KTM 250 SX-F 2006 Repair Manual

KTM 250 SX-F 2006

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250 SX-F, EXC-F, EXC-F

SIX DAYS

SIX DAYS

XCF-W, XC-F, SXS-F

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

ART.NR.: 3.206.052-E

REPAIRMANUAL2005-2008

Table of Contents

Other manuals for KTM 250 SX-F 2006

Owner's Manual70 pages

Questions and Answers:

N
Noah HardingAug 14, 2025
Why does my KTM Motorcycle engine get too hot?
- J
  Jessica FreemanAug 15, 2025
  If your KTM Motorcycle engine is overheating, several factors could be the cause. First, check and refill the cooling liquid, also inspect the cooling system for any leaks. Ensure there's adequate airflow while riding; consider retrofitting an electric fan if needed. Make sure the cooling system is properly bled and the radiators are clean. If foam is present in the cooling system, replace the coolant with a brand-name antifreeze liquid. Inspect cooling hoses for bends and replace if necessary. Check the thermostat for proper operation (opening temperature 70°C or 158°F). If you have an XC Desert model, check and replace the fan fuse if blown.
L
lindseyharperAug 18, 2025
Why my KTM Motorcycle engine will not reach full power?
- D
  Dennis PearsonAug 18, 2025
  If your KTM Motorcycle isn't reaching its full power, start by checking the fuel system and carburetor for dirt or blockages, and clean them if necessary. Replace the float if it leaks. Ensure the air filter is clean; if it's very dirty, clean or replace it. Inspect the exhaust system for damage and ensure it's tight; replace the glass fiber yarn in the exhaust silencer if needed. Also, check and adjust the valve gap. Finally, check the setting of the hand decompression cable.
S
Shawn GreenAug 25, 2025
How to fix KTM Motorcycle when engine doesn’t crank?
- T
  Tracy BakerAug 26, 2025
  If your KTM Motorcycle engine doesn't crank with the E-starter, the issue might be a blown fuse. To resolve this, dismount the left paneling and the filter box cover and replace the fuse in the starter relay. Another possibility is a discharged battery; recharge it and investigate the causes of the discharge. Also, ensure the emergency-OFF switch is turned on (Australia only).
B
Bonnie JohnsAug 28, 2025
What causes a KTM Motorcycle engine to fail to idle?
- M
  matthewbakerAug 28, 2025
  If your KTM Motorcycle engine fails to idle, the problem could be a clogged idling jet. Disassemble the carburetor and clean the jets. Also, the spark plug may be defective and require replacement.
M
Michael WilliamsAug 31, 2025
What to do if KTM Motorcycle engine stops or splutters in carburetor?
- J
  Jeremiah BautistaAug 31, 2025
  If your KTM Motorcycle engine stops or sputters in the carburetor, it could be due to insufficient fuel. Clean and check the fuel system and carburetor. Also, check the rubber sleeve and carburetor for a tight fit, as the engine might be taking in air uncontrollably.
R
Robert ScottSep 3, 2025
Why does my KTM Motorcycle have high oil consumption?
- E
  Eric ColemanSep 3, 2025
  If your KTM Motorcycle has high oil consumption, check if the hose of the engine ventilation is bent. If it is, dislocate or replace it with a non-buckling ventilation hose. Also, check the engine oil level and correct it if it's too high. If the motor oil is too thin, use a thicker engine oil.
E
ejacksonSep 7, 2025
What to do if horn, flasher lights and E-starter do not work on KTM Motorcycle?
- P
  Pam RuizSep 7, 2025
  If the horn, flasher lights, and E-starter on your KTM Motorcycle aren't working, it may be due to a blown fuse in the starter relay. To fix this, dismount the left side paneling and filter box cover, then replace the fuse.
M
Michael DavisSep 12, 2025
Why KTM Motorcycle engine does not rev high?
- T
  Tanya WolfeSep 12, 2025
  If your KTM Motorcycle engine does not rev high, the carburetor fuel level might be too high because the float needle valve is dirty or worn out. Dismount the carburetor and check if it's worn out. Also, tighten the jets.

KTM 250 SX-F 2006 Specifications

General

Engine Type	Single cylinder, 4-stroke
Displacement	249.5 cc
Compression Ratio	12.8:1
Cooling System	Liquid cooled
Starter	Kickstarter
Transmission	5-speed
Primary Drive	24:73
Final Drive	14:50
Clutch	Wet Multi-Disc Clutch, Hydraulically Operated
Bore x Stroke	76 mm x 54.8 mm
Fuel System	Keihin MX FCR 39 Carburetor
Ignition	Kokusan digital CDI
Lubrication	Pressure lubrication with 2 Eaton pumps

Summary

General Information

Bleeding the Cooling System

Changing the Oil Filter

Steps to replace the engine's oil filter and refill oil.

Removing and Refitting Engine

Dismounting the Engine

Detailed instructions for removing the engine from the motorcycle frame.

Mounting the Engine

Step-by-step guide for installing the engine back into the motorcycle frame.

Disassembling the Engine

Preparatory Work

Moving the Engine into the TDC Position

Method to align the engine's crankshaft to Top Dead Center.

Removing the Camshafts

Procedure for safely removing the camshafts from the cylinder head.

Removing the Cylinder Head and Piston

Steps to detach the cylinder head and extract the piston.

Dismantling the Clutch

Instructions for taking apart the motorcycle's clutch assembly.

Separating the Casing Halves

Guide to splitting the engine casing and removing shafts.

Servicing Individual Components

Left Casing Half

Right Casing Half

Crankshaft

Details on inspecting, measuring, and handling the crankshaft.

Piston

Clutch

Assembling the Engine

Installing Transmission Shafts and Crankshaft

Steps for assembling transmission shafts and crankshaft into engine halves.

Mounting the Oil Pumps

Mounting the Primary Pinion and Chain Drive

Mounting the Camshafts

Steps for correctly installing the camshafts into the cylinder head.

Mounting the Chain Tensioner

Checking the Valve Clearance

Electrical

Checking the Ignition Coil

Ignition System Troubleshooting

Steps to diagnose and resolve ignition system issues.

Checking the Starter

Checking the Charging Voltage

Fuel System

Dismounting and Installing the Carburetor

Step-by-step guide for removing and installing the carburetor.

Disassembling the Carburetor

Checking the Throttle Valve Sensor

Carburetor Adjusting Idling

Procedure for setting the engine's idle speed and mixture control.

Trouble Shooting

Troubleshooting Guide

Common engine problems, their causes, and recommended remedies.

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