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Harbor Freight Tools 96154 - 11HP Lawn Mower User Manual

1. Mi Short circuit button The short circuit button 2 turns off the engine When pressing this button the ignition circuit is short circuited Starter button 450 SX F G Pushing the black starter button 3 will actuate the E starter Filler cap To open the filler cap Turn the filler cap 45 counter clockwise To close the filler cap Put the filler cap on and turn it 45 clockwise Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor hi Choke If you pull the choke button 1 out as far as possible a bore in the carburetor will be opened through which the engine may take in additional fuel The result is a fat fuel air mixture of the type needed for cold starts To deactivate the choke push the choke button back into its basic position Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral is located between first and second gear Kickstarter 250 SX F The kickstarter is mounted on the right side of the engine Its upper part can be swivelled Foot brake pedal The foot brake pedal is located in front of the right footrest Its basic position can be adjusted to your seat position see maintenance work Plug in stand The plug in stand can be att
2. o oooooooo o 600 mm Motorcycle on ground unloaded dimension B 567 mm DAE A 33 mm If the static sag is lower the spring preload of the shock absorber must be reduced if the static sag is higher the spring preload must be increased See chapter Changing the spring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension A o o ooooooo o 600 mm Motorcycle on ground loaded dimension C 493 mm RIdINE SAS oen o es e o a Ge Ge a 107 mm The riding sag should lie between 102 and 112 mm If the riding sag is less than 102 mm the spring is too hard the spring rate is too high If the riding sag is more than 112 mm the spring is too soft the Spring rate is too low The spring rate is written on the outside of the spring e g 63 250 The type number of the shock absorber is embossed on the bottom of the tank The illustrations show which spring should be installed The standard spring is sho
3. 21 Check chain tension o o o ooooooo ooo ooo 21 Correct chain tension usa Sevier ao a ht 22 Adapting the chain guide to the number of rear Sprocket teeth a ada A oe EA 22 Chain maintenance 0 cee eee mom 23 CHAM WEAN asta e a 23 General information about KTM disc brakes 24 Adjusting the free travel at the hand brake lever 25 Chassis number The chassis number is stamped on the right side of the steering head tube Enter this number in the field on page no 1 Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 Clutch lever The clutch lever 1 is located on the left side of the handlebar The adjusting screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hot start lever If you pull the red hot start lever 2 during the starting procedure backward a bore in the carburetor will be opened through which the engine may take in additional air The result is a lean fuel air mixture of the type needed for hot starts Hand brake lever The hand brake lever 1 is mounted on the handlebars on the right and actuates the front wheel brake The adjusting screw A can be used to change the basic position of the hand brake lever see Maintenance
4. After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the oil level in the reservoir and mount the cover see above AND ENGIN CARBURETOR Adjust idling Keihin FCR MX 39 41 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 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
5. fuel tap To avoid any failures in of the electric system you should treat the short circuit button and socket connectors with a contact spray Should you wish to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil oil filter old engine oil contains aggressive contaminants Check antifreeze and amount of cooling liquid Warm up the engine once again close the fuel cock and wait until the engine dies Then open the drain plug of the float chamber to remove the remaining fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times or E starter motor 5 sec in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slowly operate the kickstarter until you can hear the automatic decompressor click release Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate pivot points of the control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see chapter BATTERY The storage place should be dry and not subjected to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use airtight materials as
6. Adjusting the throttle cables 34 Basic information on carburetor wear 36 Basic suspension setup for the weight of the driver 17 Battery 450 SX F lt 4 soa aca th See ache Pala Eras 30 Bleeding of the hydraulic clutch 35 Bleeding the cooling system 32 BEAN ara aia paa aa a 13 Breather plug front fork aeaa 18 Carburetor Adjust idling 36 Chain maintenance i e 23 CAMEE uri ad 23 Changing the basic position of the foot brake pedal 27 Changing the engine oil 38 Changing the fork offset caster 19 Changing the oil filters 39 Changing the original position of the clutch lever 35 Changing the spring preload on the telescopic fork 18 Changing the spring preloading of the shock absorber 16 Chassis number 2 erica a ed de bp ea ann bs 5 Check chain tension eee 21 Check the following before each start 11 Checking and adjusting the steering head bearing 20 Checking spoke tension oooooo ee eee 29 Checking the basic setup of the telescopic fork 18 Checking the brake fluid level front brake 25 Checking the coolant level 32 Checking the engine oil level 37 Checking the float level float height 36 Checking the front brake pads 25 Checking the oil level of the hy
7. Motorino d avviamento D marreur Motor de arranque el ctrico Stop button Not Aus Schalter Interrutore di aresto demergenza Bouton d arr t d urgence Interruptor de parada de emergencia Throttle position sensor TPS Vergaserpotentiometer Potenziometro carburatore sensore TPS Capteur d ouverture de carburateur Potenci metro del carburador COLOR DE CABLE CAVO COLORATO COULEUR DE CABLE CABLE COLOURS KABELFARBEN bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple bl blau ye gelb bu blau gn gr n re rot wh wei br braun or orange pi rosa gr grau pu violett bl nero ye giallo bu blu gn verde re rosso wh bianco br marrone or arancione pi rosa gr grigio pu violetto bl noir ye jaune bu bleu gn vert re rouge wh blanc br brun or orange pi rose gr gris pu violet bl negro ye amarillo bu azul gn verde re rojo wh blanco br marron or naranja pi rosado gr gris pu violeta Dr Nals 9002 9 LLIN OL04 KTM Group Partner Yin val KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at
8. RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Treat electric contacts and switches with contact spray Change hydraulic clutch fluid Change brake fluid 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 250 450 SX F 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check oil level Bleed fork legs regularly Clean and lubricate chain check tension and adjust if necessary Check tires for pressure and wear Check fuel lines for leaks Check brake performance Treat blank metal parts with the exception of brake and exhaust system with wax based anti corrosion agent Check tightness of screws nuts and hose clamps regularly 250 450 SX F 2007 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING ADDITIONAL ORDER FOR THE KTM WORKSHOP Before After For cross at least each every country once cleaning every 60 A 100 liter fuel consumption is equivalent to approx 15 operating hours
9. a possible humidity might not be able to escape and could cause corrosion i CAUTION It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust USE AFTER A PERIOD OF STORAGE Mount the charged battery regard polarity Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your mechanic at the beginning of the next biking season ENGINE 250 SX F Design Liquid cooled single cylinder 4 stroke engine Displacement 249 51 ccm Bore Stroke 76 55 mm 97 60 8 mm Fuel unleaded fuel with at least RON 95 Valve timing 4 valves controlled by finger levers and 2 camshafts driven by a pair of spur gears and a tooth type chain Camshaft 05 773 36 009 100 773 36 010 100 Valve diameter Intake 30 9 mm 40 4 mm Valve clearence cold Intake 0 10 0 20 mm 0 15 mm Valve clearence cold Exhaust 0 12 0 22 mm 0 20 mm Crank s
10. bellows out of the outer tubes and slide them downward Clean the dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with Universal oil spray Motorex Joker 440 or engine oil Then push the dust protection bellows into the outer tubes by hand AN WARNING eee No oil may reach the front tire or the brake disks since this would considerably reduce the tire s road grip and the braking effect of the front brake AND ENGIN Changing the fork offset caster The fork offset A in the 250 450 SX F models center fork legs center steering head angle can be set to either 18 or 20 mm This allows you to optimize the handling to match the race course Remove the blind screw 1 to see which offset is set If the mark B is in front the offset is 18 mm This setting will deliver more directional stability on fast race courses If the mark B is in the rear as illustrated the offset is 20 mm This setting will deliver better handling in curves The offset is set to 20 mm in the condition at delivery To adjust the offset dismount the front wheel and remove the front wheel fender Remove the screw on the starting number plate Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen th
11. brake piston into its basic position Remove the clips 4 pull out the bolt 5 and remove the brake pads Thoroughly clean the brake caliper with compressed air and check the sleeves of the guide bolts for damage Insert the left brake pad into the brake caliper and secure it with the bolt Insert the right brake pad and push the bolt 5 into the brake caliper up to the stop Reattach clips 4 AA It s very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if clips have been fitted correctly After working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established AND ENGIN Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 1 on the left side of the fork fists Loosen and remove the collar nut 21 loosen the clamping screews 3 on the right side of the fork fist Hold the front wheel pull out the wheel spindle 4 Carefully remove the front wheel from the fork i CAUTION Do not operate the hand brake when the front wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brak
12. 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 CARBURETOR 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 ADD ON PARTS Clean air filter and filter box Check electric wires for damage and bends Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks BRAKES 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 CHASSIS Check adjust steering head bearings Check tightness of chassis screws triple clamps fork leg axle passage swingarm shock aborber Check adjust steering head bearings Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wear fit and tension WHEELS Lubricate chain clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings 250 450 SX F 2007 IMPORTANT
13. gt gt gt Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet S CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear You should use normal brand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush Before cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Drain the float chamber of the carburetor Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate Once the motorcycle has cooled down oil or grease all sliding and bearing points Treat the chain with a chain spray Also oil the
14. hours 400 liter Check the clutch disks for wear Check the length of the clutch springs Check the outer clutch hub for indentations Check the cylinder and piston for wear 250 SX F Check the cylinder for wear and replace the piston 450 SX F Check the groove on the piston pin retainer 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 250 SX F 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 250 SX F Replace the crankshaft main bearings 450 SX F 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 NOTE If the inspection establishes that permissible tolerances are exceeded the respective components must be replaced Maintenance and adjusting work marked with an asterisk requires expert skills and technical know how For your own safety always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualif
15. of the frame and are not pressed down by the tank AND ENGIN How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 2 are offset from the center by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar support and tighten screws 4 to 40 Nm 30 ft lbs Mount the handlebar and handlebar clamps and tighten screws 3 to 20 Nm 15 ft lbs The gap between the handlebar support and the handlebar clamps should be the same size in the front and in the rear AA The screws 4 must be secured with loctite 243 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Press the chain upward at the end of the chain sliding component The distance between the chain and the swing arm should be approx 8 10 mm 0 31 0 39 in In the course of this procedure the upper chain portion A must be taut see drawing If necessary correct the chain tension AA Excessive tensioning of the chain will put additional load on the components of the secondary driv
16. overspeed the engine In this way you will not need to brake so much and the brakes will not overheat AN WARNING Incase of rain after washing the motorcycle after rides through water and in case of rides on wet off road tracks humid or dirty brake discs can delay the braking effect The brakes must be pulled until they are dry or clean Dirty brake discs cause increased tear of brake pads and brake discs When you brake the brake discs brake pads brake caliper and brake fluid heat up The hotter these parts get the weaker the breaking effect In extreme cases the entire braking system can fail If the resistance in the hand brake lever or foot brake pedal feels spongy too much play this is an indication that something is wrong with the brake system Don t ride your motorcycle anymore without first having the brake system looked over by a KTM dealer Stopping and parking Apply the brakes fully and put the engine into neutral To turn off the engine push the short circuit button with the engine at idling speed until the engine stops Turn the fuel tap to the OFF position park on an area where the ground is firm AN WARNING Motorcycle engines produce a great amount of heat while running The engine exhaust pipe muffler brake rotors and shock absorbers can become very hot Do not touch any of these parts after operating the motorcycle and take care to park it where pedestrians are not likely
17. 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 3 Mount the float chamber install the carburetor and adjust the idle speed AND ENGIN Draining the float chamber of the carburetor Following every wet cleaning procedure the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it Water in the float chamber leads to engine malfunction Make sure you do this while the engine is cold Close the fuel tap and place a cloth under the carburetor which is capable of absorbing the leaking fuel 250 SX F Unscrew the plug 1 and clean it with compressed air Then mount the plug together with the gasket open the fuel tap and check the float chamber for leaks 450 SX F Put the end of the hose that leads downward behind the engine into an appropriate container Open the drain plug 2 turning it counterclockwise a few times and let the fuel drain from the float chamber Then tighten the drain plug and open the fuel tap AA Fuel is easily flammable and toxic When handling fuel be sure to exercise the utmo
18. screen short 250 SX F M16x1 5 10 Nm oiled M20x1 5 15 Nm Hexagon plug oil screen long 250 SX F Plug oil screen 450 SX F M32x1 5 30 Nm oiled M5 6 Nm Collar screw for oil filter cover 250 SX F Collar screw for oil filter cover 450 SX F M4 6 Nm Plug pressure valve M12x1 5 M14x1 5 18 Nm Cylinder head screw 250 SX F M10 40 50 Nm oiled Hexagon collar screw exhaust flange M6 Loctite 243 10 Nm M18x1 5 left Loctite 243 150 Nm Hexagon nut primary gear 450 SX F M27x1 60 Nm Nut for inner clutch hub 250 SX F M18x1 5 Loctite 243 120 Nm Nut for inner clutch hub 450 SX F M18x1 5 Loctite 243 80 Nm Hexagon collar screw clutch spring M6 10 Nm Allan head screw shift roller locking piece M6 Loctite 243 10 Nm Hexagon collar screw locking lever M5 Loctite 243 6 Nm Plug for chain tensioner M24x1 5 25 Nm Hexagon collar screw stator Loctite 243 6 Nm Loctite 243 6 Nm 60 Nm Hexagon collar screw pulser coil Hexagon collar nut flywheel 250 SX F Flywheelscrew 450 SX F M10x1 80 Nm oiled Cable retaining bracket ignition M Loctite 243 6 Nm Hexagon collar screw shift lever M6 Loctite 243 10 Nm Hexagon screw engine sprocket M10 Loctite 243 60 Nm Spark plug M10 10 12 Nm igniti 6 Allan head screw kickstarter M8 Loctite 243 25 Nm BASIC CARBURATOR SETTING Type Keihin FCR MX 3925E Keihin FCR MX 4125F Jet needle OBETP OBDTP ig ke
19. 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 approx 200 hours Checking the float level float height For this purpose dismount the carburetor and remove the float chamber Hold the carburetor in a slanted
20. 2007 250 SX F 450 SX F ART NR 3 211 146 EN __ INTRODUCTION gt gt We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person All information contained is without obligation KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM may stop manufacturing certain models without previous notice K
21. 32mm allows you to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 Adapting the chain guide to the number of rear sprocket teeth NOTE The position of the chain guide must be adjusted due to the large number of rear sprockets available Up to 44 teeth insert the retaining screw on the chain guide in the lower hole C from 45 teeth in the upper hole D Loosen both screws on the chain guide and pull the chain guide off the swing arm Turn the chain guide over press out the retaining nut 5 and insert it in the other hole 61 turning the retaining nut around Remount the chain guide and tighten the screws AND ENGIN Chain maintenance For a long chain life good maintenance is very important Chains without COJO CL oo 0 0 X rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray e g Motorex Chainlube 622 AA No lubrication is allowed to reach the rear tire or the brake disks otherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily lose control i CAUTION When mounting the chain masterlink clip the closed side of the masterlink clip must point in running direction Also check sprockets and chain guides for wear and replace if necessary Chain wear To check the chain wear observe the following indications Shift t
22. 40 100 Idling air jet 100 Needle position 5 from top 4 from top Starting jet 85 Mixture control screw open 1 5 Slide 15 15 Performance restrictor Stop pump membrane 858 2 15 mm 858 2 15 mm Hot start device 2 5 mm 2 5 mm CHASSIS 250 SX F Frame 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 260 mm 10 2 in brake caliper floated Rear brake Disk brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake disc Wear limit max 2 5 mm front and 3 5 mm rear Front tires 80 100 21 Rear tires 110 90 19 Fuel tank capacity 8 liters 2 1 US gall Chain 5 8 x 1 4 Available final sprockets 38 40 42 45 48 49 50 51 52 Battery maintenance free 12V 3 Ah and 4Ah Steering head angle 03 97 Wheel base 1475 10 mm Seat height unloaded 925 mm Ground clearance unloaded 380 mm Weight without fuel approx 98 2 kg STANDARD ADJUSTMENT FORK approx 104 2 kg 250 SX F WP 4860 CC MA 14 18 7C 03 450 SX F WP 4860 CC MA 14 18 7C 05 Compression adjuster 15 15 Rebound adjuster 20 21 Spring 4 4 N mm Oil capacity without CC 385 ml Oil capacity CC Gas pressure Fork oil STANDARD ADJUSTMENT SHOCK ABSORBER 250 SX
23. 450 SAS ur a e Gules eat aoe di 30 CHOKE ara ae bre Eni 7 Charging the battery 450 SX F 31 A O aed at ah A 7 PUSE 4 DOS KEEN orrie E A oh ar A 31 Kickstarter 250 SX F 2 ee 7 GOONMS SYSTEM aia a Gs 32 Foot brake pedal siii rd s 7 Checking the coolant level 32 PIUS MES RING saca cost 7 Bleeding the cooling system 32 Compression damping of fork 8 Replacing the glassfiber yarn packing of the silencer 33 Rebound damping of fork aaa aa 8 Cleaning the air filter o o 34 Compression damping of shock absorber 8 Adjusting the throttle cableS 34 Rebound damping of shock absorber 9 Changing the original position of the clutch lever 35 Checking the oil level of the hydraulic clutch 35 4 GENERAL TIPS AND WARNINGS FOR STARTING THE Bleeding of the hydraulic clutch 35 MOTORCYCLE beastmaen pad rd 10 Carburetor Adjust idling 36 Instructions for initial operation 10 Basic information on carburetor wear 36 Running in the Racing models 4 10 Checking the float level float height 36 Draining the float chamber of the carburetor 37 DRIVING INSTRUCTIONS oz zoende mie mese Be ih 11 Checking the engine oil level 37 Check the following before each start 11 A O ee A
24. ED a Aad Wd RL BANE 2 Instructions for initial operation 10 INTOUCON rd dado dodo ao 1 Adapting the chain guide to the number of rear sprocket teeth a oia is An A ee oes 22 Kickstarter 250 SX F rs o aa eae late ada 7 Maintenance work on chassis and engine 16 Operation instruments ee 5 Periodic maintenance 0 eee eee 14 PAVOU DEINE ayera ae ana aan a a MS 16 RIUS iN Stand AER a 7 Rebound damping of fork o o o o oooooooo 8 Rebound damping of shock absorber 9 Refilling the front brake fluid reservoir 25 Refilling the rear brake fluid reservoir 26 Replacing fork springs o o o ooooooooo 18 Replacing the front brake pads 26 Replacing the glassfiber yarn packing of the silencer 33 Replacing the rear brake pads 27 FCT TTS ANG od hos es Sun ert ne ada a 10 Serial number locations o o ooooooo ooo 5 LN TE 7 SEM BEREN cas sae a fede wo genase Act see hed De atie dte as 13 Short A 6 Starter button 450 SX F o o o o ooooooooooo o 6 SLAM Oi ei a Sess a Sa aren Cay tain nat ae Ai ep ae 13 Starting when the engine is cold 12 Starting when the engine is warm 12 Stopping and parkid8 o o 13 MATES AA a ad 42 Table of contents 30 isaac 4 Technical Data Engine 00 ee eee ees 43 Tires air pressure A 30 a A aa a a a a 40 Use after a perio
25. F 450 SX F WP PDS 5018 DCC 12 18 7C 03 WP PDS 5018 DCC 12 18 7C 05 15 LS low speed Compression adjuster 1 HS high speed 15 LS low speed 1 HS high speed Rebound adjuster 25 25 Spring 63 250 66 250 b mm Spring preload 5mm Static sag 33 mm 33 mm Riding sag 107 mm 107 mm TIGHTENING TORQUES CHASSIS 250 450 SX F Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front Brake disks M8 Loctite 243 25 Nm Loctite 243 14 Nm Clamping screws top triple clamp Clamping screws bottom triple clamp 17 Nm 12 Nm Clamping screws fork stubs 15 Nm Clamping screw steering stem Steering head screw top M 20x1 5 Loctite 243 17 Nm 10 Nm Steering head screw bottom Collar nut swing arm bolt Hexagon collar screw handlebar clamp M 20x1 5 M16x1 5 M8 Loctite 243 60 Nm 100 Nm 20 Nm Allan head screw handlebar support Shock absorber top M10 M12 Loctite 243 40 Nm 70 Nm Shock absorber bottom Collar nut rear wheel spindle Sprocket screws M12 M20x1 5 M8 70 Nm 80 Nm Loctite 2701 35 Nm Ball joint for push rod Engine mounting bolt M6 10 Nm Engine brace Spoke nipple Screw adjusting ring spring preload shock abs Seat fixing nut Other screws on chassis Other collar nuts on chassis Page Adjusting the free travel at the hand brake lever 25
26. PR a 38 Starting when the engine is cold 12 Changing the engine oil o 38 Starting when the engine is warm 12 Changing the oil filter ca ssd as 39 O R 12 TROUBLESHOOTING cocoa ronca ratos 40 SLAMS sta a aos 13 Shifting Riding ooooooooo 18 CLEANING ad 42 A E aA e n E 13 STORAGE wer eduard ek do ee dee paid 42 do A o eae TECHNICAL DATA ENGINE 0eeseeeeees 43 A TECHNICAL DATA CHASSIS 0 cidad A PERIODIC MAINTENANCE ccoo nacion es 14 HEAD WORK INDEX cee eee eee eee 47 MAINTENANCE WORK ON CHASSIS AND ENGINE 16 WIRING DIAGRAM aats wea Pe is ES appendix Changing the spring preloading of the shock absorber 16 Pivot DEALING vais is Goats acta eta ack aes 16 Basic suspension setup for the weight of the driver 17 Checking the shock absorber and spring 17 Determining the static sag of the shock absorber 17 Determining the riding sag of the shock absorber 17 Checking the basic setup of the telescopic fork 18 Changing the spring preload on the telescopic fork 18 Replacing fork springs o o o ooooooooo 18 Breather plug front fork o o oo o 18 Cleaning the dust sleeves of the telescopic fork 18 Changing the fork offset caster 19 Checking and adjusting the steering head bearing 20 Checking the throttle cable installation 20 How to change the handlebar position
27. TM shall not be held liable for any deviations of availability and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2006 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations OWNERS MANUAL Please read this manual carefully and completely before going on your first ride lt contains a great deal of information and advice which will help you use and handle your bike properly Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance In your own interest please pay particular attention to notices that are marked as follows AA Ignoring these instructions can be dangerous to life and limb A CAUTION Ignoring these inst
28. To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others Enjoy driving your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine IMPORTANT INFORMATION eee 2 Checking the brake fluid level front brake 25 Refilling the front brake fluid reservoir 25 SERIAL NUMBER LOCATIONS ee 5 Checking the front brake pads 25 ChaSsiS NUMDEN cir aa a ae 5 Replacing the front brake pads 26 Engine number engine type o oo 5 Checking the rear brake fluid level 26 Refilling the rear brake fluid reservoir 26 OPERATION INSTRUMENTS asiaticas 5 Changing the basic position of the foot brake pedal 27 AE nere aw a ikaw Ses ach at Seok le a ok 5 Checking the rear brake pads 2 Hotstart lever aea Sune ae do aa 5 Replacing the rear brake pads o o o oo o 21 Hand brake lever o o o o ooooooo moro 6 Dismounting and mounting the front wheel 28 Short circuit DULLOM zet REA NEE Meecha aed 6 Dismounting and mounting the rear wheel 29 Starter button 450 SX F en ee 6 Checking spoke tension o oooooooooo o 29 FIIT COD EEE 6 Tires air preSs re aa Gee A As 30 FUE TA saca te dolores dd ia dis 6 Battery
29. accordance with the maintenance schedule Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle WARRANTY The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle AUTOMOTIVE FLUIDS The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own safety use KTM approved parts and accessories only KTM is not liable for damage that arises in connection with the use of other products TRANSPORT When transporting your motorcycle secure it with elastic straps or other mechanical devices in an upright position Be sure that the fuel tap is closed If the motorcycle topples over fuel can flow out of the carburetor or fuel tank ENVIRONMENT Offroad Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly
30. ached to the wheel spindle on the left side of the motorcycle Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjusting screws at the top of the fork legs Turn the adjusting screws 1 clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork WP 14 18 7C 03 15 clicks WP 14 18 7C 05 15 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound Remove the protecting cap 2 By turning the adjusting screw 3 REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far as It will go turn it back by as many clicks as are specified for the relevant type of fork WP 14 18 7C 03 20 clicks WP 14 18 7C 05 21 clicks Damping action during compression of shock absorber The shock absorber can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorc
31. aint remover Use only clean brake fluid taken from a tightly sealed container AND ENGIN Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw 1 The free play at the foot brake pedal must then be adjusted by means of the piston rod 2 Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal ZN WARNING eee If this free play is not present then pressure can build up in the brake system when driving causing the rear wheel to brake The braking system overheats and may even fail completely in extreme cases Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in AA At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed S CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc Replacing the rear brake pads Push the brake caliper 3 toward the chain wheel in order to move the
32. ay together Replacing fork springs If you weigh less than 75 kg or more than 85 kg you should install the respective fork springs The correct spring rate is shown in the illustrations The standard spring is shown in bold print The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork If you are uncertain which spring to use contact your KTM workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground S CAUTION Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leaking it is recommended to open the breather plugs before having the seals replaced Cleaning the dust sleeves of the telescopic fork The dust protection bellows 2 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lift the dust protection
33. clean brake fluid taken from a tightly sealed container Checking the front brake pads The brake pads can be Inspected from below The linings must be at least 1 mm 0 04 in thick AA At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed i CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc AND ENGIN Replacing the front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the sliding metal sheet 3 in the caliper support and of the leaf spring 4 AA It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circli
34. d by a water pump 1 located in the engine gt hy IE Air blowing in through the radiators cools the coolant The slower the speed le of the motorcycle the less the coolant is cooled down Dirty s radiators also reduce the cooling efficiency Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 2 a water temperature rising up to 120 C 248 F is admissible without fear of problems AN WARNING OO If possible always check level of cooling liquid when the engine is cold If you have to open the radiator cap when the engine is hot use a rag to cover the cap and open slowly to release pressure Caution scalding hazard Do not detach any radiator hoses while the engine is hot The escaping hot coolant and the steam may cause serious burns In case you get burnt hold the affected part of your body under running cold water right away Coolant is toxic Keep the coolant out of the reach of children Incase coolant is ingested consult a doctor immediately If coolant gets into your eyes rinse them out with water immediately and consult doctor A mixture of 50 antifreeze liquid and 50 destilled water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water i CAUTION The cooling syst
35. d of storage o 42 What to do when the engine is flooded 12 ENE XIONAddV 39 0N3ddV INVHNV qy stop button black ellow black brown blue white generator green red white red black 22 E ignition coil J OQ k pick up KIMI 250 SX F 2007 CDI harness 594 39 032 000 08 04 2006 a a start button starter motor start relay battery oo stop button J x sE pick up Sa B 2 ed green all CDI harness start harness 2 Ea regulator rectifier black lt brown EE blue white AAA Jo ES EE generator ignition coil CDI harness 773 39 032 000 SX F 450 2007 start harness 773 11 079 000 10 04 2007 ANHANG APPENDICE y APPENDIX APENDICE ENE XIONAddV I9IANIddV INVHNV ENGLISH DEUTSCH ITALIANO FRANCAIS ESPANOL Battery Batterie Batteria Batterie Bater a Generator Generator Generatore Alternateur Generador Ignition coil Z ndspule Bobina d accensione Bobine d allumage Bobina de encendido Pick up Impulsgeber Pick up Capteur d allumage Generador de impulsos Regulator rectifier Regelgleichrichter Regolatore raddrizzatore R gulateur redresseur Regulador rectificador Start button Starttaster Pulsante d avviamento Bouton de d marrage Bot n de arranque Start relay Startrelais Rel d avviamento Relais de d marreur Rel del arranque Starter motor Startermotor
36. draulic clutch 35 Checking the throttle cable installation 20 Checking the rear brake fluid level 26 Checking the rear brake pads 27 Checking the shock absorber and spring 17 COKE atari ia dc 7 A E A a aoe ACS 42 Cleaning the air filter nnna nananana 34 Cleaning the dust sleeves of the telescopic fork 18 Cutten TEVET dos arn ad Para a A 5 Compression damping of fork 8 A Ga nina at a Ait abe olan ha coud aia hg dott shakin 32 Correct chain tension o o oooooooooooo 22 Damping action during compression of shock absorber 8 Determining the riding sag of the shock absorber 17 Determining the static sag of the shock absorber 17 Dismounting and mounting the front wheel 28 Dismounting and mounting the rear wheel 29 Draining the float chamber of the carburetor 37 DIVINE AS HUEHONS tata ea at one ale 11 Engine number engine type o 5 ENDS Olinda as a pen nada apse nd 43 Alas eas aia tanta O BA aen Kaars 6 FOOL Drake pedal iia ada 7 ar A E E A AN 13 FOLS aa atada tipa ta Bedeker 6 FUSE ASUS AD aa ran e ee asis 31 General information about KTM disc brakes 24 General tips and warnings for starting the motorcycle 10 Hand brake lever o o o ooooooo ooo oo 6 Hot start lever ac athe AOS AAA 5 How to change the handlebar position 21 Page IMPOR mutantes ds Be
37. e collar screw 2 on the lower triple clamp 2 turns Remove the blind screw 1 from the upper triple clamp loosen the clamp screw and upper triple clamp on the seat Remove the O ring 3 and the protection ring 4 Tap gently on the lower triple clamp with a rubber hammer to loosen the steering stem 5 out of the bearing seat Take the lower triple clamp with the steering stem out of the steering head Remove the collar screw from the lower triple clamp and pull out the steering stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp tighten the collar screw all the way to the stop Grease the steering head bearing and sealing elements AA Be sure to lock the thread on the collar screw 2 with Loctite 243 Do not confuse the collar screw 2 with the blind screw 1 The collar screw is self locking AND ENGIN Mount the lower triple clamp upper steering head bearing protection ring O ring upper triple clamp and the blind screw Tighten the collar screw on the lower triple clamp to 60 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages Adjust the steering head bearing without clearance see Checking and adjusting the steering head bearing and tighten the clamp screws on the upper triple clamp to 17 Nm in 3 stages i CAUTION Secure the middle clamp screw A with Loctite 243 Mount the front wheel fender and tighte
38. e disc can be damaged To install the front wheel lift it into the fork position and mount the axle Shaft Mount the collar nut 2 tighten the clamping screws 3 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm 30ft 1b Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 15 Nm Before remounting the front wheel clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushing AA If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the front wheel keep operating the hand brake until the pressure point returns It is very important to keep the brake disk free from oil and fatty matters otherwise the braking effect would be strongly reduced AND ENGIN Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Remove the collar nut 11 remove the chain tensioner 21 and pull out the wheel spindle 3 until y
39. e fails to idle Operating error The motorcycle has been out of operation for a longer period of time Therefore old fuel has accumulated in the float chamber Fuel supply interrupted Flooded engine Sooty or wet spark plug Electrode gap too large Spark plug connector or spark plug faulty Short circuit cable scored in wiring harness short circuit button faulty The plug connection of the CDI unit the pulse generator or the ignition coil has oxydized Water in carburetor or jets blocked Glogged idling jet Incorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Open fuel tap tank fuel actuate choke Pay attention to Starting information see driving instructions 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 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 Clean and dry the spark plug or exchange It respectively Clean and dry the spark plug or exchange It respectively Adjust spark plug electrode gap to 0 6 mm Dismount s
40. efore changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 1 changes the spring pretension by approximately 1 0 mm Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclockwise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm ADJUSTMENT VALUES SPRING PRELOAD A WP 12 18 7C 03 5 mm 0 2 in WP 12 18 7C 05 5 mm 0 2 in Pivot bearing The pivot bearing 3 for PDS suspension struts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubricants Grease and other lubricants cause the Teflon coat to dissolve whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing WP12 18 7C 03 WP12 18 7 05 T oc 5 Z ac o Z 63 250 66 250 60 250 63 250 65 70 75 80 85 250 SX F 450 SX F 66 250 69 250 90 95 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM AND ENGIN Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork shock absorber swing arm and frame from being damaged the basic setup of the suspens
41. em must be bled after draining the cooling liquid or after adding more than 0 25 0 06 US gallons cooling liquid see below For the cooling system use only high grade antifreeze e g Motorex Anti Freeze Using lower grade antifreeze agents can cause corrosion and coolant foaming Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system 10 mm i CAUTION If possible always check the level of cooling liquid when the engine is cold If you have to open the radiator cap 2 when the engine is hot use a rag to when engine Ist cold cover the cap and open slowly to release pressure LALA AAA OCA AAA RADAR OOOO BAY SX F Bleeding the cooling system 5 E a By removing the screw 3 at the water pump cover you can drain the coolant RNE To bleed the cooling system add coolant up to approx 10 mm above the radiator ly A fins when the engine is cold After a short ride check the coolant level once more AND ENGIN Replacing the glassfiber yarn packing of the silencer Aluminum silencers are filled with glassfiber yarn to muffle noise Have the filling checked regularly by an authorized KTM workshop see Lubrication and Service Chart The insulating material fibers escape through the holes in the perforated pipe with time causing the silencer to burn out I
42. er remove the closure 2 since it will be damaged To avoid damage to the on board electronic system always disconnect the minus pole before you charge the battery Tocharge connect the battery to the battery charger before you switch on the battery charger When the battery is charged switch off the battery charger before you disconnect the battery Provide adequate ventilation when charging the battery in a closed room the battery emits explosive gases when charging Electrolytes will escape through the safety valves if the battery is charged too long or at an excessive voltage or amperage This will reduce battery capacity Try to avoid quick charges Fuse 450 SX F The fuse 3 is located in the starter relay of the E starter 4 underneath the left side paneling Having removed the left side paneling the air box cover and the protection cover A you will be able to see the fuse The starter relay also contains a 10 amp spare fuse 5 Replace a blown fuse only with an equivalent one If a new fuse that has just been installed gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 10 Ampere i CAUTION Under no circumstances is a stronger fuse allowed to be installed or a fuse allowed to be repaired An improper treatment could damage the whole electrical installation AND ENGIN BN 450 sxf Y Cooling system m mn Coolant is circulate
43. etrain chain bearings of transmission and rear wheel Aside from resulting premature wear if worst comes to worst the chain may rupture or the countershaft of the transmission may break Too much slack in the chain on the other hand can result in the chain jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine In either case the operator is likely to lose control of the motorcycle AND ENGIN Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks B Tighten the counter nut of the adjusting screws Clean and grease the adjusting screws regularly Motorex Long Term Grease 2000 Before tightening the collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm AA If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle Tighten the collar nut with the required torque NOTE The large adjusting range of the chain adjusters
44. ext higher gear Let clutch lever go again and accelerate If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of the throttle the fuel usage increases By shifting down use the brakes If necessary and close the throttle at the same time Pull the clutch lever and shift down to the next gear Let clutch lever go slowly and open the throttle or shift down again NOTE Dedicated to nothing but offroad racing 250 450 SX F models make no compromises in their design As such they do not include any radiator fan and the size of the radiator is dimensioned for optimum ergonomics In normal racing the cooling system is sufficient If you use your motorbike in other conditions please note that turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time more than 2 minutes Avoid letting the clutch slip frequently and for extended periods This would cause the engine oil to heat up thereby heating up the cooling system You should drive at low speeds 4 stroke style letting the engine pull you and not at high speeds not by letting the clutch slip 2 stroke style ART eee After falling with the motorcycle chec
45. filter housing about halfway with engine oil Fill oil filter with oil place the oil filter in the filter box Grease the O ring 3 of the oil filter cover and mount the cover Mount the screws and tighten them to 6 Nm Return the motorcycle to an upright position Remove the oil plug 4 at the clutch cover and fill in 1 1 liters 250 SX F or 1 3 liters 450 SX F of fully synthetic engine oil Motorex Power Synt 4T 10W 50 Start the engine and check all screwed connections and the oil filter cover for leaks Finally check the engine oil level and if necessary correct it ____ TROUBLESHOOTING gt If you had the specified maintenance work on your motorcycle carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the troubleshooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by yourself In case of uncertainty please contact a KTM dealer TROUBLE CAUSE REMEDY Engine doesn t crank E starter Blown fuse Discharged battery Low outside temperature Dismount the left paneling and the filter box cover and replace the fuse in the starter relay Recharge the battery and investigate the causes for discharging contact a KTM dealer Use the 12 V 4 A h battery included in the scope of supply Engine cranks but doesn t start E Starter Engine will not start Kickstarter Engin
46. haft 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 see below Quantity of engine oil 1 1 liters 1 3 liters Primary drive Transmission claw shifted lst gear 2nd gear 3rd gear Ath gear 5th gear 6th gear Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator no generator 42 Watts at 10 000 rpm 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 Engine oil Only use fully synthetic engine oils that meet the JASO MA quality requirements JASO T903 MA see information on the can KTM recommends Motorex Power Synt 4T in the 1OW 50 viscosity for temperatures over 5 C 41 F or 5W 40 for temperatures under 5 C 41 F TEMPERATURE E CAUTION a Poor oil quality or minor quantity cause early engine wear 9W 40 10W 50 TIGHTENING TORQUES ENGINE 250 450 SX F Hexagon collar screw engine case clutch cover ignition cover water pump cover M6 Hexagon collar screw engine case clutch case Oil drain plug M12x1 5 20 Nm Allen head plug oil
47. he gear into idling and pull the upper chain strand with approx 10 15 Kilograms 33 Ib upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different places on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets i CAUTION Secure the screws of the chain wheel by applying Loctite 243 and fasten them in a crosswise order Tightening torque for nuts 35 Nm tightening torque for screws 50 Nm max 272 mm SHO 1l 2 3 AND ENGIN General information about KTM disc brakes BRAKE CALIPERS The brake calipers of this series use a floating mount This means that the brake calipers are not solidly attached to the caliper support which enables them to float for maximum braking contact Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 HHB sintered lining at the front and TOYO B 143 FF sintered lining at the back These linings provide an optimal combination of dosing brake performance and life cycle The lining type Is stated on the back of the brake pad and also recorded in the homologation papers Other brake pads are available f
48. hen closing the filler cap check that the tank venting hose is free of kinks CHAIN A loose chain can fall from the chain wheels an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear to the chain and chain wheels Excessive tensioning of the chain will put additional load on the components of the secondary drivetrain chain bearings of transmission and rear wheel Aside from resulting in premature wear if worst comes to worst the chain may rupture or the countershaft of the transmission may break TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as complete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at the hand brake lever and foot brake lever CABLES Check correct setti
49. ied skilled staff CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear When transporting your KTM ensure that it is held upright with restraining straps or other mechanical fastening devices and that the fuel tap is in the OFF position if the motorcycle should fall over no fuel can leak from the carburetor or fuel tank Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank Using other screws or longer screws can cause leaks in the tank through which fuel can flow out Do not use toothed washers or spring rings with the engine fastening screws as these work into the frame parts and keep working loose Instead use self locking nuts Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned Dispose oils fatty matters filters fuels washing detergents etc properly Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter of used oil contaminates 1 000 000 liters of water Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring 1 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE B
50. il to lubricate the transmission and the clutch The JASO MA standard responds to these special requirements Only use fully synthetic engine oils that meet the JASO MA quality requirements see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over 5 C 41 F or 5W 40 for temperatures under 5 C 41 F i CAUTION Insufficient oil or poor quality oil results in premature wear of the engine Changing the engine oil NOTE When changing the engine oil it is necessary to clean the short and long oil screens 450 SX F only one oil screen and to replace the oil filter Engine oil has be changed with the engine at an operating temperature i CAUTION An engine at operating temperature and the engine oil it contains are very hot do not burn or scald yourself Place the motorcycle on a horizontal surface remove the plug 1 and allow the oil to drain into a receptacle Clean plug with magnet thoroughly Once the entire oil has been drained clean the sealing surface mount the plug together with the sealing ring and tighten it to 20 Nm CLEANING THE SHORT OIL SCREEN 250 SX F AND OIL SCREEN 450 SX F The oil screen is accommodated in the hex socket plug 3 at the engine bottom Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dismount the oil screen clean the components thoroughly and blow c
51. ion components must be suitable for your weight At delivery KTM s offroad motorcycles are set to accommodate a driver weighing 75 85 kg wearing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accordingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring Is suitable for your weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined Determining the static sag of the shock absorber The static sag should be as close as possible to 33 mm 250 SX F or 35 mm 450 SX F Deviations of more than 2 mm can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A
52. k all functions thoroughly before starting up operations again A twisted handlebar must always be replaced Do not adjust the handlebar it will lose stability i CAUTION High rpm rates when the engine Is cold have an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this respect need to be taken The engine has reached its operating temperature as soon as the radiators become warm Never have the throttle wide open when changing down to a lower gear The engine will over rev damaging the valves In addition the rear wheel locks so that the motorcycle can easily get out of control If any abnormal vibrations occur while driving check that the engine fastening bolts are tight In the event that while riding on your motorcycle you notice any unusual operation related noise stop immediately turn the engine off and contact an authorized KTM dealer Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Always finish braking before you enter a curve Also change down to lower gears depending on your speed When driving down hill use the braking effect of the engine Change down one or two gears but do not
53. ke lever is not released the brake pads rub continuously and the braking system is overheated Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you this should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is comprised of the following components Motorcycle ready for operation and tank full Driver with protective clothing and helmet Pay attention to the running in procedure Running in Dress properly for the ride Smart KTM drivers always wear a helmet boots gloves and the right Enduro Motocross clothing Protective clothing should be conspicuous to make sure other road users see you in time Do not drive after drinking alcohol Always switch on the light while driving to make sure other road users see you in time Only use accessories approved by KTM Always use front and rear tires with the same tread pattern The 250 450 SX F models are designed and built for 1 person only No passengers are permitted Adjust your speed to the conditions and your driving skill Drive cauti
54. n addition to causing a higher noise level it will also affect the power characteristic The insulating material suitable for your exhaust is available from your authorized KTM workshop To replace remove all screws take off the cap 1 and outer pipe 2 Pull the glass fiber yarn packing 3 out of the inner pipe 4 Clean all parts thoroughly Slide a new glass fiber yarn packing over the inner pipe Mount a new O ring 5 and slide the outer pipe over the glass fiber yarn packing Mount a new O ring 6 and insert the cap in the outer pipe mount and tighten all screws NOTE In every exhaust repair procedure the O rings must be replaced by new ones Glass fiber yarn packings are available from your licensed KTM mechanic Make sure the caps are screwed on tightly Mount the muffler stress free before tightening the fixing screws AN WARNING ee The exhaust system becomes very hot while the motorcycle is running to avoid burns do not start work on the exhaust system until it has properly cooled down AND ENGIN Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accumulated To clean lift the filter box cover 1 Detach the filter retaining clip 21 at the bottom swing aside and take the air filter 31 and filter support 4 out of the filter box CAUTION Do not clean foam filter with fuel or petroleum since these damage the foam KTM recommends the pr
55. n the screws to 10 Nm Mount the hand brake cylinder and tighten the screws to 10 Nm Mount the starting number plate Mount the front wheel see Dismounting and mounting the front wheel Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcycle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust loosen the 5 clamp screws 1 and 3 on the upper triple clamp and tighten the blind screw 2 to 10 Nm With a plastic hammer lightly tap on the triple clamp to release tension Retighten the five pinch bolts to 17 Nm AA If the steering head bearing is not adjusted to be free of play the motor cycle will exhibit unsteady driving characteristics and can get out of control Apply Loctite 243 to the clamp screw 3 to lock in place i CAUTION If you drive with play in the steering head bearing for longer periods the bearings and subsequently the bearing seats in the frame will be destroyed The steering head bearings should be regreased at least once a year e g Motorex Long Term 2000 Checking the throttle cable installation Both throttle cables must run parallel along the back of the handlebar down to the frame They must run directly on the right side of the frame above the tank roller to the carburetor i CAUTION When mounting the tank make sure the throttle cables stay on the side
56. ng and easy running of all control cables COOLING FLUID Check the level of the cooling fluid when the engine Is cold Starting when the engine is cold Open the fuel tap 1 Swing up the side stand or center stand Put the gear in neutral Operate the choke 2 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter AA If you want to start the engine make sure that you always put on sturdy motorcycle boots in order to avoid injuries You might slip off the kickstarter or the engine may kick back Always kick the kickstarter briskly all the way without opening the throttle If you do not Kick hard enought with an open throttle grip the kick back hazard will be higher Do not start the engine and allow it to idle in a closed area Exhaust fumes are poisonous and can cause loss of consciousness and death Always provide adequate ventilation while the engine is running Always verify that the transmission has been set to idle neutral before actuating the starter button If you start the motorcycle with a gear engaged the motorcycle will move forward S CAUTION Maximal period for continuous starting 5 seconds Wait at least 5 seconds before trying again Don t ride your motorcycle with full load and don t rev up the engine when cold because the piston is warming up faster than the water cooled cylinder and can cause engine damage SWN NOTE If you ha
57. ng the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw counterclockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw clockwise increases the distance between the clutch lever and the handlebar i CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force 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 screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge 250 SX F if necessary fill up with brake fluid DOT 4 or DOT 5 1 e g Motorex Brake Fluid DOT 5 1 AA Never use DOT 5 brake fluid It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes rinse with plenty of water and consult a doctor i CAUTION Don t let brake fluid get in contact with paint it is an effective paint remo
58. not provided pressure will build up in the braking system and the front wheel brake may fail due to overheating Checking the brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handle bar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not drop below the middle of the glass AA If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately Refilling the front brake fluid reservoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water AA Never use DOT 5 brake fluid It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes rinse with plenty of water and consult a doctor i CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only
59. oducts of the company Motorex for air filter maintenance Bio Dirt Remover and Liquid Bio Power Never start your motorcycle without any air filters Otherwise dust and dirt may penetrate and cause damage and increased wear Dust and dirt can accumulate and damage the engine if the air filter is not mounted correctly Thoroughly wash the air filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Place the air filter on the filter support and insert both in the center of the filter box Hold in place with the filter retaining clip Adjusting the throttle cables The throttle grip should always provide for a backlash of 3 5mm 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 5 Loosen the counternut 6 and turn the adjusting screw 7 accordingly Turning the adjusting screw counterclockwise will reduce the backlash turning the adjusting screw clockwise will increase the backlash Tighten the counternut and check whether the throttle grip can be actuated smoothly Mount tank and seat AND ENGIN Changi
60. ompressed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and tighten the plug to 10 Nm 250 SX F or 30 Nm 450 SX F CLEANING THE LONG OIL SCREEN 250 SX F The long oil screen is accommodated in the hexagon plug 31 adjacent to the engine number Dismount the plug together with the oil screen clean the components thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them To mount the long oil screen 4 place it on an approx 300 mm 12 in long pin type key or a similar tool Insert the pin type key through the opening into the bore of the opposite engine casing wall Then push the oil screen into the engine casing as far as possible Remove the pin type key mount the plug and tighten it to 15 Nm i CAUTION The oil screen is mounted slightly downwards incorrectly fitted the screen looses its function and this can cause increased engine wear AND ENGIN Changing the oil filters Place a receptacle underneath the engine to collect the drained oil Remove the 2 screws 1 and dismount the oil filter cover Using circlip pliers pull the oil filter insert 2 out of the housing Clean the oil filter cover the sealing surface of the O ring and the engine casing Check the O ring of the oil filter covers for damage and if necessary replace It Put the motorcycle on its side and fill the oil
61. op then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber WP 12 18 7C 03 25 clicks WP 12 18 7C 05 25 clicks AA The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the screw connection 2 15mm AND WARNIN NE RA Instructions for initial operation Make sure the work for the pre delivery inspection was performed by your authorized KTM workshop The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle Read these operating instructions carefully before your first ride Familiarize yourself with the operating elements Set the clutch lever the handbrake lever and the footbrake pedal to the positions that are most convenient for you Get used to handling the motorcycle on an empty parking lot or open space before starting on a longer drive Also try to drive as slowly as possible and in a standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your ability and experience Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot bra
62. or competition sports FRONT TOSHIBA H 38 SINTERED harder to dose good brake per formance long life for wet slippery terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price REAR FERODO 4424 organic better controllability shorter service life for dry terrain TOSHIBA H38 Sinter longer service life than FERODO 4424 higher braking performance BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases The brake disk must be at least 2 50 mm front 3 50 mm rear thick at the thinnest point A Check the thickness of the brake disk at several points AN WARNING A brake disk worn down to less than 2 50 mm Front 3 50 mm Rear is a safety risk Have the brake disk replaced as soon as it reaches the service limit Have any repairs on the brake system be performed by a KTM dealer BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid DOT 5 1 brake fluid one of the best brake cu
63. ou can push the rear wheel forwards Take the chain off the rear sprocket pull out the wheel spindle and carefully remove the rear wheel from the swing arm i CAUTION Do not operate the rear brake when the rear wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be damaged If the axle is dismounted clean the thread of the wheel spindle and collar nut thoroughly and apply a new coat of grease to prevent the thread from jamming The rear wheel is remounted in the reverse order Before tightening the collar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws AA If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the rear wheel keep operating the rear brake until the pressure point returns It is very important to keep the brake disk free from oil and fatty matters eitherwise the braking effects would be strongly reduced Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become
64. ount carburetor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor Replace the float Clean or replace air filter Check if exhaust is damaged replace glasfiber yarn in exhaust silencer Adjust valve gap Have ignition system checked Engine stops or splutters in carburetor Insuffient fuel Engine takes air out of control Clean and check fuel system and carburettor Check rubber sleeve and carburetor for tight fit Engine gets too hot Insufficient cooling liquid Not enough air stream Cooling system has not been bled Radiators very dirty Foam formation in cooling system Bent cooling hose Refill cooling liquid see maintenace work check cooling system for leaks Drive on briskly Bleed cooling system Clean radiators with water jet Replace cooling liquid use antifreeze liquid with brand name Shorten or replace cooling hose High oil consumption The battery is discharged Hose of engine ventilation is bent Engine oil level too high Motor oil too thin viscosity The battery isn t charged by the generator because Dislocate i e replace non buckling vetilation hose Check engine oil level and if necessary correct it Use thicker engine oil see chapter Engine oil Remove seat and fuel tank and check voltage regulator connections voltage regulator and generator should be checked by a KTM dealer CLEANING
65. ously on unfamiliar roads or in unfamiliar terrain Always have a friend accompany you on his bike when driving off road so you can help each other if you run into trouble Replace the helmet visor or the lenses in your glasses in time A scratched visor or scratched lenses can make you practically blind in back light Never leave your motorcycle running unattended 250 450 SX F models are not permitted on public roads and highways When riding your motorcycle please remember that excessive noise may disturb others Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be broken in For this reason do not load the engine more than 50 of its capacity during the first 3 operating hours Besides the engine speed must not exceed 7000 rpm Avoid going full throttle In the following 12 operating hours you may load the engine up to 75 of Its capacity Check the following before each start When you start off the motorcycle must be in perfect technical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage FUEL Check that there is sufficient fuel in the tank w
66. p defective batteries away from children and dispose of properly i CAUTION Never remove the closure since it will be damaged NOTE The 450 SX F model is delivered with 2 batteries 12 volts 3 A h and 12 volts 4 A h The 4 A h battery should be used for temperatures below 10 C STORAGE If the motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature O 35 C avoid direct sunlight Charge the battery every 3 months AND ENGIN Charging the battery 450 SX F The battery discharges every day even if it is not used Always disconnect the battery when charging Charge the battery as described in the instructions 1 on the battery housing Do not exceed the amperage and charging time Quick charging at a high amperage has an adverse effect on the service life Always use special charging devices to charge maintenance free batteries e g the KTM charging device item no 58429074000 You can also use this charging device to test the off load voltage and startability of the battery and generator It is impossible to overcharge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the battery will run down and sulfatize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time i CAUTION Nev
67. park plug connect ignition cable hold to ground blank place on engine and actuate starter a strong spark 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 faspark now occurs replace spark plug cap f no spark is produced control ignition system Dismount the fuel tank disconnect the black yellow cable 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 short circuit circuit Remove the seat and the fuel tank Clean the plug connection and treat it with contact spray Dismount and clean the carburetor Disassemble the carburetor and clean the jets Have the carburetor adjusted Replace the spark plug Have the ignition system checked TROUBLE CAUSE REMEDY Engine does not rev up Engine will not reach full power Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition timing faulty Fuel supply partially interrupted or carburetor dirty Float leaks Air filter very dirty Exhaust system is not tight deformed or the silencer does not contain enough glassfiber yarn Valve gap too small Electronic ignition timing faulty Dism
68. ps have been fitted correctly After working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point isestablished Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motorcycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked in a vertical position AA If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately Refilling the rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 5 Fill DOT 5 1 brake fluid e g Motorex Brake Fluid DOT 5 1 up to the mark B on the inside of the reservoir and remount the screw Spilled brake fluid must be rinsed off with water AA Never use DOT 5 brake fluid It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes rinse with plenty of water and consult a doctor S CAUTION Don t let brake fluid get in contact with paint it is an effective p
69. rrently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible with DOT 5 1 Never use brake fluid DOT 5 The color of this silicon oil based product is purple red The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid AA Have the brake fluid changed at least once annually If you wash your motorcycle often the brake fluid should be changed even more frequently Brake fluid tends to absorb water Therefore vapor pockets may form in old brake fluids even at low temperatures causing the brake system to fail AND ENGIN Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 In this way the position of the point of pressure i e the resis tance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary i CAUTION At the hand brake lever free travel must at least be 3 mm 0 1 in Only then may the piston in the hand brake cylinder be moved to be recognized by the greater resistance of the hand brake lever If this free travel is
70. ructions may damage parts of the motorcycle or impair the motorcycle s traffic safety At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it SERVICE Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in
71. st caution Never perform any work on the fuel system near open flames or burning cigarettes Always allow the engine to cool off first Immediately clean up any fuel which may have been spilled Materials saturated with fuel are also easily flammable In case you ingested fuel or fuel splashed into your eyes consult a doctor immediately Dispose of the fuel properly Checking the engine oil level The engine oil level can be checked with the engine either warm or cold Place the motorcycle in an upright position and on a horizontal surface not on the side stand If the engine is cold the engine oil must be visible at the lower edge of the inspection glass A If the engine is warm the engine oil must be visible up to the upper edge of the inspection glass B Replenish the engine oil if necessary i CAUTION Insufficient amounts of or low grade engine oil lead to premature wear in the engine JASO T903 MA TEMPERATURE 5 C 41 F 9W 40 10W 50 gt Engine oil Automobile engine oil used to be used for four stroke motorcycles before there were separate motorcycle specifications Different technical developments made it necessary to have a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas car engines require long changing intervals motorcycle engines require a higher power output at higher speeds Most motorcycle engines also use the same o
72. to touch it and get burned S CAUTION Close the fuel tap when leaving your vehicle Otherwise the carburettor can flood and fuel will enter the engine Never park your motorcycle in places where there are fire hazards due to dry grass or other easily flammable materials Fuel The racing engine needs unleaded fuel with at least RON 95 USA Premium RON 91 S CAUTION Use leaded or unleaded premium grade gasoline 95 octanes Never use gasoline having less than 95 octanes because it may damage the engine AN WARNING Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refuelling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately Fuel expands when ts temperature rises Therefore do not fill the tank to the top see fig 1st service after every 250 450 SX F 2007 3 hours 10 hours A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY or or 20 fuel 70 fuel Change engine oil oil filter Clean oil screen and drain plug magnet Replace spark plug after 30 hours Check and adjust valve clearance ENGINE Check engine mounting bolts for tightness Clean the spark plug
73. unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes lf necessary have the spokes retightened and the wheel centered by a KTM dealer AA Spokes can tear if you continue to ride with them loose This may lead to an unstable handling of your motorcycle Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 4 5 6 Nm TIRES AIR PRESSURE front rear AND ENGIN Tires air pressure Tire type tire condition and air pressure level affect the way your motor cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them We recommend you replace the tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pressure ensures optimum driving comfort and extends the life of your tires AA Do not mount tires which have not been approved by KTM Other tires could have ad
74. ve trouble starting the motorcycle this could be due to old fuel in the float chamber The easily inflammable components of the new fuels evaporate during longer periods of standstill 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 off when the float chamber is filled with new fuel Starting when the engine is warm Open the fuel tap 1 Swing up the side stand Put the gear in neutral Pull the hot start lever Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter SWN What to do when the engine is flooded The fork legs must be partly disassembled to change the spring preload see WP manual Pretension spacers in various thicknesses are available see spare parts catalog NOTE The carburetor has an accelerator pump Every time you open the throttle fuel will be injected into the intake passage When starting be sure that you open the throttle completely only once JR NG IND IR JN Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and open the throttle at the same time Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the conditions hill size etc you can shift to a higher gear Close throttle at the same time pull clutch lever in and shift to the n
75. ver Use only clean brake fluid taken from a tightly sealed container 450 SX F if necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Kupplungs Fluid 75 Biodegradable hydraulic oil is available from your KTM dealer 50ml S CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch of the 450 SX F model Do not mix this oil with any other hydraulic oil Always use original KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid Bleeding of the hydraulic clutch If the clutch lever starts to feel unresponsive the clutch control system needs to be bled You will need a bleeder syringe Special tool available from your KTM dealer Turn the handlebar until the master cylinder is in a horizontal position remove the screws 2 the cover 3 and the rubber boot 4 Fill the bleeder syringe 5 with brake fluid 250 SX F or biodegradable hydraulic oil 450 SX F i CAUTION KTM uses brake fluid DOT 5 1 for 250 SX F and biodegradable hydraulic mineral oil for 450 SX F to actuate the hydraulic clutch see above Remove the bleeder screw 6 from the slave cylinder and mount the bleeder syringe Press oil into the system until the oil runs out of the hole 7 in the master cylinder without bubbles Occasionally extract the oil from the master cylinder reservoir to keep it from overflowing
76. verse effects on the way your motorcycle behaves front and rear wheels may only be fitted with tires having the same tread layout For your own safety replace damaged tires immediately Worn tires can have a negative effect on how your motorcycle performs especially on wet surfaces If air pressure is too low abnormal wear and overheating of the tire can result Battery 450 SX F The battery is located under the seat and Is maintenance free Maintenance free means you will not need to check the acid level Clean the battery terminals regularly and grease with acid free grease if necessary The charge condition and type of charge are very important for the battery s service life TO REMOVE THE BATTERY First disconnect the negative pole then the positive pole from the battery Remove the filter box cover and detach the rubber band Remove the baitery Install the battery as described for the specific type of battery see illustration Connect the minus pole to the battery last AN WARNING ee Be extremely careful if any electrolyte sulfuric acid runs out of the battery Electrolyte can cause severe burns Rinse with plenty of water if coming into contact with the skin If electrolyte gets in your eyes rinse with water for at least 15 minutes and consult a doctor immediately Although the battery is sealed explosive gases can escape Keep the battery away from sparks or open flame Kee
77. wn in bold print After installing a different spring readjust the static sag to 33 35 mm 2 mm According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring WP14 18 7C 03 250 SX F WP14 18 7C 05 450 SX F 4 6 N mm 4 8 N mm SPRING RATE 65 70 79 80 85 90 95 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM AND ENGIN Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons Similar to the shock absorber smaller deviations in your weight can be compensated by adjusting the spring preload However if your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Changing the spring preload on the telescopic fork The fork legs must be partly disassembled to change the spring preload see WP manual Pretension spacers in various thicknesses are available see spare parts catalog NOTE WP precisely adjusts the spring pressure by inserting pretension spacers Fluctuations in production are compensated with pretension spacers in various heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and pretension spacers should always st
78. ycle The low and high speed technology overlaps The low speed setting Is primarily for slow to normal shock absorber compression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counter clockwise will decrease the damping STANDARD HIGH SPEED SETTING turn the adjusting screw 4 to the limit in a clockwise direction using a box wrench unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction WP 12 18 7C 03 1 turn WP 12 18 7C 05 1 turn STANDARD LOW SPEED SETTING turn the adjusting screw 5 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction WP 12 18 7C 03 15 clicks WP 12 18 7C 05 15 clicks AA The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the black screw connection 61 24mm Rebound damping of shock absorber By using the adjusting screw 1 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn the adjusting screw clockwise to the st

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