Page 1
REPAIR MANUAL 2019 250 EXC TPI 250 EXC Six Days TPI 250 XC‑W TPI 300 EXC TPI 300 EXC Six Days TPI 300 XC-W TPI 300 XC-W Six Days TPI Art. no. 3206345en...
Page 3
KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
TABLE OF CONTENTS 6.10.8 Assembling the fork legs....33 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 7 6.10.9 Lubricating the steering head Symbols used ........7 bearing ........37 Formats used........7 6.10.10 Removing the lower triple clamp ... 37 6.10.11 Installing the lower triple clamp ..
Page 5
TABLE OF CONTENTS SHOCK ABSORBER, SWINGARM ....78 11 AIR FILTER ..........116 Adjusting the high-speed 11.1 Removing the air filter box cover ..116 compression damping of the shock 11.2 Installing the air filter box cover ..116 absorber.......... 78 11.3 Removing the air filter ....
Page 6
TABLE OF CONTENTS 14.8.8 Checking the chain, rear 17.5 Changing the combination sprocket, engine sprocket, and instrument ........184 chain guide ....... 151 17.6 Combination instrument overview ..185 14.8.9 Adjusting the chain tension ..153 17.7 Activation and test ......185 14.8.10 Changing the drivetrain kit..
Page 7
TABLE OF CONTENTS 18.5 Working on individual parts..... 219 18.6.6 Installing the left engine case section ........252 18.5.1 Working on the right section of the engine case ......219 18.6.7 Installing the reed valve housing........253 18.5.2 Working on the left section of the engine case ......
Page 8
TABLE OF CONTENTS 22 LUBRICATION SYSTEM......294 27 CLEANING, CARE ........322 22.1 Changing the gear oil...... 294 27.1 Cleaning the motorcycle ....322 22.2 Checking the gear oil level ....295 27.2 Checks and maintenance steps for winter operation......323 22.3 Adding gear oil ......
MEANS OF REPRESENTATION 1 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.
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.
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.
4 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 Engine number The engine number is located on the left side of the engine over the engine sprocket.
SERIAL NUMBERS 4 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...
5 MOTORCYCLE 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) ( p.
MOTORCYCLE 5 Info If the engine is warm, the cold start button must be deactivated. – Press the electric starter button or push the kick starter robustly through its full range. Info Do not open the throttle. Press the electric starter button for a maximum of 5 seconds.
6 FORK, TRIPLE CLAMP 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.
FORK, TRIPLE CLAMP 6 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All standard EXC/XC-W 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.
6 FORK, TRIPLE CLAMP Adjusting the spring preload of the fork (All Six Days models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) Main work – Turn the adjusting wings counterclockwise all the way. The marking +0 aligns with the adjusting wing on both fork legs.
FORK, TRIPLE CLAMP 6 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) – Remove the fork protector. ( p. 19) Main work – Push dust boots of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes.
6 FORK, TRIPLE CLAMP (All standard EXC/XC-W models) – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. E00914-10 (All Six Days models) – Loosen screws . Remove the left fork leg. –...
6 FORK, TRIPLE CLAMP Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis 6.10 All standard EXC/XC-W models 6.10.1 Servicing the fork Condition The fork legs have been removed. – Disassemble the fork legs. ( p. 20) – Disassemble the cartridge. ( p.
Page 23
FORK, TRIPLE CLAMP 6 – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 374) – Remove screw . Remove adjuster. B04511-10 – Loosen the screw cover Ring wrench (T14017) ( p. 374) Info The screw cover cannot be removed yet.
Page 24
6 FORK, TRIPLE CLAMP – Clamp the fork leg with the axle clamp. Guideline Use soft jaws. – Unscrew and remove compression holder Info Place a container underneath as oil will run out in most cases. B04514-10 – Remove the cartridge. B04515-10 –...
FORK, TRIPLE CLAMP 6 – Remove upper sliding bushing Info Without using a tool, pull the stack slightly apart by hand. – Take off lower sliding bushing – Take off support ring – Take off seal ring B03525-14 – Take off lock ring –...
Page 26
6 FORK, TRIPLE CLAMP – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 374) B04528-10 – Remove nut – Completely remove shim stack B04529-10 – Remove piston – Completely remove shim stack B04530-10 –...
Page 27
FORK, TRIPLE CLAMP 6 – Remove piston ring B05418-10 Left cartridge – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 374) – Remove adjusting tube – Remove fluid barrier from the piston rod. B04517-10 – Take piston rod out of the cartridge.
6 FORK, TRIPLE CLAMP – Warm up the piston rod in area Guideline 50 °C (122 °F) – Remove piston with setting needle B04535-10 – Pull setting needle out of the piston. – Remove O-rings B04536-10 – Remove spring – Unclamp the piston rod.
FORK, TRIPLE CLAMP 6 – Remove O-ring – Remove piston – Remove shim stack B04506-10 – Remove O-ring from the tap compression. – Extract the tap compression. B04507-10 6.10.5 Checking the fork legs Condition The fork legs have been disassembled. –...
6 FORK, TRIPLE CLAMP – Check the outer tube for damage. » If damage is found: – Change the outer tube. B03584-10 – Check the surface of the sliding bushings. » When the bronze-colored layer becomes visible under the gliding layer –...
FORK, TRIPLE CLAMP 6 – Mount piston Guideline of piston from above View of piston from below View – Mount O-ring – Grease the piston O-ring. Fork oil (SAE 4) (48601166S1) ( p. 359) B04509-10 – Mount washer – Mount spring with the tighter coil facing downward.
Page 32
6 FORK, TRIPLE CLAMP – Position spring – Mount shim stack Info Mount the smaller shims at the bottom. – Press the shim stack downward against the spring force. Info B04547-10 The shim stack must be pressed downward over the collar.
Page 33
FORK, TRIPLE CLAMP 6 – Mount washer and spring seat B04533-11 – Slide piston rod into the cartridge. B04532-11 – Mount fluid barrier all the way on. Info The fluid barrier must be tightened all the way. Do not use a tool. –...
Page 34
6 FORK, TRIPLE CLAMP – Insert setting needle in the piston. – Mount and tighten piston Guideline Rebound pis- M9x1 18 Nm (13.3 lbf ft) Loctite ® 2701™ B04552-10 – Mount and lubricate piston ring Fork oil (SAE 4) (48601166S1) ( p.
FORK, TRIPLE CLAMP 6 6.10.8 Assembling the fork legs Info The operations are the same on both fork legs. Preparatory work – Check the fork legs. ( p. 27) – Assemble the cartridge. ( p. 29) – Assemble the tap compression. ( p.
Page 36
6 FORK, TRIPLE CLAMP – Warm up the outer tube in area of the lower sliding bush- ing. Guideline 50 °C (122 °F) – Push the outer tube on. – Hold the lower sliding bushing with the longer side of the spe- cial tool.
Page 37
FORK, TRIPLE CLAMP 6 – Mount and tighten tap compression Guideline Compression damp- M29x1 35 Nm (25.8 lbf ft) ing fitting B04540-10 – Mount special tool on the piston rod. Support tool (T14026S1) ( p. 374) Info The special tool must be used to prevent the adjust- ing tube from being lifted and thus to prevent oil from reaching the piston rod.
Page 38
6 FORK, TRIPLE CLAMP Info When assembling, ensure that the screw caps are mounted correctly. Rebound damping side – right fork leg, screw cap with marking REB, red adjuster. Compression damping side – left fork leg, screw cap with marking COMP, white adjuster. –...
FORK, TRIPLE CLAMP 6 Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Alternative 2 Warning Danger of accident Modifications to the suspen- sion setting may seriously alter the handling char- acteristic.
6 FORK, TRIPLE CLAMP Main work – Remove screws and hang the voltage regulator to the side. – Open the cable holder in front of the left and right radiator and detach the wiring harness. E00920-10 – Remove screw – Loosen screw .
Page 41
FORK, TRIPLE CLAMP 6 – Position the upper triple clamp with the handlebar. – Position the clutch line and wiring harness. – Mount screw but do not tighten yet. E00921-11 – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)
6 FORK, TRIPLE CLAMP – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem E00926-11 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp E00914-12 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)
Page 43
FORK, TRIPLE CLAMP 6 Main work – Remove lower bearing ring with special tool Tool bracket (58429089000) ( p. 368) Pressing tool (58429092000) ( p. 368) R02802-10 – Press the new bearing ring up to the stop with special tool Tool bracket (58429089000) ( p.
6 FORK, TRIPLE CLAMP 6.10.13 Checking the play of the steering head bearing Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. 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.
FORK, TRIPLE CLAMP 6 Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem Finishing work – Check the play of the steering head bearing. ( p. 42) – Remove the motorcycle from the lift stand. ( p. 12) 6.11 All Six Days models 6.11.1 Servicing the fork...
Page 46
6 FORK, TRIPLE CLAMP – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 374) – Remove screw . Remove adjuster. B04521-10 – Loosen the screw cover Ring wrench (T14017) ( p. 374) Info The screw cover cannot be removed yet.
Page 47
FORK, TRIPLE CLAMP 6 – Clamp the fork leg with the axle clamp. Guideline Use soft jaws. – Unscrew and remove compression holder Info Place a container underneath as oil will run out in most cases. B04514-10 – Remove the cartridge. B04515-10 –...
6 FORK, TRIPLE CLAMP – Remove upper sliding bushing Info Without using a tool, pull the stack slightly apart by hand. – Take off lower sliding bushing – Take off support ring – Take off seal ring B03525-14 – Take off lock ring –...
Page 49
FORK, TRIPLE CLAMP 6 – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 374) B04528-10 – Remove nut – Completely remove shim stack B04529-10 – Remove piston – Completely remove shim stack B04530-10 –...
Page 50
6 FORK, TRIPLE CLAMP – Remove piston ring B04538-10 Left cartridge – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 374) – Remove adjusting tube – Remove fluid barrier from the piston rod. B04517-10 – Take piston rod out of the cartridge.
FORK, TRIPLE CLAMP 6 – Warm up the piston rod in area Guideline 50 °C (122 °F) – Remove piston with setting needle B04535-10 – Pull setting needle out of the piston. – Remove O-rings B04536-10 – Remove spring – Unclamp the piston rod.
6 FORK, TRIPLE CLAMP – Remove O-ring – Remove piston – Remove shim stack B04506-10 – Remove O-ring from the tap compression. – Extract the tap compression. B04507-10 6.11.5 Checking the fork legs Condition The fork legs have been disassembled. –...
FORK, TRIPLE CLAMP 6 – Check the outer tube for damage. » If damage is found: – Change the outer tube. B03584-10 – Check the surface of the sliding bushings. » When bronze-colored layer becomes visible under glid- ing layer –...
6 FORK, TRIPLE CLAMP – Mount piston Guideline of piston from above View of piston from below View – Mount O-ring – Grease the piston O-ring. Fork oil (SAE 4) (48601166S1) ( p. 359) B04509-10 – Mount washer – Mount spring with the tighter coil facing downward.
Page 55
FORK, TRIPLE CLAMP 6 – Position spring – Mount shim stack Info Mount the smaller shims at the bottom. – Press the shim stack downward against the spring force. Info B04547-10 The shim stack must be pressed downward over the collar.
Page 56
6 FORK, TRIPLE CLAMP – Mount washer and spring seat D04749-10 – Slide piston rod into the cartridge. B04532-11 – Mount fluid barrier all the way on. Info The fluid barrier must be tightened all the way. Do not use a tool. –...
Page 57
FORK, TRIPLE CLAMP 6 – Insert setting needle in the piston. – Mount and tighten piston Guideline Compression M9x1 18 Nm (13.3 lbf ft) Loctite ® 2701™ piston B04552-10 – Mount and lubricate piston ring Fork oil (SAE 4) (48601166S1) ( p.
6 FORK, TRIPLE CLAMP 6.11.8 Assembling the fork legs Info The operations are the same on both fork legs. Preparatory work – Check the fork legs. ( p. 50) – Assemble the tap compression. ( p. 51) – Assemble the cartridge. ( p.
Page 59
FORK, TRIPLE CLAMP 6 – Warm up the outer tube in area of the lower sliding bush- ing. Guideline 50 °C (122 °F) – Push the outer tube on. – Hold the lower sliding bushing with the longer side of the spe- cial tool.
Page 60
6 FORK, TRIPLE CLAMP – Slide the cartridge all the way into the inner tube. The hexagonal part of the cartridge engages in the inner tube guide. Info When assembling, ensure that the cartridges are not mixed up. The cartridges with the holes are installed on the left. The cartridge without the hole is installed on the right.
Page 61
FORK, TRIPLE CLAMP 6 – Remove pin of the special tool. Support tool (T14026S1) ( p. 374) – Pull out the piston rod. Mount the spring. Mount the pin again. Guideline Spring rate Weight of rider: 65 … 4.0 N/mm (22.8 lb/in) 75 kg (143 …...
Page 62
6 FORK, TRIPLE CLAMP – Mount the adjuster. – Mount and tighten screw Guideline Screw, adjuster M4x0.5 2.5 Nm (1.84 lbf ft) B04521-11 Alternative 1 – Turn compression adjuster and rebound adjuster clockwise all the way. – Turn counterclockwise by the number of clicks correspond- ing to the fork type.
FORK, TRIPLE CLAMP 6 6.11.9 Lubricating the steering head bearing – Remove the lower triple clamp. ( p. 61) – Install the lower triple clamp. ( p. 62) H02387-01 6.11.10 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p.
6 FORK, TRIPLE CLAMP 6.11.11 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 360) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
Page 65
FORK, TRIPLE CLAMP 6 – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp E00919-12 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head E00927-10 – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) Loctite ®...
6 FORK, TRIPLE CLAMP – 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. 65) – Remove the motorcycle from the lift stand. ( p.
FORK, TRIPLE CLAMP 6 – Press the new bearing ring up to the stop with special tool Tool bracket (58429089000) ( p. 368) Pressing tool (58429091000) ( p. 368) R02805-10 – Remove lower steering head bearing – Remove the seal ring. –...
6 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. Play should not be detectable on the steering head bearing. » If there is detectable play: –...
HANDLEBAR, CONTROLS 7 Handlebar position (All standard EXC/XC-W 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 70
7 HANDLEBAR, CONTROLS (All standard EXC/XC-W models) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
HANDLEBAR, CONTROLS 7 (All Six Days models) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
7 HANDLEBAR, CONTROLS Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right.
HANDLEBAR, CONTROLS 7 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Turn the handlebar as far as possible to the right. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...
7 HANDLEBAR, CONTROLS – Unscrew the adjusting screw until the smooth operation or play in throttle cable is worsened. – Turn the adjusting screw approx. two turns further. – Tighten nut – Tighten nut – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work –...
Page 75
HANDLEBAR, CONTROLS 7 – Clean the outside of the handlebar and the inside of the grip tube. Mount the grip tube on the handlebar. – Attach the throttle cables to the guide plate and route cor- rectly. – Position half-shells , mount and tighten screws Guideline Screw, throttle grip...
– Change the frame. Info Always replace a frame that has been dam- aged due to a mechanical impact. Repair of the frame is not authorized by KTM. S01316-10 Removing the engine guard (All Six Days models) – Remove screws and engine guard.
Page 77
FRAME 8 – Press the spring with special tool Footrest spring plier (79029083000) ( p. 371) The special tool is applied to area on the footrest. – Remove pin R01338-10 – Position the new footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted.
Page 78
8 FRAME – Mount the washer and split pin – Remove the motorcycle from the lift stand. ( p. 12) R00755-10 Right footrest – Remove split pin and take off the washer. R01227-10 – Press the spring with special tool Footrest spring plier (79029083000) ( p.
Page 79
FRAME 8 – Position spring as shown. Spring engages in area R01230-10 – Press the spring with special tool Footrest spring plier (79029083000) ( p. 371) The special tool is applied to area on the footrest. – Mount pin R01228-10 –...
9 SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...
SHOCK ABSORBER, SWINGARM 9 – Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click. Info Do not loosen fitting – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline E00864-10 Compression damping, low-speed Comfort 18 clicks...
9 SHOCK ABSORBER, SWINGARM Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090100) Pin for sag gauge (00029990010) –...
SHOCK ABSORBER, SWINGARM 9 Checking the riding sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 80) – With another person holding the motorcycle, the rider, wear- ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
9 SHOCK ABSORBER, SWINGARM Main work – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Holding wrench (90129051000) ( p. 371) – Measure the overall spring length while the spring is not under tension.
SHOCK ABSORBER, SWINGARM 9 – Check the riding sag of the shock absorber. ( p. 81) – Adjust the rebound damping of the shock absorber. ( p. 79) Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p.
9 SHOCK ABSORBER, SWINGARM – Remove the spring. ( p. 84) – Disassemble the damper. ( p. 85) – Disassemble the piston rod. ( p. 87) – Disassemble the seal ring retainer. ( p. 86) – Check the damper. ( p.
SHOCK ABSORBER, SWINGARM 9 – Remove the spring. – Remove washer B04463-10 9.13 Disassembling the damper Preparatory work – Remove the spring. ( p. 84) Main work – Make a note of present state of rebound and compression damping – Open the adjusters of the rebound and compression damping completely.
9 SHOCK ABSORBER, SWINGARM – Remove the piston rod. B04471-10 – Remove adjusting ring with the clamping ring. – Drain the oil. B04476-10 – Remove compression adjuster . Remove the washer, spring, and piston. B04477-10 9.14 Disassembling the seal ring retainer Preparatory work –...
SHOCK ABSORBER, SWINGARM 9 – Remove seal ring – Remove washer from seal ring B04493-10 – Remove washer – Remove O-ring – Remove dust boot B04494-10 9.15 Disassembling the piston rod Preparatory work – Remove the spring. ( p. 84) –...
9 SHOCK ABSORBER, SWINGARM – Remove nut – Remove washer B04481-10 – Remove rebound shim stack Info Guide the rebound shim stack onto a screwdriver and put them to one side together. – Remove piston B04482-10 – Remove compression shim stack Info Guide the compression shim stack onto a screwdriver and put them to one side together.
SHOCK ABSORBER, SWINGARM 9 Main work – Press pilot bushing out of seal ring retainer using the special tool. Pressing tool (T1504) ( p. 375) 200796-10 – Slide the new pilot bushing onto the special tool. Pressing tool (T1504) ( p.
9 SHOCK ABSORBER, SWINGARM – Measure the diameter of the piston rod. Piston rod ≥ 17.95 mm (≥ 0.7067 in) Diameter » If the measured value is smaller than the specified value: – Replace the piston rod. – Measure the run-out of the piston rod. Piston rod ≤...
SHOCK ABSORBER, SWINGARM 9 – Place special tool underneath and press out heim joint using special tool Pressing tool (T1207S) ( p. 373) B04457-10 9.19 Installing the heim joint – Position new heim joint and the special tool in the bench vise.
9 SHOCK ABSORBER, SWINGARM – Grease the O-ring groove. Lubricant (T158) ( p. 360) – Mount O-ring – Mount washer B04495-10 – Position washer on seal ring – Grease the seal ring and mount with the washer facing down- ward. Lubricant (T14034) ( p.
Page 95
SHOCK ABSORBER, SWINGARM 9 – Mount rebound washer – Mount compression shim stack with the smaller washers facing downward. B04486-10 – Clean piston – Mount the piston. Guideline of piston from above View of piston from below View B04487-10 – Mount rebound shim stack with the smaller washers facing upward.
9 SHOCK ABSORBER, SWINGARM – Position piston with the groove facing upward. – Mount and tighten nut Guideline Nut, piston rod M10x1 30 Nm (22.1 lbf ft) Loctite ® 2701™ B04491-10 9.22 Assembling the damper Preparatory work – Assemble the seal ring retainer. ( p.
Page 97
SHOCK ABSORBER, SWINGARM 9 – Fill the damper cartridge about half full. Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 359) – Lubricate O-ring of the seal ring retainer. Lubricant (T158) ( p. 360) – Mount the piston rod carefully. B04472-10 –...
9 SHOCK ABSORBER, SWINGARM – Turn counterclockwise by the number of clicks correspond- ing to the shock absorber type. Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Alternative 2 Warning Danger of accident Modifications to the suspen- sion setting may seriously alter the handling char- acteristic.
Page 99
SHOCK ABSORBER, SWINGARM 9 – Adjust the control lever as shown. Control lever External tank is set to Closed, Damper is set to Vacuum and Oil reservoir is set to Vacuum. – Activate On/Off switch The suction process begins. Pressure gauge drops to the required value.
Page 100
9 SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn control lever Oil reservoir to Vacuum. Guideline 0 bar The vacuum gauge drops to the required value. 8 mbar 200270-10 – When the vacuum gauge reaches the required value, turn con- trol lever Oil reservoir to Equalize Pressure.
SHOCK ABSORBER, SWINGARM 9 Info The floating piston must be positioned at exactly this point when the rod is fully extended; otherwise, damage will occur during compression of the shock absorber. – Remove the special tool. – Remove adapter from connector of the vacuum pump.
9 SHOCK ABSORBER, SWINGARM Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pres- sure. – Screw the filling port shut with tap handle – Close spigot and take the damper out of the special tool. –...
If the swingarm shows signs of damage, cracking, or defor- mation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 9.27 Checking the heim joint for play Preparatory work –...
9 SHOCK ABSORBER, SWINGARM Main work – Check the top and bottom heim joints. – Move the swingarm up and down. » If there is detectable play: – Change the heim joint. ( p. 102) H01897-01 Finishing work – Remove load from the front of the vehicle. –...
SHOCK ABSORBER, SWINGARM 9 – Position the new heim joint and the special tool. Guideline Use soft jaws. Pressing tool (T1206) ( p. 373) – Press the heim joint all the way in. B04459-11 – Press the heim joint against the lock ring using the special tool.
Page 106
9 SHOCK ABSORBER, SWINGARM – Remove spacers on both sides. R02815-10 – Mount special tool Pressing tool (79629000044) ( p. 371) – Press out the heim joint by screwing in the screw. R02816-10 – Position the new heim joint. – Mount special tool Pressing tool (79629000044) ( p.
SHOCK ABSORBER, SWINGARM 9 9.30 Checking the swingarm bearing for play Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) – Place a load on the front of the vehicle. The rear wheel is not in contact with the ground. Main work –...
9 SHOCK ABSORBER, SWINGARM – Push the brake caliper forward, slip it out, and hang it to the side. Info Cover the components to protect them against damage. R02832-10 – Remove connecting link of the chain. Info Cover the components to protect them against damage. –...
Page 109
SHOCK ABSORBER, SWINGARM 9 – Lift the swingarm and position the shock absorber. – Mount and tighten screw Guideline Screw, bottom 80 Nm (59 lbf ft) Loctite ® 2701™ shock absorber R02835-11 – Mount the chain. – Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.
9 SHOCK ABSORBER, SWINGARM 9.33 Changing the swingarm bearing Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) – Remove the rear wheel. ( p. 144) – Remove the swingarm. ( p. 105) Left swingarm bearing –...
Page 111
SHOCK ABSORBER, SWINGARM 9 – Mount bushing R02758-10 – Grease the shaft seal rings. Long-life grease ( p. 360) – Position the collar bushings with the shoulder facing inward. R02763-10 Right swingarm bearing – Remove collar bushings R02760-10 – Remove bushing R02761-10...
Page 112
9 SHOCK ABSORBER, SWINGARM – Remove shaft seal rings using a suitable tool. – Press out bearing using a suitable tool. – Using a suitable tool, press in new bearing – Press in shaft seal rings R02762-10 – Mount bushing R02761-10 –...
EXHAUST 10 10.1 Removing the manifold (All EXC models) – Remove the cable tie(s) and expose the cable. R02818-10 – Disconnect plug-in connector of the lambda sensor. – Expose the cable. R02819-10 – Remove springs Spring hook (5030501700004) ( p. 371) R02820-10 –...
10 EXHAUST – Loosen screw – Remove screw R02909-10 – Loosen screw – Remove screw – Take off the exhaust manifold toward the front. R02824-10 10.2 Installing the manifold (All EXC models) – Position the manifold and mount springs Spring hook (5030501700004) ( p.
EXHAUST 10 – Route the cable without tension and secure it with a cable tie. R02818-10 (All XC‑W models) – Position the manifold and mount springs Spring hook (5030501700004) ( p. 371) R02822-10 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
10 EXHAUST – Remove screws – Pull off the main silencer at the rubber sleeve and the spring ring from the manifold. E00878-10 10.4 Installing the main silencer – Mount the main silencer with the rubber sleeve and spring ring. –...
Page 117
EXHAUST 10 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. – Fit the new glass fiber yarn filling into the inner tube.
11 AIR FILTER 11.1 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw E00873-10 – Pull off the air filter box cover in area sideways and take off toward the front. E00873-12 11.2 Installing the air filter box cover –...
AIR FILTER 11 11.3 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Note Environmental hazard Hazardous substances cause environmental damage.
11 AIR FILTER 11.5 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.
AIR FILTER 11 11.7 Sealing the air filter box Preparatory work – Remove the air filter box cover. ( p. 116) Main work – Seal the air filter box in the marked area S00847-10 Finishing work – Install the air filter box cover. ( p.
12 FUEL TANK, SEAT, TRIM 12.1 Opening the filler cap 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. –...
FUEL TANK, SEAT, TRIM 12 12.3 Removing the seat – Remove screws M01517-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.4 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward.
12 FUEL TANK, SEAT, TRIM 12.5 Removing the fuel tank 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. –...
FUEL TANK, SEAT, TRIM 12 – Remove screws with the collar bushings. (All EXC models) – Hang the horn and horn bracket to one side. E00881-10 – Remove screw with the rubber bushing. E00882-10 – Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank.
Page 126
12 FUEL TANK, SEAT, TRIM Main work – Check throttle cable routing. ( p. 70) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged.
FUEL TANK, SEAT, TRIM 12 Finishing work – Mount the seat. ( p. 121) 12.7 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
12 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Page 129
FUEL TANK, SEAT, TRIM 12 Main work – Remove nut with the gasket. – Remove fuel connection with the gasket. R02841-10 – Remove screws R02842-10 – Pull out the fuel pump. – Remove hose clamps – Remove fuel filter R02843-10 –...
Page 130
12 FUEL TANK, SEAT, TRIM – Change fuel screen – Mount the fuel pump housing. 305318-10 – Mount fuel filter Arrow points away from the fuel pump. – Mount hose clamps Hose clamp plier (60029057000) ( p. 369) R00451-10 – Position the fuel pump.
FUEL TANK, SEAT, TRIM 12 – Grease O-ring slightly. Multi-purpose grease (00062010051) ( p. 361) Info Make sure that no grease gets into the fuel connection. – Mount fuel connection with the gasket but do not tighten yet. – Tighten nut Guideline Nut, fuel pump 15 Nm (11.1 lbf ft)
Page 132
12 FUEL TANK, SEAT, TRIM Preparatory work – Drain the fuel from the fuel tank into a suitable container. – Remove the seat. ( p. 121) – Remove the fuel tank. ( p. 122) Main work – Remove nut with the gasket. –...
Page 133
FUEL TANK, SEAT, TRIM 12 – Position the new fuel pump. – Mount nut with gasket, but do not tighten yet. R02844-10 – Mount and tighten screws Guideline Screw, fuel pump EJOT PT ® 2.3 Nm (1.7 lbf ft) R02842-10 –...
12 FUEL TANK, SEAT, TRIM 12.10 Checking the fuel pressure 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 135
FUEL TANK, SEAT, TRIM 12 Guideline Maximum duration of the 3 min actuator test – Check the fuel pressure with the filler cap closed. Fuel pressure When the fuel pump is 3.35 … 3.65 bar (48.6 … active 52.9 psi) »...
13 MASK, FENDER 13.1 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 135) Main work – Remove screws V00340-10 – Remove screws . Take off front fender. V00341-10 13.2 Installing front fender Main work –...
MASK, FENDER 13 13.3 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask. – Release rubber bands . Slide the headlight mask up and swing it forward. E00899-10 (All EXC models) –...
Page 138
13 MASK, FENDER – Position the headlight mask and fix it with rubber bands The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide. E00899-11 Finishing work – Check the headlight setting. ( p.
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.
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 wear.
WHEELS 14 14.4 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. – Check the front and rear brake disc thickness at multiple points for the dimension Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings.
14 WHEELS – Check for lateral and radial run-out of the rims. Lateral runout Outside the rim joint < 1.8 mm (< 0.071 in) Radial runout Outside the rim joint < 1.8 mm (< 0.071 in) » If the measured value is greater than the specified value: –...
WHEELS 14 14.7 Front wheel 14.7.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) 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...
14 WHEELS 14.7.2 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. –...
WHEELS 14 Main work (All standard EXC/XC-W models) – Remove screws . Remove the brake disc. – Clean the contact surface of the brake disc. – Position the new brake disc with the label facing outward. – Mount and tighten screws Guideline Screw, front 14 Nm (10.3 lbf ft)
14 WHEELS – Press out bearing using a suitable tool. – Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in. D00199-10 –...
WHEELS 14 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. –...
14 WHEELS Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. ( p. 147) – Clean and grease shaft seal rings and contact surface of the spacers.
WHEELS 14 Main work (All standard EXC/XC-W models) – Remove screws . Remove the brake disc. – Clean the contact surface of the brake disc. – Position the new brake disc with the label facing outward. – Mount and tighten screws Guideline Screw, rear 14 Nm (10.3 lbf ft)
Page 150
14 WHEELS – Using a suitable tool, press bearing out from the inside to the outside. – Remove spacing tube D00212-10 – Using a suitable tool, press bearing out from the inside to the outside. – Check spacer washer for damage and wear. »...
WHEELS 14 – Mount lock ring The lock ring engages audibly. – Grease new shaft seal ring and press it in until it is flush. D00210-10 Finishing work – Install the rear wheel. ( p. 145) – Remove the motorcycle from the lift stand. ( p.
14 WHEELS Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 360) – After drying, apply chain spray. Off-road chain spray ( p. 361) 400725-01 Finishing work –...
WHEELS 14 14.8.8 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 12) Main work – Shift the transmission to idle. – Check the chain, rear sprocket and engine sprocket for wear. »...
Page 154
14 WHEELS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
WHEELS 14 – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Remaining screws, 10 Nm chassis (7.4 lbf ft) E00333-01 Finishing work – Remove the motorcycle from the lift stand. ( p.
14 WHEELS Info The wide adjustment range of the chain adjusters (32 mm (1.18 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180°. Finishing work – Remove the motorcycle from the lift stand. ( p.
Page 157
WHEELS 14 – Remove engine sprocket R02829-10 (All standard EXC/XC-W models) – Remove fittings . Take off the rear sprocket. – Position the new rear sprocket. Mount and tighten the fit- tings. Guideline Nut, rear 35 Nm (25.8 lbf ft) Loctite 2701™...
Page 158
14 WHEELS – Have an assistant operate the rear brake. – Mount and tighten screw with the washer. Guideline Screw, drive 60 Nm (44.3 lbf ft) Loctite ® 2701™ chain engine sprocket R02826-10 – Position the engine sprocket cover. – Mount and tighten screw Guideline Remaining screws,...
WIRING HARNESS, BATTERY 15 15.1 Ignition curve plug-in connector Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Info The ignition timing map connector has no function in the homologated (restricted) condition of the motorcycle. Possible states Soft –...
Page 160
15 WIRING HARNESS, BATTERY – Pull starter relay from the holder. E00897-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...
WIRING HARNESS, BATTERY 15 15.3 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work (All EXC models) – Press and hold the kill switch while the engine is idling until the engine stops.
15 WIRING HARNESS, BATTERY Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert spare fuse with the correct rating only. Fuse (75011088010) ( p.
WIRING HARNESS, BATTERY 15 15.5 Connecting the negative cable of the battery Main work – Connect negative cable of the battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) R01414-10 Finishing work – Mount the seat. ( p. 121) 15.6 Removing the battery Note...
15 WIRING HARNESS, BATTERY Main work Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batter- ies. – Only charge batteries in well-ventilated rooms. –...
WIRING HARNESS, BATTERY 15 Contact disks must be mounted under the screw the cable lug with the claws toward the battery terminal. Finishing work – Mount the seat. ( p. 121) 15.8 Recharging the battery Warning Risk of injury Batteries contain harmful substances. –...
15 WIRING HARNESS, BATTERY Main work – Connect the battery charger to the battery. Adjust the battery charger. EU battery charger XCharge-professional (00029095050) p. 362) Alternative 1 US battery charger XCharge-professional (00029095051) ( p. 363) 311910-10 Alternative 2 UK battery charger XCharge-professional (00029095052) ( p.
WIRING HARNESS, BATTERY 15 15.10 Checking the open-circuit current Preparatory work (All EXC models) – Press and hold the kill switch while the engine is idling until the engine stops. (All XC‑W models) – Press and hold the kill switch while the engine is idling until the engine stops.
15 WIRING HARNESS, BATTERY – Connect the starter relay to a 12 V power supply as per the figure. – Measure the resistance between the specified points. 0 Ω Resistance of open circuit » If the value displayed does not meet specifications: –...
BRAKE SYSTEM 16 16.1 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. – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness »...
Page 170
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.
BRAKE SYSTEM 16 – Insert the new brake linings, insert the pin, and mount the cot- ter pins. Info Always change the brake linings in pairs. – Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.
16 BRAKE SYSTEM 16.4 Adjusting free travel of hand brake lever (All EXC models) – Check the free travel of the hand brake lever. ( p. 169) – Adjust the free travel of the hand brake lever with the adjust- ment screw Info Turn the adjusting screw clockwise to reduce free...
BRAKE SYSTEM 16 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in level viewer » If an air bubble is visible in upper range of the level viewer –...
16 BRAKE SYSTEM Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane – Add brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 (...
Page 175
BRAKE SYSTEM 16 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Cover painted parts. – Remove screws – Take off cover with the membrane. – Extract the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
16 BRAKE SYSTEM – Add brake fluid up to level Guideline 5 mm (0.2 in) Dimension Brake fluid DOT 4 / DOT 5.1 ( p. 358) – Position the cover with the membrane. Mount and tighten the screws. Info 309386-10 Clean up overflowed or spilled brake fluid immediately with water.
Page 177
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.
16 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. E00352-10 – Insert the new brake linings, insert the pin, and mount the cot- ter pins. Info Always change the brake linings in pairs.
BRAKE SYSTEM 16 16.12 Adjusting the basic position of the 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.
16 BRAKE SYSTEM 16.13 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
BRAKE SYSTEM 16 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Page 182
16 BRAKE SYSTEM – Cover painted parts. – Remove screw cap with the membrane and the O-ring. – Extract the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) ( p.
Page 183
BRAKE SYSTEM 16 – Stand the vehicle upright. – Correct the brake fluid to marking Brake fluid DOT 4 / DOT 5.1 ( p. 358) – Mount and tighten the screw cap with the membrane and O- ring. Info Clean up overflowed or spilled brake fluid immediately R02784-10 with water.
17 LIGHTING SYSTEM, INSTRUMENTS 17.1 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. – Clean and degrease the bulbs before mounting. –...
LIGHTING SYSTEM, INSTRUMENTS 17 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. –...
17 LIGHTING SYSTEM, INSTRUMENTS 17.4 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 183) 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).
LIGHTING SYSTEM, INSTRUMENTS 17 Finishing work – Install the headlight mask with the headlight. ( p. 135) – Check the headlight setting. ( p. 183) – Set kilometers or miles. ( p. 185) – Adjust the combination instrument function. ( p.
17 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.
LIGHTING SYSTEM, INSTRUMENTS 17 17.10 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. –...
17 LIGHTING SYSTEM, INSTRUMENTS – Sever black/brown cable – Insulate both cable ends. D00067-10 Finishing work – Install the headlight mask with the headlight. ( p. 135) – Check the headlight setting. ( p. 183) 17.12 Setting the wheel circumference Condition The motorcycle is stationary.
Page 191
LIGHTING SYSTEM, INSTRUMENTS 17 – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1 - 10 can be viewed with the button –...
18 ENGINE 18.1 Cleaning the pressure sensor hose – Push back hose clamps – Pull off pressure sensor hose R02847-10 – Clean hose thoroughly and blow out with compressed air. R02849-10 – Mount pressure sensor hose – Position hose clamps R02847-10 18.2 Removing the engine...
Page 193
ENGINE 18 Main work – Remove screws with the washers. – Take off the main silencer. R02858-10 – Remove screws with the washers. – Remove the cable ties. – Take off the frame protector. R02859-10 – Remove screws with the washers. –...
Page 194
18 ENGINE – Raise the subframe slightly and secure. Info Pay attention to the oil pump hose. R02863-10 – Remove screw – Remove screw – Take off the engine sprocket cover. R02864-10 – Remove screws – Take off the slave cylinder of the clutch and hang it to one side.
Page 195
ENGINE 18 – Remove engine sprocket R02868-10 – Disconnect spark plug connector R02869-10 – Push back protection cap – Disconnect engine coolant temperature sensor connector. R02870-10 – Push back protection caps – Disconnect connector. R02871-10 – Pull off air release hose R02872-10...
Page 196
18 ENGINE – Remove the cable tie. R02873-10 – Disconnect plug-in connector – Disconnect plug-in connector – Expose the cable. R02874-10 – Push back hose clamp – Pull off pressure sensor hose. R02875-10 – Loosen hose clip – Pull off the radiator hose. R02876-10 –...
Page 197
ENGINE 18 – Disconnect oil pump connector R02878-10 – Remove the cable tie. R02891-10 – Push back protection cap and remove the nut. – Hang the positive cable to the side. R02879-10 – Remove spring R02880-10 – Remove fitting – Slip the foot brake lever out toward the rear.
18 ENGINE – Remove screws – Take off the engine braces. R02882-10 – Remove nut – Remove the swingarm pivot. – Carefully pull the swingarm back, and secure the swingarm. R02881-10 – Remove screws R02883-10 – Lift out the engine sideways to the right. Info Pay attention to the oil pump.
Page 199
ENGINE 18 – Mount screws but do not tighten yet. Guideline Engine bracket screw 60 Nm (44.3 lbf ft) R02883-11 – Position the swingarm. – Mount the swingarm pivot. – Mount nut , but do not tighten it yet. Guideline Nut, swingarm pivot M16x1.5 100 Nm...
Page 200
18 ENGINE – Position the positive cable on the starter motor. – Mount and tighten the nut. Guideline Remaining nuts, 10 Nm (7.4 lbf ft) chassis – Position protection cap R02879-11 – Mount the cable tie. R02891-10 – Plug in oil pump connector R02878-11 –...
Page 201
ENGINE 18 – Position pressure sensor hose. – Position hose clamp R02875-11 – Join plug-in connectors R02874-11 – Route the cable without tension and secure with cable tie(s). R02873-10 – Mount vent hose R02872-11 – Plug in the connectors. – Position protection caps R02871-10...
Page 202
18 ENGINE – Plug in the connector of the engine coolant temperature sen- sor. – Position protection cap R02870-11 – Plug in spark plug connector R02869-11 – Slide engine sprocket onto the countershaft. R02868-11 – Mount the chain. – Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.
Page 203
ENGINE 18 – Position the clutch slave cylinder with the gasket. – Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder R02865-11 – Position the engine sprocket cover. – Mount and tighten screw Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder –...
Page 204
18 ENGINE – Position the frame protector. – Mount and tighten screws with the washers. Guideline Screw, frame protec- 3 Nm (2.2 lbf ft) – Mount the cable ties. – Install the manifold. ( p. 112) R02859-11 – Mount the main silencer with rubber sleeve –...
ENGINE 18 18.4 Engine disassembly 18.4.1 Clamping the engine into the engine work stand – Mount special tool on engine work stand Engine work stand (61229001000) ( p. 370) Holder and fitting for work stand (55429002000) p. 365) – Mount the engine on special tool D04395-10 18.4.2 Removing the shift lever...
18 ENGINE 18.4.5 Removing the spacer – Remove spacer D04399-10 – Take off O-ring D04400-10 18.4.6 Removing the alternator cover – Remove screws . Take off the alternator cover. D04401-10 – Remove the dowels and alternator cover gasket D04402-10...
ENGINE 18 18.4.7 Removing the kick starter – Remove screw with the washer. – Take off the kick starter. D04403-10 18.4.8 Removing injection valves – Remove screws with insulating washers – Take off injection valves on both sides. D04404-10 18.4.9 Removing the cylinder head –...
18 ENGINE – Loosen screws in a crisscross pattern and remove them. – Remove the cylinder head. D04407-10 (All 250 models) – Remove O-rings D04408-10 (All 300 models) – Remove O-rings D04409-10 18.4.10 Removing the cylinder (All 250 models) – Remove screws –...
Page 209
ENGINE 18 – Remove nuts Info Raise the cylinder slightly to be able to remove the front nuts. – Carefully slide the cylinder up and take it off. D04416-10 – Take off gasket D04417-10 (All 300 models) – Remove screws –...
18 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. D04423-10 – Take off gasket D04425-10 18.4.11 Removing the piston (All 250 models) –...
ENGINE 18 – Remove upper conrod bearing D04432-10 18.4.12 Removing the water pump cover – Remove screws – Take off the water pump cover. – Remove the form ring. D04437-10 – Remove dowels R04638-10 18.4.13 Removing the clutch cover – Remove screws –...
18 ENGINE – Remove screws R04641-10 – Take off the clutch cover at the top and slip out the linkage. Info Ensure that the kick starter shaft remains in the engine case. R04642-10 – Remove dowels and clutch cover gasket D04444-10 –...
ENGINE 18 – Take off spring washer D04448-10 – Take off pretension ring D04450-10 – Take off pressure cap D04451-10 – Remove clutch disc pack completely. – Remove clutch throw-out D04452-10 18.4.15 Removing the clutch basket – Hold the primary gear using special tool Gear segment (56012004000) ( p.
18 ENGINE – Bend up the lock washer. – Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) ( p. 364) – Remove the nut with the lock washer. D04455-10 – Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub.
18 ENGINE 18.4.19 Removing the shift shaft – Push sliding plate away from shift drum locating unit Remove shift shaft with washer. D04469-10 18.4.20 Removing the shift drum locating unit – Remove screw – Push locking lever away from shift drum locating unit and take off the shift drum locating unit.
ENGINE 18 – Mount special tool , apply counterpressure, and pull off the rotor by screwing in the screw. Puller (58012009000) ( p. 367) D04475-10 – Remove screws – Take off the crankshaft position sensor. D04476-10 – Take off Bendix D04477-10 18.4.23 Removing the starter motor –...
18 ENGINE – Remove screw – Remove spacer using the special tool. Footrest spring plier (58429083000) ( p. 367) D04480-10 – Remove the starter motor. D04482-10 – Remove O-ring D04484-10 18.4.24 Removing the reed valve housing – Remove screws – Take off intake flange and gasket.
ENGINE 18 18.4.25 Removing the left engine case section – Remove screws – Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm. – Loosen the left section of the engine case by striking it lightly with a plastic hammer and remove it.
18 ENGINE 18.4.28 Removing the shift forks – Remove shift forks Info Do not misplace the shift rollers. D04493-10 18.4.29 Removing the transmission shafts – Remove lock ring D04494-10 – Pull both transmission shafts out of the bearing seats together. Info The stop disks of the transmission shafts usually stick to the bearings.
ENGINE 18 – Remove O-ring B04429-10 – Remove distance sleeve D04497-10 18.5 Working on individual parts 18.5.1 Working on the right section of the engine case – Remove all dowels. – Remove shaft seal ring of the crankshaft. – Remove lock ring –...
18 ENGINE Info When pressing the bearings in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in. – After the engine case section has cooled, check that the bear- ings are firmly seated.
Page 223
ENGINE 18 – Remove lock ring – Clean the engine case section thoroughly. – Warm the engine case section in an oven. Guideline 180 °C (356 °F) – Knock the engine case section against a level wooden board. This will cause the bearings to drop out of the bearing seats. B04433-10 Info Any bearings that remain in the engine case section...
18 ENGINE – Press in shaft seal ring of the shift shaft so it is flush, with the open side facing inward. – Press in shaft seal ring of the countershaft so it is flush with the open side facing in. –...
ENGINE 18 18.5.5 Changing the connecting rod, conrod bearing, and crank pin Main work – Position crankshaft in the press using special tool Separator plate (54829009000) ( p. 365) – Press the crank pin out of the upper crankweb with a suitable tool.
18 ENGINE – Position special tool with the heel pointing down. Crankshaft pressing tool insert (54829108000) ( p. 365) – Press in the upper crankweb as far as possible. Info The press mandrel must be positioned over the crank pin. –...
ENGINE 18 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 …...
Page 228
18 ENGINE – Take off gear segment D04504-10 – Remove screws – Take off the retaining bracket. D04505-10 – Remove control shaft D04506-10 – Remove screw – Remove screw with washer. – Take off the stop plate. D04507-10 – Take off gear segment D04508-10...
ENGINE 18 – Remove screws – Take off the retaining bracket. D04509-10 – Remove control shaft D04510-10 – Remove screws – Take off the exhaust flange. D04511-10 – Remove O-rings – Take off the control flap. D04512-10 18.5.10 Checking the exhaust control Condition The exhaust control and centrifugal timer are removed.
Page 230
18 ENGINE D04523-10 – Check control shafts for damage and wear. » If there is damage or wear: – Change the control shaft. – Check gear segments for damage and wear. » If there is damage or wear: – Change the gear segments. –...
ENGINE 18 R04649-10 – Check pins of the control lever for damage and wear. » If there is damage or wear: – Change the control lever. – Check ball head on the linkage for damage and wear. » If there is damage or wear: –...
Page 232
18 ENGINE – Mount the control shafts. The control shaft with marking Lis installed on the left. D04515-10 – Mount the retaining brackets. – Mount and tighten screws Guideline Screw, retain- 7 Nm (5.2 lbf ft) Loctite ® 2701™ ing bracket of exhaust control D04516-10 –...
Page 233
ENGINE 18 – Degrease the sealing surface and coat thinly with sealant. Loctite 5910 ® – Position the exhaust flange. – Mount and tighten screws Guideline Screw, exhaust 8 Nm (5.9 lbf ft) flange D04511-11 Info Do not forget the spring hangers. –...
18 ENGINE – Position the stop plate. – Mount screw but do not tighten yet. – Mount screw with the washer but do not tighten yet. Info The screws are tightened when the Z dimension is adjusted. D04507-11 18.5.12 Cylinder - Nikasil ® coating Nikasil ®...
ENGINE 18 – Measure the piston at the piston skirt, at right angles to the piston pin, at a distance Guideline 50 mm (1.97 in) Distance Piston - diameter (All 250 models) Size I 66.340 … 66.350 mm (2.61181 … 2.6122 in) Size II 66.351 …...
ENGINE 18 – Take off the inner reed valve from both reed valve holders. G01319-10 18.5.17 Checking the reed valve housing, reed valve and intake flange Condition Reed valve housing has been removed. – Check intake flange for damage and wear. »...
Page 238
18 ENGINE – Position holding strip The pins engage in the drilled holes. G01322-10 – Position the reed valve holders. G01323-10 – Mount screws and screw in all the way. Info Mount the screws at right angles to prevent damage. –...
ENGINE 18 – Position the clamping plates on both sides. After installation, the TOP marking must be visible as shown. – Mount screws on both sides and screw in all the way. – Loosen screws and tighten again. Guideline Screw, outer mem- EJOTDELTA PT ®...
Page 240
18 ENGINE – Remove form washer R04633-10 – Remove centrifugal timer 312187-10 – Remove shaft seal ring 312188-10 – Press out bearing toward the inside. 312189-10 – Remove shaft seal ring – Press in the new shaft seal ring all the way to the stop. 312190-10...
Page 241
ENGINE 18 – Press bearing all the way in to the stop from the inside. 312191-10 – Press shaft seal ring so it is flush. – Ensure that the bearing can turn freely and does not touch the shaft seal ring. 312188-10 –...
18 ENGINE 18.5.20 Checking the clutch 304690-10 – Check clutch push rod for damage and wear. » If there is damage or wear: – Change the clutch push rod. – Place clutch push rod on a flat surface and check for run-out. »...
ENGINE 18 » If there is damage or wear: – Change the clutch facing discs and the clutch basket. – Check needle bearing and collar sleeve for damage and wear. » If there is damage or wear: – Change the needle bearing and collar sleeve. –...
18 ENGINE 18.5.22 Checking the shift mechanism B04450-10 – Check shift forks on plate for damage and wear (visual check). » If there is damage or wear: – Change the shift fork. – Check shift grooves of shift drum for wear. »...
ENGINE 18 » If the guide pin is loose and/or worn: – Change the sliding plate. – Preassemble the shift shaft. ( p. 241) – Check clearance between the sliding plate and the shift quadrant. Shift shaft - sliding 0.40 … 0.80 mm (0.0157 plate/shift quadrant play …...
18 ENGINE 18.5.24 Disassembling the countershaft B04446-10 – Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk –...
Page 247
ENGINE 18 B04444-10 – Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearings. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...
18 ENGINE – Use new lock rings with every repair. 18.5.26 Assembling the main shaft Info Use new lock rings with every repair. Preparatory work – Check the transmission. ( p. 244) – Carefully lubricate all parts before assembling. B04445-11 Main work –...
Page 249
ENGINE 18 Preparatory work – Check the transmission. ( p. 244) – Carefully lubricate all parts before assembling. B04446-11 Main work – Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. – Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar fac-...
18 ENGINE 18.5.28 Checking the kick starter 311436-10 – Check the gear teeth and bearing of kick starter gear for damage and wear. » If there is damage or wear: – Change the kick starter gear. – Check the gear teeth and bearing of intermediate kick starter gear for damage and wear.
ENGINE 18 – Mount kick starter gear with washer 312202-10 – Mount lock ring 312203-10 – Mount kick starter spring The end of the kick starter spring engages in the hole. 312204-10 – Mount kick starter ratchet wheel Align markings 312205-10 –...
18 ENGINE D04546-10 – Check the gear teeth of rotor for damage and wear. » If there is damage or wear: – Change the rotor. – Check the gear teeth and bearing of the Bendix for smooth operation, damage, and wear. »...
ENGINE 18 – Position the right section of the engine case in the engine work stand. Engine work stand (61229001000) ( p. 370) Holder and fitting for work stand (55429002000) p. 365) – Warm up the crankshaft bearing. Guideline 100 °C (212 °F) D04496-11 –...
18 ENGINE – Position shift forks , and in the sliding gears. D04493-11 18.6.4 Installing the shift drum – Push shift drum into the bearing seat. – Position shift forks in the shift grooves. Info Do not misplace the shift rollers. D04492-11 18.6.5 Installing the shift rails...
ENGINE 18 – 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. Guideline D04488-11 Screw, engine case...
18 ENGINE 18.6.8 Installing the starter motor – Grease and mount O-ring Long-life grease ( p. 360) D04484-11 – Grease O-ring Long-life grease ( p. 360) – Position the starter motor in the engine case. D04483-10 – Mount screws but do not tighten yet. Guideline Screw, starter motor 10 Nm (7.4 lbf ft)
ENGINE 18 – Position cover – Mount and tighten screw Guideline Screw, starter motor 8 Nm (5.9 lbf ft) protection cap D04478-11 18.6.9 Installing the rotor – Grease and mount Bendix Lubricant (T625) ( p. 360) D04477-11 – Position the crankshaft position sensor. –...
18 ENGINE 18.6.11 Installing the shift drum locating unit – Press locking lever to the left and position the shift drum locating unit. Info The flat surfaces of the shift drum locating unit are not symmetric. – Relieve tension from the locking lever. D04473-10 –...
ENGINE 18 Main work – Mount preassembled kick starter shaft D04467-10 – Tension and attach kick starter spring Info Ensure that the distance from the kick starter spring to the kick starter shaft is the same all around. D04466-11 18.6.15 Installing the balancer shaft –...
18 ENGINE – Mount primary gear Align markings D04462-10 – Hold the primary gear using special tool Gear segment (56012004000) ( p. 366) – Mount and tighten screw with the washer. Guideline Screw, balancer 30 Nm (22.1 lbf ft) Loctite ®...
ENGINE 18 – Slide on washer and inner clutch hub D04456-11 – Position the new lock washer and mount nut . Tighten the nut, holding the inner clutch hub with a special tool. Guideline Nut, inner M18x1.5 100 Nm (73.8 lbf ft) Loctite ®...
Page 262
18 ENGINE – Mount clutch throw-out D04452-11 – Position pressure cap D04451-11 – Mount pretension ring with marking Top facing up. D04450-11 – Position spring washer D04448-11 – Position spring retainer with marking I. D04449-10...
ENGINE 18 – Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) retainer D04446-11 – Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) ( p.
Page 264
18 ENGINE – Mount dowels – Mount clutch cover gasket D04444-11 – Position the clutch cover and thread in the linkage. R04642-11 – Mount screws but do not tighten yet. Guideline Screw, intermediate M6x25 10 Nm (7.4 lbf ft) clutch cover –...
ENGINE 18 – Mount adjusting spring with the auxiliary spring and spring insert. The recess in the spring insert engages in angle lever R04643-10 – Position the cap. – Mount and tighten screws Guideline Screw, exhaust con- 5 Nm (3.7 lbf ft) trol cap R04639-11 18.6.19 Installing the water pump cover...
18 ENGINE 18.6.20 Installing the piston (All 250 models) – Oil the upper conrod bearing and position it in the con- necting rod. – Position the piston. Piston marking must face the exhaust side. D04433-10 – Cover the engine case opening with a cloth. –...
ENGINE 18 18.6.21 Installing the cylinder (All 250 models) – Place the new cylinder base gasket into position. Info If neither the piston, cylinder, crankshaft, or engine case need to be changed, the same gasket thick- ness can be used as before. –...
Page 268
18 ENGINE (All 300 models) – Place new cylinder base gasket in position. Info If neither the piston, cylinder, crankshaft, or engine case need to be changed, the same gasket thick- ness can be used as before. – Oil the cylinder and piston. D04425-11 –...
ENGINE 18 18.6.22 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. The X-distance must be checked very carefully. If the X-distance is too large, the compression decreases and the engine loses power.
Page 270
18 ENGINE Main work (All 250 models) – Remove nuts – Carefully slide the cylinder up and take it off. D04416-11 – Replace cylinder base gasket with a cylinder base gas- ket of the required X-distance. Info Multiple cylinder base gaskets can be combined. D04417-11 (All 300 models) –...
ENGINE 18 – Replace cylinder base gasket with a cylinder base gas- ket of the required X-distance. Info Multiple cylinder base gaskets can be combined. D04425-12 Finishing work – Install the cylinder. ( p. 265) 18.6.24 Adjusting the Z-distance Info The Z-distance is the distance from the lower edge of the control flap to the upper edge of the cylinder, measured in the middle of the exhaust port.
Page 272
18 ENGINE Guideline Z distance (height of control 49.0 mm (1.929 in) flap) (All 250 models) Z distance (height of control 49.5 mm (1.949 in) flap) (All 300 models) – Mount gasket – Push the control flap down all the way to the stop. –...
ENGINE 18 18.6.25 Installing the cylinder head (All 250 models) – Mount O-rings Info Ensure that the pins are seated correctly. D04408-11 (All 300 models) – Mount O-rings Info Ensure that the pins are seated correctly. D04409-11 – Put the cylinder head in place. –...
18 ENGINE 18.6.31 Installing the clutch push rod – Mount clutch push rod D04397-10 18.6.32 Installing the shift lever – Position the shift lever. Mount and tighten screw with the washers. Guideline Screw, shift 14 Nm (10.3 lbf ft) Loctite ®...
CLUTCH 19 19.1 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...
19 CLUTCH 19.2 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...
CLUTCH 19 – Now press the fluid into the system until it emerges from the hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. – Remove the bleeding syringe. Tighten the bleeder screw. Mount protection cap.
Page 280
19 CLUTCH – Detach spring R02787-10 – Remove screws – Take off the clutch cover with the gasket. R02788-10 – Loosen screws in a crisscross pattern and remove them. – Take off spring retainer R02789-10 – Take off spring washer R02792-10 –...
Page 281
CLUTCH 19 – Take off pressure cap R02794-10 – Take off clutch throw-out with clutch push rod R02795-10 – Remove sleeves R02796-10 – Remove clutch discs completely. R02797-10 – Bend up the lock washer. – Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) ( p.
Page 282
19 CLUTCH – Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub. – Take off clutch basket R02800-10 – Take off needle bearing and collar bushing Info The needle bearing and collar sleeve may be in the clutch basket.
Page 283
CLUTCH 19 » If there is damage or wear: – Change the spring washer. – Check the contact surface of pressure cap for damage and wear. » If there is damage or wear: – Change the pressure cap. – Check clutch center for damage and wear.
Page 284
19 CLUTCH – Mount clutch basket Turn the clutch basket until the gear teeth of the interme- diate kick starter gear mesh. – Mount washer and inner clutch hub R02800-10 – Position the new lock washer and mount nut . Tighten the nut, holding the inner clutch hub with a special tool.
Page 285
CLUTCH 19 – Mount clutch throw-out with clutch push rod R02795-10 – Position pressure cap R02794-10 – Mount pretension ring with marking Top facing up. R02793-10 – Position spring washer R02792-10 – Position spring retainer with marking I. – Mount screws and tighten in a crisscross pattern.
Page 286
19 CLUTCH – Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) ( p. 369) Spring washer distortion 0 … 0.10 mm (0 … 0.0039 in) » If the specified value is not reached: –...
Page 287
CLUTCH 19 – Place vehicle in upright position and lean on the side stand. R02785-10 Finishing work – Check the gear oil level. ( p. 295)
20 WATER PUMP, COOLING SYSTEM 20.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
WATER PUMP, COOLING SYSTEM 20 20.3 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.
20 WATER PUMP, 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. –...
Page 291
WATER PUMP, COOLING SYSTEM 20 – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 358) 400243-10 – Push protection cap upward over the thermostat. E00904-10 –...
Page 292
20 WATER PUMP, COOLING SYSTEM Finishing work – Check the coolant level. ( p. 287)
EXHAUST CONTROL 21 21.1 Checking/adjusting the exhaust control Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.
Page 294
21 EXHAUST CONTROL – Execute "Engine electronics" > "Actuator test" > "Exhaust con- trol". – Start the motorcycle to check the function. ( p. 13) Info Let the engine warm up. – Bring the throttle grip into the full load position. –...
Page 295
EXHAUST CONTROL 21 – Position the cover with the gasket. – Mount and tighten screws Guideline Screw, exhaust 4 Nm (3 lbf ft) Loctite ® 222™ control cover T02623-10 Finishing work – Remove the motorcycle from the lift stand. ( p.
22 LUBRICATION SYSTEM 22.1 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. – In the event of scalding, rinse the area affected immediately with lukewarm water. Note Environmental hazard Hazardous substances cause environmental damage.
LUBRICATION SYSTEM 22 (All Six Days models) – Install the engine guard. ( p. 74) 22.2 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 –...
22 LUBRICATION SYSTEM – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil monitoring screw. Engine oil (15W/50) ( p. 358) – Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level 10 Nm (7.4 lbf ft)
LUBRICATION SYSTEM 22 22.5 Opening 2-stroke oil tank cap – Fold loop upward. – Turn the 2-stroke oil tank cap counterclockwise and pull it up. E00861-10 22.6 Adding 2-stroke oil Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
22 LUBRICATION SYSTEM 22.8 Priming the oil pump Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
LUBRICATION SYSTEM 22 – Plug in wake-up connector for priming the oil pump to the diagnostics connector The combination instrument lighting is activated. Info The connector is included as part of the motorcycle's separate enclosure. – Wait for at least five seconds. –...
Page 302
22 LUBRICATION SYSTEM – Push back hose clamp – Pull off the tube from the throttle valve body. Info Residual oil may escape from the tube. R02854-10 – Push back hose clamp R02855-10 – Remove screw – Pull off the hose from the oil tank. Info Residual oil may escape from the oil tank.
Page 303
LUBRICATION SYSTEM 22 – Plug in connector R02850-10 Finishing work – Check 2-stroke oil level. ( p. 296) – Prime the oil pump. ( p. 298) – Mount the seat. ( p. 121)
23 IGNITION SYSTEM 23.1 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 immediately after measuring. –...
IGNITION SYSTEM 23 23.2 Ignition coil - checking the primary winding 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 immediately after measuring.
23 IGNITION SYSTEM 23.3 Checking the spark plug connector Condition Spark plug connector cylinder 1 has been removed. – Measure the resistance between the specified points. Measuring point 1 – Measuring point 2 Spark plug connector Resistance at: 20 °C 4.3 …...
IGNITION SYSTEM 23 601211-10 H01812-10 Stator winding - checking the short circuit to ground (terminal 31). – Measure the resistance between the specified points. Stator, connector EZ pin 1 – Measuring point Ground (−) ∞ Ω Resistance » If the indicated value does not correspond to the setpoint value: –...
23 IGNITION SYSTEM Info When using the peak voltage adapter, adjust the measuring range of the multimeter to DCV. – Start the motorcycle to check the function. ( p. 13) Check the crankshaft position sensor voltage. – Measure the voltage between the specified points. Crankshaft position sensor, connector AT pin 1 –...
IGNITION SYSTEM 23 23.7 Changing the spark plug and spark plug connector – Disconnect spark plug connector R02807-10 – Remove spark plug using a suitable tool. – Mount and tighten the new spark plug using a suitable tool. Guideline Spark plug M14x1.25 25 Nm (18.4 lbf ft) R02808-10...
23 IGNITION SYSTEM – Remove screws – Remove retaining bracket – Remove cable sleeve from the alternator cover. – Remove the stator from the alternator cover. R02907-10 23.9 Installing the stator – Position the stator in the alternator cover. – Position cable sleeve in the alternator cover.
ELECTRIC STARTER 24 24.1 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. »...
25 THROTTLE VALVE BODY 25.1 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. – Run the engine until warm. The cold start button is deactivated –...
THROTTLE VALVE BODY 25 – Start the vehicle at the new height above sea level and switch off the engine again. – Wait for at least five seconds. – Start the vehicle again and check the response of the vehicle. »...
26 TECHNICAL DATA 26.1 Engine 26.1.1 All 250 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Idle speed 1,400 …...
26 TECHNICAL DATA New condition 0.050 … 0.085 mm (0.00197 … 0.00335 in) Wear limit 0.10 mm (0.0039 in) Piston ring - end gap ≤ 0.40 mm (≤ 0.0157 in) Ring 1 ≤ 0.40 mm (≤ 0.0157 in) Ring 2 ≤...
26 TECHNICAL DATA 26.4.4 Fuel Total fuel tank capacity, approx. 9 l (2.4 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 359) Fuel reserve, approx. 1.5 l (1.6 qt.) 26.5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork (All standard EXC/XC-W models) WP SuspensionXplor 48...
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 26.8 Fork 26.8.1 All standard EXC/XC-W models Fork article number 14.18.8S.63...
26 TECHNICAL DATA Sport 12 clicks Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85 …...
TECHNICAL DATA 26 Sport 1 turn Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 57 … 63 N/mm (325 … 360 lb/in) Weight of rider: 75 …...
27 CLEANING, CARE 27.1 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. –...
CLEANING, CARE 27 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 361) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
– 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. 12) – Cover the vehicle with a tarp or similar cover that is permeable...
STORAGE 28 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.
Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ○ ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval 29.3...
Page 330
29 SERVICE SCHEDULE Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours Once after 10 operating hours ● ● Perform major engine service including removing and installing engine.
Page 335
WIRING DIAGRAM 30 Components: EFI control unit Fuse Fuse Alternator Light relay Power relay Voltage regulator X285 Radiator fan connector X295 Diagnostics connector...
Page 339
WIRING DIAGRAM 30 Components: Front brake light switch Rear brake light switch Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...
30 WIRING DIAGRAM 30.8 Page 8 of 8 (All EXC models) pu-bl pu-bl pu-bl bl-ye ye-bu ye-wh sig 1 ye-or sig 2 pu-bl ye-gn pu-bl T00489-10...
Page 347
WIRING DIAGRAM 30 Components: EFI control unit Intake air temperature sensor Engine coolant temperature sensor Rollover sensor Crankshaft speed sensor Throttle valve position sensor Crankcase pressure sensor Map‑Select switch (optional) Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White...
Page 351
WIRING DIAGRAM 30 Components: EFI control unit Fuse Fuse Alternator Light relay Power relay Voltage regulator X285 Radiator fan connector X295 Diagnostics connector...
30 WIRING DIAGRAM 30.14 Page 6 of 6 (All XC‑W models) pu-bl pu-bl pu-bl bl-ye ye-bu ye-wh sig 1 ye-or sig 2 pu-bl ye-gn pu-bl T00495-10...
Page 359
WIRING DIAGRAM 30 Components: EFI control unit Intake air temperature sensor Engine coolant temperature sensor Rollover sensor Crankshaft speed sensor Throttle valve position sensor Crankcase pressure sensor Map‑Select switch (optional) Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White...
31 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 361
SUBSTANCES 31 Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 377) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
33 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 H00518-01 EU battery charger XCharge-professional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16 A Power cable length 5 m (16 ft) approx.
Page 365
SPECIAL TOOLS 33 US battery charger XCharge-professional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable length 5 m (16 ft) H01065-01 approx. UK battery charger XCharge-professional Art.
Page 376
33 SPECIAL TOOLS Clamping stand Art. no.: T14016S Feature Diameter 12 mm (0.47 in) H01036-01 Ring wrench Art. no.: T14017 Feature Hexagonal part 50 mm (1.97 in) H00904-01 Support tool Art. no.: T14026S1 Feature Diameter 17 mm (0.67 in) H00916-01 Clamping stand Art.
Page 377
SPECIAL TOOLS 33 Mounting tool Art. no.: T14040S Feature Diameter 48 mm (1.89 in) H00922-01 Special socket Art. no.: T14087 Feature Drive 1/2 in External diameter 44 mm (1.73 in) Internal diameter 29.5 mm (1.161 in) H01737-01 Pressing tool Art. no.: T1504 Feature Diameter 18 mm (0.71 in)
STANDARDS 34 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
35 INDEX OF SPECIAL TERMS Injection into transfer ducts (Trans- Electronic fuel injection in which two injection valves fer Port Injection) in the transfer ducts of the cylinders are used Preload adjuster Device on the spring elements which enables adjust- ment of the spring preload...
Need help?
Do you have a question about the 250 EXC TPI 2019 and is the answer not in the manual?
Questions and answers