KTM 250 EXC TPI 2018 Owner's Manual
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KTM 250 EXC TPI 2018 Owner's Manual

KTM 250 EXC TPI 2018 Owner's Manual

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OWNER'S MANUAL
2018
250 EXC TPI
250 EXC Six Days TPI
250 XC‑W TPI
300 EXC TPI
300 EXC Six Days TPI
Art. no. 3213645en

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Summary of Contents for KTM 250 EXC TPI 2018

  • Page 1 OWNER'S MANUAL 2018 250 EXC TPI 250 EXC Six Days TPI 250 XC‑W TPI 300 EXC TPI 300 EXC Six Days TPI Art. no. 3213645en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new vehicle! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.13 Indicator lamps overview (250 XC‑W TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 TPI US) .......... 20 Symbols used ........6 6.14 Opening the filler cap....... 20 Formats used........6 6.15 Closing the filler cap ......21 6.16 Opening 2-stroke oil tank cap....
  • Page 5 TABLE OF CONTENTS PREPARING FOR USE......... 38 11.9 Adjusting the spring preload of the shock absorber ......58 Advice on first use ......38 11.10 Adjusting the riding sag ....59 Running in the engine ...... 39 11.11 Checking the basic setting of the Starting power of lithium-ion fork ..........
  • Page 6 TABLE OF CONTENTS 12.29 Removing the main silencer ....84 14.2 Installing the front wheel .... 112 12.30 Installing the main silencer....84 14.3 Removing the rear wheel ..... 112 12.31 Changing the glass fiber yarn filling 14.4 Installing the rear wheel ....
  • Page 7 TABLE OF CONTENTS 18.3 Timing the oil pump ....141 18.4 Checking the gear oil level ....143 18.5 Changing the gear oil ....143 18.6 Adding gear oil ......145 19 CLEANING, CARE ........146 19.1 Cleaning the motorcycle ....146 19.2 Checks and maintenance steps for winter operation......

  • Page 8: Means Of Representation

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

  • Page 9: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (All EXC models) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehi- cle complies with the currently valid regulations and categories of the top international motorsport organiza- tions.

  • Page 10: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 11: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 12: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 13: Important Notes

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

  • Page 14: Customer Service

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

  • Page 15: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) E00856-11 Hand brake lever ( p. 17) Light switch ( p. 18) (All EXC models) Kill switch ( p. 17) (All EXC models) p. 19) (All EXC models) Turn signal switch ( Horn button ( p.

  • Page 16: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) E00857-11 Filler cap Throttle grip ( p. 17) Chassis number ( p. 15) Kick starter ( p. 23) Foot brake lever ( p. 23) Level viewer for brake fluid, rear...

  • Page 17: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Key number (All EXC models) The key number for the steering lock is stamped onto the key connector.

  • Page 18: Fork Part Number

    5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inside of the axle clamp. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...

  • Page 19: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. E00817-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

  • Page 20: Kill Switch (250 Xc-W Tpi Us)

    6 CONTROLS Kill switch (250 XC‑W TPI US) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed and the engine can be started. pressed –...

  • Page 21: Turn Signal Switch (All Exc Models)

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 22: Indicator Lamps Overview (250 Xc-Wtpi Us)

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 23: Closing The Filler Cap

    6 CONTROLS – Press release button , turn the filler cap counterclockwise and lift it free. E00929-10 6.15 Closing the filler cap – Fit the filler cap and turn clockwise until release button locks in place. Info Route fuel tank breather hose without kinks.

  • Page 24: Cold Start Button

    6 CONTROLS 6.18 Cold start button The cold start button is fitted on the side of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. To help the engine burn the increased amount of fuel, it must be supplied with additional oxygen by pulling the cold start button.

  • Page 25: Shift Lever

    6 CONTROLS 6.20 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.21 Kick starter Kick starter is fitted on the right side of the engine.

  • Page 26: Side Stand

    6 CONTROLS 6.23 Side stand Side stand is located on the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 401944-10 6.24 Steering lock (All EXC models)

  • Page 27: Unlocking The Steering (All Exc Models)

    6 CONTROLS 6.26 Unlocking the steering (All EXC models) – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 28: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument overview – The button is used to select menus and make settings. – The button is used to select menus and make settings. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument...

  • Page 29: Adjusting The Combination Instrument Function

    7 COMBINATION INSTRUMENT Setting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10-12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 30: Setting The Clock

    7 COMBINATION INSTRUMENT Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Set the hour display with the button and/or button –...

  • Page 31: Display Mode Speed (Speed)

    7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 32: Setting The Unit Of Measurement

    7 COMBINATION INSTRUMENT Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 33: Display Mode Speed/Clk (Time)

    7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 34: Viewing The Lap Time

    7 COMBINATION INSTRUMENT Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 35: Display Mode Speed/Tr1 (Trip Master 1)

    7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 36: Display Mode Speed/A1 (Average Speed 1)

    7 COMBINATION INSTRUMENT Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 37: Display Mode Speed/S1 (Stop Watch 1)

    7 COMBINATION INSTRUMENT Briefly press Next display mode the button Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 38: Table Of Functions

    7 COMBINATION INSTRUMENT 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 39: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode Displays of Next display No function No function SPEED/TR1 (trip...

  • Page 40: Preparing For Use

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

  • Page 41: Running In The Engine

    8 PREPARING FOR USE (All EXC models) – Adjust the free travel of the hand brake lever. ( p. 99) (250 XC‑W TPI US) – Adjust the basic position of the hand brake lever. ( p. 100) – Adjust the basic position of the foot brake lever. p.

  • Page 42: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    8 PREPARING FOR USE Info The idle speed may change during the run-in time. » If the idle speed changes: – Adjust the idle speed. p. 136) Starting power of lithium-ion batteries at low temperatures Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F).

  • Page 43: Preparing Vehicle For Rides On Dry Sand

    Change the radiator cap. – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info See the KTM PowerParts fitting instructions. M01104-01 – Mount a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions.

  • Page 44: Preparing Vehicle For Rides On Wet Sand

    In the event of scalding, rinse the area affected immediately with lukewarm water. – Change the radiator cap. – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01...

  • Page 45: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 46: Preparing Vehicle For Low Temperatures Or Snow

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 130) Preparing vehicle for low temperatures or snow – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01...

  • Page 47: Riding Instructions

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

  • Page 48: Starting Off

    9 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber band – Shift gear to neutral. Condition Ambient temperature: < 20 °C (< 68 °F) – Pull the cold start button fully out and turn it by a ¼ turn. Info If the engine is warm, the cold start button must be 401944-10...

  • Page 49: Braking

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

  • Page 50: Stopping, Parking

    9 RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. –...

  • Page 51: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 52: Adding 2-Stroke Oil

    9 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Total fuel tank Super unleaded capacity, approx. (2.4 US gal) (ROZ 95/RON 95/PON 91) p. 163) 400382-10 Info Do not refuel using pre-mixed fuel. –...

  • Page 53: Service Schedule

    Every 20 operating hours Once after 5 operating hours Once after 1 operating hour ○ ○ ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● Check that the electrical system is functioning properly. ● ●...

  • Page 54: 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 10.3...
  • Page 55 10 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 ● ● Change the fuel filter.

  • Page 56: Tuning The Chassis

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

  • Page 57: Adjusting The High-Speed Compression Damping Of The Shock Absorber

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

  • Page 58: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 59: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 56) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.

  • Page 60: Adjusting The Spring Preload Of The Shock Absorber

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

  • Page 61: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 66) – Remove the shock absorber. p. 79) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 62: Adjusting The Compression Damping Of The Fork

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

  • Page 63: Adjusting The Rebound Damping Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All standard EXC/XC-W models) – Turn red adjusting screw clockwise as far as it will go.

  • Page 64: Adjusting The Spring Preload Of The Fork (All Six Days Models)

    11 TUNING THE CHASSIS Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.14 Adjusting the spring preload of the fork (All Six Days models) Preparatory work –...

  • Page 65: Handlebar Position

    11 TUNING THE CHASSIS 11.15 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 66 11 TUNING THE CHASSIS (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 67 11 TUNING THE CHASSIS (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 68: Service Work On The Chassis

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

  • Page 69: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 66) – Remove the fork protector. ( p. 67) Main work – Push dust boots of both fork legs downward.

  • Page 70: Installing The Fork Protector

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

  • Page 71: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS (All Six Days models) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. E00919-10 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 72: (All Standard Exc/Xc-W Models)

    12 SERVICE WORK ON THE CHASSIS – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws E00375-11 Finishing work...

  • Page 73: Removing The Lower Triple Clamp (All Six Days Models)

    12 SERVICE WORK ON THE CHASSIS – Remove O-ring . Remove protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. E00922-10 12.10 Removing the lower triple clamp (All Six Days models) Preparatory work –...

  • Page 74: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS 12.11 Installing the lower triple clamp (All standard EXC/XC-W models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 164) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 75 12 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp E00914-13 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head E00926-10 – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem E00926-11...

  • Page 76: Installing The Lower Triple Clamp (All Six Days Models)

    12 SERVICE WORK ON THE CHASSIS – 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. 76) – Remove the motorcycle from the lift stand. ( p.
  • Page 77 12 SERVICE WORK ON THE CHASSIS – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw). The compression damping is located in left fork leg COMP (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs.

  • Page 78: Checking The Play Of The Steering Head Bearing

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

  • Page 79: Adjusting The Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS – Check the steering head bearing and change if neces- sary. Finishing work – Remove the motorcycle from the lift stand. ( p. 66) 12.14 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand.

  • Page 80: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS 12.15 Lubricating the steering head bearing (All standard EXC/XC-W models) – Remove the lower triple clamp. p. 70) – Install the lower triple clamp. p. 72) (All Six Days models) – Remove the lower triple clamp. p.

  • Page 81: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work – Install the headlight mask with the headlight. ( p. 124) – Check the headlight setting. ( p.

  • Page 82: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.20 Removing the seat – Remove screws – Raise the rear of the seat, pull the seat back, and lift it off. M01517-10 12.21 Mounting the seat – Hook in the front of the seat on the collar bushing of the fuel tank, lower it at the rear and push it forward.

  • Page 83: Installing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and take off toward the front. E00873-12 12.23 Installing the air filter box cover – Insert the air filter box cover in the area and clip it into the area E00873-11...

  • Page 84: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. E00876-10 12.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 85: Preparing Air Filter Box Cover For Securing

    12 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 164) Info Only squeeze the air filter to dry it; never wring it out. –...

  • Page 86: Removing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.29 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...

  • Page 87: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screws – Pull out inner tube – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for dam- age.
  • Page 88 12 SERVICE WORK ON THE CHASSIS Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. E00879-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 89: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank. E00883-10 12.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 90 12 SERVICE WORK ON THE CHASSIS – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis (All EXC models) – Position the horn with the horn bracket. E00882-11 – Mount and tighten screws with the collar bushings.

  • Page 91: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS 12.34 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 89) 400678-01 12.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...

  • Page 92: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.36 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 93: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 94 12 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure the distance of 18 chain links in the lower chain section.
  • Page 95 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 96: Checking The Frame

    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 12.41 Checking throttle cable routing Preparatory work – Remove the seat. ( p.

  • Page 97: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Finishing work – Install the fuel tank. p. 87) – Mount the seat. ( p. 80) 12.42 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...

  • Page 98: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    12 SERVICE WORK ON THE CHASSIS 12.44 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. –...

  • Page 99: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS 12.45 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 100: Removing The Engine Guard (All Six Days Models)

    12 SERVICE WORK ON THE CHASSIS – 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. –...

  • Page 101: Brake System

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

  • Page 102: Adjusting The Basic Position Of The Hand Brake Lever (250 Xc-Wtpi Us)

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

  • Page 103: Checking The Front Brake Fluid Level

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

  • Page 104: Checking The Front Brake Linings

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

  • Page 105: Changing The Front Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 106 13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 107: Checking The Free Travel Of Foot Brake Lever

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

  • Page 108: Checking The Rear Brake Fluid Level

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

  • Page 109: Adding Rear Brake Fluid

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

  • Page 110: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 111 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 112 13 BRAKE SYSTEM – Insert the new brake linings, insert the pin, and mount the cot- ter pins. Info Always change the brake linings in pairs. – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.

  • Page 113: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 66) 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 114: Installing The Front Wheel

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

  • Page 115: Installing The Rear Wheel

    14 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 116 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 117: Checking The Tire Condition

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

  • Page 118: Checking Spoke Tension

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

  • Page 119: Electrical System

    15 ELECTRICAL SYSTEM 15.1 Removing the battery Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 120: Installing The Battery

    15 ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Insert the battery into the battery compartment with the termi- nals facing forward and secure with holding bracket Battery (HJTZ5S-FP) ( p. 157) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
  • Page 121 15 ELECTRICAL SYSTEM Preparatory work (All EXC models) – Press and hold the kill switch while the engine is idling until the engine stops. (250 XC‑W TPI US) – Press and hold the kill switch while the engine is idling until the engine stops.

  • Page 122: Changing The Main Fuse

    15 ELECTRICAL SYSTEM Battery charger (58429074000) The charging time may be longer at low temperatures. This battery charger is not suitable for the trickle charging of lithium-ion batteries. Info If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed.
  • Page 123 15 ELECTRICAL SYSTEM – Pull starter relay from the holder. E00897-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 124: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM 15.5 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 125: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

  • Page 126: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM (All EXC models) – Detach plug-in connectors and take off the headlight mask with the headlight. E00900-10 (250 XC‑W TPI US) – Detach plug-in connector and take off the headlight mask with the headlight. E00357-10 15.7 Installing the headlight mask with the headlight Main work (All EXC models) –...

  • Page 127: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 126) 15.8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...

  • Page 128: Checking The Headlight Setting

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

  • Page 129: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 126) 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 130: Diagnostics Connector

    15 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...

  • Page 131: Cooling System

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

  • Page 132: Checking The Coolant Level

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

  • Page 133: Refilling With Coolant

    16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 134 16 COOLING SYSTEM – 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. 162) 400243-10 – Push protection cap upward over the thermostat. E00904-10 – Unplug connector –...
  • Page 135 16 COOLING SYSTEM Finishing work – Check the coolant level. ( p. 130)

  • Page 136: Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Turn the handlebar as far as possible to the right. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 137: Setting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Guideline Play in throttle cable 3 … 5 mm (0.12 … 0.2 in) – Unscrew the adjusting screw until the smooth operation or play in throttle cable is worsened. – Turn the adjusting screw approx. two turns further. –...

  • Page 138: Adjusting The Idle Speed

    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. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm.

  • Page 139: Programming Ambient Pressure

    17 TUNING THE ENGINE Info Turning counterclockwise lowers the idle speed. Turning clockwise raises the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running. The idle speed adjusting screw is unscrewed 1.5 turns ex works.

  • Page 140: Ignition Curve Plug-In Connector

    17 TUNING THE ENGINE 17.6 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 141: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE Finishing work – Install the fuel tank. p. 87) – Mount the seat. ( p. 80) 17.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

  • Page 142: Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 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 143: Checking 2-Stroke Oil Level

    18 SERVICE WORK ON THE ENGINE 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 144 18 SERVICE WORK ON THE ENGINE Condition The engine is off. Preparatory work – Remove the seat. ( p. 80) Main work – Remove protection cap of the diagnostics connector. E00917-10 – Put throttle grip into full throttle position and secure. E00819-11 –...

  • Page 145: Checking The Gear Oil Level

    18 SERVICE WORK ON THE ENGINE – Check where air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount protection cap on the diagnostics connector. M01515-10 Finishing work –...
  • Page 146 18 SERVICE WORK ON THE ENGINE Info Drain the gear oil while the engine is at operating temperature. Preparatory work (All Six Days models) – Remove the engine guard. ( p. 98) – Park the motorcycle on a level surface. –...

  • Page 147: Adding Gear Oil

    18 SERVICE WORK ON THE ENGINE 18.6 Adding gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold. Preparatory work –...

  • Page 148: Cleaning, Care

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

  • Page 149: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 89) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 150: 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. 66) –...

  • Page 151: Preparing For Use After Storage

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

  • Page 152: Troubleshooting

    Defect in the fuel injection sys- Check the cabling for damage and the electrical plug-in connections for corro- sion and damage. – Read out the fault memory using the KTM diagnostics tool. – Engine has no idle Spark plug defective Change the spark plug. –...
  • Page 153 Defect in the fuel injection sys- Check the cabling for damage and the electrical plug-in connections for corro- sion and damage. – Read out the fault memory using the KTM diagnostics tool. – Faulty ignition Ignition coil - check the primary wind- ing. –...
  • Page 154 – Read out the fault memory using the KTM diagnostics tool. – The battery is discharged The battery is not being Check the charging voltage. charged by the alternator –...

  • Page 155: Technical Data

    22 TECHNICAL DATA 22.1 Engine 22.1.1 All 250 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, 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 156: Engine Tightening Torques

    22 TECHNICAL DATA Exhaust valve, beginning of adjustment 5,500 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings Engine lubrication Separate lubrication X distance (upper edge of piston to upper edge of 0 …...
  • Page 157 22 TECHNICAL DATA Screw, injection valve holder 3.5 Nm (2.58 lbf ft) Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining bracket of exhaust 7 Nm (5.2 lbf ft) Loctite ® 2701™ control Screw, stator 6 Nm (4.4 lbf ft) Loctite...

  • Page 158: Capacities

    22 TECHNICAL DATA Nut, rotor M12x1 60 Nm (44.3 lbf ft) Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite ®...

  • Page 159: Electrical System

    22 TECHNICAL DATA Tire air pressure, road (All EXC models) front 1.5 bar (22 psi) rear 1.5 bar (22 psi) Tire air pressure off road front 1.0 bar (15 psi) rear 1.0 bar (15 psi) Secondary ratio 14:50 (13:50) Chain 5/8 x 1/4"...

  • Page 160: Tires

    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 22.7 Fork 22.7.1 All standard EXC/XC-W models Fork article number 14.18.8R.63...

  • Page 161: Shock Absorber

    22 TECHNICAL DATA Sport 12 clicks Spring preload - Preload Adjuster Comfort Standard Sport 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 …...

  • Page 162: Chassis Tightening Torques

    22 TECHNICAL DATA 22.9 Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT PT Screw, fuel pump ® 2.3 Nm (1.7 lbf ft) G 3/4 " Screw, oil fill level sensor 7 Nm (5.2 lbf ft) Screw, pressure regulator EJOT PT ®...
  • Page 163 22 TECHNICAL DATA Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) standard EXC/XC-W models) Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) Six Days models) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace 25 Nm (18.4 lbf ft)

  • Page 164: Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 165 23 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 166) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification –...

  • Page 166: Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 167 24 AUXILIARY SUBSTANCES Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 168: Standards

    25 STANDARDS JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA 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 169: Index Of Special Terms

    26 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 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 170: List Of Abbreviations

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

  • Page 171: List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 172: Index

    INDEX INDEX Capacity 2-stroke oil level coolant ..... . 132, 156 checking ......141 fuel .
  • Page 173 INDEX wet surfaces ..... . . 43 Gear oil Electric starter button ....19 adding .
  • Page 174 INDEX Safe operation ......8 Main fuse changing ......120 Seat mounting .
  • Page 175 INDEX Throttle cable play checking ......134 Throttle cable routing checking ......94 Throttle grip .
  • Page 176 *3213645en* 3213645en 06/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

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