KTM 250 EXC TPI 2019 Repair Manual
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KTM 250 EXC TPI 2019 Repair Manual

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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

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  • 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.

  • Page 4: Table Of Contents

    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 ......

  • Page 9: Means Of Representation 1

    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.

  • Page 10: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.

  • Page 11: Important Notes 3

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void.

  • Page 12: Serial Numbers

    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.

  • Page 13: Shock Absorber Article Number

    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...

  • Page 14: Motorcycle

    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.

  • Page 15: Starting The Motorcycle To Check The Function

    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.

  • Page 16: Fork, Triple Clamp

    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.

  • Page 17: Adjusting The Rebound Damping Of The Fork

    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.

  • Page 18: Adjusting The Spring Preload Of The Fork (All Six Days Models)

    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.

  • Page 19: Cleaning The Dust Boots Of The 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.

  • Page 20: Installing The Fork Legs

    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. –...

  • Page 21: Removing The Fork Protector

    FORK, TRIPLE CLAMP 6 (All Six Days models) – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Tighten screws Guideline Screw, bottom 15 Nm E00919-11 triple clamp (11.1 lbf ft) – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 22: All Standard Exc/Xc-W Models

    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 –...

  • Page 25: Disassembling The Cartridge

    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.

  • Page 28: Disassembling The Tap Compression

    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.

  • Page 29: Checking The Fork Legs

    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. –...

  • Page 30: Assembling The Tap Compression

    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 –...

  • Page 31: Assembling The Cartridge

    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.

  • Page 35: Assembling The Fork Legs

    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. –...

  • Page 39: Lubricating The Steering Head Bearing

    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.

  • Page 40: Installing The Lower Triple Clamp

    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)

  • Page 42: Changing The Steering Head Bearing

    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.

  • Page 44: Checking The Play Of The Steering Head Bearing

    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.

  • Page 45: All Six Days Models

    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 –...

  • Page 48: Disassembling The Cartridge

    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.

  • Page 51: Disassembling The Tap Compression

    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.

  • Page 52: Checking The Fork Legs

    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. –...

  • Page 53: Assembling The Tap Compression

    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 –...

  • Page 54: Assembling The Cartridge

    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.

  • Page 58: Assembling The Fork Legs

    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.

  • Page 63: Lubricating The Steering Head Bearing

    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.

  • Page 64: Installing The Lower Triple Clamp

    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 ®...

  • Page 66: Changing The Steering Head Bearing

    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.

  • Page 67: Checking The Play Of The Steering Head Bearing

    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. –...

  • Page 68: Adjusting The Steering Head Bearing Play

    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: –...

  • Page 69: Handlebar, Controls 7

    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. –...

  • Page 71: Adjusting The Basic Position Of The Clutch Lever

    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. –...

  • Page 72: Checking The Rubber Grip

    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.

  • Page 73: Checking The Play In The Throttle Cable

    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 …...

  • Page 74: Setting The Characteristic Map Of The Throttle Response

    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...

  • Page 76: Frame

    – 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 –...

  • Page 80: Shock Absorber, Swingarm

    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. –...

  • Page 81: Adjusting The Rebound Damping Of The Shock Absorber

    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...

  • Page 82: Measuring The Rear Wheel Dimension Unloaded

    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) –...

  • Page 83: Checking The Riding Sag Of The Shock Absorber

    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.

  • Page 84: Adjusting The Riding Sag

    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.

  • Page 85: Removing The Shock Absorber

    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.

  • Page 86: Removing The Spring

    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.

  • Page 87: Disassembling The Damper

    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.

  • Page 88: Disassembling The Seal Ring Retainer

    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 –...

  • Page 89: Disassembling The Piston Rod

    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) –...

  • Page 90: Replacing The Pilot Bushing

    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.

  • Page 91: Checking The Damper

    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.

  • Page 92: Removing The Heim Joint

    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 ≤...

  • Page 93: Installing The Heim Joint

    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.

  • Page 94: Assembling The Piston Rod

    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.

  • Page 96: Assembling The Damper

    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 –...

  • Page 98: Bleeding And Filling The Damper

    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.

  • Page 101: Filling Damper With Nitrogen

    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.

  • Page 102: Installing The Spring

    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. –...

  • Page 103: Checking The Swingarm

    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 –...

  • Page 104: Changing The Heim Joint

    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. –...

  • Page 105: Changing The Heim Joint On The Swingarm

    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.

  • Page 107: Checking The Swingarm Bearing For Play

    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 –...

  • Page 108: Installing The Swingarm

    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.

  • Page 110: Changing The Swingarm Bearing

    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 –...

  • Page 113: Exhaust 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 –...

  • Page 114: Installing The Manifold

    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.

  • Page 115: Removing The Main Silencer

    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 –...

  • Page 116: Installing The Main Silencer

    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.

  • Page 118: Air Filter

    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 –...

  • Page 119: Removing The Air Filter

    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.

  • Page 120: Cleaning The Air Filter And Air Filter Box

    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.

  • Page 121: Sealing The Air Filter Box

    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.

  • Page 122: Fuel Tank, Seat, Trim

    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. –...

  • Page 123: Removing The Seat

    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.

  • Page 124: Removing The Fuel Tank

    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. –...

  • Page 125: Installing The Fuel Tank

    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.

  • Page 127: Changing The Fuel Screen

    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.

  • Page 128: Changing The Fuel Filter

    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.

  • Page 131: Changing 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 –...

  • Page 134: Checking The Fuel Pressure

    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) »...

  • Page 136: Mask, Fender

    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 –...

  • Page 137: Removing The Headlight Mask With The Headlight

    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.

  • Page 139: Wheels 14

    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.

  • Page 140: Checking The Wheel Bearing For Play

    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.

  • Page 141: Checking The Brake Discs

    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.

  • Page 142: Checking Spoke Tension

    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: –...

  • Page 143: Front Wheel

    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...

  • Page 144: Installing The Front Wheel

    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. –...

  • Page 145: Changing Front Wheel Bearing

    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)

  • Page 146: Rear Wheel

    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 –...

  • Page 147: Installing The Rear Wheel

    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. –...

  • Page 148: Changing The Rear Brake Disc

    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.

  • Page 149: Changing The Rear Wheel Bearing

    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. »...

  • Page 151: Checking The Chain For Dirt

    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.

  • Page 152: Checking The Chain Tension

    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 –...

  • Page 153: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    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. »...

  • Page 155: Adjusting The Chain Tension

    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.

  • Page 156: Changing The Drivetrain Kit

    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,...

  • Page 159: Wiring Harness, Battery 15

    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. –...

  • Page 161: Changing The Fuses Of Individual Power Consumers

    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.

  • Page 162: Disconnecting The Negative Cable Of The Battery

    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.

  • Page 163: Connecting The Negative Cable Of The Battery

    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...

  • Page 164: Installing The Battery

    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. –...

  • Page 165: Recharging The Battery

    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. –...

  • Page 166: Checking The Charging Voltage

    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.

  • Page 167: Checking The Open-Circuit Current

    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.

  • Page 168: Diagnostics Connector

    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: –...

  • Page 169: Brake System 16

    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.

  • Page 171: Checking The Free Travel Of The Hand Brake Lever

    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.

  • Page 172: Adjusting Free Travel Of Hand Brake Lever (All Exc Models)

    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...

  • Page 173: Adding Front Brake Fluid

    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 –...

  • Page 174: Changing The Front Brake Fluid

    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.

  • Page 176: Checking The Brake Linings Of The Rear Brake

    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.

  • Page 178: Checking The Free Travel Of Foot Brake Lever

    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.

  • Page 179: Adjusting The Basic Position Of The Foot Brake Lever

    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.

  • Page 180: Checking The Rear Brake Fluid Level

    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.

  • Page 181: Changing The Rear Brake Fluid

    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.

  • Page 184: Lighting System, Instruments

    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. –...

  • Page 185: Checking The Headlight Setting

    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. –...

  • Page 186: Adjusting The Headlight Range

    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).

  • Page 187: Combination Instrument Overview

    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.

  • Page 188: Adjusting The Combination Instrument Function

    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.

  • Page 189: Setting The Clock

    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. –...

  • Page 190: Setting The Wheel Circumference

    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 –...

  • Page 192: Engine

    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.

  • Page 198: Installing The Engine

    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 –...

  • Page 205: Engine Disassembly

    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...

  • Page 206: Removing The Spacer

    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...

  • Page 207: Removing The Kick Starter

    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 –...

  • Page 208: Removing The Cylinder

    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 –...

  • Page 210: Removing The Piston

    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) –...

  • Page 211: Removing The Water Pump Cover

    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 –...

  • Page 212: Removing The Clutch Discs

    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 –...

  • Page 213: Removing The Clutch Basket

    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.

  • Page 214: Removing The Balancer Shaft

    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.

  • Page 215: Removing The Kick Starter Shaft

    ENGINE 18 – Remove balancer shaft drive wheel D04463-10 – Remove woodruff key D04464-10 – Remove balancer shaft D04465-10 18.4.17 Removing the kick starter shaft – Detach kick starter spring – Remove kick starter shaft Info Turn the kick starter shaft slightly to the left. D04466-10 18.4.18 Removing the intermediate kick starter gear –...

  • Page 216: Removing The Shift Shaft

    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.

  • Page 217: Removing The Starter Motor

    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 –...

  • Page 218: Removing The Reed Valve Housing

    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.

  • Page 219: Removing The Left Engine Case Section

    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.

  • Page 220: Removing The Shift Forks

    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.

  • Page 221: Working On Individual Parts

    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 –...

  • Page 222: Working On The Left Section Of The Engine Case

    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...

  • Page 224: Removing The Crankshaft Bearing Inner Race

    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. –...

  • Page 225: Changing The Connecting Rod, Conrod Bearing, And Crank Pin

    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.

  • Page 226: Checking The Crankshaft Run-Out At The Bearing Pin

    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. –...

  • Page 227: Cleaning The Pressure Sensor Cylinder Connection

    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...

  • Page 229: Checking The Exhaust Control

    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. –...

  • Page 231: Installing The Exhaust Control

    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. –...

  • Page 234: Cylinder - Nikasil Coating

    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 ®...

  • Page 235: Checking The Piston Ring End Gap

    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 …...

  • Page 236: Disassemble The Reed Valve Housing

    18 ENGINE Guideline Piston/cylinder - mounting clearance (All 250 models) New condition 0.050 … 0.074 mm (0.00197 … 0.00291 in) Wear limit 0.10 mm (0.0039 in) Piston/cylinder - mounting clearance (All 300 models) New condition 0.050 … 0.085 mm (0.00197 … 0.00335 in) Wear limit 0.10 mm (0.0039 in) 18.5.16 Disassemble the reed valve housing...

  • Page 237: Checking The Reed Valve Housing, Reed Valve And Intake Flange

    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. –...

  • Page 239: Working On The Clutch Cover

    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 –...

  • Page 242: Checking The Clutch

    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. »...

  • Page 243: Preassembling Shift Shaft

    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. –...

  • Page 244: Checking The Shift Mechanism

    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. »...

  • Page 245: Disassembling The Main Shaft

    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 …...

  • Page 246: Disassembling The Countershaft

    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: –...

  • Page 248: Assembling The Main Shaft

    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-...

  • Page 250: Checking The Kick Starter

    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.

  • Page 251: Checking The Electric Starter Drive

    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 –...

  • Page 252: Engine Assembly

    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. »...

  • Page 253: Installing The Transmission Shafts

    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 –...

  • Page 254: Installing The Shift Drum

    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...

  • Page 255: Installing The Reed Valve Housing

    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...

  • Page 256: Installing The Starter Motor

    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)

  • Page 257: Installing The Rotor

    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. –...

  • Page 258: Installing The Shift Drum Locating Unit

    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 –...

  • Page 259: Installing The Balancer Shaft

    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 –...

  • Page 260: Installing The Clutch Basket

    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 ®...

  • Page 261: Installing The Clutch Discs

    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...

  • Page 263: Installing The Clutch Cover

    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 –...

  • Page 265: Installing The Water Pump 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...

  • Page 266: Installing The Piston

    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. –...

  • Page 267: Installing The Cylinder

    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 –...

  • Page 269: Checking The X-Distance

    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) –...

  • Page 271: Adjusting The Z-Distance

    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. –...

  • Page 273: Installing The Cylinder Head

    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. –...

  • Page 274: Installing Injection Valves

    18 ENGINE 18.6.26 Installing injection valves – Position injection valves on both sides. – Mount and tighten screws with insulating washers Guideline Screw, injection 5 Nm (3.7 lbf ft) Loctite ® 243™ valve holder D04404-10 18.6.27 Installing the kick starter –...

  • Page 275: Installing The Spacer

    ENGINE 18 – Position the alternator cover. – Mount and tighten screws Guideline Screw, alternator M6x20 8 Nm (5.9 lbf ft) cover – Mount and tighten screws Guideline Screw, alternator M6x25 8 Nm (5.9 lbf ft) D04401-11 cover 18.6.29 Installing the spacer –...

  • Page 276: Installing The Clutch Push Rod

    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 ®...

  • Page 277: Clutch 19

    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. –...

  • Page 278: Changing The Hydraulic Clutch Fluid

    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. –...

  • Page 279: Checking The Clutch

    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)

  • Page 288: Water Pump, Cooling System

    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.

  • Page 289: Checking The Coolant Level

    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.

  • Page 290: Refilling With Coolant

    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)

  • Page 293: Exhaust Control 21

    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.

  • Page 296: Lubrication System

    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.

  • Page 297: Checking The Gear Oil Level

    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 –...

  • Page 298: Checking 2-Stroke Oil Level

    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)

  • Page 299: Opening 2-Stroke Oil Tank Cap

    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.

  • Page 300: Priming The Oil Pump

    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. –...

  • Page 301: Replacing The Oil Pump

    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)

  • Page 304: Ignition System

    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. –...

  • Page 305: Ignition Coil - Checking The Primary Winding

    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.

  • Page 306: Checking The Spark Plug Connector

    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 …...

  • Page 307: Checking The Crankshaft Position Sensor

    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: –...

  • Page 308: Changing The Spark Plug

    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 –...

  • Page 309: Changing The Spark Plug And Spark Plug Connector

    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...

  • Page 310: Installing The Stator

    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.

  • Page 311: Electric Starter 24

    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. »...

  • Page 312: Throttle Valve Body

    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 –...

  • Page 313: Cold Start Button

    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. »...

  • Page 314: Technical Data

    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 …...

  • Page 315: Tolerance, Engine Wear Limits

    TECHNICAL DATA 26 Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings Engine lubrication Separate lubrication X distance (upper edge of piston to upper edge of 0 …...

  • Page 316: Engine Tightening Torques

    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 ≤...

  • Page 317: Capacities

    TECHNICAL DATA 26 Screw, intermediate clutch cover 10 Nm (7.4 lbf ft) Screw, kick starter stop plate 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, outer clutch cover 8 Nm (5.9 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 318: Fuel

    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...

  • Page 319: Electrical System

    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...

  • Page 320: All Six Days Models

    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 …...

  • Page 321: Chassis Tightening Torques

    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 …...
  • Page 322 26 TECHNICAL DATA Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, manifold on silent block 6 Nm (4.4 lbf ft) Screw, oil pump 7 Nm (5.2 lbf ft) Screw, oil pump holder on oil tank 6 Nm (4.4 lbf ft)
  • Page 323 TECHNICAL DATA 26 Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Screw, front wheel spindle...

  • Page 324: Cleaning, Care

    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. –...

  • Page 325: Checks And Maintenance Steps For Winter Operation

    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.

  • Page 326: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 12) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 327: Preparing For Use After Storage

    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.

  • Page 328: Service Schedule

    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.

  • Page 329: Recommended Work

    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 331 SERVICE SCHEDULE 29...

  • Page 332: Wiring Diagram

    30 WIRING DIAGRAM 30.1 Page 1 of 8 (All EXC models) wh-rd wh-rd bu-rd wh-rd wh-rd , wh-rd bu-rd wh-gr wh-gr wh-gr T00482-10...
  • Page 333 WIRING DIAGRAM 30 Components: EFI control unit Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 334: All Exc Models)

    30 WIRING DIAGRAM 30.2 Page 2 of 8 (All EXC models) wh-rd wh-pk wh-rd wh-rd wh-pk bl-wh EY/3 EZ/3 bl-wh wh-rd bl-wh bl-wh wh-rd rd-ye bl-gn bl-gn ye-lbu wh-bl wh-bl ye-lbu ye-lbu ye-bu ye-bu ye-bu T00483-10...
  • 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 336: All Exc Models)

    30 WIRING DIAGRAM 30.3 Page 3 of 8 (All EXC models) ye-bu wh-gr bu , bu br , br T00484-10...
  • Page 337 WIRING DIAGRAM 30 Components: Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

  • Page 338: All Exc Models)

    30 WIRING DIAGRAM 30.4 Page 4 of 8 (All EXC models) ye-bu wh-gn ye-bu wh-gn ye-bu ye-bu ye-bu ye-bu wh-gn wh-gn , wh-gn wh , wh wh , wh br , br , br br , br , br ye-bu ye-bu ye-bu br , br , br...
  • 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...

  • Page 340: All Exc Models)

    30 WIRING DIAGRAM 30.5 Page 5 of 8 (All EXC models) wh-gn br , br br , br T00486-10...
  • Page 341 WIRING DIAGRAM 30 Components: License plate lamp Brake/tail light...

  • Page 342: All Exc Models)

    30 WIRING DIAGRAM 30.6 Page 6 of 8 (All EXC models) rd-ye pu-bl pu-bl pu-bl pu-bl gn-rd gn-rd wh-bu wh-bu rd-br rd-br gn-pk gn-pk T00487-10...
  • Page 343 WIRING DIAGRAM 30 Components: EFI control unit Fuel level sensor Oil level sensor Lambda sensor Fuse Speedometer Oil level warning lamp Ignition coil...

  • Page 344: All Exc Models)

    30 WIRING DIAGRAM 30.7 Page 7 of 8 (All EXC models) bu-or bu-or bl-gr bl-gr br-gr br-gr bu-wh bu-bl bu-bl bu-bl bu-wh bu-wh br , br br , br rd-ye bu-or bu-gr bu-or bu-gr bu-gr bu-gr bu-gr T00488-10...
  • Page 345 WIRING DIAGRAM 30 Components: EFI control unit Front wheel speed sensor Fuse Fuel pump Oil pump Injection valve 0 Injection valve 1 Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 346: All Exc Models)

    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 348: All Xc-W Models)

    30 WIRING DIAGRAM 30.9 Page 1 of 6 (All XC‑W models) wh-rd wh-rd bu-rd wh-rd wh-rd , wh-rd bu-rd wh-gr wh-gr T00490-10...
  • Page 349 WIRING DIAGRAM 30 Components: EFI control unit Battery Starter relay with main fuse Electric starter system E-tip switch Kill switch...

  • Page 350: All Xc-W Models)

    30 WIRING DIAGRAM 30.10 Page 2 of 6 (All XC‑W models) wh-rd wh-pk wh-rd wh-rd wh-pk bl-wh EY/3 EZ/3 bl-wh wh-rd bl-wh bl-wh wh-rd rd-ye bl-gn bl-gn ye-lbu wh-bl wh-bl ye-lbu T00491-10...
  • 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...

  • Page 352: All Xc-W Models)

    30 WIRING DIAGRAM 30.11 Page 3 of 6 (All XC‑W models) br , br br , br br , br T00492-10...
  • Page 353 WIRING DIAGRAM 30 Components: Low beam, high beam Parking light Brake/tail light Light switch...

  • Page 354: All Xc-W Models)

    30 WIRING DIAGRAM 30.12 Page 4 of 6 (All XC‑W models) rd-ye pu-bl pu-bl pu-bl wh-bu wh-bu rd-br rd-br gn-pk gn-pk T00493-10...
  • Page 355 WIRING DIAGRAM 30 Components: EFI control unit Fuel level sensor Oil level sensor Fuse Speedometer Oil level warning lamp Ignition coil...

  • Page 356: All Xc-W Models)

    30 WIRING DIAGRAM 30.13 Page 5 of 6 (All XC‑W models) bu-or bu-or bl-gr bl-gr br-gr br-gr bu-wh bu-bl bu-bl bu-bl bu-wh bu-wh br , br br , br rd-ye bu-or bu-gr bu-or bu-gr bu-gr bu-gr bu-gr T00494-10...
  • Page 357 WIRING DIAGRAM 30 Components: EFI control unit Front wheel speed sensor Fuse Fuel pump Oil pump Injection valve 0 Injection valve 1 Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 358: All Xc-W Models)

    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...

  • Page 360: Substances

    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.

  • Page 362: Auxiliary Substances

    32 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 363 AUXILIARY SUBSTANCES 32 Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Multi-purpose grease (00062010051) Recommended supplier Klüber Lubrication ® – CENTOPLEX 2 EP Off-road chain spray Recommended supplier Motorex ® – Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ®...

  • Page 364: Special Tools

    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 366 33 SPECIAL TOOLS Syringe Art. no.: 50329050000 H00565-01 Pressing tool Art. no.: 50429005000 H00568-01 Holding wrench Art. no.: 51129003000 H00575-01 Holding wrench Art. no.: 54629012200 H00580-01...
  • Page 367 SPECIAL TOOLS 33 Setting gauge Art. no.: 54829001100 H00583-01 Separator plate Art. no.: 54829009000 H00584-01 Crankshaft pressing tool insert Art. no.: 54829108000 H00994-01 Holder and fitting for work stand Art. no.: 55429002000 H01175-01...
  • Page 368 33 SPECIAL TOOLS Holding wrench Art. no.: 55429012000 H01176-01 Socket wrench Art. no.: 55529021000 Feature Square 5 mm (0.2 in) H02866-01 Adjusting gauge Art. no.: 55529022000 H02867-01 Gear segment Art. no.: 56012004000 H00588-01...
  • Page 369 SPECIAL TOOLS 33 Puller Art. no.: 58012009000 H00592-01 Puller Art. no.: 58429037043 Feature Inside diameter 43.9 mm (1.728 in) H00598-01 Peak voltage adapter Art. no.: 58429042000 H00599-01 Footrest spring plier Art. no.: 58429083000 H00601-01...
  • Page 370 33 SPECIAL TOOLS Tool bracket Art. no.: 58429089000 H00603-01 Pressing tool Art. no.: 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 H00605-01 Torque wrench kit Art. no.: 58429094000 Feature Torque 3 … 15 Nm (2.2 … 11.1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in)
  • Page 371 SPECIAL TOOLS 33 Feeler gauge Art. no.: 59029041100 Feature 5 piece 0.10 … 0.25 mm (0.0039 … 0.0098 in) H00616-01 Hose clamp plier Art. no.: 60029057000 H00650-01 Testing hose Art. no.: 61029093000 H00659-01 Pressure testing tool Art. no.: 61029094000 H00660-01...
  • Page 372 33 SPECIAL TOOLS Engine work stand Art. no.: 61229001000 H00662-01 Pressing tool Art. no.: 75029044010 H00712-01 Crankshaft pressing tool Art. no.: 75029047000 H00714-01 Lift stand Art. no.: 78129955100 Feature Height 315 … 425 mm (12.4 … 16.73 in) ≤ 150 kg (≤ 331 lb.) Load H00980-01...
  • Page 373 SPECIAL TOOLS 33 Footrest spring plier Art. no.: 79029083000 H00804-01 Pressing tool Art. no.: 79629000044 H01750-01 Holding wrench Art. no.: 90129051000 H00831-01 Spring hook Art. no.: 5030501700004 H00973-01...
  • Page 374 33 SPECIAL TOOLS Depth micrometer Art. no.: T107S H00842-01 Drift Art. no.: T120 Feature Diameter 8 mm (0.31 in) H00844-01 Mounting sleeve Art. no.: T1204 Feature Diameter 25.5 … 30.5 mm (1.004 … 1.201 in) H00878-01 Calibrating unit Art. no.: T1205 Feature Diameter 18 mm (0.71 in)
  • Page 375 SPECIAL TOOLS 33 Pressing tool Art. no.: T1206 Feature Diameter 15 … 30 mm (0.59 … 1.18 in) H00880-01 Pressing tool Art. no.: T1207S H00881-01 Vacuum pump Art. no.: T1240S H00890-01 Protecting sleeve Art. no.: T1401 Feature Diameter 48 mm (1.89 in) H00894-01...
  • 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)
  • Page 378 33 SPECIAL TOOLS Mounting sleeve Art. no.: T1554 Feature Diameter 18 mm (0.71 in) H00903-01 Filling adapter Art. no.: T1565 H02354-01 Filling tool Art. no.: T170S1 H00855-01...

  • Page 379: Standards 34

    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.

  • Page 380: Index Of Special Terms

    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...

  • Page 381: List Of Abbreviations 36

    LIST OF ABBREVIATIONS 36 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 382: Index

    INDEX front brake, checking ....167 INDEX of rear brake, changing ....174 rear brake, checking .
  • Page 383 INDEX clutch basket, installing ....258 clutch cover, installing ....261 Diagnostics connector ....166 clutch discs, installing .
  • Page 384 INDEX shift drum locating unit, removing ..214 Front fender shift drum, removing ....217 installing ......134 shift forks, removing .
  • Page 385 INDEX Rear wheel installing ......145 Idle speed removing ......144 adjusting .
  • Page 386 INDEX Spark plug connector Turn signal bulb checking ......304 changing ......182 Speedometer Type label .
  • Page 387 *3206345en* 3206345en 04/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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