Related Manuals for Husqvarna 125 XC-W 150 2017
Summary of Contents for Husqvarna 125 XC-W 150 2017
- Page 1 OWNER'S MANUAL 2017 125 XC‑W 150 XC‑W 250 EXC 250 XC‑W 300 EXC 300 XC‑W Art. no. 3213477en...
- Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will DEAR KTM CUSTOMER give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new vehicle! Enter the serial numbers of your vehicle below.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.23 Locking the steering (All EXC/EXC Six Days TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 models, 125 XC‑W EU)........19 Symbols used ........... 5 6.24 Unlocking the steering (All EXC/EXC Six Days Formats used............ 5 models, 125 XC‑W EU)........19 SAFETY ADVICE............ - Page 5 TABLE OF CONTENTS 11.4 Adjusting the high-speed compression 12.38 Checking the chain, rear sprocket, motor damping of the shock absorber......42 sprocket, and chain guide ........ 70 11.5 Adjusting the rebound damping of the shock 12.39 Checking the frame ........72 absorber............
- Page 6 TABLE OF CONTENTS 16.2 Checking the antifreeze and coolant level ..99 22.10.5 300 EXC EU, 300 EXC AU, 300 EXC Six Days EU ....... 133 16.3 Checking the coolant level ......100 22.10.6 300 XC‑W US, 300 XC‑W Six Days US..133 16.4 Draining the coolant ........
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Page 7: Means Of Representation
MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). 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. -
Page 8: Safety Advice
SAFETY ADVICE Use definition – intended use (All EXC/EXC Six Days models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public road traffic in the homologated (reduced) version only. -
Page 9: Safe Operation
SAFETY ADVICE 1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu- facturer. -
Page 10: Owner's Manual
SAFETY ADVICE Owner's Manual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus- tomize the vehicle ideally for your own use and how you can protect yourself from injury. -
Page 11: Important Notes
IMPORTANT NOTES Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) E00320-10 Hand brake lever ( p. 14) Light switch ( p. 15) Kill switch ( p. 14) Turn signal switch ( p. 15) Horn button ( p. 15) Clutch lever ( p. -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) E00319-10 Filler cap Throttle grip ( p. 14) Chassis number ( p. 12) Kick starter ( p. 18) Foot brake lever ( p. 18) Level viewer for brake fluid, rear... -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis 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. 401945-10 Key number (All EXC/EXC Six Days models, 125 XC‑W EU) ... -
Page 15: Fork Part Number
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. 0 0 1 401948-10... -
Page 16: Controls
CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. V00322-10 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 17: Horn Button (All Exc/Exc Six Days Models, 125 Xc-W Eu)
CONTROLS Horn button (All EXC/EXC Six Days models, 125 XC‑W EU) (125 XC‑W EU) The horn button is fitted on the left side of the handlebar. Info The horn button has no function when the vehicle is delivered. (All EXC/EXC Six Days models) ... -
Page 18: Electric Starter Button (All 250/300 Models, Xc-W Us, Xc-W Six Days Us)
CONTROLS 6.11 Electric starter button (All 250/300 models, XC‑W US, XC‑W Six Days US) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. •... -
Page 19: Closing The Filler Cap
CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Press release button , turn the filler cap counterclockwise and lift it free. V00325-10 6.15 Closing the filler cap... -
Page 20: Shift Lever
CONTROLS 6.18 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.19 Kick starter ... -
Page 21: Steering Lock (All Exc/Exc Six Days Models, 125 Xc-W Eu)
CONTROLS The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 401944-10 6.22 Steering lock (All EXC/EXC Six Days models, 125 XC‑W EU) Steering lock ... -
Page 22: Speedometer
SPEEDOMETER Speedometer 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. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. -
Page 23: Setting The Speedometer Functions
SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. -
Page 24: Display Mode Speed (Speed)
SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –... -
Page 25: Setup Menu
SPEEDOMETER Setup menu Condition • The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached. -
Page 26: Display Mode Speed/Clk (Time)
SPEEDOMETER 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 button The display changes to the Setup menu of the clock. for 2–3 seconds. -
Page 27: Viewing The Lap Time
SPEEDOMETER 7.14 Viewing the lap time Condition • The motorcycle is stationary. – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button Press the button The stop watch and the lap time are reset. for 2–3 seconds. -
Page 28: Display Mode Speed/Tr2 (Trip Master 2)
SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) – Repeatedly press the button briefly until TR2 appears at the top right of the dis- play. TR2 (trip master 2) runs constantly and counts up to 999.9. Press the button Clears the values TR2 and A2. for 2–3 seconds. -
Page 29: Display Mode Speed/A2 (Average Speed 2)
SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) – Repeatedly press the button briefly until A2 appears at the top right of the dis- play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running. -
Page 30: Table Of Functions
SPEEDOMETER 7.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service... -
Page 31: Table Of Conditions And Menu Activation
SPEEDOMETER 7.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •... -
Page 32: Preparing For Use
PREPARING FOR USE Advice on first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. –... -
Page 33: Running In The Engine
PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –... -
Page 34: Preparing For Rides On Dry Sand
PREPARING FOR USE Preparing for rides on dry sand – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the indicated value does not correspond to the required value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. -
Page 35: Preparing For Rides On Wet Sand
PREPARING FOR USE Preparing for rides on wet sand – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the indicated value does not correspond to the required value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. -
Page 36: Preparing For Rides At High Temperature And Slow Speed
PREPARING FOR USE – Mount the steel sprocket. – Clean the motorcycle. ( p. 115) – Carefully align bent radiator fins. 600868-01 Preparing for rides at high temperature and slow speed – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) »... -
Page 37: Riding Instructions
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 38: Start Off
RIDING INSTRUCTIONS – Pull the choke lever out as far as possible. (All 250/300 models, XC‑W US, XC‑W Six Days US) – Press the electric starter button or press the kick starter robustly through its full range. Info Do not turn the throttle. (125 XC‑W EU) –... -
Page 39: Stopping, Parking
RIDING INSTRUCTIONS Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet or slippery surfaces, use the rear brake. –... -
Page 40: Refueling
RIDING INSTRUCTIONS – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against acci- dents or falling over. 401475-01 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –... -
Page 41: Service Schedule
SERVICE SCHEDULE 10.1 Additional information Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately. 10.2 Required work Every 40 operating hours/after every race Every 20 operating hours Once after 5 operating hours Once after 1 operating hour ○... -
Page 42: Recommended Work
SERVICE SCHEDULE 10.3 Recommended work Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours/every 10 operating hours when used for motorsports Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. -
Page 43: Tuning The Chassis
TUNING THE CHASSIS 11.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. -
Page 44: Adjusting The High-Speed Compression Damping Of The Shock Absorber
TUNING THE CHASSIS Guideline Compression damping, low-speed (All 125/150 models) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, low-speed (All 250/300 models) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. -
Page 45: Measuring The Rear Wheel Dimension Unloaded
TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (All 125/150 models) Comfort 18 clicks Standard 15 clicks Sport 12 clicks V00331-10... -
Page 46: Checking The Static Sag Of The Shock Absorber
TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 43) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and marking SAG on the rear fender using the sag gauge. -
Page 47: Adjusting The Riding Sag
TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (90129051000) – Measure the overall spring length while the spring is not under tension. –... -
Page 48: Checking The Basic Setting Of The Fork
TUNING THE CHASSIS – Check the static sag of the shock absorber. ( p. 44) – Check the riding sag of the shock absorber. ( p. 44) – Adjust the rebound damping of the shock absorber. ( p. 42) 11.11 Checking the basic setting of the fork Info For various reasons, no exact riding sag can be determined for the fork. -
Page 49: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All standard EXC/XC-W models) –... -
Page 50: Adjusting The Spring Preload Of The Fork (All Six Days Models)
TUNING THE CHASSIS 11.14 Adjusting the spring preload of the fork (All Six Days models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) Main work – Turn the adjusting wings counterclockwise all the way. The marking +0 aligns with the right wing on both fork legs. -
Page 51: Adjusting The Handlebar Position
TUNING THE CHASSIS (All Six Days models) On the upper triple clamp, there are 2 holes at a distance of to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. - Page 52 TUNING THE CHASSIS (All Six Days 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 damage. Do not kink the cables and lines. –...
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Page 53: Service Work On The Chassis
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 54: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS 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 55: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS (All standard EXC/XC-W models) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. E00376-10 (All Six Days models) – Loosen screws . -
Page 56: Removing The Lower Triple Clamp (All Standard Exc/Xc-W Models)
SERVICE WORK ON THE CHASSIS – Position the brake caliper, and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws E00375-11 Finishing work –... -
Page 57: Installing The Lower Triple Clamp (All Standard Exc/Xc-W Models)
SERVICE WORK ON THE CHASSIS Main work – Remove screw . Remove screw . Pull off the upper triple clamp with the han- dlebar and hang it to one side. Info Protect the components against damage by covering them. Do not bend the cables and lines. - Page 58 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) V00338-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) V00337-10...
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Page 59: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (All Six Days models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 143) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 60: Checking The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) V00361-10 – Position the brake caliper, and mount and tighten screws Guideline Loctite ® 243™ Screw, front brake caliper 25 Nm (18.4 lbf ft) -
Page 61: Adjusting The Steering Head Bearing Play
SERVICE WORK ON THE CHASSIS 12.14 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) Main work (All standard EXC/XC-W models) – Loosen screws – Loosen and retighten screw Guideline Screw, top steering head M20x1.5... -
Page 62: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 12.16 Removing the front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 94) Main work – Remove screws V00340-10 – Remove screws . Remove the front fender. V00341-10 12.17 Installing the front fender Main work... -
Page 63: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS Main work – Remove screw and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Secure the rear wheel in this position. – Remove screw , push splash protector to the side, and remove the shock absorber. -
Page 64: Removing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) V00342-10 12.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw V00346-10 –... -
Page 65: Removing The Air Filter
SERVICE WORK ON THE CHASSIS 12.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 66: Securing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS Preparatory work – Remove the air filter box cover. ( p. 62) – Remove the air filter. p. 63) Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. -
Page 67: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS 12.29 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 68: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove screws – Pull out inner tube – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –... -
Page 69: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. – Remove the tube from the fuel tank breather. V00351-10 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. V00352-10 12.33 Installing the fuel tank... -
Page 70: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS – Mount and tighten screws with the collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the fuel hose. V00350-11 Finishing work – Mount the seat. ( p. 61) 12.34 Checking the chain for dirt –... -
Page 71: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12.36 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. -
Page 72: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide
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 ... - Page 73 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pin is at the level of or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.
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Page 74: Checking The Frame
SERVICE WORK ON THE CHASSIS 12.39 Checking the frame – Check the frame for cracks and deformation. » If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. -
Page 75: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.42 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the han- dle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. -
Page 76: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »... -
Page 77: Removing The Engine Guard (All Six Days Models, Exc Au)
SERVICE WORK ON THE CHASSIS – Now inject the fluid into the system until it emerges from drill hole of the mas- ter cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –... -
Page 78: Brake System
BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –... -
Page 79: Checking The Brake Discs
BRAKE SYSTEM 13.4 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.) – Check the thickness of the front and rear brake discs at multiple points on each ... -
Page 80: Adding Front Brake Fluid
BRAKE SYSTEM 13.6 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. -
Page 81: Checking The Front Brake Linings
BRAKE SYSTEM 13.7 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 82 BRAKE SYSTEM 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. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
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Page 83: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM 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 84: Checking The Rear Brake Fluid Level
BRAKE SYSTEM 13.11 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. -
Page 85: Checking The Rear Brake Linings
BRAKE SYSTEM Preparatory work – Check the rear brake linings. ( p. 83) Main work – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. - Page 86 BRAKE SYSTEM Warning 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 regu- lations. 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.
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Page 87: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 88: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) –... -
Page 89: Installing The Rear Wheel
WHEELS, TIRES 14.4 Installing the rear 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. Main work –... -
Page 90: Checking The Tire Condition
WHEELS, TIRES 14.5 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 air pressure of the tires all have a major impact on the handling of the motorcycle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces. -
Page 91: Checking Spoke Tension
WHEELS, TIRES 14.7 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. -
Page 92: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery (All 250/300 models, XC‑W US, XC‑W Six Days US) Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 93: Installing The Battery (All 250/300 Models, Xc-W Us, Xc-W Six Days Us)
ELECTRICAL SYSTEM 15.2 Installing the battery (All 250/300 models, XC‑W US, XC‑W Six Days US) Main work – Insert the battery into the battery compartment with the terminals facing forward and secure with holding bracket (XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models) Battery (HJTZ5S-FP) ( p. - Page 94 ELECTRICAL SYSTEM Main work (XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models) Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. –...
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Page 95: Changing The Main Fuse (All 250/300 Models, Xc-W Us, Xc-W Six Days Us)
ELECTRICAL SYSTEM (300 EXC BR) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 96: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. E00361-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a defective fuse by a burned-out fuse wire A spare fuse is located in the starter relay. -
Page 97: Installing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM (All XC‑W/XC‑W Six Days models) – Detach plug-in connector and take off the headlight mask with the head- light. E00357-10 15.6 Installing the headlight mask with the headlight Main work (All EXC/EXC Six Days models) – Connect plug-in connectors E00356-11 (All XC‑W/XC‑W Six Days models) -
Page 98: Changing The Turn Signal Bulb (All Exc/Exc Six Days Models)
ELECTRICAL SYSTEM Main work – Turn protection cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull bulb socket of the parking light out of the reflector. E00358-10 – Pull out headlight bulb –... -
Page 99: Checking The Headlight Setting
ELECTRICAL SYSTEM 15.9 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark. - Page 100 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...
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Page 101: Cooling System
COOLING SYSTEM 16.1 Cooling system (All 125/150 models) 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 operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 102: Checking The Coolant Level
COOLING SYSTEM – Mount the radiator cap. 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 103: Refilling With Coolant
COOLING SYSTEM – Place a suitable container under the water pump cover. (All 125/150 models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover 8 Nm (5.9 lbf ft) - Page 104 COOLING SYSTEM (All 250/300 models) – Make sure that screw is tightened. – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant ( p. 141) V00376-10 – Loosen screw and wait until coolant escapes without bubbles. –...
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Page 105: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Turn the handlebar as far as possible to the right. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 106: Carburetor Setting
TUNING THE ENGINE 17.3 Carburetor setting Effects of the carburetor setting H01400-01 The different carburetor components must be tuned both to one another and for the use intended. 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 107 TUNING THE ENGINE K00496-01 When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindri- cal part of the needle is less. When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling jet is only minimal.
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Page 108: Carburetor - Idle
TUNING THE ENGINE 17.4 Carburetor - idle The idle setting of the carburetor has a big influence on the starting behavior, stable idling, and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle speed is set wrongly. Info The carburetor and its components are subject to increased wear caused by engine vibration. -
Page 109: Ignition Curve Plug-In Connector
TUNING THE ENGINE Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle air adjusting screw to the end without any change of engine speed, mount a smaller idling jet. -
Page 110: Engine Characteristic - Auxiliary Spring
TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure. - Page 111 TUNING THE ENGINE – Remove cap , adjusting spring , auxiliary spring , and spring insert from the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring ( p.
- Page 112 TUNING THE ENGINE – Mount the required auxiliary spring ( p. 108) and adjusting spring and position them together in the clutch cover. Auxiliary spring with yellow marking (54637072300) Auxiliary spring with green marking (54837072100) Auxiliary spring with red marking (54837072000) ...
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Page 113: Service Work On The Engine
SERVICE WORK ON THE ENGINE 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 114: Changing The Gear Oil
SERVICE WORK ON THE ENGINE Main work (All 125/150 models) – Remove gear oil monitoring screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. » If no gear oil runs out: –... - Page 115 SERVICE WORK ON THE ENGINE Main work (All 125/150 models) – Remove gear oil drain plug with magnet. – Remove gear oil drain plug – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug. –...
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Page 116: Adding Gear Oil
SERVICE WORK ON THE ENGINE (All Six Days models, EXC AU) – Install the engine guard. ( p. 75) 18.4 Adding 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 117: Cleaning, Care
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 118: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precautions against aggres- sive road salt. If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water enhances the corrosive effects of salt. -
Page 119: Storage
STORAGE 20.1 Storage 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 120: Preparing For Use After Storage
STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 51) (All 250/300 models, XC‑W US, XC‑W Six Days US) – Install the battery. p. 91) – Perform checks and maintenance measures when preparing for use. ( p. -
Page 121: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 35) tric starter) – Battery discharged Recharge the battery. p. 91) (All 250/300 models, XC‑W US, – Check the charging voltage. XC‑W Six Days US) –... - Page 122 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Lack of fuel of the fuel tap to the ON posi- Turn handle carburetor tion. (Figure V00326-10 p. 17) – Refuel. ( p. 38) – Engine takes in bad air Check the intake flange and carburetor for tightness.
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Page 123: Technical Data
TECHNICAL DATA 22.1 Engine 22.1.1 125 XC‑W EU Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Idle speed 1,400… 1,500 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing... -
Page 124: All 250 Models
TECHNICAL DATA Second gear 15:31 Third gear 17:28 Fourth gear 19:26 Fifth gear 21:25 Sixth gear 20:20 Alternator 12 V, 75 W Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Cooling... -
Page 125: Engine Tightening Torques
TECHNICAL DATA Exhaust valve, beginning of adjustment 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 X distance (upper edge of piston to upper edge of cylinder) 0…... -
Page 126: 150 Xc-W Us
TECHNICAL DATA – Screw, intermediate clutch cover M6x30 10 Nm (7.4 lbf ft) Screw, kick starter stop plate 10 Nm (7.4 lbf ft) Loctite ® 243™ – Screw, outer clutch cover M6x20 8 Nm (5.9 lbf ft) – Screw, outer clutch cover M6x50 8 Nm (5.9 lbf ft) Screw, shift drum locating... -
Page 127: All 250/300 Models
TECHNICAL DATA Loctite ® 243™ Screw, stator 8 Nm (5.9 lbf ft) Screw, stop plate of exhaust control 10 Nm (7.4 lbf ft) Loctite ® 243™ – Screw, water pump cover 10 Nm (7.4 lbf ft) – Screw, cylinder head 18 Nm (13.3 lbf ft) –... -
Page 128: Capacities
TECHNICAL DATA – Nut, rotor M12x1 60 Nm (44.3 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) Loctite ®... -
Page 129: Electrical System
TECHNICAL DATA Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase (All 125/150 models) 1,471±10 mm (57.91±0.39 in) Wheelbase (All 250/300 models) 1,482±10 mm (58.35±0.39 in) Seat height unloaded 960 mm (37.8 in) Ground clearance unloaded 370 mm (14.57 in) -
Page 130: Fork
TECHNICAL DATA 22.7 Fork 22.7.1 All 125/150 models Fork part number 14.18.8Q.61 Fork WP Performance Systems MXMA 4860 upside down Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with preload spacer(s) 474 mm (18.66 in) -
Page 131: Shock Absorber
TECHNICAL DATA Standard 15 clicks Sport 12 clicks Spring preload - Preload Adjuster Comfort Standard Sport Spring length with preload spacer(s) 477 mm (18.78 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75…... -
Page 132: Chassis Tightening Torques
TECHNICAL DATA Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload Comfort 8 mm (0.31 in) Standard 8 mm (0.31 in) Sport 8 mm (0.31 in) Spring rate... - Page 133 TECHNICAL DATA – Screw, bottom triple clamp (All stan- 15 Nm (11.1 lbf ft) dard EXC/XC-W models) – Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) Six Days models) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace 25 Nm (18.4 lbf ft) Loctite...
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Page 134: Carburetor
TECHNICAL DATA 22.10 Carburetor 22.10.1 125 XC‑W EU Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 77 Needle position 3rd position from top Jet needle 6BFY44‑73 (6BFY43‑73) Main jet 480 (470, 490, 500, 520) Idling jet 45 (42.5) Starting jet Needle jet R‑8... -
Page 135: 22.10.5 300 Exc Eu, 300 Exc Au, 300 Exc Six Days Eu
TECHNICAL DATA Idle air adjusting screw Open 1.5 turns Throttle slide 22.10.5 300 EXC EU, 300 EXC AU, 300 EXC Six Days EU Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 78 Needle position 1st position from top Jet needle 6BFY43‑74 (6BFY44‑73, 6BFY43‑73) Main jet... -
Page 136: Carburetor Tuning
CARBURETOR TUNING 23.1 Carburetor tuning (125 XC‑W EU) 402698-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. -
Page 137: Carburetor Tuning (150 Xc-W Us)
CARBURETOR TUNING 23.2 Carburetor tuning (150 XC‑W US) 402699-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. -
Page 138: Carburetor Tuning (250 Exc Eu, 250 Exc Au, 250 Exc Six Days Eu)
CARBURETOR TUNING 23.3 Carburetor tuning (250 EXC EU, 250 EXC AU, 250 EXC Six Days EU) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. -
Page 139: Carburetor Tuning (250 Xc-W Us)
CARBURETOR TUNING 23.4 Carburetor tuning (250 XC‑W US) 402701-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. -
Page 140: Carburetor Tuning (300 Exc Eu, 300 Exc Au, 300 Exc Six Days Eu)
CARBURETOR TUNING 23.5 Carburetor tuning (300 EXC EU, 300 EXC AU, 300 EXC Six Days EU) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. -
Page 141: Carburetor Tuning (300 Xc-W Us, 300 Xc-W Six Days Us)
CARBURETOR TUNING 23.6 Carburetor tuning (300 XC‑W US, 300 XC‑W Six Days US) 402703-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. -
Page 142: Carburetor Tuning (300 Exc Br)
CARBURETOR TUNING 23.7 Carburetor tuning (300 EXC BR) 402729-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Does not apply on sandy terrain. -
Page 143: Substances
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 corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 144 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 144) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
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Page 145: Auxiliary Substances
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 Motorex... -
Page 146: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 147: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 148: List Of Symbols
LIST OF SYMBOLS 28.1 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 28.2 Green and blue symbols Green and blue symbols reflect information. -
Page 149: Index
INDEX Chassis number ....... 12 INDEX Choke ........17 Accessories . - Page 150 INDEX Fork Indicator lamps overview ......16 article number ......13 Intended use .
- Page 151 INDEX Service schedule ......39-40 Troubleshooting ......119-120 Shift lever .
- Page 152 *3213477en* 3213477en 07/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...