Related Manuals for KTM 250 EXC Six Days TPI 2019
Summary of Contents for KTM 250 EXC Six Days TPI 2019
- Page 1 OWNER'S 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. 3213853en...
- 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 riding this motorcycle! Enter the serial numbers of your vehicle below.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.14 Indicator lamps overview (All XC‑W TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 models)........... 20 Symbols used ........6 6.15 Opening the filler cap....... 20 Formats used........6 6.16 Closing the filler cap ......21 6.17 Opening 2-stroke oil tank cap.... - Page 5 TABLE OF CONTENTS PREPARING FOR USE......... 38 11.10 Adjusting the riding sag ....59 11.11 Checking the basic setting of the Advice on first use ......38 fork ..........59 Running in the engine ...... 39 11.12 Adjusting the compression damping Starting power of lithium-ion of the fork ........
- Page 6 TABLE OF CONTENTS 12.31 Changing the glass fiber yarn filling 14.5 Checking the tire condition ..... 115 in the main silencer ...... 85 14.6 Checking the tire air pressure..115 12.32 Removing the fuel tank ....85 14.7 Checking spoke tension ....116 12.33 Installing the fuel tank ....
- Page 7 TABLE OF CONTENTS 19 CLEANING, CARE ........146 19.1 Cleaning the motorcycle ....146 19.2 Checks and maintenance steps for winter operation......147 20 STORAGE ..........148 20.1 Storage ......... 148 20.2 Preparing for use after storage..149 21 TROUBLESHOOTING ........ 150 22 TECHNICAL DATA........
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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 2 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 Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury 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 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 14 3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...
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Page 15: View Of Vehicle 4
VIEW OF VEHICLE 4 View of vehicle, front left (example) E01221-10 Hand brake lever ( p. 17) Clutch 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) E01222-10 Filler cap Throttle grip ( p. 17) Chassis number ( p. 15) Kick starter ( p. 24) Foot brake lever ( p. 24) Level viewer for brake fluid, rear... -
Page 17: Serial Numbers 5
SERIAL NUMBERS 5 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 6 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 (All Xc-W Models)
6 CONTROLS Kill switch (All XC‑W models) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed and the engine can be started. pressed –... -
Page 21: Turn Signal Switch (All Exc Models)
CONTROLS 6 Turn signal switch (All EXC models) Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – The turn signal switch is in the cen- tral position. Left turn signal, on – The turn signal switch is turned to the left. -
Page 22: Indicator Lamps Overview (All Exc Models)
– 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
CONTROLS 6 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –... -
Page 24: Closing 2-Stroke Oil Tank Cap
6 CONTROLS 6.18 Closing 2-stroke oil tank cap – Put the 2-stroke oil tank cap on and turn it clockwise. – Fold loop down. The 2-stroke oil tank cap engages. E00861-11 6.19 Cold start button The cold start button is fitted on the side of the throttle valve body. -
Page 25: Idle Speed Adjusting Screw
CONTROLS 6 6.20 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly. -
Page 26: Kick Starter
6 CONTROLS 6.22 Kick starter Kick starter is fitted on the right side of the engine. The top part of the kick starter pivots. Info 0 0 1 Before riding, swing the top part of the kick starter inward toward the engine. 401954-10 6.23 Foot brake lever... -
Page 27: Steering Lock (All Exc Models)
CONTROLS 6 6.25 Steering lock (All EXC models) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and there- fore riding, is no longer possible. E00862-10 6.26 Locking the steering (All EXC models) Note Danger of damage The parked vehicle can roll away or fall over. -
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
COMBINATION INSTRUMENT 7 – 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)
COMBINATION INSTRUMENT 7 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)
COMBINATION INSTRUMENT 7 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)
COMBINATION INSTRUMENT 7 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)
COMBINATION INSTRUMENT 7 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
COMBINATION INSTRUMENT 7 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 Clears the Next display Reduces Reduces SPEED/TR2 (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
PREPARING FOR USE 8 (All EXC models) – Adjust the free travel of the hand brake lever. ( p. 99) (All XC‑W models) – 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 » 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 9 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: < 10 °C (< 50 °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 Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
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.) Note 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 10
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 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 SERVICE SCHEDULE 10 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.
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Page 56: 11 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 move around if the shock absorber is detached 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
TUNING THE CHASSIS 11 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 spring length. -
Page 61: Adjusting The Riding Sag
TUNING THE CHASSIS 11 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
TUNING THE CHASSIS 11 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. Info Adjusting screw is located at the upper end of the right fork leg. -
Page 64: Adjusting The Spring Preload Of The Fork (All Six Days Models)
11 TUNING THE CHASSIS 11.14 Adjusting the spring preload of the fork (All Six Days models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 66) Main work – Turn the adjusting wings counterclockwise all the way. The marking +0 aligns with the adjusting wing on both fork legs. -
Page 65: Handlebar Position
TUNING THE CHASSIS 11 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 TUNING THE CHASSIS 11 (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. –...
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Page 68: 12 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
SERVICE WORK ON THE CHASSIS 12 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
SERVICE WORK ON THE CHASSIS 12 12.8 Installing the fork legs Main work – 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 COM (white adjusting screw). -
Page 72: Removing The Lower Triple Clamp (All Standard Exc/Xc-W Models)
12 SERVICE WORK ON THE CHASSIS 12.9 Removing the lower triple clamp (All standard EXC/XC-W models) Preparatory work – Raise the motorcycle with a lift stand. ( p. 66) – Remove the front wheel. p. 111) – Remove the headlight mask with the headlight. ( p. -
Page 73: Installing The Lower Triple Clamp (All Standard Exc/Xc-W Models)
SERVICE WORK ON THE CHASSIS 12 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. E00923-10 – Remove screw –... - Page 74 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Position the clutch line and wiring harness. – Mount screw but do not tighten yet. E00921-11 – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws,...
- Page 75 SERVICE WORK ON THE CHASSIS 12 – 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)
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Page 76: Installing The Lower Triple Clamp (All Six Days Models)
12 SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (All Six Days 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 77 SERVICE WORK ON THE CHASSIS 12 – 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)
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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 SERVICE WORK ON THE CHASSIS 12 Main work (All standard EXC/XC-W models) – Loosen screws – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Using a plastic hammer, tap lightly on the upper triple E00868-10 clamp to avoid stresses.
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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. 71) (All Six Days models) – Remove the lower triple clamp. p. -
Page 81: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS 12 – 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 M01517-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.21 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 83: Removing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 12 12.22 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 12.23 Installing the air filter box cover... -
Page 84: Removing The Air Filter
12 SERVICE WORK ON THE CHASSIS 12.24 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 85: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS 12 12.26 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 86: Sealing The Air Filter Box
12 SERVICE WORK ON THE CHASSIS 12.28 Sealing the air filter box Preparatory work – Remove the air filter box cover. ( p. 81) Main work – Seal the air filter box in the marked area S00847-10 Finishing work – Install the air filter box cover. -
Page 87: Changing The Glass Fiber Yarn Filling In The Main Silencer
SERVICE WORK ON THE CHASSIS 12 12.31 Changing the glass fiber yarn filling in 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. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"... - Page 88 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...
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Page 89: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS 12 – Remove screw with the rubber bushing. E00882-10 – 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 – 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. E00883-11 –...
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Page 91: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS 12 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, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS 12 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 distance of 18 chain rollers in the lower chain section.
- Page 95 SERVICE WORK ON THE CHASSIS 12 – 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.
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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
SERVICE WORK ON THE CHASSIS 12 – 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 right. -
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
SERVICE WORK ON THE CHASSIS 12 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 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 (All Xc-W Models)
Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple... -
Page 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.
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Page 107: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM 13 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.) Note Environmental hazard Hazardous substances cause environmental damage. -
Page 110: Checking The Brake Linings Of The Rear Brake
Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. - Page 111 BRAKE SYSTEM 13 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 112 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 162) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. E00348-10...
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Page 113: Wheels, Tires 14
WHEELS, TIRES 14 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
WHEELS, TIRES 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 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.
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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 15.1 Removing the battery Note 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. Note 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 ELECTRICAL SYSTEM 15 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. –...
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Page 122: Changing The Main Fuse
15 ELECTRICAL SYSTEM 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 ELECTRICAL SYSTEM 15 – 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. – Install a new main fuse.
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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
ELECTRICAL SYSTEM 15 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 126: Installing The Headlight Mask With The Headlight
15 ELECTRICAL SYSTEM (All XC‑W models) – 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) – Connect plug-in connectors E00900-11 (All XC‑W models) –... -
Page 127: Changing The Headlight Bulb
ELECTRICAL SYSTEM 15 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. – Clean and degrease the bulbs before mounting. –... -
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
ELECTRICAL SYSTEM 15 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 Finishing work – Install the headlight mask with the headlight. ( p. 124) – Check the headlight setting. ( p. 126) – Set kilometers or miles. ( p. 26) – Adjust the combination instrument function. ( p. 27) –... -
Page 131: Cooling System 16
COOLING SYSTEM 16 16.1 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 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
COOLING SYSTEM 16 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 COOLING SYSTEM 16 Finishing work – Check the coolant level. ( p. 130)
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Page 136: 17 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
TUNING THE ENGINE 17 – 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. -
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
TUNING THE ENGINE 17 Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running. 17.5 Programming ambient pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. -
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
TUNING THE ENGINE 17 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: 18 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
SERVICE WORK ON THE ENGINE 18 – Start the engine and check the response. 18.2 Checking 2-stroke oil level 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 144 18 SERVICE WORK ON THE ENGINE Main work – Remove protection cap of the diagnostics connector. E00917-10 – Put throttle grip into full throttle position and secure. E00819-11 – Plug in wake-up connector for priming the oil pump to the diagnostics connector The combination instrument lighting is activated.
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Page 145: Checking The Gear Oil Level
SERVICE WORK ON THE ENGINE 18 18.4 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Detach the foot brake lever spring. –... -
Page 146: Adding Gear Oil
18 SERVICE WORK ON THE ENGINE Main work – Remove gear oil drain plug with magnet. – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug with magnet. – Clean the sealing surface on the engine. –... - Page 147 SERVICE WORK ON THE ENGINE 18 – Remove filler plug – Add gear oil until it emerges from the drill hole of the gear oil monitoring screw. Engine oil (15W/50) ( p. 162) – Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level 10 Nm (7.4 lbf ft)
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Page 148: 19 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
CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 164) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. -
Page 150: 20 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) – Cover the vehicle with a tarp or similar cover that is permeable... -
Page 151: Preparing For Use After Storage
STORAGE 20 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: 21 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 –...
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Page 155: Technical Data 22
TECHNICAL DATA 22 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 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 TECHNICAL DATA 22 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 ® 243™ Cap nut, water pump impeller 5 Nm (3.7 lbf ft) Loctite ®...
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Page 158: Capacities
22 TECHNICAL DATA Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite ® 648™ Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite ® 648™ 22.3 Capacities 22.3.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. -
Page 159: Electrical System
TECHNICAL DATA 22 front 1.0 bar (15 psi) rear 1.0 bar (15 psi) Secondary ratio 14:50 (13:50) Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase 1,482 ± 10 mm (58.35 ± 0.39 in) Seat height unloaded 960 mm (37.8 in) Ground clearance unloaded... -
Page 160: Tires
(All XC‑W models) 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 14.18.8S.63... -
Page 161: Shock Absorber
TECHNICAL DATA 22 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 … 85 kg (165 … 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85 …... -
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) G 3/4 " Screw, oil fill level sensor 7 Nm (5.2 lbf ft) EJOT PT ® Screw, pressure regulator K60x25‑Z 2.3 Nm (1.7 lbf ft) Screw, seat fixing EJOTEJOFORM PT ®... - Page 163 TECHNICAL DATA 22 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) Loctite ®...
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Page 164: 23 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 SUBSTANCES 23 Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 166) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
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Page 166: 24 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 AUXILIARY SUBSTANCES 24 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...
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Page 168: 25 Standards
25 STANDARDS 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 169: Index Of Special Terms 26
INDEX OF SPECIAL TERMS 26 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: 27 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 28
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 Electric starter button ....19 Gear oil Emergency OFF switch ....19 adding .
- Page 174 INDEX removing ......80 Service ......11 Main fuse Service schedule .
- Page 175 INDEX Tire air pressure checking ......115 Tire condition checking ......115 Transporting .
- Page 176 *3213853en* 3213853en 03/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...