2005-2010 KTM 250 SX-F, EXC-F, EXC-F SIIX DAYS XCF-W, XC-F, SXS-F service manual

Table of Contents

1. Introduction

• General Information
• Safety Precautions
• Model Identification

2. Exploded View

• Front Fork
• Rear Shock
• Engine Components
• Electrical System

3. Disassembly Forkleg

• Removal of Forkleg
• Disassembly of Forkleg Components

4. Disassembly Cartridge

• Cartridge Removal
• Disassembly of Cartridge Components

5. Disassembly Compression Holder

• Compression Holder Removal
• Disassembly of Compression Holder Components

6. Assembling Compression Holder

• Reassembly of Compression Holder Components
• Installation of Compression Holder

7. Disassembly Tap Rebound

• Rebound Tap Removal
• Disassembly of Rebound Tap Components

8. Assembling Tap Rebound

• Reassembly of Rebound Tap Components
• Installation of Rebound Tap

9. Assembling Cartridge

• Reassembly of Cartridge Components
• Installation of Cartridge

10. Assembling Forkleg

• Reassembly of Forkleg Components
• Installation of Forkleg

11. Engine

• Engine Removal
• Engine Disassembly
• Engine Inspection
• Engine Reassembly
• Engine Installation

12. Fuel System

• Fuel Tank Removal
• Carburetor Disassembly
• Fuel Pump Inspection
• Fuel System Reassembly

13. Cooling System

• Radiator Removal
• Water Pump Disassembly
• Cooling System Inspection
• Cooling System Reassembly

14. Electrical System

• Battery Inspection
• Wiring Harness Inspection
• Electrical Components Testing
• Electrical System Reassembly

15. Transmission

• Transmission Removal
• Transmission Disassembly
• Transmission Inspection
• Transmission Reassembly
• Transmission Installation

16. Suspension

• Front Suspension Inspection
• Rear Suspension Inspection
• Suspension Adjustment
• Suspension Reassembly

17. Brakes

• Brake System Inspection
• Brake Pad Replacement
• Brake Fluid Replacement
• Brake System Reassembly

18. Wheels and Tires

• Wheel Removal
• Tire Replacement
• Wheel Inspection
• Wheel Installation

19. Frame and Bodywork

• Frame Inspection
• Body Panel Removal
• Body Panel Installation

20. Maintenance Schedule

• Periodic Maintenance Chart
• Lubrication Points
• Maintenance Procedures

21. Troubleshooting

• Engine Troubleshooting
• Electrical Troubleshooting
• Suspension Troubleshooting
• Transmission Troubleshooting

22. Wiring Diagrams

• Electrical Schematic
• Wiring Diagram

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