KTM 250 EXC TPI Owner's Manual
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KTM 250 EXC TPI Owner's Manual

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OWNER'S MANUAL
2020
250 EXC Six Days TPI
250 XC‑W TPI
300 EXC Six Days TPI
300 XC-W TPI
300 XC-W Six Days TPI
300 EXC Erzberg Edition TPI
Art. no. 3214007en
250 EXC TPI
300 EXC TPI

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Summary of Contents for KTM 250 EXC TPI

  • Page 1 OWNER'S MANUAL 2020 250 EXC TPI 250 EXC Six Days TPI 250 XC‑W TPI 300 EXC TPI 300 EXC Six Days TPI 300 XC-W TPI 300 XC-W Six Days TPI 300 EXC Erzberg Edition TPI Art. no. 3214007en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.13 Overview of indicator lamps (All EXC TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 models)........... 19 Symbols used ........6 6.14 Overview of indicator lamps (All Formats used........6 XC‑W models) ........19 6.15 Opening the fuel tank filler cap ..19 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 7.24 Table of conditions and menu 11.8 Checking the riding sag of the shock activation ........36 absorber.......... 56 11.9 Adjusting the spring preload of the PREPARING FOR USE......... 37 shock absorber ......57 11.10 Adjusting the riding sag ....
  • Page 6 TABLE OF CONTENTS 12.28 Removing the main silencer ....83 14.3 Removing the rear wheel ..... 112 12.29 Installing the main silencer....83 14.4 Installing the rear wheel ....113 12.30 Changing the glass fiber yarn filling 14.5 Checking the tire condition ..... 114 of the main silencer ......
  • Page 7 TABLE OF CONTENTS 18.4 Cleaning the oil screen in the oil tank .......... 144 18.5 Checking the gear oil level ....147 18.6 Changing the gear oil ....147 18.7 Adding the gear oil ..... 148 19 CLEANING, CARE ........150 19.1 Cleaning the motorcycle ....

  • Page 8: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use (All EXC models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • Page 11: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 12: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 13: Important Notes 3

    Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S03465-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Light switch ( p. 17) (All EXC models) Switch-off button ( p. 16) (All EXC models) p. 18) (All EXC models) Turn signal switch ( Horn button ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S03467-10 Fuel tank filler cap Throttle grip ( p. 16) Vehicle identification number ( p. 14) Foot brake lever ( p. 23) Level viewer for brake fluid, rear...

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Key number (All EXC models) The key number for the steering lock is stamped onto the key connector.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the inside of the axle clamp. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. E00817-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

  • Page 19: Switch-Off Button (All Xc-W Models)

    CONTROLS 6 Switch-off button (All XC‑W models) Switch-off button is fitted on the left side of the handlebar. Possible states is in the basic position – In this • The switch-off button position, the ignition circuit is closed and the engine can be started.

  • Page 20: Turn Signal Switch (All Exc Models)

    6 CONTROLS Turn signal switch (All EXC models) Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – The turn signal switch is in the cen- tral position. Left turn signal, on – The turn signal switch is turned to the left.

  • Page 21: Overview Of Indicator Lamps (All Exc Models)

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 23: Closing 2-Stroke Oil Tank Cap

    CONTROLS 6 6.18 Closing 2-stroke oil tank cap – Put the 2-stroke oil tank cap on and turn it clockwise. – Fold loop down. The 2-stroke oil tank cap engages. E00861-11 6.19 Straps (300 EXC Erzberg Edition TPI EU) The straps are located at the front and rear of the vehicle.

  • Page 24: Idle Speed Adjusting Screw

    6 CONTROLS 6.21 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi- cle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 25: Foot Brake Lever

    CONTROLS 6 6.23 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.24 Side stand The side stand is located on the left of the vehicle. 401943-10 The side stand is used for parking the motorcycle.

  • Page 26: Locking The Steering (All Exc Models)

    6 CONTROLS 6.26 Locking the steering (All EXC models) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn handlebar as far as possible to the right. –...

  • Page 27: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Combination instrument overview – The button is used to select menus and make settings. – The button is used to select menus and make settings. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument...

  • Page 28: Adjusting Combination Instrument Function

    7 COMBINATION INSTRUMENT – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 29: Setting The Clock

    COMBINATION INSTRUMENT 7 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust hour display with the button and/or button –...

  • Page 30: Display Mode Speed (Speed)

    7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 31: Adjusting The Unit Of Measurement

    COMBINATION INSTRUMENT 7 Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 32: Display Mode Speed/Clk (Time)

    7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 33: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 34: Display Mode Speed/Tr1 (Trip Master 1)

    7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 35: Display Mode Speed/A1 (Average Speed 1)

    COMBINATION INSTRUMENT 7 Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 36: Display Mode Speed/S1 (Stop Watch 1)

    7 COMBINATION INSTRUMENT Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 37: Table Of Functions

    COMBINATION INSTRUMENT 7 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 38: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode Clears the Next display Reduces Reduces SPEED/TR2 (trip...

  • Page 39: Preparing For Use 8

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 40: Running In The Engine

    8 PREPARING FOR USE (All EXC models) – Adjust the free travel of the handbrake lever. ( p. 98) (All XC‑W models) – Adjust the basic position of the hand brake lever. ( p. 99) – Adjust the basic position of the foot brake lever. p.

  • Page 41: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    PREPARING FOR USE 8 Starting power of lithium-ion batteries at low temperatures Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batter- ies.
  • Page 42 – Change the radiator cap. – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the KTM PowerParts fitting instructions. M01104-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the KTM PowerParts fitting instructions.

  • Page 43: Preparing The Vehicle For Riding On Wet Sand

    – Change the radiator cap. – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01 – Clean the chain. Chain cleaner ( p. 168) –...

  • Page 44: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    8 PREPARING FOR USE Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01 – Mount the steel sprocket. – Clean motorcycle. ( p.

  • Page 45: Preparing The Vehicle For Low Temperatures Or Snow

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 131) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01...

  • Page 46: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 47: Starting Off

    RIDING INSTRUCTIONS 9 – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission to neutral position. Condition Ambient temperature: < 10 °C (< 50 °F) – Pull the cold start button fully out and turn it by a ¼ turn. Info If the engine is warm, the cold start button must be 401944-10...

  • Page 48: Braking

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 49: Stopping, Parking

    RIDING INSTRUCTIONS 9 Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 50: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 51: Adding 2-Stroke Oil

    RIDING INSTRUCTIONS 9 – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Total fuel tank Super unleaded capacity, approx. (2.4 US gal) (ROZ 95/RON 95/PON 91) p. 167) 400382-10 Info Do not refuel using pre-mixed fuel. –...

  • Page 52: 10 Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 53: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ○ ● ● ● Make a service entry in KTM Dealer.net.
  • Page 54 10 SERVICE SCHEDULE Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Every 80 operating hours Every 40 operating hours After 20 operating hours After 10 operating hours every 12 months ● Clean the oil screen in the oil tank. p.

  • Page 55: Tuning The Chassis 11

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock...

  • Page 56: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 57: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 58: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 55) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 59: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 60: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 65) – Remove the shock absorber. p. 78) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 61: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (All standard EXC/XC-W models, 300 EXC Erzberg Edition TPI EU) – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left...

  • Page 62: Adjusting The Rebound Damping Of The Fork

    11 TUNING THE CHASSIS 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All standard EXC/XC-W models, 300 EXC Erzberg Edition TPI EU) – Turn red adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the right...

  • Page 63: Adjusting The Spring Preload Of The Fork (All Six Days Models)

    TUNING THE CHASSIS 11 11.14 Adjusting the spring preload of the fork (All Six Days models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 65) Main work – Turn the adjusting wings counterclockwise all the way. The marking +0 aligns with the adjusting wing on both fork legs.

  • Page 64: Handlebar Position

    11 TUNING THE CHASSIS 11.15 Handlebar position (All standard EXC/XC-W models) On the upper triple clamp, there are 2 holes at a distance to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance from the center.
  • Page 65 TUNING THE CHASSIS 11 (All standard EXC/XC-W models) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
  • Page 66 11 TUNING THE CHASSIS (All special models) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 67: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 68: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 65) – Remove the fork protector. ( p. 66) Main work – Push dust boots of both fork legs downward.

  • Page 69: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 70: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster).

  • Page 71: (All Standard Exc/Xc-W Models)

    SERVICE WORK ON THE CHASSIS 12 12.9 Removing the lower triple clamp (All standard EXC/XC-W models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 65) – Remove the front wheel. p. 110) – Remove the headlight mask with the headlight. ( p.

  • Page 72: Installing The Lower Triple Clamp (All Standard Exc/Xc-W Models)

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screws and hang the combination instrument holder to the side. S03515-10 – Remove screw – Remove screw . Take off the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage.
  • Page 73 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Position the clutch line and wiring harness. – Mount screw , but do not tighten yet. E00921-11 – Position the combination instrument holder, and mount and tighten screws Guideline Remaining screws,...
  • Page 74 12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem S03508-11 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp S03525-10 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 75: (All Special Models)

    SERVICE WORK ON THE CHASSIS 12 12.12 Installing the lower triple clamp (All special models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 168) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 76 12 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp S03524-11 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head S03523-10 – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft)

  • Page 77: Checking Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
  • Page 78 12 SERVICE WORK ON THE CHASSIS Main work (All standard EXC/XC-W models) – Loosen screws – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Using a plastic hammer, tap lightly on the upper triple S03477-10 clamp to avoid stresses.

  • Page 79: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12 12.15 Lubricating the steering head bearing (All standard EXC/XC-W models) – Remove the lower triple clamp. p. 69) – Install the lower triple clamp. p. 70) (All special models) – Remove the lower triple clamp. p.

  • Page 80: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work – Install the headlight mask with the headlight. ( p. 125) – Check the headlight setting. ( p.

  • Page 81: Removing The Seat

    SERVICE WORK ON THE CHASSIS 12 12.20 Removing the seat – Remove screw on the left side. S03480-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.21 Mounting the seat – Mount the front of the seat on the two collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.

  • Page 82: Removing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 79) Condition The air filter box cover is secured. – Remove screw S03526-10 – Pull off the air filter box cover in area laterally and take it off at the front.

  • Page 83: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 12.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 84: Cleaning The Air Filter And Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.26 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 85: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.28 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...

  • Page 86: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screws . Pull out inner tube with O-ring – Pull glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for dam- age.
  • Page 87 SERVICE WORK ON THE CHASSIS 12 Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. S03485-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 88: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS 12.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 89: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 12 – Mount and tighten screws with the collar bushings. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis E00881-11 – Remove the wash cap set. – Thoroughly clean the plug-in connection of the fuel line using compressed air.

  • Page 90: Cleaning The Chain

    12 SERVICE WORK ON THE CHASSIS 12.34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 91: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info The lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...

  • Page 92: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 93 SERVICE WORK ON THE CHASSIS 12 – Pull on the upper chain section with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure the distance of 18 chain rollers in the lower chain section.
  • Page 94 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 95: Checking The Frame

    If the link fork shows signs of damage, cracking, or defor- mation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S01317-10 12.40 Checking throttle cable routing Preparatory work –...

  • Page 96: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS – Mount the seat. ( p. 79) 12.41 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right.

  • Page 97: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12 12.43 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. –...

  • Page 98: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...

  • Page 99: Removing The Engine Guard (All Special Models)

    SERVICE WORK ON THE CHASSIS 12 – Now press the fluid into the system until it emerges from the hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 100: 13 Brake System

    13 BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 101: Adjusting The Basic Position Of The Hand Brake Lever (All Xc-W Models)

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 102: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 103: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 104: Changing The Brake Linings Of The Front Brake

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 105 BRAKE SYSTEM 13 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 106: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM Info Immediately clean up any brake fluid that has over- flowed or spilled with water. 13.9 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 107: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 108: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 109: Checking The Brake Linings Of The Rear Brake

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 110 13 BRAKE SYSTEM Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 111 BRAKE SYSTEM 13 – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 166) – Mount screw cap with membrane and O-ring. Info Immediately clean up any brake fluid that has over- flowed or spilled with water. S03487-10...

  • Page 112: 14 Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 65) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 113: Installing The Front Wheel

    WHEELS, TIRES 14 (300 EXC Erzberg Edition TPI EU) – Remove spacer and brake disc guard H01890-10 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. –...

  • Page 114: Removing The Rear Wheel

    14 WHEELS, TIRES – Align the brake disc guard so that distance equal in size. S01633-10 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc.

  • Page 115: Installing The Rear Wheel

    WHEELS, TIRES 14 Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.

  • Page 116: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 117: Checking Tire Pressure

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)
  • Page 118 14 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica- tion of different spoke tensions.

  • Page 119: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 120 15 ELECTRICAL SYSTEM – Pull EFI control unit upward off rubber lugs and hang to the side. S03490-10 – Remove starter relay and fuse box from the battery compartment and hang to the side. S03491-10 – Detach wiring harness , disconnect relays and plug and hang to the side.

  • Page 121: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 15.2 Installing the 12-V battery Main work – Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP-C) ( p. 161) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 122: Charging The 12-V Battery

    15 ELECTRICAL SYSTEM – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal.
  • Page 123 ELECTRICAL SYSTEM 15 Info Even if there is no load on the 12-V battery, it discharges each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current or charging voltage are exceeded, the 12 V battery will be destroyed.

  • Page 124: Changing Main Fuse

    15 ELECTRICAL SYSTEM This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Power Parts instructions. Info Never remove cover – Switch off the battery charger after charging and disconnect it from the 12-V battery.

  • Page 125: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109120) ( p.
  • Page 126 15 ELECTRICAL SYSTEM Main work – Open fuse box cover – Remove the faulty fuse. Guideline (All EXC models) Fuse 1 - 10 A - EFI control unit, lambda sensor, oil pump, combination instrument, electronic fuel injection, diagnostics connector Fuse 2 - 10 A - horn, brake light, radiator fan (optional), S03498-10 turn signal (optional) Fuse 3 - 10 A - high beam, low beam, position light, tail...

  • Page 127: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 15.6 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask. – Loosen rubber strap . Slide the headlight mask up and swing it forward. E00899-10 (All EXC models) –...

  • Page 128: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide. E00899-11 Finishing work – Check the headlight setting. ( p.

  • Page 129: Changing The Turn Signal Bulb (All Exc Models)

    ELECTRICAL SYSTEM 15 15.9 Changing the turn signal bulb (All EXC models) Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting.

  • Page 130: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider. » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 128) 15.11 Adjusting the headlight range Preparatory work...

  • Page 131: Diagnostics Connector

    ELECTRICAL SYSTEM 15 – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...

  • Page 132: 16 Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 133: Checking The Coolant Level

    COOLING SYSTEM 16 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 134: Refilling With Coolant

    16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 135 COOLING SYSTEM 16 – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 166) 400243-10 – Push protection cap upward over the thermostat. E00904-10 – Unplug connector –...
  • Page 136 16 COOLING SYSTEM Finishing work – Check the coolant level. ( p. 131)

  • Page 137: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the throttle cable play – Check the throttle grip for smooth operation. – Turn handlebar as far as possible to the right. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...

  • Page 138: Setting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE – Tighten nut – Tighten nut – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work – Check the throttle cable play. ( p. 135) 17.3 Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.

  • Page 139: Adjusting The Idle Speed

    Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm.

  • Page 140: Programming Ambient Pressure

    17 TUNING THE ENGINE Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running. 17.5 Programming ambient pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 141: Ignition Curve Plug-In Connector

    TUNING THE ENGINE 17 17.6 Ignition curve plug-in connector Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Info The ignition timing map connector has no function in the homologated (restricted) condition of the motorcycle. Possible states Soft –...

  • Page 142: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE Finishing work – Install the fuel tank. p. 86) – Mount the seat. ( p. 79) 17.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

  • Page 143: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 144: Checking 2-Stroke Oil Level

    18 SERVICE WORK ON THE ENGINE 18.2 Checking 2-stroke oil level Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
  • Page 145 SERVICE WORK ON THE ENGINE 18 Main work – Pull the EFI control unit upward off the rubber plugs and hang to the side. – Remove protection cap of the diagnostics connector. S03510-10 – Put throttle grip into full throttle position and secure. S03511-10 –...

  • Page 146: Cleaning The Oil Screen In The Oil Tank

    18 SERVICE WORK ON THE ENGINE – Check whether air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount protection cap on the diagnostics connector. –...
  • Page 147 SERVICE WORK ON THE ENGINE 18 – Loosen clamps of the throttle valve body. – Disconnect plug-in connector of the rear brake light switch. – Lift the subframe slightly and secure it. Info Pay attention to intake flange – Pull throttle valve body towards the rear, out of the intake flange, and hang it to the side.
  • Page 148 18 SERVICE WORK ON THE ENGINE – Mount throttle valve body – Remove the locking piece and position the subframe. Info Pay attention to intake flange – Join plug-in connector of the rear brake light switch. – Position and tighten clamps of the throttle valve body.

  • Page 149: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 18 18.5 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Detach the foot brake lever spring. –...

  • Page 150: Adding The Gear Oil

    18 SERVICE WORK ON THE ENGINE Main work – Remove gear oil drain plug with magnet. – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug with magnet. – Clean the sealing surface on the engine. –...
  • Page 151 SERVICE WORK ON THE ENGINE 18 – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw. Engine oil (15W/50) ( p. 166) – Mount and tighten the gear oil level monitoring screw. Guideline Screw, gear oil level 10 Nm (7.4 lbf ft)

  • Page 152: 19 Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 153: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 168) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 154: 20 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 65) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 155: Preparing For Use After Storage

    STORAGE 20 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus- ing engine parts and the exhaust system to rust.

  • Page 156: 21 Troubleshooting

    Defect in the fuel injection sys- Check the cabling for damage and the electrical plug-in connections for corro- sion and damage. – Read out the fault memory using the KTM diagnostics tool. – Engine has no idle Spark plug defective Change the spark plug. –...
  • Page 157 Defect in the fuel injection sys- Check the cabling for damage and the electrical plug-in connections for corro- sion and damage. – Read out the fault memory using the KTM diagnostics tool. – Faulty ignition Ignition coil - check the primary wind- ing. –...
  • Page 158 – Read out the fault memory using the KTM diagnostics tool. – 12-V battery discharged The 12-V battery is not being Check the charging voltage. charged by the alternator –...

  • Page 159: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine 22.1.1 All 250 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Idle speed 1,400 …...

  • Page 160: Engine Tightening Torques

    22 TECHNICAL DATA Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings Engine lubrication Separate lubrication X distance (upper edge of piston to upper edge of 0 …...
  • Page 161 TECHNICAL DATA 22 Screw, retaining bracket of exhaust 6 Nm (4.4 lbf ft) Loctite ® 2701™ control Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Cap nut, water pump impeller 5 Nm (3.7 lbf ft) Loctite ® 243™ Drain plug, water pump cover 10 Nm (7.4 lbf ft) Pressure connection, cylinder...

  • Page 162: Capacities

    22 TECHNICAL DATA 22.3 Capacities 22.3.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 166) 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 166) 22.3.3 Fuel Total fuel tank capacity, approx. 9 l (2.4 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 163: Electrical System

    90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...

  • Page 164: Fork

    22 TECHNICAL DATA 22.7 Fork 22.7.1 All standard EXC/XC-W models, 300 EXC Erzberg Edition TPI EU Fork article number 14.18.8T.63 WP XPLOR 5348 Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport...

  • Page 165: Shock Absorber

    TECHNICAL DATA 22 22.8 Shock absorber Shock absorber article number 12.18.7T.63 WP XPLOR 5746 Shock absorber Low-speed compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks High-speed compression damping Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort 18 clicks...
  • Page 166 22 TECHNICAL DATA Screw, light switch (All EXC mod- 1 Nm (0.7 lbf ft) els) Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring Screw, turn signal switch (All EXC 1 Nm (0.7 lbf ft) models) Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft)
  • Page 167 TECHNICAL DATA 22 Screw, top steering stem (All stan- 20 Nm (14.8 lbf ft) dard EXC/XC-W models) Screw, top steering stem (All spe- 17 Nm (12.5 lbf ft) Loctite ® 243™ cial models) Screw, top triple clamp (All stan- 20 Nm (14.8 lbf ft) dard EXC/XC-W models) Screw, top triple clamp (All special 17 Nm (12.5 lbf ft)

  • Page 168: 23 Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 169 SUBSTANCES 23 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 170) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 170: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 171 AUXILIARY SUBSTANCES 24 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 172: 25 Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 173: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 Injection into transfer ducts (Trans- Electronic fuel injection in which two injection valves fer Port Injection) in the transfer ducts of the cylinders are used On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 174: 27 List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 175: List Of Symbols 28

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 176: Index

    INDEX INDEX Capacity 12-V battery coolant ..... . 133, 160 installing ......119 fuel .
  • Page 177 INDEX Emergency OFF switch ....18 Gear oil Engine adding ......148 running in .
  • Page 178 INDEX Service ......11 Service schedule ..... 50-52 Main fuse Shift lever .
  • Page 179 INDEX Tire condition checking ......114 Tire pressure checking ......115 Transporting .
  • Page 180 *3214007en* 3214007en 05/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

This manual is also suitable for:

250 exc six days tpi300 exc tpi250 xc-w tpi300 exc six days tpi300 xc-w tpi300 xc-w six days tpi ... Show all

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