Page 1 REPAIR MANUAL 2014 250 EXC EU 250 EXC SIX DAYS EU 250 EXC AUS 250 XC‑W USA 300 EXC EU 300 EXC SIX DAYS EU 300 EXC AUS 300 XC‑W USA 300 XC‑W SIX DAYS USA Art. no. 3206179en...
Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
Page 4: Table Of Contents
TABLE OF CONTENTS 6.2.6 Positioning the fork protection ..... 34 TABLE OF CONTENTS MEANS OF REPRESENTATION ........6 6.2.7 Removing the fork legs ........ 34 Symbols used ........... 6 6.2.8 Installing the fork legs......... 35 Formats used............ 6 6.2.9 Removing the fork protector ......35 SAFETY ADVICE............
Page 5 TABLE OF CONTENTS 9.21 Assembling the rebound adjuster...... 70 15.5 Disconnecting the negative cable of the battery ............102 9.22 Assembling the seal ring retainer ...... 70 15.6 Connecting the negative cable of the battery..103 9.23 Assembling the piston rod........ 71 15.7 Removing the battery ........
Page 6 TABLE OF CONTENTS 18.3.10 Removing the cylinder....... 136 18.5.7 Installing the reed valve housing ....172 18.3.11 Removing the piston ......... 137 18.5.8 Installing the rotor ........172 18.3.12 Removing the water pump cover....138 18.5.9 Installing the locking lever ......173 18.3.13 Removing the clutch cover......
Page 7 29.2 Service work (as additional order) ....224 30 WIRING DIAGRAM ........... 226 30.1 Page 1 of 5 (250 EXC EU, 300 EXC EU)..226 30.2 Page 2 of 5 (250 EXC EU, 300 EXC EU)..228 30.3 Page 3 of 5 (250 EXC EU, 300 EXC EU)..230 30.4...
Page 8: 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). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
Page 9: Safety Advice
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.
Page 10: Important Information
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.
Page 11: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 602696-10 Type label The type label is fixed to the front of the steering head. 602696-11 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.
Page 12: Motorcycle
MOTORCYCLE Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) ( p.
Page 13: Starting The Motorcycle For Checking
MOTORCYCLE Starting the motorcycle for checking Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
Page 14: Fork, Triple Clamp
FORK, TRIPLE CLAMP EXC EU/AUS, XC‑W 6.1.1 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.
Page 15: Bleeding The Fork Legs
FORK, TRIPLE CLAMP Guideline Spring preload - Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Info Turn clockwise to increase spring preload; turn counterclockwise to reduce spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping.
Page 16: Loosening The Fork Protection
FORK, TRIPLE CLAMP 6.1.6 Loosening the fork protection – Remove screws and take off the clamp. – Remove screws on the left fork leg. Push the fork protection downwards. – Remove the screws on the right fork leg. Push the fork protection downwards. B01515-10 6.1.7 Positioning the fork protection...
Page 17: Removing The Fork Protector
FORK, TRIPLE CLAMP – 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) 602711-10 – Position the brake caliper and mount and tighten screws Guideline Loctite 243™...
Page 18: Performing A Fork Service
FORK, TRIPLE CLAMP 6.1.12 Performing a fork service Info These operations are the same on both fork legs. Condition The fork legs have been removed. – Disassemble the fork legs. ( p. 16) – Disassemble the cartridge. ( p. 19) –...
Page 19 FORK, TRIPLE CLAMP – Loosen Preload Adjuster Pin wrench (T103) ( p. 276) Info The Preload Adjuster cannot be taken off yet. 200737-10 – Take out the fork leg and clamp with the axle clamp. Info Use soft jaws. 200690-10 –...
Page 20 FORK, TRIPLE CLAMP – Drain the fork oil. Info Pull out and push in the piston rod a few times to empty the cartridge. 201349-10 – Clamp the fork leg with the axle clamp. Guideline Use soft jaws. – Unscrew and remove the compression damping fitting Info Place a fluid collector beneath it, as usually some oil will drain out.
Page 21: Cartridge Disassembly
FORK, TRIPLE CLAMP – Remove upper sliding bushing Info Gently pull them apart without using any tool. 200658-01 – Take off the lower sliding bushing – Take off support ring – Take off seal ring – Take off lock ring –...
Page 22 FORK, TRIPLE CLAMP – Degrease the cartridge and clamp using the pecial tool. Clamping stand (T14015S) ( p. 278) – Warm up the cartridge in the area of Guideline 50 °C (122 °F) – Unscrew and remove screwsleeve Info 200749-10 This step is unnecessary for the further disassembly.
Page 23: Disassembling The Compression Damping Fitting
FORK, TRIPLE CLAMP 6.1.15 Disassembling the compression damping fitting Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p. 16) Main work – Clamp the compression damping fitting in a bench vise using soft jaws. –...
Page 24: Assembling The Compression Damping Fitting
FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Inner tub run-out » If the measured value is greater than the specified value: – Change the inner tube. 200685-10 – Check the outer tube for damage. »...
Page 25: Assembling The Cartridge
FORK, TRIPLE CLAMP – Mount shim stack Info Mount the smaller shims below. – Mount pistons with O-ring Info The side with the largest inside diameter faces upward. 200705-10 – Grease the piston O-ring. Fork oil (SAE 4) (48601166S1) ( p.
Page 26: Assembling The Fork Legs
FORK, TRIPLE CLAMP Info The side with the largest inside diameter faces downward. – Mount shim stack Info Align the triangular plate exactly with the piston opening. – Mount and tighten nut Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft) 200720-10 Info Mount the nut with the collar facing downward.
Page 27 FORK, TRIPLE CLAMP Preparatory work – Check the fork legs. ( p. 21) – Assemble the cartridge. ( p. 23) – Assemble the compression damping fitting. ( p. 22) Main work – Clamp in the inner tube with the axle clamp. Guideline Use soft jaws.
Page 28 FORK, TRIPLE CLAMP – Position the support ring. – Hold the seal ring with the shorter shoulder of the special tool. Assembly tool (T1402S) ( p. 279) – Press the outer tube all the way in. 201355-10 – Mount lock ring Info The lock ring must audibly lock into place.
Page 29 FORK, TRIPLE CLAMP – Clamp in the fork vertically. – Fill with fork oil. Fork oil per fork 625 ml Fork oil (SAE 4) (48601166S1) (21.13 fl. oz.) p. 268) Info Pull out the piston rod and push back in a number of times to bleed the car- tridge.
Page 30 FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the outer tube in the area of lower triple clamp. Clamping stand (T1403S) ( p. 279) – Grease the Preload Adjuster O-ring. Lubricant (T158) ( p. 270) – Screw on and tighten the Preload Adjuster. Guideline 200744-10 Preload Adjuster on the outer tube...
Page 31: Greasing The Steering Head Bearing
FORK, TRIPLE CLAMP 6.1.20 Greasing the steering head bearing – Remove the lower triple clamp. ( p. 29) – Install the lower triple clamp. ( p. 30) 800010-10 6.1.21 Removing the lower triple clamp Preparatory work – Raise the motorcycle with the lift stand. ( p.
Page 32: Installing The Lower Triple Clamp
FORK, TRIPLE CLAMP 6.1.22 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 270) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
Page 33: Checking The Play Of The Steering Head Bearing
FORK, TRIPLE CLAMP – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) 602723-10 – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) 602723-12 – Position the brake caliper. Mount and tighten screws Guideline Loctite ®...
Page 34: Adjusting The Play Of The Steering Head Bearing
FORK, TRIPLE CLAMP Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...
Page 35: Adjusting The Rebound Damping Of The Fork
FORK, TRIPLE CLAMP Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 6.2.2 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn the red adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the right fork leg.
Page 36: Loosening The Fork Protection
FORK, TRIPLE CLAMP Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray ( p.
Page 37: Installing The Fork Legs
FORK, TRIPLE CLAMP – Loosen screws . Remove the fork leg on the left. – Loosen screws . Remove the fork leg on the right. 602732-10 6.2.8 Installing the fork legs Main work – Position the fork legs. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw).
Page 38: Installing The Fork Protector
FORK, TRIPLE CLAMP Main work – Remove screws on the left fork leg. Lift off the fork protector. – Remove the screws on the right fork leg. Lift off the fork protector. 101327-10 6.2.10 Installing the fork protector Main work –...
Page 39 FORK, TRIPLE CLAMP – Note down the current state of rebound damping REB (red adjuster of right fork leg). – Note down the current state of compression damping COMP (white adjuster of left fork leg). – Fully open the adjusters of the rebound and compression damping. 201699-10 –...
Page 40: Removing The Spring
FORK, TRIPLE CLAMP – Remove dust boot – Remove fork protection ring Info The fork protection ring does not necessarily need to be removed for repair work. 201705-10 – Remove lock ring Info The lock ring has a ground end against which a screwdriver can be posi- tioned.
Page 41: Disassembling The Cartridge
FORK, TRIPLE CLAMP Main work – Pull the spring down. Mount the open end wrench on the hexagonal part. 201722-11 – Clamp the open end wrench in the vise. Release screw cap but do not remove it yet. Special socket (T14047) ( p.
Page 42: Disassembling The Piston Rod
FORK, TRIPLE CLAMP – Clamp the tube of the cartridge into a vise. Clamping stand (T14049S) ( p. 280) – Release seal ring retainer and remove with the washer. 202481-10 – Remove lock ring – Pull reservoir off of the tube. 201794-10 –...
Page 43: Disassembling The Hydrostop Unit
FORK, TRIPLE CLAMP – Remove the rebound shim stack – Remove piston 201729-10 – Remove the compression shim stack – Remove spring. 201730-10 – Remove adapter with spring and washer. – Remove spring 201788-10 – Remove valve needle from the piston rod. Info The adjusting tube can be used for this.
Page 44: Disassembling The Seal Ring Retainer
FORK, TRIPLE CLAMP – Remove adapter – Remove hub with washers Info It is possible that only one washer or no washer is present. – Remove the O-ring from the hub. 201781-10 – Remove shim stack – Remove washer – Remove O-ring 201782-10 6.2.17...
Page 45: Assembling The Seal Ring Retainer
FORK, TRIPLE CLAMP – Measure the outside diameter at multiple locations of the inner tube. Outside diameter of inner tube 47.975… 48.005 mm (1.88878… 1.88996 in) » If the measured value is smaller than the specified value: – Change the inner tube. 200684-10 –...
Page 46: Assembling The Hydrostop Unit
FORK, TRIPLE CLAMP – Mount and grease seal ring Lubricant (T158) ( p. 270) – Mount and grease O-ring Lubricant (T158) ( p. 270) – Position pilot bushing support 201800-10 6.2.20 Assembling the hydrostop unit Info The steps are identical for both fork legs. –...
Page 47 FORK, TRIPLE CLAMP – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14049S) ( p. 280) – Lubricate the O-ring. Mount valve needle in the piston rod. Lubricant (T158) ( p. 270) 201790-10 –...
Page 48: Assembling The Cartridge
FORK, TRIPLE CLAMP – Unclamp the piston rod. 6.2.22 Assembling the cartridge Info The steps are identical for both fork legs. Preparatory work – Assemble the seal ring retainer. ( p. 43) – Assemble the piston rod. ( p. 44) Main work –...
Page 49: Assembling The Fork Legs
FORK, TRIPLE CLAMP – Degrease piston rod and clamp in the vise. Clamping stand (T14049S) ( p. 280) – Screw spring guide all the way on. Info The nut must be firmly tightened against the stop by hand. Do not use a tool.
Page 50 FORK, TRIPLE CLAMP – Slide on the lower sliding bushing – Mount the upper sliding bushing Info Do not use a tool; pull the ends apart slightly by hand. 201716-10 – Warm the outer tube in area of the lower sliding bushing. Guideline 50 °C (122 °F) –...
Page 51 FORK, TRIPLE CLAMP – Turn the fork. Have the entire filling quantity of fork oil available. Oil capacity per 635 ml Fork oil (SAE 4) (48601166S1) fork leg (21.47 fl. oz.) p. 268) – Add some of the fork oil while pulling out and pushing in the piston rod numerous times.
Page 52: Greasing The Steering Head Bearing
FORK, TRIPLE CLAMP – Push the outer tube up. – Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 279) – Tighten screw cap Guideline Cartridge on outer tube M51x1.5 40 Nm (29.5 lbf ft) 201701-11 Special socket (T14047) (...
Page 53: Removing The Lower Triple Clamp
FORK, TRIPLE CLAMP 6.2.25 Removing the lower triple clamp Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Remove the front wheel. ( p. 93) – Remove the headlight mask with the headlight. ( p. 89) –...
Page 54 FORK, TRIPLE CLAMP – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws toward the front. 602737-10 – Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft)
Page 55: Checking The Play Of The Steering Head Bearing
FORK, TRIPLE CLAMP Finishing work – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly. – Check the play of the steering head bearing. ( p. 53) – Remove the motorcycle from the lift stand. ( p.
Page 56: Handlebar, Controls
HANDLEBAR, CONTROLS Handlebar position On the upper triple clamp, there are two holes a distance of apart. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in four different positions.
Page 57: Checking The Routing Of The Throttle Cable
HANDLEBAR, CONTROLS Checking the routing of the throttle cable Preparatory work – Remove the seat. ( p. 85) – Remove the fuel tank. ( p. 86) Main work – Check the routing of the throttle cable. The throttle cable must be routed behind the handlebar, on the right of the upper frame tube, and to the carburetor.
Page 58: Adjusting The Play In The Throttle Cable
HANDLEBAR, CONTROLS Adjusting the play in the throttle cable Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster – Loosen nut –...
Page 59: Frame
FRAME Removing the engine guard (250/300 SIX DAYS) – Turn quick release counterclockwise until it disengages. Remove the engine guard. B01204-10 Installing the engine guard (250/300 SIX DAYS) – Attach the engine guard at the back of the frame and swing it up at front. –...
Page 60: Shock Absorber, Swingarm
SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. –...
Page 61: Adjusting The Rebound Damping Of The Shock Absorber
SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. – Turn adjusting screw clockwise with a screwdriver to the last click.
Page 62: Checking The Riding Sag Of The Shock Absorber
SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of the unloaded rear wheel. ( p. 59) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
Page 63: Adjusting The Riding Sag
SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Remove the shock absorber. ( p. 61) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring.
Page 64: Servicing The Shock Absorber
SHOCK ABSORBER, SWINGARM 9.11 Servicing the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. –...
Page 65: Disassembling The Damper
SHOCK ABSORBER, SWINGARM 9.13 Disassembling the damper Preparatory work – Remove the spring. ( p. 62) Main work – Note down the present state of rebound damping and compression damping – Completely open the adjustment elements of the rebound damping and compres- sion damping.
Page 66: Disassembling The Piston Rod
SHOCK ABSORBER, SWINGARM – Remove the piston rod. Drain the remaining oil. 201620-10 – Remove adjusting ring with the intermediate washer. 201621-10 – Remove compression adjuster . Remove the spring and piston. 200760-10 9.14 Disassembling the piston rod Preparatory work –...
Page 67: Disassembling The Seal Ring Retainer
SHOCK ABSORBER, SWINGARM – Unscrew and remove mount – Remove rebound damping shim stack Info Guide the rebound damping shim stack onto a screwdriver and put them aside together. 200763-10 – Remove piston – Remove compression damping shim stack Info Guide the compression damping shim stack onto a screwdriver and put them aside together.
Page 68: Replacing The Pilot Bushing
SHOCK ABSORBER, SWINGARM – Remove seal ring – Remove washer from seal ring 200786-10 – Remove washer – Remove O-ring – Remove dust boot 200787-10 9.16 Replacing the pilot bushing Preparatory work – Remove the spring. ( p. 62) – Disassemble the damper.
Page 69: Checking The Damper
SHOCK ABSORBER, SWINGARM 9.17 Checking the damper Condition The damper has been disassembled. – Measure the inside diameter on both ends and in the middle of the damper car- tridge. Damper cartridge Diameter 50.08 mm (1.9716 in) » If the measured value is greater than the specified value: –...
Page 70: Removing The Heim Joint
SHOCK ABSORBER, SWINGARM – Remove screwsleeve – Remove adjusting screw Info Do not lose balls and spring. 200806-10 – Remove rubber plug – From the opposite side, press rebound needle out of the piston rod. 200807-10 9.19 Removing the heim joint Condition The shock absorber has been demounted.
Page 71: Installing The Heim Joint
SHOCK ABSORBER, SWINGARM – Place special tool underneath and press out heim joint using special tool Pressing tool (T1207S) ( p. 277) 200802-10 9.20 Installing the heim joint – Position new heim joint and special tool. Pressing tool (T1206) ( p.
Page 72: Assembling The Rebound Adjuster
SHOCK ABSORBER, SWINGARM 9.21 Assembling the rebound adjuster – Grease O-ring of the rebound needle. Lubricant (T158) ( p. 270) – Mount rebound needle in the piston rod. Info Push in the rebound needle to the point where it is possible to mount the rebound damping adjusting screw.
Page 73: Assembling The Piston Rod
SHOCK ABSORBER, SWINGARM – Position washer on seal ring – Grease the seal ring and mount with the washer facing downward. Lubricant (T511) ( p. 270) 200794-10 – Mount centering disk – Mount rebound rubber 200795-10 9.23 Assembling the piston rod Preparatory work –...
Page 74: Assembling The Damper
SHOCK ABSORBER, SWINGARM – Mount rebound damping shim stack with the smaller shims at the top. – Apply thread locker to the threads of the piston rod. Loctite ® 2701™ – Screw on mount to the point where the piston can still be turned. 200769-10 –...
Page 75 SHOCK ABSORBER, SWINGARM Main work – Slide the spring and piston onto compression adjuster – Grease the O-ring. Lubricant (T158) ( p. 270) – Grease the threads. Lubricant (T159) ( p. 270) – Mount and tighten the compression adjuster. 200774-10 Guideline Compression adjuster M31x1...
Page 76 SHOCK ABSORBER, SWINGARM – Mount rubber cap of the reservoir. – Turn adjusting ring completely down toward the bottom. 201623-10 Alternative 1 – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type.
Page 77: Bleeding And Filling The Damper
SHOCK ABSORBER, SWINGARM 9.25 Bleeding and filling the damper Info Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound and compression damping. – Remove the screw from the filling port. –...
Page 78 SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum.
Page 79: Filling The Damper With Nitrogen
SHOCK ABSORBER, SWINGARM – Slide O-ring to the end of the special tool by the specified value (distance minus specified value). Guideline 10 mm Depth micrometer (T107S) ( p. 276) – Push the floating piston into the reservoir to the distance described above using the special tool.
Page 80: Installing The Spring
SHOCK ABSORBER, SWINGARM – Close spigot and remove the damper from the special tool. – Tighten the screw of the filling port. Guideline Reservoir filling port screw 3.5 Nm (2.58 lbf ft) 9.27 Installing the spring – Ensure that adjusting ring is screwed on with the intermediate washer.
Page 81: Changing The Heim Joint
SHOCK ABSORBER, SWINGARM – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) 201613-11 9.28 Changing the heim joint Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel.
Page 82 SHOCK ABSORBER, SWINGARM – Position the new heim joint. – Mount special tool Mounting tool, heim joint (50329000044) ( p. 272) – Press in the heim joint by screwing in the screw. 303612-10 – Press in shaft seal rings on both sides with the open side facing inward. Info The heim joint for the shock absorber at the swing arm is Teflon coated.
Page 83: Exhaust
EXHAUST 10.1 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. Do not touch hot components. – Remove screws – Pull the main silencer off of the manifold at the rubber sleeve 602718-10 10.2 Installing the main silencer...
Page 84 EXHAUST Main work – Remove screws . Pull out inner tube – Pull the glass fiber yarn filling from the inner tube. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling on the inner tube. –...
Page 85: Air Filter
AIR FILTER 11.1 Removing the air filter box lid – Pull off the air filter box lid in area sideways and remove it toward the front. 602716-10 11.2 Installing the air filter box lid – Insert the air filter box lid into the rear area and clip it into the front area 602716-11 11.3...
Page 86: Cleaning The Air Filter And Air Filter Box
AIR FILTER – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage. 602717-11 Finishing work –...
Page 87: Fuel Tank, Seat, Trim
FUEL TANK, SEAT, TRIM 12.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
Page 88: Mounting The Seat
FUEL TANK, SEAT, TRIM 12.4 Mounting the seat – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. – Make sure that the seat is correctly locked in. 602715-01 –...
Page 89: Installing The Fuel Tank
FUEL TANK, SEAT, TRIM – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 602721-10 12.6 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
Page 90: Fuel Tap
FUEL TANK, SEAT, TRIM 12.7 Fuel tap The fuel tap is on the left side of the fuel tank. Tap handle on the fuel tap is used to open or close the supply of fuel to the carbure- tor. Possible states Fuel supply closed OFF –...
Page 91: Mask, Fender
MASK, FENDER 13.1 Removing the front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 89) Main work – Remove screws 602712-10 – Remove screws . Remove the front fender. 602713-10 13.2 Installing the front fender Main work –...
Page 92: Refitting The Headlight Mask With The Headlight
MASK, FENDER – Disconnect the electrical plug-in connection and take off the headlight mask with the headlight. 602763-11 13.4 Refitting the headlight mask with the headlight Main work – Connect the electric plug connector 602763-10 – Position the headlight mask and fix it with the rubber band Info Ensure that the holding lugs engage in the fender.
Page 93: Wheels
DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires are changed at the latest after 5 years, regardless of the actual state of wear. »...
Page 94: Checking The Brake Discs
WHEELS 14.3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the...
Page 95: Front Wheel
WHEELS 14.5 Front wheel 14.5.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.
Page 96: Removing The Brake Disc Of The Front Brake
WHEELS – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc.
Page 97: Installing The Rear Wheel
WHEELS Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
Page 98: Removing The Brake Disc Of The Rear Brake
WHEELS – Position chain adjuster . Mount nut , but do not tighten it yet. – Make sure that chain adjusters are fitted correctly on adjusting screws – Check the chain tension. ( p. 97) – Tighten nut Guideline Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Info...
Page 99: Cleaning The Chain
WHEELS 14.6.6 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...
Page 100: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
WHEELS Finishing work – Remove the motorcycle from the lift stand. ( p. 10) 14.6.8 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) Main work –...
Page 101: Adjusting The Chain Tension
WHEELS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness. »...
Page 102 WHEELS 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 the reference marks .
Page 103: Wiring Harness, Battery
Environmental hazard The battery contains elements that are harmful to the environment. – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
Page 104: Disconnecting The Negative Cable Of The Battery
WIRING HARNESS, BATTERY Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery.
Page 105: Connecting The Negative Cable Of The Battery
WIRING HARNESS, BATTERY 15.6 Connecting the negative cable of the battery Main work – Attach negative cable Guideline Screw, battery terminal 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted between battery terminal and cable lugs with the claws facing up. 309401-10 Finishing work –...
Page 106: Installing The Battery
WIRING HARNESS, BATTERY 15.8 Installing the battery Main work – Insert the battery into the battery compartment with the terminals facing to the front. Battery (YTX4L-BS) ( p. 212) – Attach rubber band – Attach positive cable Guideline Screw, battery terminal 2.5 Nm (1.84 lbf ft) Info...
Page 107: Checking The Starter Relay
WIRING HARNESS, BATTERY Main work – Disconnect the negative (minus) cable of the battery. – Measure the current between battery ground (−) and the negative cable. Info The value of the open-circuit current applies only to vehicles in the original state, i.e.
Page 108: Brake System
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
Page 109 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Manually press the brake caliper toward the brake disc to push back the brake pis- tons.
Page 110: Checking The Free Travel Of The Hand Brake Lever
BRAKE SYSTEM 16.3 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.
Page 111: Checking The Front Brake Fluid Level
BRAKE SYSTEM 16.6 Checking the front brake fluid level Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding.
Page 112: Changing The Front Brake Fluid
BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Add brake fluid to level Guideline Dimension (brake fluid level below 5 mm (0.2 in) top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p.
Page 113: Checking The Rear Brake Linings
BRAKE SYSTEM – Open shut-off valve Info Follow the operating instructions of the bleeding device. – Ensure that the filling pressure is correctly set at pressure gauge . If necessary, adjust the filling pressure at pressure regulator Guideline Filling pressure 2…...
Page 114: Changing The Brake Linings Of The Rear Brake
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
Page 115: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the brake linings, insert the pin, and mount the cotter pins. – Operate the foot brake lever several times until the brake linings are lying against the brake disc and there is a pressure point.
Page 116: Checking The Rear Brake Fluid Level
BRAKE SYSTEM – Disconnect spring – Loosen nut and, with push rod , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever individually, loosen nut turn screw accordingly. Info The range of adjustment is limited.
Page 117: Changing The Rear Brake Fluid
BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in 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 118 BRAKE SYSTEM – Open shut-off valve Info Follow the operating instructions of the bleeding device. – Ensure that the filling pressure is correctly set at pressure gauge . If necessary, adjust the filling pressure at pressure regulator Guideline Filling pressure 2…...
Page 119: Lighting System, Instruments
LIGHTING SYSTEM, INSTRUMENTS 17.1 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 a distance under the first mark.
Page 120: Activation And Test
LIGHTING SYSTEM, INSTRUMENTS 17.3.2 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. Display test To enable you to check that the display is functioning properly, all display segments light up briefly.
Page 121: Setting The Clock
LIGHTING SYSTEM, INSTRUMENTS – Press the button briefly and repeatedly until H appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The Setup menu is displayed and the activated functions are shown. –...
Page 122: Setting The Wheel Circumference
LIGHTING SYSTEM, INSTRUMENTS Main work – Expose connector CZ 301287-10 – Sever the black/brown cable – Insulate both cable ends. 301288-10 Finishing work – Refit the headlight mask with the headlight. ( p. 90) – Check the headlight setting. ( p.
Page 123: 250/300 Six Days
LIGHTING SYSTEM, INSTRUMENTS Condition The motorcycle is stationary. – briefly and repeatedly until LAP appears at the bottom right of Press the button the display. – Press the button briefly. LAP 1 appears on the left side of the display. –...
Page 124: Setting The Speedometer Functions
LIGHTING SYSTEM, INSTRUMENTS – 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 is displayed and the active functions are shown. – Repeatedly press the button briefly until Km/h/Mph flashes.
Page 125: Setting The Wheel Circumference
LIGHTING SYSTEM, INSTRUMENTS Info The seconds can only be set to zero. If no button is actuated for 15–-20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the Setup menu is closed. 17.4.6 Setting the wheel circumference Condition...
Page 126: Engine
ENGINE 18.1 Removing the engine Preparatory work (250/300 SIX DAYS) – Remove the engine guard. ( p. 57) – Raise the motorcycle with the lift stand. ( p. 10) – Remove the seat. ( p. 85) – Remove the fuel tank. ( p.
Page 127 ENGINE – Push back cover – Remove nut and hang the positive cable to the side. 308545-10 – Release hose clip 308546-10 – Remove screw – Loosen screw – Repeat these steps on the opposite side. – Swing up the subframe and secure it. 308547-10 –...
Page 128 ENGINE – Remove screws – Take off the clutch slave cylinder and hang it to one side. Info Do not kink the clutch line. Do not activate the clutch lever while the clutch slave cylinder is removed. 308550-10 – Remove the connecting link of the chain. –...
Page 129 ENGINE – Loosen hose clip – Pull off the radiator hose. 308556-10 – Loosen hose clip – Pull off the radiator hose. 308557-10 – Loosen hose clip – Pull off the radiator hose. 308558-10 – Loosen hose clip – Pull the carburetor rearward out of the intake flange and hang it to one side. 308559-10 –...
Page 130: Installing The Engine
ENGINE – Remove screws 308562-10 – Lift out the engine sideways. Info The help of an assistant is useful in this step. Ensure that the motorcycle is sufficiently secured against falling over. Protect the frame and attachments against damage. 308563-10 18.2 Installing the engine Main work...
Page 131 ENGINE Guideline Engine bracket screw 60 Nm (44.3 lbf ft) Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Slide the carburetor into the intake flange. – Position and tighten hose clip 308559-11 – Mount the radiator hose. – Position and tighten hose clip 308558-11 –...
Page 132 ENGINE – Plug in connector – Plug in connector – Route the cable and secure with a cable binder. 308554-11 – Mount the spark plug connector. – Mount vent hose 308553-11 – Position the shift lever. – Mount and tighten screw Guideline Screw, shift lever 14 Nm...
Page 133 ENGINE – Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) 308548-11 – Remove the fixation and position the subframe. Info Watch out for the intake flange. – Mount and tighten screw Guideline Screw, subframe 35 Nm Loctite ®...
Page 134 ENGINE – Mount the frame protector. – Tighten screw Guideline Screw, frame protector 3 Nm (2.2 lbf ft) – Mount the cable binders. 308543-11 – Position the exhaust manifold. – Mount springs Spring hooks (50305017000) ( p. 272) 308540-11 – Mount and tighten screw Guideline Remaining screws, chassis...
Page 135: Engine Disassembly
ENGINE 18.3 Engine disassembly 18.3.1 Clamping the engine into the engine work stand – Mount special tool on engine work stand Engine assembly stand (61229001000) ( p. 275) Engine fixing arm (56029002030) ( p. 274) – Mount the engine on special tool 308114-10 18.3.2 Draining the gear oil...
Page 136: Removing The Spacer
ENGINE 18.3.6 Removing the spacer – Remove spacer 308118-10 – Remove O-ring 308119-10 18.3.7 Removing the starter motor – Remove screws – Take off cover 308120-10 – Remove screws – Remove starter motor. 308121-10 – Remove screws – Remove the cover. 308122-10...
Page 137: Removing The Kick Starter
ENGINE – Remove gasket and dowels 308123-10 – Remove starter idler gear 308124-10 – Remove screws – Remove the alternator cover. 308125-10 – Remove gasket and dowels 308126-10 – Take off Bendix 308127-10 18.3.8 Removing the kick starter – Remove screw with the washer.
Page 138: Removing The Cylinder Head
ENGINE 18.3.9 Removing the cylinder head – Alternately loosen screws and remove them. – Remove the cylinder head. 308129-10 (All 250 models) – Remove O-rings 308130-10 (All 300 models) – Remove O-rings 302963-10 18.3.10 Removing the cylinder – Remove screws –...
Page 139: Removing The Piston
ENGINE – Remove nuts Info Raise the cylinder slightly to be able to remove the front nuts. – Carefully slide the cylinder up and take it off. 308133-10 (All 250 models) – Take off gasket 308134-10 (All 300 models) – Take off gasket 302967-10 18.3.11 Removing the piston...
Page 140: Removing The Water Pump Cover
ENGINE – Remove the upper conrod bearing 308144-10 18.3.12 Removing the water pump cover – Remove screws – Take off the water pump cover. – Remove the form ring. 308145-10 18.3.13 Removing the clutch cover – Remove screws . Take off the clutch cover. Info Ensure that the kick starter shaft remains in the engine case.
Page 141: Removing The Clutch Basket
ENGINE – Take off spring washer 308149-10 – Take off pretension ring 308150-10 – Take off pressure cap 308151-10 – Remove clutch disc pack entirely. – Remove clutch pressure piece 308152-10 18.3.15 Removing the clutch basket – Hold the primary gear using special tool Gear segment (56012004000) ( p.
Page 142: Removing The Kick Starter Shaft
ENGINE – Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub. – Take off clutch basket 308157-10 – Take off needle bearing and collar bushing 308158-10 – Take off primary gear – Remove the distance sleeve.
Page 143: Removing The Shift Shaft
ENGINE 18.3.18 Removing the shift shaft – Push sliding plate away from the shift drum locating unit . Remove shift shaft with the washer. 308164-10 18.3.19 Removing the shift drum locating unit – Remove screw – Push away locking lever from shift drum locating unit and remove the shift drum locating unit.
Page 144: Removing The Reed Valve Housing
ENGINE 18.3.22 Removing the reed valve housing – Remove screws – Take off the intake flange. 308172-10 – Remove reed valve housing – Take off the gasket. 308173-10 18.3.23 Removing the left engine case section – Remove screws – Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm.
Page 145: Removing The Shift Drum
ENGINE 18.3.25 Removing the shift drum – Tilt shift forks to the side. Info Do not misplace the shift rollers. – Remove shift drum 308177-10 18.3.26 Removing the shift forks – Remove shift forks Info Do not misplace the shift rollers. 308178-10 18.3.27 Removing the transmission shafts –...
Page 146: Work On Individual Parts
ENGINE 18.4 Work on individual parts 18.4.1 Work on the right section of the engine case – Remove all dowels. – Remove shaft seal ring of the crankshaft. – Remove screws . Remove the bearing retainers. – Clean the engine case section thoroughly. –...
Page 147: Work On The Left Section Of The Engine Case
ENGINE 18.4.2 Work on the left section of the engine case – Remove all dowels. – Remove shaft seal ring of the crankshaft, shift shaft and countershaft. – Clean the engine case section thoroughly. – Warm the engine case section in an oven. Guideline 150 °C (302 °F) –...
Page 148: Installing The Crankshaft Bearing Inner Race
ENGINE – Push the warmed up special tool onto the crankshaft bearing inner race, press firmly together and pull jointly from the crankshaft. 18.4.4 Installing the crankshaft bearing inner race – Fixate the crankshaft in the vice with special tool Separator plate (54829009000) ( p.
Page 149: Checking The Crankshaft Run-Out At The Bearing Pin
ENGINE – Position special tool on the press. Pressing device for crankshaft, complete (75029047000) ( p. 276) Insert for crankshaft pressing tool (54829108000) ( p. 274) – Insert the crank web with connecting rod and bearing. Position the second crank web.
Page 150: Removing The Exhaust Control
ENGINE Guideline Cylinder - drill hole diameter (All 250 models) Size I 66.400… 66.412 mm (2.61417… 2.61464 in) Size II 66.412… 66.425 mm (2.61464… 2.61515 in) Cylinder - drill hole diameter (All 300 models) Size I 72.000… 72.012 mm (2.83464… 2.83511 in) Size II 72.012…...
Page 151 ENGINE – Remove control shaft 303069-10 – Remove screw – Remove screw with the washer. – Take off the stop plate. 303070-10 – Take off gear segment 303071-10 – Remove screws – Take off the retaining bracket. 303072-10 – Remove control shaft 303073-10 –...
Page 152: Checking The Exhaust Control
ENGINE – Remove O-rings – Take off the control flap. 303075-10 18.4.9 Checking the exhaust control 303042-10 – Check control shafts for damage and wear. » If there is damage or wear: – Change the control shaft. – Check gear segments for damage and wear.
Page 153 ENGINE – Mount the control shafts. 303618-10 – Mount the retaining brackets. – Mount and tighten screws Guideline Screw, retaining bracket of 7 Nm Loctite ® 243™ exhaust control (5.2 lbf ft) 303619-10 – Mount and grease O-rings Long-life grease ( p.
Page 154: Cylinder - Nikasil ® Coating
ENGINE – Position gear segment 303624-10 – Position the spring with the short leg toward the outside. – Mount screw with the bushing and spring but do not tighten yet. Guideline Screw, control flap, 10 Nm Loctite ® 243™ exhaust control (7.4 lbf ft) –...
Page 155: Checking/Measuring The Piston
ENGINE 18.4.12 Checking/measuring the piston (All 250 models) – Check the piston sliding surface for damage. » If the piston sliding surface is damaged: – Replace the piston and, if necessary, the cylinder. – Check that the piston rings move easily in the piston ring grooves. »...
Page 156: Checking The Piston Ring End Gap
ENGINE Guideline Distance 50 mm (1.97 in) Piston - diameter (All 250 models) Size I 66.340… 66.350 mm (2.61181… 2.6122 in) Size II 66.351… 66.360 mm (2.61224… 2.61259 in) Piston - diameter (All 300 models) Size I 71.940… 71.950 mm (2.83228… 2.83267 in) Size II 71.951…...
Page 157: Checking The Reed Valve Housing, Reed Valve, And Intake Flange
ENGINE Guideline Piston/cylinder - mounting clearance New condition 0.050… 0.085 mm (0.00197… 0.00335 in) Piston/cylinder - mounting clearance Wear limit 0.10 mm (0.0039 in) 18.4.15 Checking the reed valve housing, reed valve, and intake flange – Check intake flange for damage and wear. »...
Page 158 ENGINE – Remove screw with the washer. 303034-10 – Take off angle lever – Remove linkage 303035-10 – Remove adjusting lever with the washers. 303036-10 – Remove screw – Take off water pump impeller – Remove the centrifugal timer. 303037-10 –...
Page 159 ENGINE – Press out bearing toward the inside. 303039-10 – Remove shaft seal ring 303040-10 303031-10 – Check pin of the adjusting lever for damage and wear. » If there is damage or wear: – Change the adjusting lever. – Check ball heads of the linkage for damage and wear.
Page 160 ENGINE – Press bearing all the way in to the stop from the inside. 303039-10 – Press shaft seal ring so it is flush. – Ensure that the bearing can turn freely and does not touch the shaft seal ring. 303038-10 –...
Page 161: Checking The Clutch
ENGINE – Mount and tighten screw with the washer. Guideline Screw, angle lever, 6 Nm Loctite ® 243™ exhaust control (4.4 lbf ft) 303034-10 – Mount adjusting spring with the auxiliary spring and spring insert. 303033-10 – Position the locking cap. –...
Page 162: Preassembling The Shift Shaft
ENGINE » If there is damage or wear: – Change the spring retainer. – Check pretension ring for damage and wear. » If there is damage or wear: – Change the pretension ring. – Check spring washer for damage and wear. »...
Page 163: Checking The Shift Mechanism
ENGINE 18.4.19 Checking the shift mechanism 303007-10 – Check shift forks on disc for damage and wear (visual check). » If there is damage or wear: – Change the shift fork and gear wheel pair. – Check shift grooves of shift drum for wear.
Page 164: Disassembling The Main Shaft
ENGINE – Preassemble the shift shaft. ( p. 160) – Check clearance between the sliding plate and the shift quadrant. Shift shaft - sliding plate/shift quad- 0.40… 0.80 mm (0.0157… rant clearance 0.0315 in) » If the measured value does not meet specifications: –...
Page 165: Disassembling The Countershaft
ENGINE 18.4.21 Disassembling the countershaft 303335-10 – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Remove stop disk and 1st-gear idler gear – Remove needle bearing and stop disk – Remove 6th-gear sliding gear –...
Page 166: Assembling The Main Shaft
ENGINE 303336-10 – Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearing. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...
Page 167: Assembling The Countershaft
ENGINE Preparatory work – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 163) Main work 303334-11 – Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws – Mount needle bearing –...
Page 168 ENGINE Main work 303335-11 – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Mount needle bearing and 2nd-gear idler gear onto the countershaft with the protruding collar facing downward. – Mount stop disk and lock ring –...
Page 169: Checking The Kick Starter
ENGINE 18.4.25 Checking the kick starter 303010-10 – Check the gear mesh and bearing of kick starter gear for damage and wear. » If there is damage or wear: – Change the kick starter gear. – Check the gear mesh and bearing of intermediate kick starter gear for damage and wear.
Page 170 ENGINE – Mount driving hub The cut-out must be aligned with the hole in the kick starter shaft. 303049-10 – Mount kick starter spring The end of the kick starter spring engages in the hole. 303050-10 – Mount kick starter ratchet wheel with the spring.
Page 171: Checking The Electric Starter Drive
ENGINE 18.4.27 Checking the electric starter drive 303006-10 – Check the gear mesh and bearing of starter idler gear for damage and wear. » If there is damage or wear: – Change the starter idler gear. – Check the gear mesh and bearing of Bendix for smooth operation, damage and wear.
Page 172: Engine Assembly
ENGINE – Move starter idler gear back and forth in the direction of rotation. – Check for play. Guideline Play may not exceed half the tooth width. » If the play is greater: – Remove the cover. – Add enough compensating disks to eliminate the play.
Page 173: Installing The Shift Forks
ENGINE 18.5.3 Installing the shift forks – Arrange the shift forks as shown above. 303023-10 – Position shift forks in the shift grooves. 308178-10 18.5.4 Installing the shift drum – Push shift drum into the bearing seat. – Put shift forks in the shift drum.
Page 174: Installing The Reed Valve Housing
ENGINE – Mount the left section of the engine case. Info Do not use the screws to pull the two sections of the engine case together. – Mount screws and, once all screws of the left section of the engine case have been mounted, tighten them.
Page 175: Installing The Locking Lever
ENGINE 18.5.9 Installing the locking lever – Position locking lever with the sleeve and spring – Mount and tighten screw Guideline Screw, shift drum locating 10 Nm Loctite ® 243™ (7.4 lbf ft) 308168-10 18.5.10 Installing the shift drum locating unit –...
Page 176: Installing The Clutch Basket
ENGINE Main work – Mount the preassembled kick starter shaft with the washer. – Tension the kick starter spring and mount and tighten screw Guideline Screw, kick starter spring 10 Nm Loctite ® 243™ (7.4 lbf ft) Info Ensure that the distance from the kick starter spring to the kick starter shaft 308162-11 is the same all around.
Page 177: Installing The Clutch Discs
ENGINE – Secure the nut with the lock washer. – Hold the primary gear using special tool Gear segment (56012004000) ( p. 274) – Mount and tighten nut with the washer. Guideline Nut, primary gear M18LHx1.5 150 Nm Loctite ® 648™...
Page 178: Installing The Clutch Cover
ENGINE – Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring retainer 6 Nm (4.4 lbf ft) 308148-11 – Using a straightedge and the special tool, check the spring washers for distortion. Feeler gauge (59029041100) ( p. 275) Spring washer distortion 0…...
Page 179: Installing The Water Pump Cover
ENGINE 18.5.17 Installing the water pump cover – Mount the form ring. Info Ensure that the dowels are seated properly. – Position the water pump cover. – Mount and tighten screws Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 308145-10 18.5.18 Installing the piston (All 250 models)
Page 180: Installing The Cylinder
ENGINE – Slide piston pin into the connecting rod by hand. 302975-10 – Cover the engine case opening with a cloth. – Position the piston pin retainer in the 6 o'clock or 12 o'clock position. – Ensure that the piston pin retainer is seated properly on both sides. –...
Page 181: Checking The X-Distance
ENGINE – Slide the cylinder over the piston. – Push the cylinder down carefully. 308142-10 – Mount nuts on both sides and tighten in a crisscross pattern. Guideline Nut, cylinder base 35 Nm (25.8 lbf ft) 308139-10 18.5.20 Checking the X-distance Info The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and the piston is at top dead center.
Page 182: Adjusting The X-Distance
ENGINE » If the specified value is not attained: – Adjust the X-distance. ( p. 180) 18.5.21 Adjusting the X-distance Info The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses. Preparatory work – Check the X-distance. ( p.
Page 183 ENGINE – Adjust the Z-distance using the depth gauge. Guideline Z (height of control flap) (All 250 mod- 48 mm (1.89 in) els) Z (height of control flap) (All 300 mod- 48.5 mm (1.909 in) els) – Move control flap up and position the depth gauge.
Page 184: Installing The Cylinder Head
ENGINE 18.5.23 Installing the cylinder head (All 250 models) – Mount O-rings Info Ensure that the dowels are seated correctly. 308130-11 (All 300 models) – Mount O-rings Info Ensure that the dowels are seated correctly. 302963-11 – Put the cylinder head in place. Mount screws with the washers and tighten them in a crisscross pattern.
Page 185 ENGINE – Mount dowels – Position the gasket. 308126-11 – Position the alternator cover. – Mount and tighten screw Guideline Screw, alternator cover 8 Nm (5.9 lbf ft) 308125-11 – Grease and mount starter idler gear Lubricant (T625) ( p. 270) 308124-11 –...
Page 186: Installing The Spacer
ENGINE – Position cover – Mount and tighten screws Guideline Screw, alternator cover 8 Nm (5.9 lbf ft) 308120-11 18.5.26 Installing the spacer – Before mounting, grease spacer in area and O-Ring Long-life grease ( p. 270) – Position the O-ring in the cut-out of the spacer. 302140-10 –...
Page 187: Installing The Clutch Push Rod
ENGINE 18.5.29 Installing the clutch push rod – Mount clutch push rod 308115-10 18.5.30 Installing the gear oil drain plug – Mount and tighten the gear oil drain plug with the magnet and the new seal ring. Guideline Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)
Page 188: Carburetor
2.0 turns Idle air adjusting screw (250/300 EXC AUS) Open 3.5 turns Idle air adjusting screw (250 EXC EU, 250 EXC SIX DAYS EU) B00048-11 Open 1.5 turns Idle air adjusting screw (300 EXC EU, 300 EXC SIX DAYS EU) Open 1.75 turns...
Page 189: Emptying The Carburetor Float Chamber
CARBURETOR 19.3 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
Page 190: Installing The Carburetor
CARBURETOR Main work – Loosen hose clip – Loosen hose clip – Pull the carburetor out of the intake flange toward the rear. 308534-10 – Pull the carburetor forward out of the intake flange. 308535-10 – Remove screws – Remove the throttle slide cover and pull the throttle slide out of the carburetor. –...
Page 191: Checking/Adjusting The Carburetor Components
CARBURETOR – Position the carburetor on the intake flange. 308535-10 – Position the carburetor on the intake flange. – Position and tighten hose clip – Position and tighten hose clip 303404-11 Finishing work – Install the fuel tank. ( p. 87) –...
Page 192: Disassembling The Carburetor
CARBURETOR – Check the float needle valve. ( p. 192) – Assemble the carburetor. ( p. 192) 19.7 Disassembling the carburetor Condition The carburetor has been removed. – Remove screws – Remove the float chamber. – Pull the hoses off of the carburetor. 303351-10 –...
Page 193: Checking The Choke Slide
CARBURETOR – Remove needle screw cap – Pull the jet needle out of the throttle slide. 303354-10 19.8 Checking the choke slide Condition The choke slide has been removed. – Check the choke slide for smooth operation. » If the choke slide is difficult to move or is dirty: –...
Page 194: Checking The Float Needle Valve
CARBURETOR 19.11 Checking the float needle valve Condition The float needle valve has been removed. – Check the float needle valve including the valve seat for deposits. » If there are deposits: – Clean the valve seat. Clean or change the float needle valve. –...
Page 195: Checking/Adjusting The Float Level
CARBURETOR – Mount the hoses on the carburetor. – Position the float chamber. – Mount and tighten screws Guideline Other screws, carburetor 2 Nm (1.5 lbf ft) 303351-11 – Position the jet needle in the throttle slide. – Mount and tighten needle screw cap Guideline Needle screw cap 3.5 Nm...
Page 196: Clutch
CLUTCH 20.1 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws –...
Page 197: Water Pump, Cooling System
WATER PUMP, COOLING SYSTEM 21.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions.
Page 198: Draining The Coolant
WATER PUMP, COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in) »...
Page 199 WATER PUMP, COOLING SYSTEM – Make sure that screw is tightened. – Position the motorcycle upright. – Fill the radiator completely with coolant. Coolant 1.2 l (1.3 qt.) Coolant ( p. 268) Coolant (mixed ready to use) p. 268) B00072-10 –...
Page 200: Exhaust Control
EXHAUST CONTROL 22.1 Engine characteristic - setting the auxiliary spring Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them.
Page 201: Lubrication System
LUBRICATION SYSTEM 23.1 Changing the gear oil – Drain the gear oil. ( p. 199) 400721-01 – Refill with gear oil. ( p. 200) 400722-01 23.2 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –...
Page 202: Refilling With Gear Oil
LUBRICATION SYSTEM 23.3 Refilling with gear oil Info Too little gear oil or poor-quality oil results in premature wear of the transmission. Main work – Remove screw cap and fill up gear oil. Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p.
Page 203 LUBRICATION SYSTEM – Remove screw cap – Add gear oil until it emerges from the opening used to check the gear oil level. Engine oil (15W/50) ( p. 268) – Mount and tighten the screw in the opening used to check the gear oil level. Guideline Screw, gear oil level check 10 Nm (7.4 lbf ft)
Page 204: Ignition System
IGNITION SYSTEM 24.1 Checking the ignition system Warning Risk of injury The ignition system is under high voltage. – To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme- diately after measuring.
Page 205: Ignition Coil - Checking The Secondary Winding
IGNITION SYSTEM Condition Ignition coil cylinder 1 is disconnected. Ignition coil cylinder 1 - check the primary winding resistance – Measure the resistance between the specified points. Ignition coil pin 1 (+) – Ignition coil pin 2 (−) Ignition coil 0.255…...
Page 206: Alternator - Checking The Charging Coil Of The Ignition
IGNITION SYSTEM – Measure the resistance between the specified points. Measuring point 1 – Measuring point 2 Spark plug connector Resistance at: 20 °C (68 °F) 4.3… 5.7 kΩ » If the specification is not reached: – Change the spark plug connector. 601207-10 24.5 Alternator - checking the charging coil of the ignition...
Page 207: Alternator - Checking The Light Winding
IGNITION SYSTEM » The specifications have not been met: – Replace the stator. 24.7 Alternator - checking the light winding Condition The alternator has been disconnected. – Measure the resistance between the specified points. Alternator, connector CR pin 1 (White) – Alternator, connector CR pin 1 (Yel- low) Alternator 0.1…...
Page 208: Removing The Stator And Crankshaft Position Sensor
IGNITION SYSTEM Check the ignition pulse generator voltage – Measure the voltage between the specified points. Alternator, charging coil/ignition pulse generator, connector AN pin 3 – Alternator, charging coil/ignition pulse generator, connector AN pin 4 Crankshaft position sensor Voltage 2… 4 V »...
Page 209: Electric Starter
ELECTRIC STARTER 25.1 Checking the starter motor Condition The starter motor has been removed. – Clamp the negative cable of a 12 Volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly to the connection of the starter motor.
Page 210: Technical Data
TECHNICAL DATA 26.1 Engine 26.1.1 All 250 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Bore 66.4 mm (2.614 in) Exhaust valve - Beginning of adjustment 5,600 rpm Exhaust valve - end of adjustment with red auxiliary spring 7,200 rpm...
Page 211: Engine Tolerance, Wear Limits
TECHNICAL DATA Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydraulically activated Gearbox 6-gear, claw shifted Transmission ratio 1st gear 14:32 2nd gear 16:26 3rd gear 20:25 4th gear 22:23 5th gear 25:22 6th gear 26:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.9 mm (0.075 in)
Page 212: Engine Tightening Torques
TECHNICAL DATA 26.3 Engine tightening torques – EJOT DELTA PT Screw, inner reed petals ® 35x25 1 Nm (0.7 lbf ft) – Screw, membrane core plate EJOT DELTA PT ® 30x12 1 Nm (0.7 lbf ft) – Screw, outer reed petals EJOT DELTA PT ®...
Page 213: Fuel
TECHNICAL DATA 26.4.3 Fuel Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded gasoline (95 octane), mixed with 2-stroke approx. (250/300 EXC EU, engine oil (1:60) ( p. 269) EXC SIX DAYS) Total fuel tank capacity, 10 l (2.6 US gal) Super unleaded gasoline (95 octane), mixed with 2-stroke approx.
Page 214: Electrical System
(all 250/300 XC‑W) 80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51 Additional information is available in the Service section under: http://www.ktm.com 26.8 Fork 26.8.1 EXC EU/AUS, XC‑W Fork part number 14.18.7L.63...
Page 215: 250/300 Six Days
TECHNICAL DATA Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 268) 26.8.2 250/300 SIX DAYS Fork part number 24.18.7N.63 WP Suspension Up Side Down 4860 4CS Fork Compression damping Comfort 15 clicks Standard 13 clicks Sport...
Page 216: Chassis Tightening Torques
TECHNICAL DATA 26.10 Chassis tightening torques – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, frame protector 3 Nm (2.2 lbf ft) –...
Page 217: Carburetor
TECHNICAL DATA 26.11 Carburetor 26.11.1 250 EXC EU, 250 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N8RW / N8RJ / N8RK) Main jet 110 (165 / 168)
Page 218: Exc Aus
TECHNICAL DATA Throttle slide 7 with cut-out Slide stop Present 26.11.5 300 EXC AUS Carburetor type KEIHIN PWK 36S AG Carburetor identification number 3600 Needle position 1. Position from top Jet needle N3CJ (N8RW / N8RJ / N8RK / N4DW / N4DJ / N4DK) Main jet 160 (165 / 168) Idling jet...
Page 219: Carburetor Tuning
TECHNICAL DATA 26.12 Carburetor tuning 26.12.1 Carburetor tuning (All 250 models) 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. 401770-01 M/FT ASL Sea level...
Page 220: Carburetor Tuning (All 300 Models)
TECHNICAL DATA 26.12.2 Carburetor tuning (All 300 models) 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. 401767-01 M/FT ASL Sea level...
Page 221: General Carburetor Tuning
TECHNICAL DATA 26.12.3 General carburetor tuning 1... 5 Needle position from above The five needle positions are shown here. 0 0 1 The carburetor tuning depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4 0 0 5 B00075-10...
Page 222: Cleaning, Care
CLEANING, CARE 27.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.
Page 223: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 27.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.
Page 224: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 10) – Cover the vehicle with a tarp or cover that is permeable to air.
Page 225: Service Schedule
Check the headlight setting. ( p. 117) ● ● Check the idle. ● ● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in KTM DEALER.NET and in the service record. ● Periodic interval...
Page 226: Service Work (As Additional Order)
SERVICE SCHEDULE 29.2 Service work (as additional order) Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours ● Change the front brake fluid. ( p. 110) ● Change the rear brake fluid. ( p.
Page 228: Wiring Diagram
WIRING DIAGRAM 30.1 Page 1 of 5 (250 EXC EU, 300 EXC EU) bl-rd bl-rd wh-rd wh-rd wh-rd ye-rd bu-rd wh-rd bu-rd bu-rd ye-rd wh-rd bu-rd wh-gr bl-ye bl-ye wh-rd wh-rd 308681-01...
Page 229 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Electric starter button Voltage regulator...
Page 230: 250 Exc Eu, 300 Exc Eu)
WIRING DIAGRAM 30.2 Page 2 of 5 (250 EXC EU, 300 EXC EU) wh-rd wh-gr 308682-01...
Page 231 WIRING DIAGRAM Components: Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, kill switch...
Page 232: 250 Exc Eu, 300 Exc Eu)
WIRING DIAGRAM 30.3 Page 3 of 5 (250 EXC EU, 300 EXC EU) DA/4 DB/4 wh-rd CX/2 CW/2 wh-rd wh-gn wh-gn wh-gn wh-gn wh-gn wh-rd ye-bu 308683-01...
Page 233 WIRING DIAGRAM Components: Wheel speed sensor, front Brake light switch, front Brake light switch, rear License plate lamp Speedometer Brake/tail light Tripmaster switch X285 Connector for radiator fan (optional)
Page 234: 250 Exc Eu, 300 Exc Eu)
WIRING DIAGRAM 30.4 Page 4 of 5 (250 EXC EU, 300 EXC EU) ye-bu 308684-01...
Page 235 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...
Page 236: 250 Exc Eu, 300 Exc Eu)
WIRING DIAGRAM 30.5 Page 5 of 5 (250 EXC EU, 300 EXC EU) wh-bu wh-bu wh-bl wh-bl 308685-01...
Page 237 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode (optional) X280 Connector, ignition timing map X281 Connector, ignition timing map Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...
Page 238: 250 Exc Six Days Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM 30.6 Page 1 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU) bl-rd bl-rd wh-rd wh-rd wh-rd ye-rd bu-rd wh-rd bu-rd bu-rd ye-rd wh-rd bu-rd wh-rd wh-rd 308691-01...
Page 239 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Electric starter button Voltage regulator...
Page 240: 250 Exc Six Days Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM 30.7 Page 2 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU) wh-rd wh-gr bl-ye bl-ye wh-gr 308692-01...
Page 241 WIRING DIAGRAM Components: CDI controller Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, kill switch...
Page 242: 250 Exc Six Days Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM 30.8 Page 3 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU) wh-rd wh-rd wh-rd wh-gn wh-gn wh-gn wh-gn wh-gn wh-rd ye-bu 308693-01...
Page 243 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Speedometer Brake/tail light X285 Connector for radiator fan (optional)
Page 244: 250 Exc Six Days Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM 30.9 Page 4 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU) ye-bu 308694-01...
Page 245 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...
Page 246: 250 Exc Six Days Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM 30.10 Page 5 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU) wh-bu wh-bu wh-bl wh-bl 308695-01...
Page 247 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode (optional) X280 Connector, ignition timing map X281 Connector, ignition timing map Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...
Page 248: 250/300 Exc Aus)
WIRING DIAGRAM 30.11 Page 1 of 5 (250/300 EXC AUS) bl-rd bl-rd wh-rd wh-rd wh-rd ye-rd bu-rd wh-rd bu-rd bu-rd ye-rd wh-rd bu-rd wh-rd wh-rd 202557-01...
Page 249 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button Voltage regulator...
Page 250: 250/300 Exc Aus)
WIRING DIAGRAM 30.12 Page 2 of 5 (250/300 EXC AUS) wh-rd wh-gr bl-ye bl-ye wh-gr BA/1 BF/1 202558-01...
Page 251 WIRING DIAGRAM Components: CDI controller Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button...
Page 252: 250/300 Exc Aus)
WIRING DIAGRAM 30.13 Page 3 of 5 (250/300 EXC AUS) DA/4 DB/4 wh-rd CX/2 CW/2 wh-rd wh-gn wh-gn wh-gn wh-gn wh-gn wh-rd ye-bu 202559-01...
Page 253 WIRING DIAGRAM Components: Wheel speed sensor, front Brake light switch, front Brake light switch, rear License plate lamp Speedometer Brake/tail light Tripmaster switch X285 Connector for radiator fan...
Page 254: 250/300 Exc Aus)
WIRING DIAGRAM 30.14 Page 4 of 5 (250/300 EXC AUS) ye-bu 202560-01...
Page 255 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...
Page 256: 250/300 Exc Aus)
WIRING DIAGRAM 30.15 Page 5 of 5 (250/300 EXC AUS) wh-bu wh-bu wh-bl wh-bl 202561-01...
Page 257 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Map switch for ride mode X280 Connector, ignition timing map X281 Connector, ignition timing map Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...
Page 258: 250 Xc-W Usa, 300 Xc-W Usa)
WIRING DIAGRAM 30.16 Page 1 of 3 (250 XC‑W USA, 300 XC‑W USA) bl-rd bl-rd wh-rd wh-rd wh-rd bu-rd wh-rd bu-rd wh-rd wh-rd wh-rd 308721-01...
Page 259 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Electric starter button Voltage regulator...
Page 260: 250 Xc-W Usa, 300 Xc-W Usa)
WIRING DIAGRAM 30.17 Page 2 of 3 (250 XC‑W USA, 300 XC‑W USA) DA/4 DB/4 wh-rd CX/2 CW/2 wh-rd 308722-01...
Page 261 WIRING DIAGRAM Components: Wheel speed sensor, front Low beam Light switch Tripmaster switch (optional) Speedometer Parking light Tail light X285 Connector for radiator fan (optional)
Page 262: 250 Xc-W Usa, 300 Xc-W Usa)
WIRING DIAGRAM 30.18 Page 3 of 3 (250 XC‑W USA, 300 XC‑W USA) wh-bu wh-bu bl-ye bl-ye wh-bl wh-bl 308723-01...
Page 263 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Kill switch Map switch for ride mode (optional) X280 Connector, ignition timing map X281 Connector, ignition timing map Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White...
Page 264: 300 Xc-W Six Days Usa)
WIRING DIAGRAM 30.19 Page 1 of 3 (300 XC‑W SIX DAYS USA) bl-rd bl-rd wh-rd wh-rd wh-rd bu-rd wh-rd bu-rd wh-rd wh-rd wh-rd 308731-01...
Page 265 WIRING DIAGRAM Components: CDI controller Battery Alternator Starter relay with main fuse Starter motor Electric starter button Voltage regulator...
Page 266: 300 Xc-W Six Days Usa)
WIRING DIAGRAM 30.20 Page 2 of 3 (300 XC‑W SIX DAYS USA) wh-rd wh-rd wh-rd 308732-01...
Page 267 WIRING DIAGRAM Components: Wheel speed sensor, front Low beam Light switch Speedometer Parking light Tail light X285 Connector for radiator fan (optional)
Page 268: 300 Xc-W Six Days Usa)
WIRING DIAGRAM 30.21 Page 3 of 3 (300 XC‑W SIX DAYS USA) wh-bu wh-bu bl-ye bl-ye wh-bl wh-bl 308733-01...
Page 269 WIRING DIAGRAM Components: CDI controller Crankshaft position sensor Ignition coil (cylinder 1) Kill switch Map switch for ride mode (optional) X280 Connector, ignition timing map X281 Connector, ignition timing map Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White...
Page 270: Substances
SUBSTANCES 2-stroke engine oil Standard/classification – JASO FC ( p. 282) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 Standard/classification –...
Page 271 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) Standard/classification – SAE ( p. 282) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
Page 272: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Recommended supplier Motorex ® – Moto Protect Fuel additive Recommended supplier Motorex...
Page 273 AUXILIARY SUBSTANCES Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Off-road chain spray Recommended supplier Motorex ® – Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ® – Twin Air Liquid Bio Power Universal oil spray Recommended supplier Motorex ®...
Page 274: Special Tools
SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 201597-10 Bleeder cover Art. no.: 00029013006 201598-10 Bleeding device Art. no.: 00029013100 201491-10 Spring hooks Art. no.: 50305017000 400363-01 Mounting tool, heim joint Art. no.: 50329000044 201428-01...
Page 275 SPECIAL TOOLS Bleed syringe Art. no.: 50329050000 400058-01 Clutch holder Art. no.: 51129003000 400289-01 Adjustment gauge Art. no.: 54829001100 303079-10 Separator plate Art. no.: 54829009000 303483-10 Lift stand Art. no.: 54829055000 500071-01...
Page 276 SPECIAL TOOLS Insert for crankshaft pressing tool Art. no.: 54829108000 303484-10 Holding spanner, rotor Art. no.: 55129001000 302997-10 Gear segment Art. no.: 56012004000 302982-10 Engine fixing arm Art. no.: 56029002030 302945-10 Extractor Art. no.: 58012009000 400073-01...
Page 277 SPECIAL TOOLS Tool for inner bearing race Art. no.: 58429037040 400082-01 Peak voltage adapter Art. no.: 58429042000 400083-01 Torque wrench with various accessories in set Art. no.: 58429094000 200910-10 Feeler gauge Art. no.: 59029041100 400110-01 Engine assembly stand Art. no.: 61229001000 200306-01...
Page 278 SPECIAL TOOLS Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01 Pin wrench Art. no.: T103 200734-10 Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10...
Page 279 SPECIAL TOOLS Mounting sleeve Art. no.: T1204 200788-10 Calibration pin Art. no.: T1205 200790-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Centering sleeve Art. no.: T1214 200777-10...
Page 280 SPECIAL TOOLS Mounting sleeve Art. no.: T1215 300568-10 Disassembly tool Art. no.: T1216 200816-10 Vacuum pump Art. no.: T1240S 200273-10 Protecting sleeve Art. no.: T1401 200635-10 Clamping stand Art. no.: T14015S 200733-10...
Page 281 SPECIAL TOOLS Clamping stand Art. no.: T14016S 200688-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10 Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10...
Page 282 SPECIAL TOOLS Mounting tool Art. no.: T14040S 200634-10 Special socket Art. no.: T14047 201710-01 Clamping stand Art. no.: T14049S 202338-10 Press-out tool Art. no.: T14051 201779-10 Press drift Art. no.: T1504 200789-10...
Page 283 SPECIAL TOOLS Assembly tool Art. no.: T150S 200791-10 Nitrogen filling tool Art. no.: T170S1 300574-10...
Page 284: Standards
STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –...
Page 285: Index
INDEX installing ....... . 188 INDEX removing ....... . 187 technical data - carburetor .
Page 286 INDEX work on individual parts ..... . 144 spacer, installing ......184 starter motor, installing .
Page 287 INDEX compression damping fitting, disassembling ..21 Hydrostop unit disassembling ......16, 36 fork legs, assembling .
Page 288 INDEX removing ....... . . 85 chassis ....... . . 211 chassis tightening torques .
Page 289 *3206179en* 3206179en 09/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

250 exc aus 250 xc-w usa 300 exc eu 300 exc aus 300 xc-w usa 300 xc-w six days usa ... Show all

KTM 250 EXC EU Repair Manual

1 Means of Representation

2 Safety Advice

3 Important Information

4 Serial Numbers

5 Motorcycle

6 Fork, Triple Clamp

7 Handlebar, Controls

8 Frame

9 Shock Absorber, Swingarm

10 Exhaust

11 Air Filter

12 Fuel Tank, Seat, Trim

13 Mask, Fender

14 Wheels

15 Wiring Harness, Battery

16 Brake System

17 Lighting System, Instruments

18 Engine

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Summary of Contents for KTM 250 EXC EU