KTM 300 EXC Owner's Manual
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KTM 300 EXC Owner's Manual

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OWNER'S MANUAL
2021
300 EXC
Art. no. 3214221en

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  • Page 1 OWNER'S MANUAL 2021 300 EXC Art. no. 3214221en...
  • 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 6.16 Foot brake lever ....... 19 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.17 Side stand........20 Symbols used ........6 6.18 Steering lock ........20 Formats used........6 6.19 Locking the steering ......20 SAFETY ADVICE..........7 6.20 Unlocking the steering......
  • Page 5 TABLE OF CONTENTS Preparing the vehicle for low 12.4 Cleaning the dust boots of the fork temperatures or snow ....... 39 legs ..........57 12.5 Removing the fork protector ....57 RIDING INSTRUCTIONS......40 12.6 Installing the fork protector....58 Checks and maintenance measures 12.7 Removing the fork legs...
  • Page 6 TABLE OF CONTENTS 13.2 Adjusting the free travel of the 17.2 Adjusting the throttle cable handbrake lever ....... 84 play .......... 116 13.3 Checking the brake discs ....84 17.3 Carburetor tuning......117 Carburettor – idle speed....120 13.4 Checking the front brake fluid level ... 85 17.4 Carburetor –...
  • Page 7 TABLE OF CONTENTS 27 LIST OF SYMBOLS........150 27.1 Yellow and orange symbols....150 27.2 Green and blue symbols....150 INDEX ............. 151...

  • 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 This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies 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: Tampering Warning

    The vehicle should only be used by trained persons. An appropriate driver's license is needed to drive the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 12: Important Notes

    Manufacturer warranty, 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 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) S04257-01 Hand brake lever ( p. 15) Clutch lever ( p. 15) Light switch ( p. 16) Switch-off button ( p. 15) Turn signal switch ( p. 16) Horn button ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) S04258-01 Fuel tank filler cap Throttle grip ( p. 15) Vehicle identification number ( p. 13) Foot brake lever ( p. 19) Level viewer for brake fluid, rear...

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 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 The key number for the steering lock is stamped onto the key connector.

  • Page 16: Fork Part Number

    5 SERIAL NUMBERS 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. H02222-10...

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. S03609-10 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 18: Horn Button

    6 CONTROLS Horn button Horn button is fitted on the left side of the handlebar. Info The horn button has no function when the vehicle is deliv- ered. Possible states • The horn button is in the basic position The horn button is pressed – The horn is operated in this •...

  • Page 19: Start Button

    CONTROLS 6 Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. S03614-10 6.10 Overview of indicator lamps...

  • Page 20: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. S03647-10 6.12 Closing the fuel tank filler cap – Mount the fuel tank filler cap and turn it clockwise until release button engages.

  • Page 21: Choke

    CONTROLS 6 6.14 Choke Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deacti- vated.

  • Page 22: Side Stand

    6 CONTROLS 6.17 Side stand The side stand is located on the left of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.18 Steering lock...

  • Page 23: Unlocking The Steering

    CONTROLS 6 6.20 Unlocking the steering – Insert the key for the steering lock into the steering lock, turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock. The handlebar can now be moved again.

  • Page 24: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. 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 The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 25: Adjusting Combination Instrument Function

    COMBINATION INSTRUMENT 7 – 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 26: Setting The Clock

    7 COMBINATION INSTRUMENT 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 27: Display Mode Speed (Speed)

    COMBINATION INSTRUMENT 7 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 28: Adjusting The Unit Of Measurement

    7 COMBINATION INSTRUMENT 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 29: Display Mode Speed/Clk (Time)

    COMBINATION INSTRUMENT 7 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 30: Viewing The Lap Time

    7 COMBINATION INSTRUMENT 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 31: Display Mode Speed/Tr1 (Trip Master 1)

    COMBINATION INSTRUMENT 7 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 32: Display Mode Speed/A1 (Average Speed 1)

    7 COMBINATION INSTRUMENT 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 33: Display Mode Speed/S1 (Stop Watch 1)

    COMBINATION INSTRUMENT 7 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 34: Table Of Functions

    7 COMBINATION INSTRUMENT 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 35: Table Of Conditions And Menu Activation

    COMBINATION INSTRUMENT 7 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 36: Preparing For Use

    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 37: Running In The Engine

    PREPARING FOR USE 8 – Adjust the basic position of the foot brake lever. p. 90) – Adjust the basic position of the shift lever. p. 122) – Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip. Info When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.

  • Page 38: Preparing The Vehicle For Riding On Dry Sand

    – In the event of scalding, rinse the area affected immediately with lukewarm water. – Change the radiator cap. – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the KTM PowerParts fitting instructions. M01104-01...

  • Page 39: Preparing The Vehicle For Riding On Wet Sand

    Air filter sand cover (79006922000) Info Observe the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info M01105-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 146) –...

  • Page 40: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 146) –...

  • Page 41: Preparing Vehicle For High Temperatures Or Slow Riding

    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. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 42: 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 43: Starting Off

    Do not change into a low gear at high engine speed. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an autho- rized KTM workshop. First-gear is used for starting off and for steep inclines. –...

  • Page 44: 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 45: Transporting

    RIDING INSTRUCTIONS 9 – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...
  • Page 46 9 RIDING INSTRUCTIONS 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 47: Service Schedule 10

    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 48: Recommended Work

    ● Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ● Periodic interval 10.3 Recommended work Every 40 operating hours when used for motorsports...

  • Page 49: 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 50: 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 51: 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 52: 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. 49) – 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 53: 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 54: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) – Remove the shock absorber. p. 65) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 55: 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. – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 56: Handlebar Position

    11 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.14 Handlebar position On the upper triple clamp, there are 2 holes at a distance of each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of...
  • Page 57 TUNING THE CHASSIS 11 – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws .

  • Page 58: 12 Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 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 59: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) – Remove the fork protector. ( p. 57) Main work – Push dust boots of both fork legs downward.

  • Page 60: Installing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 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 61: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 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 62: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screws and hang the combination instrument holder to the side. S03514-10 – Remove screw – Loosen 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 63 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. V00336-11 – Position the combination instrument holder, and mount and tighten screws Guideline Remaining screws,...

  • Page 64: Checking Steering Head Bearing Play

    108) 12.11 Checking steering head bearing play Warning 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.)

  • Page 65: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 12 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. Preparatory work – Raise the motorcycle with a lift stand.

  • Page 66: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 59) – Install the lower triple clamp. p. 60) H02387-01 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p.

  • Page 67: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12 – 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. 106) – Check the headlight setting. ( p.

  • Page 68: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.18 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 12.19 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.

  • Page 69: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.20 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 66) Condition The air filter box cover is secured. – Remove screw K01348-10 – Pull off the air filter box cover in area laterally and take it off at the front.

  • Page 70: Removing The Air Filter

    12 SERVICE WORK ON THE CHASSIS 12.22 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. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 71: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 12 12.24 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 72: Removing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.26 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 73: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 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 74: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Turn tap handle of the fuel tap to the OFF position. – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws with the collar bushings. –...

  • Page 75: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 12 Main work – Check throttle cable routing. ( p. 79) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged.

  • Page 76: Cleaning The Chain

    12 SERVICE WORK ON THE CHASSIS 12.32 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 77: 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 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 78: 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 79 SERVICE WORK ON THE CHASSIS 12 – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.
  • Page 80 12 SERVICE WORK ON THE CHASSIS – Check 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 81: Checking The Frame

    – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S01317-10 12.38 Checking throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 82: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. The throttle cable must be routed behind the handlebar, on the right of the frame, and to the carburetor. The throttle cable must be secured behind the fuel tank contact area rubber strap.

  • Page 83: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 12.40 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 84: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( p. 144) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water.
  • Page 85 SERVICE WORK ON THE CHASSIS 12 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 144) – On the clutch slave cylinder, remove the bleeder protection cap, release bleeder screw and mount bleeding syringe E00843-10...

  • Page 86: 13 Brake System

    Do not make any adjustments while riding. 13.3 Checking the brake discs 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.)

  • Page 87: 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 88: Adding Front 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 89: 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 90 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 91 BRAKE SYSTEM 13 Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pin , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. E00344-10 –...

  • Page 92: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM 13.8 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 93: 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 94 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 95: 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 96 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 97 BRAKE SYSTEM 13 – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 144) – Mount screw cap with membrane and O-ring. Info Immediately clean up any brake fluid that has over- flowed or spilled with water. E00348-10...

  • Page 98: 14 Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) 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 99: Installing The Front Wheel

    WHEELS, TIRES 14 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. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 100: Installing The Rear Wheel

    14 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 101 WHEELS, TIRES 14 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 102: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 103: Checking Spoke Tension

    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 104: 15 Electrical System

    15 ELECTRICAL SYSTEM 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 105: 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 (YTX5L-BS) ( p. 140) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 106 15 ELECTRICAL SYSTEM Main work Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. 400240-10 –...

  • Page 107: Changing Main Fuse

    ELECTRICAL SYSTEM 15 15.4 Changing main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. Preparatory work –...

  • Page 108: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM 15.5 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. E00355-10 – Detach plug-in connectors and take off the headlight mask with the headlight.

  • Page 109: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 15.7 Changing the headlight bulb 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 110: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze orange cap in the area of the holding lugs and take it off. – Press the turn signal bulb lightly into the socket, turn it coun- terclockwise by about 30°, and take it out of the socket.

  • Page 111: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 108) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).
  • Page 112 15 ELECTRICAL SYSTEM Finishing work – Install the headlight mask with the headlight. ( p. 106) – Check the headlight setting. ( p. 108) – Set the kilometers or miles. ( p. 22) – Adjust combination instrument function. ( p. 23) –...

  • Page 113: Cooling System 16

    COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine circulates 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 114: Checking The Coolant Level

    16 COOLING SYSTEM 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 115: Refilling With Coolant

    COOLING SYSTEM 16 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 116: Changing The Coolant

    16 COOLING SYSTEM – Loosen screw and wait until coolant escapes without bub- bles. – Mount and tighten screw Guideline Bleeder screw, cylin- 10 Nm (7.4 lbf ft) der head K01211-10 – Completely fill the radiator with coolant. Coolant ( p.
  • Page 117 COOLING SYSTEM 16 Main work – Place an appropriate container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump 10 Nm (7.4 lbf ft) cover K01212-12...

  • Page 118: 17 Tuning The Engine

    17 TUNING THE ENGINE 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 throt- tle grip back and forth slightly and determine the play in the throttle cable.

  • Page 119: Carburetor Tuning

    TUNING THE ENGINE 17 Main work – Turn handlebar as far as possible to the right. – Push back sleeve – Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster – Loosen nut – Turn barrel adjuster so that there is play in the throttle cable at the throttle grip.
  • Page 120 17 TUNING THE ENGINE Main jet MJ The main jet MJ has the greatest influence with the throttle slide open (full throttle). If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger main jet needs to be used.
  • Page 121 TUNING THE ENGINE 17 K00497-01 When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence. When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.

  • Page 122: Carburettor - Idle Speed

    17 TUNING THE ENGINE Carburettor – idle speed 17.4 The idle setting of the carburetor has a big influence on the start- ing behavior, stable idle speed, and the response to throttle open- ing. This means that an engine with a correctly set idle speed will be easier to start than one with an incorrectly set idle speed.

  • Page 123: Ignition Curve Plug-In Connector

    TUNING THE ENGINE 17 Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 19) Idle speed 1,400 … 1,500 rpm – Turn idle air adjusting screw slowly in a clockwise direc- tion until the idle speed begins to fall. –...

  • Page 124: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 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 125: Engine Characteristic - Auxiliary Spring

    TUNING THE ENGINE 17 Engine characteristic – auxiliary spring 17.10 The auxiliary spring is located on the right side of the engine below the water pump cover. Possible states Auxiliary spring with green color coding – Auxiliary spring for • soft performance.
  • Page 126 17 TUNING THE ENGINE – Remove cap , adjusting spring , auxiliary spring and spring insert from the clutch cover. – Pull both springs off of the spring insert. – Mount the required auxiliary spring ( p. 123) adjusting spring and position them together in the clutch cover.

  • Page 127: Service Work On The Engine 18

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

  • Page 128: Checking The Gear Oil Level

    18 SERVICE WORK ON THE ENGINE 18.2 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 129: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 18 Guideline Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft) with magnet – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.80 l Engine oil (0.85 qt.) (15W/50) p.
  • Page 130 18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 131: Cleaning, Care 19

    CLEANING, CARE 19 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 132: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 74) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 133: Storage 20

    – 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. 56) – Cover the vehicle with a tarp or a similar cover that is perme-...

  • Page 134: Preparing For Use After Storage

    20 STORAGE 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 135: Troubleshooting 21

    TROUBLESHOOTING 21 Faults Possible cause Action – The engine cannot be cranked Operating error Carry out start procedure. ( p. 40) (starter motor) – 12-V battery discharged Charge the 12-V battery. p. 103) – Check the charging voltage. – Check the closed current. –...
  • Page 136 21 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Exhaust system leaky, Check exhaust system for damage. deformed or too little glass – Change the glass fiber yarn filling in fiber yarn filling in main the main silencer. p.

  • Page 137: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole 72 mm (2.83 in) Idle speed 1,400 … 1,500 rpm Exhaust control - setting measurement mm (0.091 + 0.2...
  • Page 138 22 TECHNICAL DATA Screw, crankshaft speed sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, exhaust control bearing 6 Nm (4.4 lbf ft) Loctite ® 243™ support Screw, exhaust control cap 5 Nm (3.7 lbf ft) Screw, exhaust control cover 4 Nm (3 lbf ft) Screw, locking lever 6 Nm (4.4 lbf ft)
  • Page 139 TECHNICAL DATA 22 Stud, cylinder base 20 Nm (14.8 lbf ft) Lubricated with engine oil Nut, rotor M12x1 55 Nm (40.6 lbf ft) Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)

  • Page 140: Carburetor

    22 TECHNICAL DATA 22.3 Carburetor Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 86 Needle position 3rd position from top Jet needle 6BFY43-73 (6BFY42-73, 6BFY42-74, 6BFY43-74) Main jet 470 (460, 480, 490) Idling jet 35 (32.5/37.5/40) Choke nozzle Needle jet Idle air adjusting screw Open...

  • Page 141: Capacities

    TECHNICAL DATA 22 Main jet Does not apply on sandy terrain. 22.4 Capacities 22.4.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 144) 22.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 144) 22.4.3 Fuel Total fuel tank capacity, approx.

  • Page 142: Electrical System

    140/80 - 18 M/C 70R M+S TT MAXXIS Maxx EnduPro MAXXIS Maxx EnduPro The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.8 Fork Fork article number 14.18.8T.63...

  • Page 143: Shock Absorber

    TECHNICAL DATA 22 Weight of rider: 65 … 75 kg (143 … 165 lb.) 3.8 N/mm (21.7 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.2 N/mm (24 lb/in) Fork length 928 mm (36.54 in)
  • Page 144 22 TECHNICAL DATA Screw, battery terminal 2.5 Nm (1.84 lbf ft) Screw, light switch 1 Nm (0.7 lbf ft) Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring Screw, turn signal switch 1 Nm (0.7 lbf ft) Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft)
  • Page 145 TECHNICAL DATA 22 Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle...

  • Page 146: 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 147 SUBSTANCES 23 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 148) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 148: 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 149 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 150: 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 151: List Of Abbreviations 26

    LIST OF ABBREVIATIONS 26 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
  • Page 152 27 LIST OF SYMBOLS 27.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp – inoperative Fuel level warning lamp – inoperative 27.2 Green and blue symbols Green and blue symbols reflect information.
  • Page 153 INDEX Chain INDEX checking ......76 cleaning ......74 12-V battery charging .
  • Page 154 INDEX Engine number ......13 Engine sprocket Hand brake lever ..... . . 15 checking .
  • Page 155 INDEX raising with lift stand ....56 Steering locking ......20 unlocking .
  • Page 156 INDEX Work rules ......9...
  • Page 157 *3214221en* 3214221en 07/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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