User manual KTM 250 XCF-W USA 2009

[. . . ] OWNER'S MANUAL 2009 250 EXC-F EU 250 EXC-F AUS 250 EXC-F SIX DAYS EU 250 XCF-W USA 250 XCF-W ZA 250 XC-F USA 250 SX-F EU 250 SX-F USA ART. 3211348en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. [. . . ] 72) MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork protector 13. 30 50 x ­ ­ ­ Remove the fork legs. Remove the fork protector upwards. 500105-10 Installing the fork protector 13. 31 x ­ Position the fork protection on the left fork leg. Guideline Remaining screws, chassis ­ Guideline Remaining screws, chassis ­ 500105-10 M6 10 Nm (7. 4 lbf ft) Position the fork protection on the right fork leg. 49) 10 Nm (7. 4 lbf ft) Install the fork legs. x( Removing the lower triple clamp 13. 32 x (EXCF SIX DAYS, XCFW USA, XCF, SXF) ­ Remove the fork legs. ( (250 EXC-F SIX DAYS EU) ­ Remove the headlight mask with the headlight. 53) Remove screws and hang the CDI control unit to the side. Info Do not unplug the CDI control unit. Remove screw , take off the top triple clamp with the handlebar and place it on one side. Info 500099-10 Protect the motorcycle and its attachments from damage by covering them. Remove the upper steering head bearing. 500100-10 MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp 13. 33 51 x (EXCF EU, EXCF AUS, XCFW ZA) ­ ­ ­ ­ Remove the fork legs. ( Remove screws and hang the CDI control unit to the side. Info Do not unplug the CDI control unit. Take off top triple clamp with the handlebar and place it on one side. Info 500149-10 Protect the motorcycle and its attachments from damage by covering them. Remove the upper steering head bearing. 500150-10 Installing the lower triple clamp 13. 34 x (EXCF SIX DAYS, XCFW USA, XCF, SXF) ­ Clean the bearing and sealing elements, check for damage, and grease. Mount the upper steering head bearing. 3 0 2 0 1 0 Info Check whether the top steering head seal is correctly positioned. ­ Push up protective ring and O-ring . 500098-10 ­ ­ Position the upper triple clamp with the steering. Guideline Screw, top steering head M20x1. 5 10 Nm (7. 4 lbf ft) ­ Position the clutch line, wiring harness and CDI control unit. 54) 10 Nm (7. 4 lbf ft) 500099-11 ­ Install the front fender. ( MAINTENANCE WORK ON CHASSIS AND ENGINE (250 EXC-F SIX DAYS EU) ­ Refit the headlight mask with the headlight. M8 17 Nm (12. 5 lbf ft) Loctite® 243TM Check the cable harness, cable, brake and clutch line for free movement and free laying. 46) Installing the lower triple clamp 13. 35 x (EXCF EU, EXCF AUS, XCFW ZA) ­ Clean the bearing and sealing elements, check for damage, and grease. Mount the upper steering head bearing. 2 0 1 0 ­ Info Check whether the top steering head seal is correctly positioned. Push on protective ring . 500151-10 ­ ­ Position the upper triple clamp with the steering. Guideline Screw, top steering head M20x1. 5 10 Nm (7. 4 lbf ft) ­ Position the clutch line, wiring harness and CDI control unit. 49) 10 Nm (7. 4 lbf ft) 500149-11 ­ ­ ­ ­ Install the front fender. [. . . ] 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 35 mm (1. 38 in) 105 mm (4. 13 in) 411 mm (16. 18 in) 26 clicks 24 clicks 22 clicks 9 mm (0. 35 in) 2 turns 1. 5 turns 1 turn 18 clicks 15 clicks 12 clicks 12. 18. 7E. 04 WP Suspension PDS 5018 DCC 250 XC-F USA 22. 2 Shock absorber part number Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Spring rate Weight of rider: 65. . . 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 12. 18. 7E. 28 WP Suspension PDS 5018 DCC 17 clicks 15 clicks 13 clicks 1 turn 1 turn 3/4 turn 25 clicks 25 clicks 23 clicks 5 mm (0. 2 in) 66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 33 mm (1. 3 in) 112 mm (4. 41 in) 411 mm (16. 18 in) TECHNICAL DATA - SHOCK ABSORBER 250 SX-F EU 22. 3 104 Shock absorber part number Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Spring rate Weight of rider: 65. . . 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 12. 18. 7E. 03 WP Suspension PDS 5018 DCC 17 clicks 15 clicks 13 clicks 1. 5 turns 1. 5 turns 1 turn 24 clicks 22 clicks 21 clicks 6 mm (0. 24 in) 66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 33 mm (1. 3 in) 105 mm (4. 13 in) 411 mm (16. 18 in) 250 SX-F USA 22. 4 Shock absorber part number Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Spring rate Weight of rider: 65. . . 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 12. 18. 7E. 22 WP Suspension PDS 5018 DCC 17 clicks 15 clicks 13 clicks 1 turn 1 turn 3/4 turn 25 clicks 24 clicks 22 clicks 7 mm (0. 28 in) 66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 33 mm (1. 3 in) 107 mm (4. 21 in) 411 mm (16. 18 in) TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 23 105 ­ ­ ­ ­ ­ ­ ­ ­ ­ Loctite® 243TM ­ ­ ­ Loctite® 243TM ­ Spoke nipple, front wheel Spoke nipple, rear wheel Screw, spoiler on fuel tank (250 XCFW USA, 250 XC-F USA) Remaining nuts, chassis Remaining screws, chassis Screw, rear brake disc Screw, front brake disc Screw, shock absorber adjusting ring Screw, ball joint of push rod on footbrake cylinder Nut, rear sprocket screw Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, front brake caliper Screw, top triple clamp (EXCF SIX DAYS, XCFW USA, XCF, SXF) Screw, top triple clamp (EXCF EU, EXCF AUS, XCFW ZA) Screw, bottom triple clamp (EXCF SIX DAYS, XCFW USA, XCF, SXF) Screw, bottom triple clamp (EXCF EU, EXCF AUS, XCFW ZA) Screw, fork stub Screw, top steering stem (EXCF SIX DAYS, XCFW USA, XCF, SXF) Screw, top steering stem (EXCF EU, EXCF AUS, XCFW ZA) Screw, handlebar clamp (EXCF EU, EXCF AUS, XCFW, XCF, SXF) Screw, handlebar clamp (250 EXCF SIX DAYS EU) Screw, engine brace Screw, subframe Screw, side stand fixing Engine carrying screw Remaining nuts, chassis Remaining screws, chassis Screw, handlebar support Nut, seat fixing Screw, top shock absorber Screw, bottom shock absorber Nut, swingarm pivot Screw-in nozzles, cooling system Nut, rear wheel spindle Screw, top steering head Screw, bottom steering head (XCFW USA, XCF, SXF) Screw, front wheel spindle M4, 5 M5 M5x12 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 5 Nm (3. 7 lbf ft) 5 Nm (3. 7 lbf ft) 1. 5 Nm (1. 11 lbf ft) 15 Nm (11. 1 lbf ft) 10 Nm (7. 4 lbf ft) 14 Nm (10. 3 lbf ft) 14 Nm (10. 3 lbf ft) 5 Nm (3. 7 lbf ft) 10 Nm (7. 4 lbf ft) 35 Nm (25. 8 lbf ft) 10 Nm (7. 4 lbf ft) 30 Nm (22. 1 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 17 Nm (12. 5 lbf ft) M8 M8 20 Nm (14. 8 lbf ft) 12 Nm (8. 9 lbf ft) ­ ­ M8 M8 M8 15 Nm (11. 1 lbf ft) 15 Nm (11. 1 lbf ft) 17 Nm (12. 5 lbf ft) ­ ­ Loctite® 243TM M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M12x1 M12 M12 M16x1. 5 M20x1. 5 M20x1. 5 M20x1. 5 M20x1. 5 M24x1. 5 20 Nm (14. 8 lbf ft) 20 Nm (14. 8 lbf ft) 16 Nm (11. 8 lbf ft) 33 Nm (24. 3 lbf ft) 35 Nm (25. 8 lbf ft) 40 Nm (29. 5 lbf ft) 60 Nm (44. 3 lbf ft) 50 Nm (36. 9 lbf ft) 45 Nm (33. 2 lbf ft) 40 Nm (29. 5 lbf ft) 20 Nm (14. 8 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 100 Nm (73. 8 lbf ft) 12 Nm (8. 9 lbf ft) 80 Nm (59 lbf ft) 10 Nm (7. 4 lbf ft) 60 Nm (44. 3 lbf ft) 45 Nm (33. 2 lbf ft) ­ ­ ­ ­ Loctite® 243TM Loctite® 243TM ­ ­ ­ Loctite® 243TM ­ Loctite® 243TM Loctite® 243TM ­ Loctite® 243TM ­ ­ Loctite® 243TM ­ WIRING DIAGRAM WIRING DIAGRAM 24 24. 1 106 Wiring diagram (EXC-F EU, EXCF SIX DAYS) H18 H2 H4 bu br H15 P1 H7 H11 bl pu CX/2 CW/2 CZ/3 CY/3 DB/4 DA/4 S2 AK1/2 CW3/2 CX3/2 DG/4 BP/4 CW2/2 CX2/2 AH1/2 1 3 2 1 2 3 1 2 4 v B3 br-bl bu re br br ye-re wh S5 bl bl 1 2 1 2 1 pu 2 br bl-wh br bu-wh L2 1 2 BU/18 1 gn EH/1 bu-wh br gr ye-bl re-wh 3 wh 2. 1 4 br EI/1 2 ye bl br wh-gn bu 3 wh bu gn ye re br ye-bl gr ye-bl 1 BF1/1 BA1/1 BC/6 AC/6 S6 64 5 1 2 S7 re ye-re BA/1 BF/1 K2 ye-bl ye-re br ye-re BO/2 BV/2 H13 ye-re or 2 1 2 AH2/2 G br 1 CD I A6 AM/3 AR/3 4 5 7 6 11 10 12 13 14 3 2 1 S8 3 re-bl gn re bu ye bl M H14 br bl or pu bl ye-bl BT/3 BG/3 br t br bl S10 2 1 BA2/1 E6 5A bl ye bu ye-re br bl br ye-re BR/4 BK/4 1 2 wh-re B1 br 3 bl 2 1 re gn br L1 M1 4 AL/2 AT/2 3 G G2 CX1/2 CW1/2 re-bl re-wh ye K1 wh bl ye 1 3 wh-gn BG1/3 2 1 AT1/2 CR/1 CR1/1 AL1/2 M 43 AJ1/3 pu 2 bl AF/4 br 12 AH/2 AK/2 wh-re ye-re S1 10 A 2 G1 br ye-re 1 ye wh 2 4 3 bl br pu 1 br CA/4 br 1 2 wh-gn wh CE/4 2 3 2. 2 2. 1 wh br 2 DI/2 BV/2 BS/2 CX/2 2 1 AJ/3 BG/3 CW/2 1 H5 U H9 H3 H1 N2 600699-01 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H1 H2 H3 H4 H5 H7 H9 H11 H13 H14 H15 H18 K1 K2 L1 L2 M1 N2 P1 S1 S2 S5 S6 S7 S8 S10 Cable colors bl bl-wh br br-bl bu bu-wh gn gr or pu re re-bl re-wh wh wh-gn wh-re ye ye-bl Black Black-white Brown Brown-black Blue Blue-white Green Gray Orange Violet Red Red-black Red-white White White-green White-red Yellow Yellow-black CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC-F SIX DAYS) Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC-F SIX DAYS) Flasher indicator light High beam indicator light Starter relay with main fuse Flasher relay Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Rear brake light switch Front brake light switch Tripmaster switch (optional) Light switch Horn button, short circuit button Flasher switch Electric starter button 107 WIRING DIAGRAM ye-re Yellow-red 108 WIRING DIAGRAM 109 WIRING DIAGRAM Wiring diagram (250 EXC-F AUS) 24. 2 110 H18 H2 H4 bu br H15 P1 H7 H11 bl pu CX/2 CW/2 CZ/3 CY/3 DB/4 DA/4 1 S2 AK1/2 3 2 1 2 3 1 2 4 v B3 bu re br-bl br br ye-re wh S5 bl bl CW3/2 CX3/2 DG/4 BP/4 CW2/2 CX2/2 AH1/2 1 2 1 2 1 gn 3 wh 2 4 1 2 ye bl br wh-gn br bu 3 wh bu gn ye re br ye-bl BF1/1 S6 br pu br L2 bu-wh BC/6 AC/6 64 5 1 2 BA1/1 S7 ye-bl BA/1 BF/1 re H13 K2 ye-re ye-bl ye-re br ye-re br bu-wh ye-re or 1 BU/18 BO/2 2 2 BV/2 G AH2/2 br ye-bl re-wh 2 1 1 CD I A6 AM/3 AR/3 5 7 6 11 10 12 13 14 3 2 1 S8 3 re-bl gn re bu ye or pu bl BT/3 BG/3 2 1 ye-bl S10 BA2/1 bl ye-re wh-re 43 BR/4 BK/4 bl ye br bl 21 S11 bu br B1 L1 2 1 re ye-re gn br AL/2 AT/2 M1 21 M BS/2 K1 bl 43 AF/4 3 G G2 CX1/2 CW1/2 2 1 re-bl re-wh AT1/2 wh-re CR1/1 AL1/2 10 A 2 ye-re CR/1 ye G1 wh bl pu 3 BG1/3 AJ1/3 CA/4 CE/4 br 1 bl br ye wh-gn 12 AH/2 AK/2 br ye-re ye wh S1 2 1 4 3 2 br pu br wh wh-gn 1 1 2 2 3 CX/2 2 AJ/3 1 CW/2 BG/3 wh br 2 DI/2 BV/2 BS/2 U N2 1 H5 H9 H3 H1 600698-01 WIRING DIAGRAM Components A6 B1 B3 G1 G2 H1 H2 H3 H4 H5 H7 H9 H11 H13 H15 H18 K1 K2 L1 L2 M1 N2 P1 S1 S2 S5 S6 S7 S8 S10 S11 Cable colors bl br br-bl bu bu-wh gn or pu re re-bl re-wh wh wh-gn wh-re ye ye-bl ye-re Black Brown Brown-black Blue Blue-white Green Orange Violet Red Red-black Red-white White White-green White-red Yellow Yellow-black Yellow-red CDI controller Throttle position sensor Wheel speed sensor Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Flasher indicator light High beam indicator light Starter relay with main fuse Flasher relay Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Rear brake light switch Front brake light switch Tripmaster switch (optional) Light switch Horn button, short circuit button Flasher switch Electric starter button Emergency OFF switch 111 WIRING DIAGRAM Wiring diagram (XCFW, 250 XC-F USA) 24. 3 112 P1 H7 H11 v re bu wh br B3 bl bl br ye-re wh br wh S5 S12 br ye-bl S6 wh bl-wh L2 S10 ye bu-wh br ye-bl re-wh re-bl gn re bu ye bl ye-re wh-re black ye-bl CD I A6 B1 L1 br H14 br bl E6 M br t bl 5A ye bu ye-re br bl br bl br M1 re M gn K1 re-bl re-wh ye br wh-re 3 G G2 10 A ye-re G1 wh br ye-re ye wh br wh U N2 H5 600700-01 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H5 H7 H11 H14 K1 L1 L2 M1 N2 P1 S5 S6 S10 S12 Cable colors bl bl-wh br bu bu-wh gn re re-bl re-wh wh wh-re ye ye-bl ye-re Black Black-white Brown Blue Blue-white Green Red Red-black Red-white White White-red Yellow Yellow-black Yellow-red CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XCF-W ZA) Battery Generator Brake/tail light (XCF-W ZA) Parking light (XCF-W ZA) Low beam (XCF-W ZA) Radiator fan (XCF-W ZA) Starter relay with main fuse Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Tripmaster switch (optional) Light switch Electric starter button Short circuit button 113 114 G 3 S12 G2 bl ye-bl re-wh re-bl gn re br bu-wh 12576 11 10 12 13 14 CD I A6 3 AM/3 AR/3 2 1 WIRING DIAGRAM B1 L1 L2 Wiring diagram (SXF) 24. 4 600701-01 WIRING DIAGRAM Components A6 B1 G2 L1 L2 S12 Cable colors bl br bu-wh gn re re-bl re-wh ye-bl Black Brown Blue-white Green Red Red-black Red-white Yellow-black CDI controller Throttle position sensor Generator Pulse generator Ignition coil Short circuit button 115 SUBSTANCES SUBSTANCES 25 116 Brake fluid DOT 4 / DOT 5. 1 According to ­ DOT Guideline ­ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. 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