KTM 2012 250 SX-F Betriebsanleitung

In-Depth Engine and Fuel

System Maintenance and

Repair Manual

2012 KTM 250 SX-F

Jeremy Jonas

December 2, 2013

Denton, TX

iii

Table of Contents

Table of Contents................................................ ii

Introduction ....................................................... 1

Troubleshooting.................................................. 3

Fuel System .................................................... 3

Engine ............................................................ 4

Common Maintenance and Repairs: Fuel System .... 5

Replacing the Fuel Filter.................................... 5

Changing the Fuel Injector ................................ 7

Replacing the ECU...........................................8

Testing the Fuel Pump…………………………………………10

Common Maintenance and Repairs: Engine .......... 11

Checking Valve Clearance……………………………………11

Changing the Piston…………………………………………….13

Checking the Cylinder for Wear and Damage…….18

Checking the Crank Rod Bearings for Wear……….20

Checking the Main Crank Bearings for Wear………21

Checking the Timing…………………………………………….22

Engine Tightening Torques ................................. 23

Bibliography ..................................................... 26

Index…………………………………………………………………..……27

Introduction

Congratulations on your purchase of the 2012 KTM

250 SX-F. The purpose of this manual is to assist

you in completing important maintenance and

repairs for your KTM motorcycle. Through following

the original KTM Owners’ Manual and this additional

reference, you will be able to more independently

work your motorcycle. This manual covers two main

sections, Fuel, and Engine. When a problem arises

with your motorcycle, refer to the troubleshooting

section and then look to the suggested instructions

for the diagnosed issue. For maintenance, you

should follow the original maintenance procedures

from the KTM Owners’ Manual. The instructions for

the common Engine and Fuel maintenance that are

not included in the Owners’ Manual can be found in

this Manual.

Note: This manual only covers in-depth Fuel and

Engine work that is not included in the Owner’s

Manual.

Troubleshooting

Troubleshooting: Fuel System

Problem

Possible

Cause

Solutions

Bike speeds

up too

slowly or

sputters

when

accelerating

Dirty Fuel Filter

Replace fuel

filter (pg. 4)

Faulty Fuel

Injector

Replace fuel

injector (pg. 7)

Bad Fuel

Empty fuel tank

and re-fill with

new unleaded

ethanol-free

gas.

Loss of fuel

pressure/Bad

fuel pump

Check fuel

hoses for loose

fittings and

possible leaks

Test fuel pump

(pg.10)

ECU Issue

Replace ECU

(pg.8)

Take existing

ECU to KTM

dealership for

re-mapping

Engine

cranks but

does not

start

Bad fuel pump

Check fuel

hoses for loose

fittings and

possible leaks

Test fuel pump

(pg.10)

Troubleshooting: Engine

Problem

Possible Cause

Solutions

Engine

Rattling

Improper Valve

Clearance

Adjust

Valves(pg.11)

Engine timing off

Adjust

Timing(pg.23)

Excess Piston

Wear

Replace piston

and rings(pg.13)

Excess Rod

Bearing Wear

Check crank rod

bearings(pg.21)

Loss of

Power

Excess Piston

Wear

Replace piston

and rings(pg.13)

Smoke

coming

out of

exhaust

Damaged

Cylinder

Check and

replace Cylinder,

piston, and rings

(pg.13)

Check oil level

Engine

will

crank

but

won’t

start

Improper Valve

Clearance

Adjust Valves

(pg.11)

Engine timing off

Adjust Timing

(pg.23)

Engine

won’t

turn over

Possible damaged

Piston, Cylinder,

or Crankshaft

Check Piston

Check Cylinder

Check Crank

Inhaltsverzeichnis

Andere KTM Motorrad Handbücher

KTM

KTM 250 EXC-F Six Days 2021 Handbuch

KTM

KTM 125 EXC EU 2012 Handbuch

KTM

KTM 125 EXC EU 2014 Handbuch

KTM

KTM 400 EXC EU 2009 Handbuch

KTM

KTM 1190 Adventure R EU Bedienungsanleitung

KTM

KTM 450 SX F EU 2010 Handbuch

KTM

KTM 690 Enduro R EU 2009 Betriebsanleitung

KTM

KTM 450 SMR 2021 Handbuch

KTM

KTM 1290 Super Adventure S 2017 Handbuch

KTM

KTM 990 Super Duke R EU 2013 Handbuch

KTM

KTM 85 SX 2017 Handbuch

KTM

KTM 250 EXC TPI 2019 Betriebsanleitung

KTM

KTM 790 Adventure 2019 Bedienungsanleitung

KTM

KTM F8475S0 2019 Bedienungsanleitung

KTM

KTM RC 125 2016 Handbuch

KTM

KTM 125 Duke 2016 Handbuch

KTM

KTM 450SMS 2004 Bedienungsanleitung

KTM

KTM 125 DUKE EU Betriebsanleitung

KTM

KTM F5303U5 2021 Bedienungsanleitung

KTM

KTM 390 ADVENTURE 2022 Handbuch

KTM

KTM 1190 Adventure R EU 2013 Handbuch

KTM

KTM 1290 Super Adventure S 2018 Bedienungsanleitung

KTM

KTM 1290 SUPERDUKE R Bedienungsanleitung

KTM

KTM 3214489en Handbuch

Beliebte Motorrad Handbücher anderer Marken

OHVALE

OHVALE GP-0 Stücklistenhandbuch

Yamaha

Yamaha Star XV19CTSZ 2009 Bedienungsanleitung

HYOSUNG

HYOSUNG ST7 Bedienungsanleitung

Husqvarna

Husqvarna FC 250 2016 Bedienungsanleitung

Ducati

Ducati SCRAMBLER 800 Gebrauchsanweisung

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Bedienungsanleitung

Yamaha

Yamaha 2006 YZF-R1V Bedienungsanleitung

Fantic

Fantic Enduro 125 Bedienungsanleitung

Ducati

Ducati Supersport 750 desmodue Bedienungsanleitung

MV Agusta

MV Agusta 2008 F4 312RR 1078 Gebrauchsanweisung

Yamaha

Yamaha XVS650A Bedienungsanleitung

Yamaha

Yamaha YZF-R6T(C) Handbuch

Ducati

Ducati 748 monoposto strada Bedienungsanleitung

ATK

ATK 1988 250 Bedienungsanleitung

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Bedienungsanleitung

Triumph

Triumph Thunderbird Bedienungsanleitung

Yamaha

Yamaha 2006 FJR1300A Bedienungsanleitung

Ducati

Ducati 996 Bedienungsanleitung