KTM 250 XC-W 2018 Owner's Manual
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KTM 250 XC-W 2018 Owner's Manual

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OWNER'S MANUAL
2018
250 XC‑W
300 XC‑W
300 XC‑W Six Days
Art. no. 3213644en
250 EXC
300 EXC

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Summary of Contents for KTM 250 XC-W 2018

  • Page 1 OWNER'S MANUAL 2018 250 EXC 250 XC‑W 300 EXC 300 XC‑W 300 XC‑W Six Days Art. no. 3213644en...
  • 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 DEAR KTM CUSTOMER sports motorcycle that will 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.
  • Page 4 TABLE OF CONTENTS 6.14 Indicator lamps overview (All XC‑W TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 models)........... 20 Symbols used ........6 6.15 Opening the filler cap....... 20 Formats used........6 6.16 Closing the filler cap ......21 6.17 Fuel tap ..........
  • Page 5 TABLE OF CONTENTS PREPARING FOR USE......... 37 11.11 Checking the basic setting of the fork ..........56 Advice on first use ......37 11.12 Adjusting the compression damping Running in the engine ...... 38 of the fork ........57 Starting power of lithium-ion 11.13 Adjusting the rebound damping of batteries at low temperatures (All the fork...........
  • Page 6 TABLE OF CONTENTS 12.32 Removing the fuel tank ....81 15 ELECTRICAL SYSTEM ....... 113 12.33 Installing the fuel tank ....82 15.1 Removing the battery ....113 12.34 Checking the chain for dirt....84 15.2 Installing the battery ....114 12.35 Cleaning the chain ......
  • Page 7 TABLE OF CONTENTS 19.2 Checks and maintenance steps for winter operation......144 20 STORAGE ..........145 20.1 Storage ......... 145 20.2 Preparing for use after storage..146 21 TROUBLESHOOTING ........ 147 22 TECHNICAL DATA........149 22.1 Engine .......... 149 22.1.1 All 250 models......

  • Page 8: Means Of Representation

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

  • Page 9: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (All EXC models) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehi- cle complies with the currently valid regulations and categories of the top international motorsport organiza- tions.
  • Page 10 2 SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
  • Page 11 – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.
  • Page 12 If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the...

  • Page 13: 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.
  • Page 14 3 IMPORTANT NOTES Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 15: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) E00815-10 Hand brake lever ( p. 17) Light switch ( p. 18) (All EXC models) Kill switch ( p. 17) (All EXC models) p. 19) (All EXC models) Turn signal switch ( Horn button ( p.
  • Page 16 4 VIEW OF VEHICLE View of vehicle, rear right (example) E00816-10 Filler cap Throttle grip ( p. 17) Chassis number ( p. 15) Kick starter ( p. 22) Foot brake lever ( p. 23) Level viewer for brake fluid, rear...

  • Page 17: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Key number (All EXC models) The key number for the steering lock is stamped onto the key connector.
  • Page 18 5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inside of the axle clamp. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...

  • Page 19: Kill Switch (All Exc Models)

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. E00817-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.
  • Page 20 6 CONTROLS Kill switch (All XC‑W models) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed and the engine can be started. pressed –...

  • Page 21: Map Switch (All Six Days Models)

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

  • Page 22: Indicator Lamps Overview (All Exc Models)

    6 CONTROLS 6.13 Indicator lamps overview (All EXC models) Possible states The high beam indicator lamp lights up blue – The high beam is switched on. Malfunction indicator lamp – inoperative Fuel level warning lamp – inoperative Turn signal indicator lamp flashes green – The turn E00314-01 signal is switched on.
  • Page 23 6 CONTROLS – Press release button , turn the filler cap counterclockwise and lift it free. V00325-10 6.16 Closing the filler cap – Replace the filler cap and turn clockwise until the release but- locks in place. Info Run the fuel tank breather hose without kinks.
  • Page 24 6 CONTROLS 6.18 Choke Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deacti- vated.
  • Page 25 6 CONTROLS 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.22 Side stand Side stand is located on the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.
  • Page 26 6 CONTROLS 6.24 Locking the steering (All EXC models) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –...

  • Page 27: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.
  • Page 28 7 COMBINATION INSTRUMENT Setting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10 -12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.
  • Page 29 7 COMBINATION INSTRUMENT Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Set the hour display with the button and/or button –...
  • Page 30 7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.
  • Page 31 7 COMBINATION INSTRUMENT Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...
  • Page 32 7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.
  • Page 33 7 COMBINATION INSTRUMENT Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.
  • Page 34 7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.
  • Page 35 7 COMBINATION INSTRUMENT Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.
  • Page 36 7 COMBINATION INSTRUMENT Briefly press Next display mode the button Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.
  • Page 37 7 COMBINATION INSTRUMENT 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...
  • Page 38 7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode Displays of Next display No function No function SPEED/TR1 (trip...

  • Page 39: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 40: Running In The Engine

    8 PREPARING FOR USE (All EXC models) – Adjust the free travel of the hand brake lever. ( p. 95) (All XC‑W models) – Adjust the basic position of the hand brake lever. ( p. 96) – Adjust the basic position of the foot brake lever. p.

  • Page 41: Batteries At Low Temperatures (All Au/Us Models)

    8 PREPARING FOR USE Starting power of lithium-ion batteries at low temperatures (All AU/US models) Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batter- ies.

  • Page 42: Preparing For Rides On Dry Sand

    Fit a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info M01105-01 Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 43: Preparing For Rides On Wet Sand

    Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 44: Preparations For Riding On Wet And Muddy Surfaces

    Waterproofing device for air filter (79006921000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Mount the steel sprocket. – Clean the motorcycle. ( p. 143) –...

  • Page 45: Temperatures Or In Snow

    Mount the rain cover for the air filter. Waterproofing device for air filter (79006921000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 46: Riding Instructions

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

  • Page 47: Start Off

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

  • Page 48: Braking

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

  • Page 49: Transporting

    9 RIDING INSTRUCTIONS Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. – Park the vehicle on a firm and level surface. –...

  • Page 50: Refueling

    9 RIDING INSTRUCTIONS Refueling 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. – Switch off the engine for refueling.

  • Page 51: Service Schedule

    10 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. Different service intervals may apply in your country, depending on the local operating conditions. 10.2 Required work Every 10 operating hours when used for motorsports...

  • Page 52: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval 10.3...

  • Page 53: Tuning The Chassis

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

  • Page 54: Absorber

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

  • Page 55: The Shock Absorber

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

  • Page 56: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 53) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.

  • Page 57: The Shock Absorber

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

  • Page 58: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 63) – Remove the shock absorber. p. 75) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 59: Adjusting The Compression Damping Of The Fork

    11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (All standard EXC/XC-W models) – Turn white adjusting screw clockwise as far as it will Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 60: The Fork

    11 TUNING THE CHASSIS Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counter- clockwise 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 61: Adjusting The Spring Pretension Of The Fork (All Six Days Models)

    11 TUNING THE CHASSIS (All Six Days models) – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 62: Handlebar Position

    11 TUNING THE CHASSIS Info Adjust the spring preload to the numerical values only as the preload will not engage between the numerical values. Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. Adjusting the spring pretension has no influence on the absorption setting of the rebound.
  • Page 63 11 TUNING THE CHASSIS (All Six Days models) On the upper triple clamp, there are 2 holes at a distance to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance from the center.
  • Page 64 11 TUNING THE CHASSIS Info Make sure the cables and wiring are positioned cor- rectly. – Position the handlebar clamps. Mount screws tighten evenly. Guideline Screw, handlebar 20 Nm clamp (14.8 lbf ft) Info Make sure the gap widths are even. (All Six Days models) –...

  • Page 65: Raising The Motorcycle With A Lift Stand

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

  • Page 66: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 63) – Remove the fork protector. ( p. 64) Main work – Push dust boots of both fork legs downward.

  • Page 67: Installing The Fork Protector

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

  • Page 68: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS (All Six Days models) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. E00377-10 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front.
  • Page 69 12 SERVICE WORK ON THE CHASSIS – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws E00375-11 Finishing work...
  • Page 70 12 SERVICE WORK ON THE CHASSIS 12.10 Removing the lower triple clamp (All Six Days models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 63) – Remove the front wheel. p. 107) – Remove the headlight mask with the headlight. ( p.
  • Page 71 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Position the clutch line and wiring harness. – Mount screw but do not tighten yet. V00336-11 – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw).
  • Page 72 12 SERVICE WORK ON THE CHASSIS – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws E00375-12 Finishing work...
  • Page 73 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. – Position the clutch line and wiring harness. V00356-10 – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 74: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 75: Adjusting The Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS – Check the steering head bearing and change if neces- sary. Finishing work – Remove the motorcycle from the lift stand. ( p. 63) 12.14 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand.

  • Page 76: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS 12.15 Lubricating the steering head bearing (All standard EXC/XC-W models) – Remove the lower triple clamp. p. 67) – Install the lower triple clamp. p. 68) (All Six Days models) – Remove the lower triple clamp. p.

  • Page 77: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work – Install the headlight mask with the headlight. ( p. 120) – Check the headlight setting. ( p.

  • Page 78: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.20 Removing the seat – Remove screws – Raise the rear of the seat, pull the seat back, and lift it off. V00342-10 12.21 Mounting the seat – Hook in the front of the seat on the collar bushing of the fuel tank, lower it at the rear and push it forward.

  • Page 79: Installing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and take off toward the front. V00346-11 12.23 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area V00346-12...

  • Page 80: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. E00835-10 12.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 81: Securing The Air Filter Box Cover 12.28 Sealing The Air Filter Box

    12 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 167) Info Only squeeze the air filter to dry it; never wring it out. –...

  • Page 82: Removing The Main Silencer

    12 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 83: Removing The Fuel Tank

    12 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 dam- age.

  • Page 84: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Turn handle of the fuel tap to the OFF position. (Figure E00826-10 p. 21) – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws with the collar bushings.
  • Page 85 12 SERVICE WORK ON THE CHASSIS 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. –...

  • Page 86: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS 12.34 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 84) 400678-01 12.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...

  • Page 87: Checking The Chain Tension

    12 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. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 88: Checking The Chain, Rear Sprocket Motor Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 89 12 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure the distance of 18 chain links in the lower chain section.
  • Page 90 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 91: Checking The Frame

    – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 12.41 Checking throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 92: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. The throttle cable must be routed behind the handle- bar, on the right of the frame, and to the carburetor. The throttle cable must be secured behind the fuel tank con- tact area rubber band.

  • Page 93: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.43 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 94: Fluid

    12 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 4 mm (0.16 in) »...

  • Page 95: Removing The Engine Guard (All Six Days Models, Exc Au)

    12 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane E00337-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 96: Installing The Engine Guard (All Six Days Models, Exc Au)

    12 SERVICE WORK ON THE CHASSIS 12.47 Installing the engine guard (All Six Days models, EXC AU) – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis...

  • Page 97: Brake System

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

  • Page 98: Hand Brake Lever (All Xc‑W Models)

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

  • Page 99: Checking The Front Brake Fluid Level

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

  • Page 100: Checking The Front Brake Linings

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

  • Page 101: Changing The Front Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 102 13 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 pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 103: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM Info Clean up overflowed or spilled brake fluid immediately with water. 13.9 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 104: Level

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

  • Page 105: Adding Rear Brake Fluid

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

  • Page 106: Checking The Brake Linings Of The Rear Brake

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 107 13 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 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 108 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 164) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. E00348-10...

  • Page 109: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 63) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 110: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 111: Installing The Rear Wheel

    14 WHEELS, TIRES 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 112 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 113: Checking The Tire Condition

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

  • Page 114: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 115: Electrical System

    15 ELECTRICAL SYSTEM 15.1 Removing the battery 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 116: Installing The Battery

    15 ELECTRICAL SYSTEM (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 safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 117: Recharging The Battery

    15 ELECTRICAL SYSTEM Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal. Finishing work – Mount the seat. ( p. 76) 15.3 Recharging the battery Warning Environmental hazard Batteries contain environmentally-hazardous materials.
  • Page 118 15 ELECTRICAL SYSTEM Main work (All 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. S00863-10 – Only charge batteries in well-ventilated rooms. –...
  • Page 119 15 ELECTRICAL SYSTEM Info If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed. If the battery is left in a discharged state for an extended period, it will become over- discharged and sulfated, destroying the bat- tery.

  • Page 120: Changing The Main Fuse

    15 ELECTRICAL SYSTEM You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info If the charging current, charging voltage and charg- ing time are exceeded, electrolyte escapes through the safety valves.

  • Page 121: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. E00813-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 122: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM (All EXC models) – Detach plug-in connectors and take off the headlight mask with the headlight. E00356-10 (All XC‑W models) – Detach plug-in connector and take off the headlight mask with the headlight. E00357-10 15.6 Installing the headlight mask with the headlight Main work (All EXC models) –...

  • Page 123: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 122) 15.7 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...

  • Page 124: Checking The Headlight Setting

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

  • Page 125: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 122) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower marking for a motorcycle with rider (instructions on how to apply the marking: Checking the headlight setting).
  • Page 126 15 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...

  • Page 127: Cooling System

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

  • Page 128: Checking The Coolant Level

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

  • Page 129: Refilling With Coolant

    16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 130 16 COOLING SYSTEM – Loosen screw and wait until coolant escapes without bub- bles. – Mount and tighten screw Guideline Bleeder screw, cylin- 10 Nm (7.4 lbf ft) der head F01058-10 – Completely fill the radiator with coolant. Coolant ( p.

  • Page 131: Tuning The Engine

    17 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.
  • Page 132 17 TUNING THE ENGINE Main work – Turn the handlebar as far as possible to the right. – Push back sleeve – Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster – Loosen nut – Turn barrel adjuster so that there is play in the throttle...

  • Page 133: Carburetor Setting

    17 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 134 17 TUNING THE ENGINE Influence of throttle slide adjustment K00495-01 The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence. When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influence.

  • Page 135: Carburetor - Idle

    17 TUNING THE ENGINE 402674-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 corresponds to a needle which is half a clip richer. Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the carburation.

  • Page 136: Speed

    17 TUNING THE ENGINE (EXC BR) Height above sea 751 … 1,500 m (2,464 … 4,921 ft) level Ambient tempera- 16 … 24 °C (61 … 75 °F) ture Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil, 1:60) ( p.

  • Page 137: Ignition Curve Plug-In Connector

    17 TUNING THE ENGINE – Turn idle air adjusting screw slowly in a clockwise direc- tion until the idle speed begins to fall. – Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall. –...

  • Page 138: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 139: Engine Characteristic – Auxiliary Spring

    17 TUNING THE ENGINE Engine characteristic – auxiliary spring 17.10 The auxiliary spring is located on the right side of the engine below the water pump cover. Possible states Auxiliary spring with green color coding – Auxiliary spring for • soft performance.
  • Page 140 17 TUNING THE ENGINE – Remove cap , adjusting spring , auxiliary spring and spring insert from the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring ( p. 137) adjusting spring and position them together in the clutch cover.

  • Page 141: Service Work On The Engine

    18 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 142: Checking The Gear Oil Level

    18 SERVICE WORK ON THE ENGINE 18.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Detach the foot brake lever spring. –...

  • Page 143: Adding Gear Oil

    18 SERVICE WORK ON THE ENGINE Main work – Remove gear oil drain plug with magnet. – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug with magnet. – Clean the sealing surface on the engine. –...
  • Page 144 18 SERVICE WORK ON THE ENGINE Main work – Remove screw for checking gear oil level E00366-10 – Remove filler plug – Add gear oil until it emerges from the drill hole of the gear oil monitoring screw. Engine oil (15W/50) ( p.

  • Page 145: Cleaning, Care

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

  • Page 146: Winter Operation

    19 CLEANING, CARE – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 84) – Treat bare metal parts (except for brake discs and exhaust sys- tem) with anti-corrosion materials. Preserving materials for paints, metal and rubber p.

  • Page 147: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 63) –...

  • Page 148: Preparing For Use After Storage

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

  • Page 149: Troubleshooting

    21 TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked Operating error Carry out the start procedure. (electric starter) p. 44) – Battery discharged Recharge the battery. p. 115) – Check the charging voltage. – Check the closed current. –...
  • Page 150 21 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Air filter very dirty Clean the air filter and air filter box. p. 78) – Exhaust system leaky, Check exhaust system for damage. deformed or too little glass –...

  • Page 151: Technical Data

    22 TECHNICAL DATA 22.1 Engine 22.1.1 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) Hole 66.4 mm (2.614 in) Idle speed 1,400 … 1,500 rpm Exhaust valve, beginning of adjustment 5,250 rpm Crankshaft bearing...

  • Page 152: Engine Tightening Torques

    22 TECHNICAL DATA Exhaust valve, beginning of adjustment 5,500 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings Engine lubrication Mixture oil lubrication X distance (upper edge of piston to upper edge of 0 …...
  • Page 153 22 TECHNICAL DATA Screw, locking lever 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket of exhaust 7 Nm (5.2 lbf ft) Loctite ® 2701™ control Screw, water pump impeller 6 Nm (4.4 lbf ft) Loctite ® 243™ Bleeder screw, cylinder head 10 Nm (7.4 lbf ft) Outer clutch cover...
  • Page 154 22 TECHNICAL DATA Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite ® 648™...

  • Page 155: Carburetor

    22 TECHNICAL DATA 22.3 Carburetor 22.3.1 EXC AU Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 78 Needle position 1st position from top Jet needle 6BFY43‑74 (6BFY43‑75, 6BFY42‑75) Main jet 100 (430, 440, 450, 460) Idling jet 17.5 (22.5/25/27.5) Starting jet 50 (80) Needle jet...

  • Page 156: All Xc‑W Models

    22 TECHNICAL DATA 402896-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Needle jet Info Do not use on sandy terrain. In the derestricted condition, the needle jet must be changed if necessary. 22.3.3 All XC‑W models Carburetor type...
  • Page 157 22 TECHNICAL DATA Carburetor identification number TMX 38 80 Needle position 2nd position from top Jet needle 6BFY43‑75 (6BFY42-75) Main jet 450 (430, 440, 460) Idling jet 25 (22.5/27.5) Starting jet Needle jet Idle air adjusting screw Open 1.5 turns Throttle slide 22.3.4 Carburetor tuning (All XC‑W models)

  • Page 158: Exc Br

    22 TECHNICAL DATA Idling jet Needle Needle position from top Main jet Needle jet Info Do not use on sandy terrain. 22.3.5 EXC BR Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 86 Needle position 3rd position from top Jet needle 6BFY43-73 (6BFY42-73, 6BFY42-74, 6BFY43-74) Main jet...

  • Page 159: Carburetor Tuning (Exc Br)

    22 TECHNICAL DATA 22.3.6 Carburetor tuning (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 160: Capacities

    22 TECHNICAL DATA 22.4 Capacities 22.4.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 164) 22.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 164) 22.4.3 Fuel Total fuel tank capacity, approx. 9.5 l (2.51 US gal) Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) p.

  • Page 161: Electrical System

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

  • Page 162: Fork

    22 TECHNICAL DATA 22.8 Fork 22.8.1 All 250 models, EXC AU, 300 XC‑W US Fork article number 14.18.8R.63 WP Performance SystemsXplor 48 Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks...

  • Page 163: All Six Days Models

    22 TECHNICAL DATA 22.8.3 All Six Days models Fork article number 14.15.8R.63 Fork WP Performance SystemsXplor 48 PA Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload - Preload Adjuster Comfort Standard...

  • Page 164: Chassis Tightening Torques

    22 TECHNICAL DATA Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 60 N/mm (343 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 63 N/mm (360 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 66 N/mm (377 lb/in) Spring length 225 mm (8.86 in)
  • Page 165 22 TECHNICAL DATA Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ Nut, rim lock 12 Nm (8.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) standard EXC/XC-W models) Screw, bottom triple clamp (All...

  • Page 166: Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 167 23 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 169) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification –...
  • Page 168 23 SUBSTANCES Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil, 1:60) Standard/classification – ANP (Agência Nacional do Petróleo) #57 (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil) – JASO FD ( p. 169) (1:60) Mixture ratio 1:60 Engine oil, 2-stroke (...

  • Page 169: Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 170 24 AUXILIARY SUBSTANCES Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 171: Standards

    25 STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no sepa- rate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 172: List Of Abbreviations

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

  • Page 173: List Of Symbols

    27 LIST OF SYMBOLS 27.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp – inoperative Fuel level warning lamp – inoperative 27.2 Green and blue symbols Green and blue symbols reflect information.

  • Page 174: Index

    INDEX Chain INDEX checking ......86 Accessories ......11 cleaning .
  • Page 175 INDEX Engine characteristic Gear oil level auxiliary spring ..... 137 checking ......140 auxiliary spring, setting .
  • Page 176 INDEX Map switch ......19 removing ......75 Misuse .
  • Page 177 INDEX Type label ......15 Use definition ......7 View of vehicle front left .
  • Page 178 *3213644en* 3213644en 03/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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