Related Manuals for KTM 25 EXC 2016
Summary of Contents for KTM 25 EXC 2016
- Page 1 SETUP INSTRUCTIONS 2016 125 EXC 200 EXC 200 XC‑W 250 EXC 250 XC‑W 300 EXC 300 XC‑W Art. no. 3213437en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
-
Page 4: 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 5 SETUP Unpacking and setting up the vehicle Package 2 – Remove the box and the plastic packaging. Info An assistant prevents the motorcycle from falling over. To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you have finished. –...
- Page 6 SETUP – Route the clutch line with the clutch master cylinder toward the front between the upper and lower triple clamps. B02183-01 (XC-W, 300 EXC BR) – Position the fork legs and tighten the screws of the triple clamp. Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft)
- Page 7 SETUP (Six Days, EXC EU/AU) – Remove screws . Take off the handlebar clamps. – Remove screws . Take off the handlebar supports. – Place the handlebar supports in the required position. Mount and tighten screws Guideline Screw, handlebar support M10 40 Nm Loctite...
- Page 8 SETUP (All EXC models) – Position the controls on the left half of the handlebar. Info The figure shows how to route the clutch line and wiring harness. V00040-01 (XC-W, 300 XC‑W Six Days US) – Position the controls on the left half of the handlebar. Info The figure shows how to route the clutch line and wiring harness.
- Page 9 SETUP (XC-W, 300 XC‑W Six Days US) – Connect pull switch with the yellow and white cables. – Install the front fender. ( p. 14) – Mount the fuel tank breather correctly. – Install the front wheel. ( p. 12) –...
- Page 10 18) – Position all controls in their exact positions on the handlebar. Tighten all screws. – Refuel. ( p. 17) – Prepare the vehicle according to the specifications in the KTM Dealer.net for han- B00909-01 dover to the customer.
- Page 11 WORK Raising the motorcycle with a 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 (78129955100) Neither wheel is in contact with the ground.
- Page 12 WORK – Mount and tighten screw of the seat fixation. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00817-10 Removing 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 13 WORK 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. Clean up spilt fuel immediately. –...
- Page 14 WORK Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. (All 250/300 models) –...
-
Page 15: Tighten Screws
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 16 WORK Finishing work – Mount the seat. ( p. 9) 3.10 Installing the battery (All 200/250/300 models) Main work – Insert the battery into the battery compartment with the terminals facing forward. (All 200/250/300 EU/AU/US models) Battery (YTX4L-BS) (300 EXC BR) Battery (YTX5L-BS) –...
-
Page 17: Checking The Headlight Setting
WORK 3.12 Refitting the headlight mask with the headlight Main work (All EXC models) – Connect plug-in connectors M00589-11 (XC-W, 300 XC‑W Six Days US) – Connect plug-in connector M00590-11 – Position the headlight mask and fix it with rubber straps The holding lugs engage. -
Page 18: Tighten Screw
WORK 3.14 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 15) Main work – Loosen screw – Adjust the headlight range by swiveling the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the headlight setting). - Page 19 WORK 3.17 Refueling 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 20: Setting The Clock
WORK 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. 3.19 Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. -
Page 21: Technical Data
TECHNICAL DATA Chassis tightening torques – Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) – Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) – Remaining nuts, chassis 5 Nm (3.7 lbf ft) – Remaining screws, chassis 5 Nm (3.7 lbf ft) –... - Page 22 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 22) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
-
Page 23: Auxiliary Substances
AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000... - Page 24 STANDARDS JASO FD JASO FD 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.
- Page 25 *3213437en* 3213437en 11/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...