KTM 300 EXC ERZBERGRODEO 2023 Owner's Manual
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KTM 300 EXC ERZBERGRODEO 2023 Owner's Manual

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OWNER'S MANUAL
2023
250 EXC
250 EXC SIX DAYS
250 XC‑W
300 EXC
300 EXC SIX DAYS
300 XC-W
300 EXC ERZBERGRODEO
300 XC-W ERZBERGRODEO
Art. no. 3214644en

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Summary of Contents for KTM 300 EXC ERZBERGRODEO 2023

  • Page 1 OWNER'S MANUAL 2023 250 EXC 250 EXC SIX DAYS 250 XC‑W 300 EXC 300 EXC SIX DAYS 300 XC-W 300 EXC ERZBERGRODEO 300 XC-W ERZBERGRODEO Art. no. 3214644en...
  • 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 lights (All TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 EXC models)........19 Symbols used ........6 6.14 Overview of indicator lights (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 ....82 14.5 Checking the tire condition ..... 113 12.29 Installing the main silencer....82 14.6 Checking tire pressure ....114 12.30 Changing the glass fiber yarn filling 14.7 Checking spoke tension ....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 ....148 18.7 Adding the gear oil ..... 149 19 CLEANING, CARE ........150 19.1 Cleaning the motorcycle ....

  • Page 8: Means Of Representation

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special 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 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: Owner's Manual

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 13: Important Notes 3

    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 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S05303-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Fuel tank filler cap Seat Air filter box cover Side stand ( p. 23) Shift lever ( p. 22)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S05304-10 2-stroke oil tank cap Horn button ( p. 17) (All EXC models) Turn signal switch ( p. 18) (All EXC models) Light switch ( p. 17) (All EXC models) Stop button ( p.

  • 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. S04872-10 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: Stop Button (All Xc-W Models)

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

  • 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 Lights (All Exc Models)

    – The OBD has detected a malfunction in the vehi- cle 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 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • 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 Supporting strap (All ERZBERGRODEO models) The supporting straps are located at the front and rear 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: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 – 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 – Wait 3 - 5 seconds.

  • 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 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. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – briefly until S1 appears at the Repeatedly press the button top right of the display. S1 (Stop watch 1) shows the riding time based on TR1 and contin- ues running as soon as an impulse arrives from the wheel speed sensor.

  • 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. Adjusting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • 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. 97) (All XC‑W models) – Adjust the basic position of the hand brake lever. ( p. 98) – 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. 170) –...

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

    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 the motorcycle. ( p.

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

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 130) 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 injury People who act without authorization may not be familiar with the vehicle. – 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) p. 169) Info 400382-10 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 48 months every 12 months Every 80 operating hours Every 40 operating hours After 20 operating hours After 10 operating hours ●...

  • 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 the 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. 64) – Remove the shock absorber. p. 77) – 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. – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 62: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 63: Handlebar Position

    TUNING THE CHASSIS 11 11.15 Handlebar position (All standard 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 64 11 TUNING THE CHASSIS (All standard 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 65 TUNING THE CHASSIS 11 Info Make sure the cables and wiring are positioned cor- rectly. – Position the handlebar clamps. Mount screws tighten evenly. Guideline Screw, handlebar 20 Nm clamp (14.8 lbf ft) Info Make sure the gap widths are even.

  • Page 66: 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 67: 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. 64) – Remove the fork protector. ( p. 65) Main work – Push dust boots of both fork legs downward.

  • Page 68: 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 69: 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 70: Removing The Lower Triple Clamp (All Standard Models)

    12 SERVICE WORK ON THE CHASSIS 12.9 Removing the lower triple clamp (All standard models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 64) – Remove the front wheel. p. 109) – Remove the headlight mask with the headlight. ( p.

  • Page 71: Installing The Lower Triple Clamp (All Standard Models)

    SERVICE WORK ON THE CHASSIS 12 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 72 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Position the clutch line and the 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 73 SERVICE WORK ON THE CHASSIS 12 – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem S04880-10 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp S04894-13 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 74: Installing The Lower Triple Clamp (All Special Models)

    12 SERVICE WORK ON THE CHASSIS 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. 170) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 75 SERVICE WORK ON THE CHASSIS 12 – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp S04893-12 – 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 76: Checking The 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 77: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 12 12.14 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 64) Main work (All standard models) – Loosen screws – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)

  • Page 78: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS 12.15 Lubricating the steering head bearing (All standard models) – Remove the lower triple clamp. p. 68) – Install the lower triple clamp. p. 69) Info The steering head bearing is cleaned and lubri- cated in the course of removal and installation of the lower triple clamp.

  • Page 79: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-11 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work...

  • Page 80: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS Guideline Screw, bottom 80 Nm (59 lbf ft) shock absorber Loctite ® 2701™ Info The heim joint for the shock absorber on the link fork is Teflon coated. It must not be lubricated with grease, nor with any other lubricants.

  • Page 81: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 – Mount and tighten screw on the left side. Guideline Screw, seat fixing 10 Nm (7.4 lbf ft) S03480-10 12.22 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 78) Condition The air filter box cover is secured.

  • Page 82: Removing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box EJOT PT ® 3 Nm (2.2 lbf ft) cover K60x20-Z S03526-10 Finishing work – Mount the seat. ( p.

  • Page 83: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 12 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned. – Insert retaining tab Retaining pin is secured with retaining tab Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

  • Page 84: Preparing Air Filter Box Cover For Securing

    12 SERVICE WORK ON THE CHASSIS 12.27 Preparing air filter box cover for securing Preparatory work – Remove the seat. ( p. 78) – Remove the air filter box cover. ( p. 79) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in)

  • Page 85: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.30 Changing the glass fiber yarn filling of 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. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"...
  • Page 86 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • Page 87: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 – Remove screw with the rubber bushing. E00882-10 – Pull both spoilers off laterally from the radiator mount and lift off the fuel tank. E00883-10 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.
  • Page 88 12 SERVICE WORK ON THE CHASSIS – 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. E00883-11 –...

  • Page 89: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 12 12.33 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 87) 400678-01 12.34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...

  • Page 90: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 91: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 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 92 12 SERVICE WORK ON THE CHASSIS – 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 93 SERVICE WORK ON THE CHASSIS 12 – 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 94: Checking The Frame

    12 SERVICE WORK ON THE CHASSIS 12.38 Checking the frame – Check the frame for damage, cracks, and deformation. » If the frame shows signs of damage, cracks, or deforma- tion: – Change the frame. Guideline Repairs on the frame are not permitted. 401347-01 12.39 Checking the link fork...

  • Page 95: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 96: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.42 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 97: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 Brake fluid DOT 4 / DOT 5.1 ( p. 168) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water. 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation.

  • Page 98: Removing The Engine Guard (All Special Models)

    12 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 168) – On the clutch slave cylinder, remove bleeder protection cap, release the bleeder screw and mount bleeding syringe S04882-10 –...

  • Page 99: Brake System 13

    BRAKE SYSTEM 13 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 100: 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 101: 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 102: 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 103: 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 104 13 BRAKE SYSTEM – 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, extract some if necessary.

  • Page 105: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 Info Use water to immediately clean up any brake fluid that has overflowed or spilled. 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 106: 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 107: 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 108: 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 109 BRAKE SYSTEM 13 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 110 13 BRAKE SYSTEM – Correct brake fluid level to marking Brake fluid DOT 4 / DOT 5.1 ( p. 168) – Mount screw cap with membrane and O-ring. Info Use water to immediately clean up any brake fluid that has overflowed or spilled. S03487-10...

  • Page 111: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 64) 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 112: Installing The Front Wheel

    14 WHEELS, TIRES (All ERZBERGRODEO models) – 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 113: Removing The Rear Wheel

    WHEELS, TIRES 14 – 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 114: Installing The Rear Wheel

    14 WHEELS, TIRES – Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork. Info Do not operate the foot brake lever when the rear wheel is removed. – Remove spacers H03002-10 14.4 Installing the rear wheel Warning...

  • Page 115: 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 116: 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 117 WHEELS, TIRES 14 – 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 118: 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 119 ELECTRICAL SYSTEM 15 – Pull off starter relay and fuse box from the battery compartment and hang to the side. S04884-11 – Detach wiring harness , disconnect relays and plug and hang to the side. S04884-12 – Remove screw and detach the battery compartment. –...

  • Page 120: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM 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. 163) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 121: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 – 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 122 12-V battery with this battery charger. The charging time may be longer at low temperatures. 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 123: 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 electrical power consumers of the vehicle. Preparatory work –...

  • Page 124: Changing The Fuses Of Individual Electrical Power Consumers

    15 ELECTRICAL SYSTEM – Mount the EFI control unit on the rubber lugs S04883-11 Finishing work – Mount the seat. ( p. 78) 15.5 Changing the fuses of individual electrical power consumers Info The fuse box containing the fuses of individual electrical power consumers is located under the seat. Preparatory work –...

  • Page 125: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert the spare fuse with the correct rating. Fuse (75011088010) ( p.

  • Page 126: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM 15.7 Installing the headlight mask with the headlight Main work (All EXC models) – Join plug-in connectors E00900-11 (All XC‑W models) – Join plug-in connector E00357-11 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender.

  • Page 127: Changing The Turn Signal Bulb (All Exc Models)

    ELECTRICAL SYSTEM 15 Main work – Turn protection cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull bulb socket of the position light out of the reflector. E00358-10 – Pull out headlight bulb –...

  • Page 128: 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 129: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 126) 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 130: Diagnostics Connector

    15 ELECTRICAL SYSTEM Finishing work – Install the headlight mask with the headlight. ( p. 124) – Check the headlight setting. ( p. 126) – Set kilometers or miles. ( p. 25) – Adjust combination instrument function. ( p. 26) –...

  • Page 131: Cooling System 16

    COOLING SYSTEM 16 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 132: 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 133: Refilling With Coolant

    COOLING SYSTEM 16 Warning Danger of poisoning Coolant is harmful to health. – 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 134 16 COOLING SYSTEM – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 168) 400243-10 – Push protection cap upward over the coolant temperature sensor. E00904-10 –...

  • Page 135: Changing The Coolant

    COOLING SYSTEM 16 Finishing work – Check the coolant level. ( p. 130) 16.6 Changing the coolant 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 136 16 COOLING SYSTEM – Unplug connector – Remove coolant temperature sensor with the O-ring and wait until the coolant escapes without bubbles. – Mount and tighten coolant temperature sensor with the O- ring. Guideline Screw, cylinder head M10x1.25 12 Nm (8.9 lbf ft) temperature sensor S04259-10 –...

  • Page 137: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the play in the throttle cable – 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 Play in throttle cable 3 …...

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

    17 TUNING THE ENGINE – Tighten nut – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work – Check the play in the throttle cable. ( 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 Air 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 air 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. 85) – Mount the seat. ( p. 78) 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 144: Checking 2-Stroke Oil Level

    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 145 SERVICE WORK ON THE ENGINE 18 Preparatory work – Remove the seat. ( p. 78) – Stand the motorcycle upright on a horizontal surface. – Check 2-stroke oil level. ( p. 142) Main work – Pull the EFI control unit upward off the rubber plugs and hang to the side.

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

    18 SERVICE WORK ON THE ENGINE – Plug in wake-up connector for priming the oil pump to the diagnostics connector The combination instrument lighting is activated. Info The connector is included as part of the motorcycle's separate enclosure. – Wait for at least five seconds. –...
  • Page 147 SERVICE WORK ON THE ENGINE 18 Main work – Remove screw with washer. – Remove the cable ties and take off the frame protector. S04901-10 – Remove screws – Loosen screws S04902-10 – Loosen clamps of the throttle valve body. –...
  • Page 148 18 SERVICE WORK ON THE ENGINE – Remove oil screen and clean it. – Check the oil screen for damage. » If the oil screen is damaged: – Change the oil screen. S03505-10 – Insert the oil screen and mount the angle piece with a new hose clamp.

  • Page 149: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 18 – Position the frame protector. – Mount and tighten screw with washer. Guideline Remaining screws, 5 Nm (3.7 lbf ft) chassis – Mount the cable ties. S04901-10 Finishing work – Install the air filter box cover. ( p.

  • Page 150: Changing The Gear Oil

    18 SERVICE WORK ON THE ENGINE 18.6 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. – In the event of scalding, rinse the area affected immediately with lukewarm water. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 151: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 18 18.7 Adding the gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold. Preparatory work –...

  • 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. 170) – 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. 64) – 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

    Check wiring for damage and electrical fuel injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – The engine has no idle speed Spark plug defective Change the spark plug. –...
  • Page 157 Check wiring for damage and electrical fuel injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.
  • 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: Blink Code 22

    BLINK CODE 22 Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine control Error level condition unit Blink code for malfunction...
  • Page 160 22 BLINK CODE Blink code for malfunction indicator lamp 34 Malfunction indicator lamp flashes 3x long, 4x short Injection valve 1, cylinder 1 – input signal too low Error level condition Injection valve 1, cylinder 1 - input signal too high Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short...

  • Page 161: Technical Data 23

    TECHNICAL DATA 23 23.1 Engine 23.1.1 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 162: Engine Tightening Torques

    23 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 163 TECHNICAL DATA 23 Screw, retaining bracket of exhaust 6 Nm (4.4 lbf ft) control Loctite ® 2701™ Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 2701™ Cap nut, water pump impeller 5 Nm (3.7 lbf ft) Loctite ® 243™ Drain plug, water pump cover 10 Nm (7.4 lbf ft) Screw, alternator cover...

  • Page 164: Capacities

    23 TECHNICAL DATA Nut, primary gear wheel M18LHx1.5 150 Nm (110.6 lbf ft) Loctite ® 243™ 23.3 Capacities 23.3.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 168) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 165: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM...

  • Page 166: Fork

    23 TECHNICAL DATA 23.7 Fork Fork article number 0797C164V401000 WPXPLOR OC Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload – preload adjuster Comfort Standard Sport Spring length with preload spacer(s)

  • Page 167: Chassis Tightening Torques

    TECHNICAL DATA 23 Spring length 225 mm (8.86 in) Gas pressure 10 bar (145 psi) Static sag 37 mm (1.46 in) Riding sag 110 mm (4.33 in) Fitted length 415 mm (16.34 in) Shock absorber fluid ( p. 169) SAE 2.5 23.9 Chassis tightening torques Remaining screws, chassis...
  • Page 168 23 TECHNICAL DATA Screw, chain sliding guard 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, clutch lever 5 Nm (3.7 lbf ft) Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, fuel tank spoiler on radiator 6 Nm (4.4 lbf ft) Screw, manifold on silent block 6 Nm (4.4 lbf ft)
  • Page 169 TECHNICAL DATA 23 Screw, top steering stem (All spe- 17 Nm (12.5 lbf ft) cial models) Loctite ® 243™ Screw, top triple clamp (All stan- 20 Nm (14.8 lbf ft) dard models) Screw, top triple clamp (All special 17 Nm (12.5 lbf ft) models) Screw, wheel speed sensor on axle 4.5 Nm (3.32 lbf ft)

  • Page 170: 24 Substances

    24 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 171 SUBSTANCES 24 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 172) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 172: 25 Auxiliary Substances

    25 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 173 AUXILIARY SUBSTANCES 25 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray 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 174: 26 Standards

    26 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 175: Index Of Special Terms 27

    INDEX OF SPECIAL TERMS 27 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 176: 28 List Of Abbreviations

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

  • Page 177: List Of Symbols 29

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected a malfunction 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 178: Index

    INDEX INDEX Capacity 12-V battery coolant ..... . 132, 162 charging ......119 fuel .
  • Page 179 INDEX Difficult riding conditions Fuse high temperatures ....42 changing for individual electrical power consumers ......122 slow speed .
  • Page 180 INDEX Low-speed compression damping shock absorber, adjusting ....53 Safe operation ......8 Seat mounting .
  • Page 181 INDEX Throttle cable routing checking ......92 Throttle grip ......16 Tire condition checking .
  • Page 182 *3214644en* 3214644en 22.06.2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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