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 DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment riding this vehicle! Enter the serial numbers of your vehicle below. Chassis number ( Engine number ( p. 10) p. 10) p. 10) Dealer's stamp Key number (EXC-F, EXCF SIX DAYS) ( The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria TABLE OF CONTENTS TABLE OF CONTENTS 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 (EXCF, EXCF 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 (SXF)............................................... 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 (EXCF, EXCF 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 (EXCF EU, EXCF AUS, XCFW ZA) .................................................. Adjusting the play of the steering head bearing (SXF, 250 EXC-F SIX DAYS EU) .............................................. Removing the fork legs................................................... Installing the fork legs Removing the fork protector 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 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, EXCF 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 (XCFW, SXF) .................................. 12 Short circuit button (EXC-F, EXCF SIX DAYS).................. 12 Emergency OFF switch (EXCF AUS) ............................... 12 Electric starter button (EXCF EU, EXCF SIX DAYS, XCFW)......................................................................... 13 Electric starter button (EXCF AUS)................................. 13 Light switch (EXC-F, EXCF SIX DAYS) ............................ 13 Horn button (EXC-F, EXCF SIX DAYS)............................. 13 Turn signal switch (EXC-F, EXCF SIX DAYS).................... 13 Overview of indicator lamps (EXC-F, EXCF SIX DAYS) ...... 14 CONTROLS (EXCF, EXCF 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 (EXCF, EXCF SIX DAYS, XCF-W)....................... 22 Fuel tap (SXF).............................................................. 22 Opening filler cap .......................................................... 22 Closing filler cap ........................................................... 23 Choke (EXC-F EU, EXCF SIX DAYS)................................ 23 Choke (XCFW, SXF, EXCF AUS) ................................... 23 Shift lever..................................................................... 23 Foot brake lever............................................................. 24 Kick starter ................................................................... 24 Side stand (EXCF, EXCF SIX DAYS, XCF-W) ................... 24 Plug-in stand (SXF) ...................................................... 24 Steering lock (EXC-F, EXCF SIX DAYS) ........................... 25 Locking the steering (EXC-F, EXCF SIX DAYS)................. 25 Unlocking the steering (EXC-F, EXCF SIX DAYS).............. 25 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 26 Advice on first use ......................................................... 26 x x............................................. x..................................... x..................................... x x x............................................... x....................................... TABLE OF CONTENTS Installing the fork protector ....................................... Removing the front fender .............................................. Installing the front fender............................................... Removing headlight mask with headlight (EXCF, EXCF SIX DAYS, XCF-W) ............................................... Refitting the headlight mask with the headlight (EXCF, EXCF SIX DAYS, XCF-W) ............................................... Removing the start number plate (SXF) .......................... Installing the start number plate (SXF) ........................... 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 (EXCF, EXCF SIX DAYS, XCF-W)......................................................................... Adjusting the chain guide (SXF) ................................ Checking brake discs ..................................................... Checking free travel of hand brake lever........................... Adjusting basic position of hand brake lever (XCFW, SXF)............................................................................ Adjusting free travel of hand brake lever (EXC-F, EXCF SIX DAYS)............................................... Checking the brake fluid level of the front brake ............... Topping up the front brake fluid Checking the front brake linin ...