KTM 250 EXC 2024 Owner's Manual
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KTM 250 EXC 2024 Owner's Manual

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OWNER'S MANUAL
2024
250 EXC
250 EXC SIX DAYS
250 XC‑W
300 EXC
300 EXC SIX DAYS
300 XC-W
300 EXC HARDENDURO
300 XC-W HARDENDURO
Art. no. 3214838en

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  • Page 1 OWNER'S MANUAL 2024 250 EXC 250 EXC SIX DAYS 250 XC‑W 300 EXC 300 EXC SIX DAYS 300 XC-W 300 EXC HARDENDURO 300 XC-W HARDENDURO Art. no. 3214838en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.13 Opening the fuel tank filler cap ..19 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.14 Closing the fuel tank filler cap... 20 Symbols used ........6 6.15 Opening 2-stroke oil tank cap.... 20 Formats used........6 6.16 Closing 2-stroke oil tank cap .....
  • Page 5 TABLE OF CONTENTS Running in the engine ...... 37 11.12 Adjusting the compression damping of the fork ........55 Starting power of lithium-ion batteries at low temperatures .... 38 11.13 Adjusting the rebound damping of the fork........... 55 Preparing the vehicle for difficult operating conditions......
  • Page 6 TABLE OF CONTENTS 12.38 Checking the frame ...... 85 15.8 Changing the turn signal bulb (All EXC models)........115 12.39 Checking the link fork ....85 15.9 Checking the headlight setting ..116 12.40 Checking the throttle cable routing ..85 15.10 Adjusting the headlight range..
  • Page 7 TABLE OF CONTENTS 22 TROUBLESHOOTING ........ 145 23 BLINK CODE ..........148 24 TECHNICAL SPECIFICATIONS ....150 24.1 Engine .......... 150 24.1.1 All 250 models......150 24.1.2 All 300 models......150 24.2 Engine tightening torques ....151 24.3 Capacities ........152 24.3.1 Gear oil........

  • Page 8: Means Of Representation

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use (All EXC models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with transponder key) or the motor must be at a standstill (models without ignition lock or transponder key).

  • Page 12: Owner's Manual

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 13: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) I00464-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Fuel tank filler cap Seat Air filter box cover Side stand ( p. 22) Shift lever ( p. 21)

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) I00465-10 2-stroke oil tank cap Horn button ( p. 16) (All EXC models) Turn signal switch ( p. 17) (All EXC models) Light switch ( p. 17) (All EXC models) Start button ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering 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 17: Fork Part Number

    SERIAL NUMBERS 5 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. 401948-10...

  • Page 18: 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. W00295-10 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 19: Light Switch (All Exc Models)

    CONTROLS 6 Light switch (All EXC models) Light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central posi- tion. In this position, the low beam and tail light are switched on.

  • Page 20: Stop Button

    – The OBD has detected a malfunction in the vehi- cle 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 21: Overview Of Indicator Lights (All Xc-W Models)

    – The OBD has detected a malfunction in the vehi- cle 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 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS 6.14 Closing the fuel tank filler cap – Mount the fuel tank filler cap and turn it clockwise until release button engages. Info Route fuel tank breather hose without kinks. E00930-10 6.15 Opening 2-stroke oil tank cap – Fold loop upward.

  • Page 23: Cold Start Button

    CONTROLS 6 6.18 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 24: Foot Brake Lever

    6 CONTROLS 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 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.22 Side stand...

  • Page 25: Steering Lock (All Exc Models)

    CONTROLS 6 6.23 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. W00352-10 6.24 Locking the steering (All EXC models) Note Danger of damage The parked vehicle can roll away or fall over.

  • Page 26: 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 27: Adjusting 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 28: Viewing The Lap Time

    7 COMBINATION INSTRUMENT – 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. – Adjust hour display with the button and/or button – Wait 3 - 5 seconds.

  • Page 29: 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 30: Adjusting 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 31: 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 32: Viewing The Lap Time

    7 COMBINATION INSTRUMENT 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 33: 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 34: 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 35: Display Mode Speed/S1 (Stop Watch 1)

    COMBINATION INSTRUMENT 7 Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – briefly until S1 appears at the Repeatedly press the button top right of the display. S1 (Stop watch 1) shows the riding time based on TR1 and contin- ues running as soon as an impulse arrives from the wheel speed sensor.

  • Page 36: 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 37: 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. Adjusting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • Page 38: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 39: Running In The Engine

    PREPARING FOR USE 8 (All XC‑W models) – Adjust the basic position of the hand brake lever. – Adjust the basic position of the foot brake lever. p. 96) – Adjust the basic position of the shift lever. p. 129) –...

  • Page 40: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    40) – Riding at low temperatures and in snow. ( p. 40) Preparing the vehicle for rides on dry sand – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the KTM PowerParts fitting instructions. M01104-01...

  • Page 41: Preparing The Vehicle For Rides On Wet Sand

    PREPARING FOR USE 8 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the KTM PowerParts fitting instructions. M01105-01 – Clean the chain. Chain cleaner ( p. 161) – Mount the steel sprocket. – Grease the chain.

  • Page 42: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 43: 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 44: Starting Off

    9 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission to neutral position. Condition Ambient temperature: < 10 °C (< 50 °F) – Push the cold start button in all the way. Info If the engine is warm, the cold start button must be 401944-10...

  • Page 45: 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 46: Stopping, Parking

    9 RIDING INSTRUCTIONS Stopping, parking Warning Risk of injury People who act without authorization may not be familiar with the vehicle. – 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 hot when the vehicle is operated.

  • Page 47: 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 48: 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) p. 160) Info 400382-10 Do not refuel using pre-mixed fuel. –...

  • Page 49: 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 50 Final check: Check the vehicle for operating safety and take for a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make a service entry in KTM Dealer.net.

  • Page 51: Tuning The Chassis 11

    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 compression adjuster can be seen in slow to normal compression of the shock...

  • Page 52: 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 compression adjuster can be seen in the fast compression of the shock absorber.

  • Page 53: 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 54: 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. 51) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 55: 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 56: Adjusting The Rider Sag

    11 TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 59) 11.10 Adjusting the rider sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 59) – Remove the seat. ( p. 70) –...

  • Page 57: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 – As with the shock absorber, smaller differences in the rider's weight can be compensated by the spring preload. – However, if the fork frequently bottoms out (hard end stop on compression), harder springs must be fitted to avoid damage to the fork and frame.

  • Page 58: Handlebar Position

    11 TUNING THE CHASSIS Guideline Rebound damping Comfort 19 clicks Standard 17 clicks Sport 9 clicks Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.14 Handlebar position (Option: Triple clamp forged) The holes on the handlebar support are placed at a distance from the center.

  • Page 59: Adjusting The Handlebar Position

    TUNING THE CHASSIS 11 (Option: Triple clamp milled) The holes on the handlebar support are placed at a distance from the center. 3.5 mm (0.138 in) Hole distance The handlebar support can be mounted in two different posi- tions. W00322-10 11.15 Adjusting the handlebar position Warning...
  • Page 60 11 TUNING THE CHASSIS – Position the handlebar clamp. Mount screws tighten evenly. Guideline Screw, handlebar 20 Nm clamp (14.8 lbf ft) Info Make sure the installed gaps are even. (Option: Triple clamp milled) – Remove screws . Take off the handlebar clamp. Take off the handlebar and lay it to one side.

  • Page 61: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 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 62: 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. 59) – Remove the fork protector. ( p. 60) Main work – Push dust boots of both fork legs downward.

  • Page 63: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 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 64: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 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 on the bottom of fork leg REB (red adjuster). The compression damping is located at the top of fork leg COMP (white adjuster).

  • Page 65: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12 12.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 59) – Remove the front wheel. p. 102) – Remove the fork legs. p. 61) – Remove the headlight mask with the headlight.

  • Page 66: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 161) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 67 SERVICE WORK ON THE CHASSIS 12 (Option: Triple clamp forged) – Tighten screws Guideline Screw, bottom 15 Nm triple clamp (11.1 lbf ft) (Option: Triple clamp milled) – Tighten screws Guideline W00341-13 Screw, bottom 12 Nm (8.9 lbf ft) triple clamp –...

  • Page 68: Checking The Steering Head Bearing Play

    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 69: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12 (Option: Triple clamp forged) – Tighten screws Guideline Screw, top triple 20 Nm clamp (14.8 lbf ft) (Option: Triple clamp milled) – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) –...

  • Page 70: Installing Front Fender

    12 SERVICE WORK ON THE CHASSIS – Remove screws . Take off front fender. V00341-10 12.15 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-11 – Mount and tighten screws Guideline Remaining screws,...

  • Page 71: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12 Main work – Loosen and remove screws . Disconnect the tail light and turn signal plug-in connections. – Loosen screws and screws and remove them. – Take off the license plate holder with tail light toward the rear. W00327-10 –...

  • Page 72: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS – Position the right side cover on the tail section. Position the right side cover correctly behind the spoiler. Ensure that it is correctly seated on the tail section. – Mount and tighten screw Tighten screw hand-tight.

  • Page 73: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12 – Pull seat toward the fuel tank and lift it off. W00311-10 12.19 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat to the rear. The holding lugs engage in the recesses at the back.

  • Page 74: Removing The Frame Protector

    12 SERVICE WORK ON THE CHASSIS 12.20 Removing the frame protector – Remove the cable ties. – Remove screws with the bushings. – Take off the left frame protector. – Push the right frame protector to the front and take off at the bottom.

  • Page 75: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.23 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area I00438-10 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 76: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS 12.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 161) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 77: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Install the air filter. p. 74) – Install the air filter box cover. ( p. 73) 12.27 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p.

  • Page 78: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.30 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets 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 filling escape and the damper "burns"...
  • Page 79 SERVICE WORK ON THE CHASSIS 12 Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • Page 80: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings. (All EXC models) – Hang the horn and horn bracket to one side. S05360-10 – Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank. S05361-10 12.32 Installing the fuel tank...
  • Page 81 SERVICE WORK ON THE CHASSIS 12 – 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. (All EXC models) –...

  • Page 82: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS 12.33 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 80) 400678-01 12.34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...

  • Page 83: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 12.35 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 84: Checking The Chain, Rear Sprocket, Engine 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 85 SERVICE WORK ON THE CHASSIS 12 – Pull on the top section 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 86 12 SERVICE WORK ON THE CHASSIS – Check 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 87: Checking The Frame

    SERVICE WORK ON THE CHASSIS 12 12.38 Checking the frame – Check the frame for damage, cracks, and deformation. » If the frame shows signs of damage, cracks, or deforma- tion: – Change the frame. Guideline Repairs on the frame are not permitted. W00308-10 12.39 Checking the link fork...

  • Page 88: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank roller on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 89: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 12.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 90: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS – Position the cover with the membrane. Mount and tighten the screws. Info Use water to immediately clean up any brake fluid that has overflowed or spilled. 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid is a harmful substance.

  • Page 91: Removing The Engine Guard (All Special Models, All Xc-W Models)

    SERVICE WORK ON THE CHASSIS 12 – Now press the fluid into the system until it emerges from hole of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reser- voir to prevent overflowing. – Remove the bleeding syringe.

  • Page 92: 13 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 93: Checking The Brake Discs

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

  • Page 94: Adding Front Brake Fluid

    – 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.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 95: Checking That The Brake Linings Of The Front Brake Are Secured

    Checking that the brake linings of the front brake are secured 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 lining thickness ≥...

  • Page 96: Changing The Brake Linings Of The Front 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 97 BRAKE SYSTEM 13 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off 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, extract some if necessary.

  • Page 98: Checking The Free Travel Of Foot Brake Lever

    If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake. – Set the free travel on the foot brake lever in accordance with the specification. – Ensure that the adjustment steps are performed properly. (Your authorized KTM workshop will be glad to help.) – Disconnect spring –...

  • Page 99: Checking The Rear 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.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 100: Adding Rear Brake Fluid

    – 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.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 101: Checking That The Brake Linings Of The Rear Brake Are Secured

    Checking that the brake linings of the rear brake are secured 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 lining thickness ≥...
  • Page 102 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 103 BRAKE SYSTEM 13 – Check that spring plate in the brake caliper and brake pad sliding plate in the brake caliper bracket are seated cor- rectly. E00352-10 – Insert the new brake linings, insert the pin, and mount the cot- ter pins.

  • Page 104: 14 Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 59) Main work – Manually press the brake caliper toward the brake disc 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 pistons.

  • Page 105: Installing The Front Wheel

    WHEELS, TIRES 14 (All HARDENDURO models) – Remove spacer and brake disc guard H01890-10 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. –...

  • Page 106: Removing The Rear Wheel

    14 WHEELS, TIRES – Align the brake disc guard so that distance equal in size. S01633-10 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc.

  • Page 107: Installing The Rear Wheel

    WHEELS, TIRES 14 – Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork. Info Do not operate the foot brake lever when the rear wheel is removed. – Remove spacers H03002-10 14.4 Installing the rear wheel Warning...

  • Page 108: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 109: Checking Tire Pressure

    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 110 14 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica- tion of different spoke tensions.

  • Page 111: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 112: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM – Pull up battery holding bracket and remove the 12-V bat- tery to the rear. Info Pay attention to the wiring harness. W00358-10 15.2 Installing the 12-V battery Main work – Pull up battery holding bracket , insert the 12-V battery into the battery compartment with the terminals facing upward and secure with battery holding bracket 12-V battery (HJTZ5S-FP-C) (...

  • Page 113: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 Finishing work – Install the fuel tank. p. 78) – Mount the seat. ( p. 71) 15.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. –...

  • Page 114: Changing The Main Fuse

    12-V battery with this battery charger. The charging time may be longer at low temperatures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Power Parts instructions. Info Never remove cover – Switch off the battery charger after charging and disconnect it from the 12-V battery.

  • Page 115: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 Preparatory work – Remove the seat. ( p. 70) Main work – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 116: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM (All XC‑W models) – Disconnect plug-in connector and take off the head- light mask together with the headlight. W00351-10 15.6 Installing the headlight mask with the headlight Main work (All EXC models) – Join plug-in connectors W00350-11 (All XC‑W models) –...

  • Page 117: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 15.7 Changing the headlight bulb Note Impairments to reflectors and lamps Grease on the reflector reduces the emitted light. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service life.

  • Page 118: 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 119: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 116) 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 mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

  • Page 120: Diagnostics Connector

    15 ELECTRICAL SYSTEM Finishing work – Install the headlight mask with the headlight. ( p. 114) – Check the headlight setting. ( p. 116) – Set kilometers or miles. ( p. 24) – Adjust combination instrument function. ( p. 25) –...

  • Page 121: 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 122: Checking The Coolant Level

    16 COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets 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 123: Refilling With Coolant

    COOLING SYSTEM 16 Warning Danger of poisoning Coolant is harmful to health. – 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 124 16 COOLING SYSTEM – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 159) 400243-10 – Remove screw and wait until coolant emerges without bub- bles. –...

  • Page 125: Changing The Coolant

    COOLING SYSTEM 16 16.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets 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 126 16 COOLING SYSTEM – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant ( p. 159) 400243-10 – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 127: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Turn 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 128: Setting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 129 TUNING THE ENGINE 17 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 130: 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 131: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 – Start the vehicle at the new height above sea level and switch off the engine again. – Wait for at least five seconds. – Start the vehicle again and check the response of the vehicle. »...

  • Page 132: 18 Exhaust Control

    18 EXHAUST CONTROL 18.1 Programming the end positions of the exhaust control Info If work has been carried out on the exhaust control, the end positions must be reprogrammed. Condition The engine is off. Preparatory work – Remove the seat. ( p.
  • Page 133 EXHAUST CONTROL 18 – Mount diagnostics connector on the holder. D08200-10 Finishing work – Mount the seat. ( p. 71)

  • Page 134: 19 Service Work On The Engine

    19 SERVICE WORK ON THE ENGINE 19.1 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 135: Checking 2-Stroke Oil Level

    SERVICE WORK ON THE ENGINE 19 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 effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 136 19 SERVICE WORK ON THE ENGINE Preparatory work – Remove the seat. ( p. 70) – Stand the motorcycle upright on a horizontal surface. – Check 2-stroke oil level. ( p. 133) Main work – Pull diagnostics connector off the holder. I00451-10 –...

  • Page 137: Cleaning The Oil Screen In The Oil Tank

    SERVICE WORK ON THE ENGINE 19 – Check whether air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount the diagnostics connector on the holder. I00454-10 Finishing work –...
  • Page 138 19 SERVICE WORK ON THE ENGINE – Loosen clamps of the throttle valve body. (All EXC models) – Disconnect plug-in connector of the rear brake light switch. I00458-10 – Lift the subframe slightly and secure it. Info Pay attention to intake flange –...
  • Page 139 SERVICE WORK ON THE ENGINE 19 – Mount throttle valve body – Remove the locking piece and position the subframe. Info Pay attention to intake flange I00459-10 (All EXC models) – Join plug-in connector of the rear brake light switch. –...

  • Page 140: Checking The Gear Oil Level

    19 SERVICE WORK ON THE ENGINE 19.5 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 – Remove gear oil level monitoring screw –...

  • Page 141: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 19 Guideline Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft) with magnet – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.80 l Engine oil (0.85 qt.) (15W/50) p.
  • Page 142 19 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw. Engine oil (15W/50) ( p. 159) – Mount and tighten the gear oil level monitoring screw. Guideline Screw, gear oil level 8 Nm (5.9 lbf ft)

  • Page 143: Cleaning, Care 20

    CLEANING, CARE 20 20.1 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 144: Checks And Maintenance Steps For Winter Operation

    20 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 161) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 145: Storage 21

    – 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. 59) – Cover the vehicle with a tarp or a similar cover that is perme-...

  • Page 146: Preparing For Use After Storage

    21 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 147: Troubleshooting 22

    Check wiring for damage and electrical fuel injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – The engine has no idle speed Spark plug defective Change the spark plug. –...
  • Page 148 Check wiring for damage and electrical fuel injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.
  • Page 149 – Read out the fault memory using the KTM diagnostics tool. – 12-V battery discharged The 12-V battery is not being Check the charging voltage. charged by the alternator –...

  • Page 150: 23 Blink Code

    23 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine control Error level condition unit Blink code for malfunction...
  • Page 151 BLINK CODE 23 Blink code for malfunction indicator lamp 34 Malfunction indicator lamp flashes 3x long, 4x short Injection valve 1, cylinder 1 – input signal too low Error level condition Injection valve 1, cylinder 1 - input signal too high Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short...

  • Page 152: 24 Technical Specifications

    24 TECHNICAL SPECIFICATIONS 24.1 Engine 24.1.1 All 250 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Idle speed 1,400 … 1,500 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing...

  • Page 153: Engine Tightening Torques

    TECHNICAL SPECIFICATIONS 24 Piston rings 2 rectangular rings Engine lubrication Mixed lubrication X-distance (upper edge of piston to special tool) 0 … 0.10 mm (0 … 0.0039 in) Z distance (height of control flap) 50.0 mm (1.969 in) Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydraulically activated...

  • Page 154: Capacities

    24 TECHNICAL SPECIFICATIONS Bleeder screw, cylinder head 10.5 Nm (7.74 lbf ft) Bleeder screw, water pump cover M6x25 8 Nm (5.9 lbf ft) Nut, water pump impeller 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, alternator cover 8 Nm (5.9 lbf ft) Screw, clutch cover 10 Nm (7.4 lbf ft) Screw, clutch cover...

  • Page 155: Chassis

    TECHNICAL SPECIFICATIONS 24 Fuel reserve, approx. 1.5 l (1.6 qt.) 2-stroke oil tank content approx. 0.8 l (0.8 qt.) Engine oil, 2-stroke ( p. 159) 24.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XPLOR CC Shock absorber WP PDS Suspension travel...

  • Page 156: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM 24.7 Fork Fork article number...

  • Page 157: Shock Absorber

    TECHNICAL SPECIFICATIONS 24 Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.6 N/mm (26.3 lb/in) Fork length 940 mm (37.01 in)
  • Page 158 24 TECHNICAL SPECIFICATIONS Screw, fuel pump EJOT PT ® K60x30 Z 2.5 Nm (1.84 lbf ft) Screw, hose clip, inlet sleeve 2.8 Nm (2.07 lbf ft) Screw, intake air temperature sen- EJOT DELTA PT ® K50x18 T20 0.7 Nm (0.52 lbf ft) Screw, oil fill level sensor EJOT PT ®...
  • Page 159 TECHNICAL SPECIFICATIONS 24 Screw, oil tank on frame 5 Nm (3.7 lbf ft) Screw, push rod ball joint on the 10 Nm (7.4 lbf ft) rear brake cylinder Loctite ® 243™ Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ®...
  • Page 160 24 TECHNICAL SPECIFICATIONS Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, brake caliper on brake 45 Nm (33.2 lbf ft) caliper bracket Loctite ® 243™ Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Temperature sensor water to t- 10 Nm (7.4 lbf ft) plate Nut, fuel pump...

  • Page 161: Substances 25

    SUBSTANCES 25 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 162 25 SUBSTANCES Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 163) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 163: Auxiliary Substances 26

    AUXILIARY SUBSTANCES 26 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 164 26 AUXILIARY SUBSTANCES Silicone spray Recommended supplier MOTOREX ® – Silicone Spray 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 165: Standards 27

    STANDARDS 27 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 166: 28 Index Of Special Terms

    28 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 167: List Of Abbreviations 29

    LIST OF ABBREVIATIONS 29 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 168: 30 List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected a malfunction 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 169: Index

    INDEX of rear brake, checking ....99 INDEX of the rear brake, changing ... . . 99 12-V battery charging .
  • Page 170 INDEX snow ......40 Fuel tank filler cap wet sand ......39 closing .
  • Page 171 INDEX Seat mounting ......71 Main fuse removing ......70 changing .
  • Page 172 INDEX Tire condition checking ......106 Tire pressure checking ......107 Transporting .
  • Page 173 *3214838en* 3214838en 30.11.2023 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

This manual is also suitable for:

250 exc six days 2024250 xc-w 2024300 exc 2024300 exc six days 2024300 xc-w 2024300 exc hardenduro 2024 ... Show all

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