression 1, (Size 17).
1
– Screw the tap compression out of the rod.
1
– Remove the the tap compression complete.
1
– Remove the adjustment tube 2.
2
4-40 – Take the membrane 1 out of the groove 2 of the screw-cap.
2 1 – The screw-cap with the membrane CC with the components.
Art.No.: 3.211.199-E
– Place the rod of the screw-cap in clamping-block T14.016.
– Push the rubber plug 3 out of the screw-cap.
Repair manual WP Fork “Closed Cartridge”
3
– Place the rod with screw-cap in the clamping-block according to the picture.
4-41 – Heat the screw-cap to a temperature of approx. 50°C near the rod.
– Untighten the screw-cap with T14.018.
– Unscrew the screw-cap 1 of the rod.
1 2
– Turn the adjustment screw 2 fully clockwise and remove the adjustment needle.
2
6 3 4 5
– – – –
Screw-cap 3 Adjustment needle 4 Rubber plug 5 Rod 6
4-42 Dissembling (from 2006 model on): – Hold the screw cap with T103 1 or clamp in a vise with T103 (see photo). NOTE: tighten vise gently.
1
– Loosen the compression damping fixture 2 (A/F 13).
– Unscrew the compression damping fixture.
2
Art.No.: 3.211.199-E
– Pull the membrane 3 out of the groove in the screw cap and remove.
3
– Pull the clamping disk 4 off the piston rod.
Repair manual WP Fork “Closed Cartridge”
4
4-43 – Loosen the nut 1 on the piston rod and screw a few turns away from the screw cap.
1
– Clamp the piston rod with T14.016S, heat the screw cap to approx. 50°C and unscrew with T103. NOTE: the piston rod and screw cap come as a unit for SX models starting in 2007 and do not need to be disassembled.
– Take the adjusting screw 2 out of the piston rod, remove the O-ring. NOTE: do not lose the two balls and the spring for the adjusting screw. – Unscrew the needle on the compression damping adjustment 3 from the piston rod, remove the O-ring. – Press the rubber plug 4 out of the screw cap.
2
3 Assembly (2006 model onwards): NOTE: assemble in the reverse order. Apply T131 to the thread on the piston rod and the compression damping fixture. Replace all O-rings and the rubber plug in the screw cap; grease the O-rings with T158.
4-44 Assembling the screw-cap/membrane CC
1
– Always assemble a new rubber plug when the rubber plug 1 is removed out of the screwcap.
– Push the rubber plug 1 as far as posibble into the screw-cap.
1
Art.No.: 3.211.199-E
– Assemble the needle. 2.
2
Repair manual WP Fork “Closed Cartridge”
– Turn the adjustment screw anti-clockwise fully open.
– Wet the thread of the rod 3 with T132.
3
4-45 – Turn the rod 1 in the screw-cap 2.
2 1 – Clamp the rod in the clamping-block T14.016 3 and tighten the screw-cap with T14.018 4.
4 3 – Assemble the Allen bolt 5 with the seal.
5
– Place the O-ring 6.
6 – Place the screw-cap in the vice according to the picture.
4-46 – Place the membrane 1.
1
– Assemble the membrane in the groove of the screw-cap.
– Assemble the membrane over the rod 2.
Art.No.: 3.211.199-E
2
– The complete tap compression.
Repair manual WP Fork “Closed Cartridge”
NOTE: the adjusting screw stays in the piston rod starting with the 2006 model. The following steps will not be necessary. Continue at the bottom of page 4-48.
– Remove the adjustment needle 3 with spring.
3
4-47 – Apply the thread with T131.
– Remove the spring from the needle. – Grease the O-ring 1 of the needle with T158.
1 – Replace the adjustment needle with the assembled spring into the tap compression.
– Place the adjustment tube 2 on the end of the needle.
2
– Place the compression unit in the vice according to the picture.
4-48 – Place the screw-cap with membrane CC 1 over the adjustment tube 2.
1 2 – Screw the membrane on the tap compression.
Art.No.: 3.211.199-E
– Place the screw-cap in the vice according to the picture.
Repair manual WP Fork “Closed Cartridge”
3
– Tighten the compression tap 3.
3
4-49 Disassembling the tap compression – Unscrew the lock nut 1, (Size 10).
1
up to the 2005 model: – Remove the lock nut 1.
1
– Take off the shuttle valve 2. – Take off the check-valve spring 3.
2
3
starting with the 2006 model: – Remove the lock nut 4.
4
5
– Remove the check valve spring 5 and check valve 6.
6
– Place a screwdriver on top of the tap.
4-50 – Slide the complete compression setting 1 over the shaft of the screwdriver.
1
– Disassemble the O-ring 2 of the compression piston 3.
2
3
Art.No.: 3.211.199-E
– Compression setting with the components.
Repair manual WP Fork “Closed Cartridge”
– Compression piston, check-valve setting side shown.
– Compression piston, setting side shown.
4-51 Inspection of the compression setting – Polish both sides of the compression piston 1 with sandpaper 600 on a flat plate.
1 – Check the first shim 2 of the compression setting that is assembled on the compression piston if it is not bended. – If bended check the second shim and so on. Inspect also the check valve shim(s). – Always replace bended shims!
2 Assembling the tap compression – Place the complete compression shim setting 3 on the tap compression.
3 – Place the O-ring 4 in the groove of the compression piston.
4
– Place the compression piston on the tap.
4-52 up to the 2005 model: – Place the compression check-valve setting 1.
2 1
– Place the check-valve spring 2.
– Place the shuttle valve 3. NOTE: Assure that the check-valve shim(s) is fitting over the shuttle valve!
3
Art.No.: 3.211.199-E
– Screw a new lock nut 4 on the compression tap.
4
7 Repair manual WP Fork “Closed Cartridge”
– Tighten the lock nut to a torque of 6 Nm.
starting with the 2006 model: – Mount the check valve 5 and the check valve spring 6.
6 5
NOTE: – the check valve spring must be mounted with the smaller diameter of the coil facing up. – Center the check valve and check valve spring with the collar on the lock nut. – Mount the lock nut 7 and tighten to 3 Nm.
– Assure that the check-valve 8 is functioning.
8
4-53 Assembling the holder membrane – Blow with high air pressure through the valve 1.
1 – Blow with high air pressure through the other side of the valve.
– Place the valve spring 2.
2
– Turn the adjustment screw at the level of the edge of the hole. 3.
3
– Adjust with one complete turn (clockwise) the adjustment screw
4-54 – Assemble the O-ring 1 in the groove inside the membrane holder.
1
– Place the O-ring 2. NOTE: the filling screw is in this position starting with the 2007 model. Do not mount yet.
2
Art.No.: 3.211.199-E
– Screw the plug 3 in the holder and tighten the plug.
3 – Assemble the spring ring 4 in the groove as noticed before.
Repair manual WP Fork “Closed Cartridge”
4
Check valve SX/SXS 2007: – Squeeze the control valve with spring and O-ring together with T 14033, move the control valve into position. – Check the control valve and O-ring for a proper fit.
4-55 – Assemble the O-ring 1.
1
– Apply the O-ring with T158.
– Apply the inside O-ring 2 with T158.
2
– Membrane holder complete.
4-56 Assembling the tap rebound – Place a new O-ring 1.
1
– Place the tap rebound in the vice.
Art.No.: 3.211.199-E
– Place the check-valve spring 2.
2
– Place the check-valve setting 3. NOTE: the disks must be pressed down against the spring force; they are centered by the collar.
Repair manual WP Fork “Closed Cartridge”
3
– Place the rebound piston 4.
4
4-57 – Place the shim setting 1.
1
– Place the bush 2.
2
NOTE: a nut with a collar is used instead of a bushing starting in 2007. Mount with the collar facing the disks and lock the thread with T131.
– Screw a new lock nut 3 on the tap (up to the 2006 model). – Tighten the nut to a torque of 5 Nm.
3
NOTE: Pay attention to the position of the triangular shims 4 on the rebound piston!
4
– Check the functioning of the check-valve 5.
5
4-58 – Place the O-ring 1.
1
– Place the spring 2.
2
Art.No.: 3.211.199-E
– Grease the O-ring with T158.
Repair manual WP Fork “Closed Cartridge”
– Assemble the adjustment needle in the tap rebound.
4-59 Assembling the rebound adjustment adaptor – Place a new O-ring in the adaptor.
– Assemble the O-ring in the groove inside the adaptor.
– Assemble the needle 1.
1
– Turn the adjustment screw 2 anti-clockwise fully open.
2 – Place a new copper washer 3.
3
4-60 – Assemble the O-ring 1 in the groove.
1
– Rebound adjustment adaptor complete.
Art.No.: 3.211.199-E
Assembling the screw sleeve – Screw T14.023 2 on the screw sleeve and then press in the new guide bush with T14.022 3.
2
3
– Apply the calibrate mandrel T14.021 4 with front fork oil.
Repair manual WP Fork “Closed Cartridge”
4
5 6
– Use T 14.024 5 to press T 14.021 completely through the guide bush 6.
4-61 – Place the screw-sleeve 1 in the clamping block and heat the screw sleeve to a temperature of approx. 50°C.
1
– Apply the outside of the new oil seal 2 with front fork oil. !
CAUTION
DO
!
NOT MOUNT THE OIL GASKET YET FOR FORKS STARTING WITH THE MODEL. IT WILL BE MOUNTED DURING ASSEMBLY.
2
2006
NOTE: Pay attention to the assembling direction!
3
– Press the oil seal 3 into the screw sleeve with T14.025. (not on picture)
– Place the check-valve ring 4. – Assemble the spring ring 5.
4
5
4-62 Assembling the closed cartridge (Model 2005) – Assemble the guiding ring 1 in the groove 2 of the tube.
2 1
– Tube complete.
Art.No.: 3.211.199-E
– Screw the screw sleeve 3 in the tube 4 completely.
3
4
Repair manual WP Fork “Closed Cartridge”
– Wet the thread of the tube with T132.
– Clamp the tube in the clamping-block T14.015.
4-63 – Screw the membrane holder 1 on the tube 2.
1 2 – Tighten the membrane holder with T14.017 3.
3
– Unscrew the screw sleeve 4 out of the tube.
4
– – – –
Piston rod 5 Rebound spring 6 Washer 7 Contra nut 8
5 6
7
8 – Screw the contra nut to the end of the thread of the piston rod.
4-64 – Place the piston rod 1 in the clamping block T14.016 2. – Slide carefully the screw sleeve over the piston rod.
1 2
3
4
– Place the washer 3. – Assemble the rebound spring 4.
Art.No.: 3.211.199-E
– Wet the thread of the tap rebound with T131 5.
5
– Screw the tap rebound in the piston rod.
Repair manual WP Fork “Closed Cartridge”
– Tighten the tap rebound.
– Slide the tube on the tube of the cartridge. Pay attention to the assembling direction!
4-65 – Piston ring 1, always place a new piston ring! – Roll the piston ring over the shaft of a screwdriver!
1
– Place the piston ring in the groove of the rebound piston.
– Assemble carefully and slowly the piston into the tube of the cartridge. NOTE: make sure the piston ring stays in position!
– Wet the thread of the screw sleeve with T131.
– Place the membrane holder 2 in the vice according to the picture.
2
– Tighten the screw sleeve.
4-66 Assembling the closed cartridge (starting with the 2006 model) – Assemble the guiding ring 1 in the groove 2 of the tube (SXS) or the guiding ring adapters (SX).
2 1
– Clamp the piston rod 3 with T14.016S 4 (inner thread facing up). – Slide on the rebound spring 5 with spring guiding. – Apply T131 to the thread on the rebound support 6, screw the rebound support in the piston rod and tighten. Unclamp the piston rod again.
6
5 3 4 Art.No.: 3.211.199-E
SXS: – Slide on the tube 7. SX: – Mount the lock ring 8. Slide on the support ring 9 and guiding ring adapter bk.
bk 7
9
8
Repair manual WP Fork “Closed Cartridge”
– Clamp the tube/membrane holder, do not clamp too tightly.
– Wrap the rebound damping piston ring over a screwdriver shaft. NOTE: always replace the piston ring. – Mount the piston ring in the groove.
4-67 – Oil the piston ring. – Slide the piston rod into the pipe, use a T-type wrench (10 mm) to center if necessary.
– Slide on the washer 1.
1
– Slide the special tool T 14.029 2 over the thread in the piston rod.
3
2
– Oil the seal ring 3 and slip on the piston rod, open end first, remove T 14.029.
– Slide the screw bushing 4 on the piston rod.
4
– Press the seal ring 3 into the screw bushing, using the washer as a pad if necessary.
1 3
4-68 – Screw the locknut 1 on the piston rod.
1
– Apply T 131 to the screw bushing.
Art.No.: 3.211.199-E
– Screw on the screw bushing.
Repair manual WP Fork “Closed Cartridge”
– Clamp the cartridge as shown in the photo and tighten the screw bushing to 40 Nm.
4-69 Bleeding the closed cartridge (model 2005) – Place the membrane holder in the vice according to the picture. – Drain slowly front fork oil in the closed cartridge. The oil level must be about 70 mm from the top of the membrane holder. The piston rod must be fully extended!
70 mm
– Slowly move the piston rod 1 several times the up and down. NOTE: Be sure that all air is out of the oil, this can take several minutes!
1 – Adjust the O-ring 2 of the squeeze bottle T137S 3 to 120 mm. – Adjust the oil level in the membrane holder to 120 mm, by keeping the O-ring of the squeeze bottle at the top level of the membrane holder.
2 3 4
– If the membrane 4 has not the correct shape (see picture) open the membrane at the groove of the screw cap and press with a little bit of air pressure the membrane to the correct shape.
4-70 – Place slowly the membrane 1 into the membrane holder 2.
1
2 – Screw the screw-cap in the membrane holder 3. NOTE: Oil has to overflow from bleedhole to assure 100% bleeding.
3
– Place T14.018 4 on the screw-cap.
Repair manual WP Fork “Closed Cartridge”
Art.No.: 3.211.199-E
– Tighten the screw-cap to a torque of 30 Nm.
4
4-71 Bleeding the closed cartridge (starting with the 2006 model) – Clamp the membrane holder in the vise as illustrated. – Slowly pour fork oil into the closed cartridge. The oil level should be approx. 185 mm under the upper edge of the membrane holder. The piston rod should be fully extended.
185 mm
1
– If the membrane 1 does not have the right shape (see photo), open the membrane at the groove in the screw cap and press the membrane into the right shape with a small amount of compressed air.
– Slowly insert the membrane 2 in the membrane holder 3.
2 3 – Screw the cap 4 in the membrane holder. – Tighten the screw cap with the T 103.
4
5
– Unclamp the cartridge and remove the AH screw 5 together with the O-ring.
4-72 – Screw on the adapter T 14.030 1 and tighten by hand.
2
– Screw the filling adapter "A" 2 in the adapter T 14.030. – Connect the filling adapter "A" to the vacuum/filling device T 1240S.
1
!
CAUTION
!
VACUUM/FILLING DEVICE SHOULD ONLY BE OPERATED BY PERSONS WHO HAVE READ AND UNDERSTOOD THE OPERATING INSTRUCTIONS. THE CARTRIDGE MUST BE HELD LOWER THAN THE VACUUM/FILLING DEVICE WHILE FILLING FOR THE BEST POSSIBLE FILLING RESULTS.
– THE –
Art.No.: 3.211.199-E
Ventilation/filling process – Move the control levers into the positions shown in the photo.
7 3 45
8 6
NOTE: "External tank" control lever 3 to "Closed", "Damper" 4 to "Vacuum" and "Oil reservoir" 5 to "Equalize Pressure". – Actuate the "On/Off" switch 6 and wait a few seconds until the vacuum gauge 8 drops to approx. 2 mbar.
– Turn the "Oil reservoir" control lever 5 to "Vacuum".
Repair manual WP Fork “Closed Cartridge”
NOTE: the vacuum gauge 8 (mbar) will drop to 10 mbar and the piston rod will be retracted.
– As soon as the vacuum gauge 8 (mbar) reaches 10 mbar, turn the "Oil reservoir" control lever 5 back to "Equalize Pressure".
– Turn the "Damper" control lever 4 to "Pressure". NOTE: oil will be pumped into the cartridge, the pressure gauge 7 (bar) will rise to approx. 3 bar and the piston rod will be extended again.
4-73
1
– As soon as the pressure gauge (bar) reaches approx. 3 bar, turn the "Damper" control lever 1 back to "Vacuum". NOTE: the pressure gauge (bar) will drop to 0 bar. – Switch off the vacuum/filling device.
2
– Lay the cartridge down as shown in the photo, remove the filling adapter "A" 2 and adapter T 14.030 3.
3 – Screw on the AH screw 4 with a new O-ring and tighten.
4
4-74 On pressure with nitrogen – Nitrogen filling gauge T14.019 1.
1
– Remove the protecting cap 2 of the needle 3.
3 2
Art.No.: 3.211.199-E
– Place the needle in the center of the filling hole 4 of the screw-cap and push the needle completely through the rubber plug!
4
Repair manual WP Fork “Closed Cartridge”
– Adjust the nitrogen pressure to 1.0 - 1.1 bar (up to model 2006) and 1.2 bar (from model 2007 on). – Push the piston rod inside the tube! Then when the piston rod is fully extend by it self remove the charging device out the rubber plug and close the tap of the device!
– Place the seal in the screw-cap or on the Allen bolt. 5.
5
4-75 – Screw the Allen bolt 1 into the screw-cap.
1
– Tighten the Allen bolt.
2
3
Starting with the 2007 model: – Mount the compression adjusting screw 2 and apply T131 to the thread on the screw 3. Hold the compression adjusting screw and tighten the screw.
– Push through the complete stroke to release excessive oil and to assure a frction less extension of the piston rod 4.
4
4-76 Assembling the inner-tube / outer-tube – Place the hydraulic sleeve 1 in the axle-clamp 2.
1
2
3 – Place a new O-ring 3 in the groove inside the axle-clamp.
– Place the spacer 4.
Art.No.: 3.211.199-E
4
Repair manual WP Fork “Closed Cartridge”
– Grease the thread of bolts 5 with T159.
5
– Wet the thread of the inner-tube 6 with T132.
6
4-77 – Screw the inner-tube in the axle-clamp.
– Place the inner-tube with axle clamp in the vice according to the picture.
– Tighten the inner-tube with T 1404S 1.
1
– Apply the surface of the inner-tube with front fork oil!
– Place T 1401 2 on the inner-tube. – Apply also the special tool with front fork oil.
2
4-78 – Grease the inside of the dust stripper 1 with T 511. – Slide the dust stripper over the tool and inner-tube.
1
– Place the lock ring 2.
2
– Grease the innerside of the oil seal 3 with T 511.
3
Art.No.: 3.211.199-E
– Slide the oil seal over the tool and innertube.
– Remove T 1401.
Repair manual WP Fork “Closed Cartridge”
4
– Place the support ring 4.
– Polish with sandpaper the edges of the DU-bush 5 outer-tube, (Sandpaper 400 / 600). – Clean the DU-bush after polishing!
5
– Place the DU-bush outer-tube.
4-79 – Polish with sandpaper the edges of the DU-bush 1 inner-tube, (Sandpaper 400 / 600). – Clean the DU-bush after polishing!
1
– Assemble the DU-bush inner-tube.
– Apply the outerside of the dust stripper 2 and oil seal 3 with front fork oil.
32
– Slide carefully the outer-tube 4 over the inner-tube 5.
4 5
– Heat the outer-tube to a temperatur of approx. 50°C at the level of oil seal chamber of the outer-tube. NOTE: Rotate the outer-tube while heating!
4-80 – T 1402S, assembling side for the DU-bush outer-tube.
– Press the DU-bush and the support ring into the outer-tube with T 1402S 1.
1
Art.No.: 3.211.199-E
– T 1402S, assembling side for the oil seal.
Repair manual WP Fork “Closed Cartridge”
– Press the oil seal into the outer-tube.
4-81 – Assemble the lock ring 1 in the groove of the outer-tube. NOTE: be sure that the lock washer is correctly assembled into the groove!!!
1 – Assemble the dust stripper 2.
2
– Outer-tube / inner-tube complete!
4-82 Assembling the cartridge in the front fork leg – Place the front fork leg in the vice according to the picture.
– Assemble the spring 1 with spacer(s) 2.
2
NOTE: do not forget the bush (Modell 2006).
1 – Assemble the closed cartridge 3 into the front fork leg..
Art.No.: 3.211.199-E
3
– Push the cartridge 3 against the spring preload and place T 14.020 4 between the contra nut and axle-clamp.
Repair manual WP Fork “Closed Cartridge”
3 4 – Assemble the adjustment tube 5 into the piston rod.
5
4-83 – Place the needle of the rebound adjustment adaptor into the adjustment tube and screw the rebound adjustment 1 adaptor fully on the thread of the piston rod.
2 1 – Tighten the rebound adjustment adaptor against the contra nut 2 to a torque of 30 Nm.
– Push the closed cartridge 3 downwards and remove T 14.020 4.
3 4
– Screw the rebound adjustment adaptor 5 into the axle-clamp and tighten it to a torque of 30 Nm.
5 – Set the position of the rebound adjustment! – Replace the rubber cap 6!
6
4-84 Filling oil in the front fork leg – Fill the measuring jug with the correct amount of front fork oil, siehe see-list! Max. amount of oil = 425 ml Min. amount of oil = 360 ml
– Fill the amount of oil into the front fork leg.
Art.No.: 3.211.199-E
– Pull the outer-tube 1 upwards and turn the membrane holder 2 into the outer-tube.
2 1
Repair manual WP Fork “Closed Cartridge”
– Clamp the front fork leg in the clampingblock T 1403S 3.
3
– Tighten the membrane holder with T 14.017 4.
4
