Page 1 250 EXC 250 EXC SIX DAYS 250 XC‑W 300 EXC 300 EXC SIX DAYS 300 XC-W 300 EXC HARDENDURO 300 XC-W HARDENDURO...
Page 3 INTRODUCTION 250 EXC EU 250 EXC SIX DAYS EU 250 XC‑W US 300 EXC EU 300 EXC SIX DAYS BR 300 EXC BR 300 EXC SIX DAYS CN 300 EXC SIX DAYS EU 300 XC‑W US 300 EXC SIX DAYS ASEAN...
Page 4 INDEX 6.18 Assembling the piston rod....32 INDEX MEANS OF REPRESENTATION ...... 7 6.19 Assembling the cartridge ....34 Symbols used ........7 6.20 Assembling the fork legs....36 Formats used........7 6.21 Lubricating the steering head bearing ........... 39 SAFETY ADVICE..........
Page 5 INDEX 9.10 Installing the shock absorber..... 62 13.4 Installing the headlight mask with the headlight ......... 109 9.11 Servicing the shock absorber..... 63 9.12 Removing the spring......64 14 WHEELS ..........111 9.13 Disassembling the damper ....65 14.1 Checking tire pressure ....111 9.14 Disassembling the piston rod ....
Page 6 INDEX 16.4 Adjusting the free travel of the 18.4.3 Removing the crankshaft handbrake lever ......143 bearing inner race...... 187 16.5 Checking the front brake fluid 18.4.4 Installing the crankshaft bearing level ..........143 inner race ......... 188 16.6 Adding front brake fluid....144 18.4.5 Changing the connecting rod, conrod bearing and crank pin..
Page 7 255 26.4.3 Coolant ........282 21.5 Performing the basic setting of the 26.4.4 Fuel ......... 282 throttle valve with the KTM diagnostics tool......256 26.5 Chassis ......... 283 26.6 Electrical system......284 21.6 Adjusting the idle speed ....256 26.7...
Page 8 INDEX 34 STANDARDS ..........335 35 LIST OF ABBREVIATIONS......336 INDEX ............. 337...
Page 9: Means Of Representation
MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
Page 10: Safety Advice
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips to help you repair and service your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
Page 11 SAFETY ADVICE 2 After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After completing a repair or service work, check the operating safety of the vehicle.
Page 12: Important Notes
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 13: Serial Numbers
SERIAL NUMBERS 4 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 Engine number The engine number is located on the left side of the engine over the engine sprocket.
Page 14 4 SERIAL NUMBERS 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 15 MOTORCYCLE 5 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) ( p.
Page 16 5 MOTORCYCLE – Press the start button. Info Do not open the throttle. Press the start button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at start- ing. At temperatures below 6 °C (45 °F), several attempts at starting may be necessary to warm-up the lithium-ion battery and thereby increase the starting power.
Page 17: Fork, Triple Clamp
FORK, TRIPLE CLAMP 6 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjuster clockwise as far as it will go. Info Adjusters COMP are located at the top end of the fork legs.
Page 18 6 FORK, TRIPLE CLAMP Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 13) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. W00297-11 Finishing work –...
Page 19: (All Standard Models)
FORK, TRIPLE CLAMP 6 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 13) – Remove the front wheel. ( p. 115) Main work – Remove screws and take off the clamp. – Remove the cable tie.
Page 20: Remove Screws
6 FORK, TRIPLE CLAMP Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Tighten screws Guideline Screw, bottom 12 Nm (8.9 lbf ft) triple clamp – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite...
Page 21 FORK, TRIPLE CLAMP 6 Servicing the fork Info The operations are the same on both fork legs. Condition The fork legs have been removed. – Disassemble the fork legs. ( p. 19) – Disassemble the cartridge. ( p. 22) – Disassemble the piston rod.
Page 22 6 FORK, TRIPLE CLAMP – Clamp the fork leg in the area of the lower triple clamp with the special tool. Clamping stand (T1403S) ( p. 332) – Remove screw . Remove the adjuster on the compression damping. D07926-10 – Undo cartridge Ring wrench (T14017) ( p.
Page 23 FORK, TRIPLE CLAMP 6 – Push dust boot downwards. – Remove fork protection ring D07935-10 – Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied. D07936-10 – Warm up the outside fork tube in area of the lower sliding bushing.
Page 24 6 FORK, TRIPLE CLAMP 6.11 Disassembling the cartridge Info The steps are the same for both cartridges. Preparatory work – Disassemble the fork legs. ( p. 19) Main work – Allow oil to drain from breathing hole Info Place a suitable container underneath. D07943-10 –...
Page 25 FORK, TRIPLE CLAMP 6 – Remove spacing tube D07951-10 – Unclamp the cartridge, turn it round, and clamp it on the flat surface of the pressure vessel. Guideline Use soft jaws. – Loosen pressure stage unit using the special tool. Special socket (T14084) ( p.
Page 26 6 FORK, TRIPLE CLAMP 6.12 Disassembling the piston rod Info The steps are the same for both piston rods. Preparatory work – Disassemble the fork legs. ( p. 19) – Disassemble the cartridge. ( p. 22) Main work – Clamp the piston rod using the special tool. Clamping stand (T14016S) ( p.
Page 27 FORK, TRIPLE CLAMP 6 – Remove spring – Warm up the piston rod in area Guideline 50 °C (122 °F) – Remove tap rebound – Remove O-ring D07966-10 – Remove needle with the spring and the O-ring. – Remove O-ring –...
Page 28 6 FORK, TRIPLE CLAMP – Remove gasket support Info If the gasket support is below the clamping tool, unclamp the piston rod and remove the gasket support. D07973-10 6.13 Disassembling the pressure stage unit Info The steps are the same for both pressure stage units. Preparatory work –...
Page 29 FORK, TRIPLE CLAMP 6 – Remove washer – Remove tap compression D07984-10 – Remove piston – Remove spring seats with spring D07986-10 – Remove X-ring – Remove O-ring D07978-10 6.14 Disassembling the gasket support Info The steps are the same for both gasket supports. Preparatory work –...
Page 30 6 FORK, TRIPLE CLAMP – Remove O-ring – Remove seal ring D07958-10 – Press out the pilot bushing using special tool Guideline Use soft jaws. Pressing tool (T14076) ( p. 333) D07959-10 6.15 Checking the fork legs Info The operations are the same on both fork legs. Condition The fork legs have been disassembled.
Page 31 FORK, TRIPLE CLAMP 6 – Measure the run-out of the inside fork tube. ≤ 0.20 mm (≤ 0.0079 in) Run-out of the inside fork tube » If the measured value is greater than the specified value: – Change the inside fork tube. D07917-11 –...
Page 32 6 FORK, TRIPLE CLAMP » If the measured value is greater than the specified value: – Replace the piston rod. – Check the spring length. Guideline Spring length with preload 476 mm (18.74 in) spacer(s) » If the measured value is greater than the specified value: –...
Page 33 FORK, TRIPLE CLAMP 6 – Mount ring The label faces upward. – Mount lock ring D07957-10 6.17 Assembling the pressure stage unit Info The steps are the same for both pressure stage units. – Mount O-ring – Mount X-ring D07978-11 –...
Page 34 6 FORK, TRIPLE CLAMP – Mount compression shim stack Info Note the setting list. D07983-10 – Mount piston with seal ring. Guideline of piston from above View of piston from below View D07982-10 – Mount rebound shim stack Info Note the setting list. –...
Page 35 FORK, TRIPLE CLAMP 6 – Lightly grease the seal ring of the gasket support. Lubricant (T14034) ( p. 316) – Lightly grease the O-ring of the gasket support. Lubricant (T159) ( p. 316) – Mount gasket support on the piston rod with the thread facing upward.
Page 36 6 FORK, TRIPLE CLAMP – Mount spring – Mount compression shim stack Info Note the setting list. – Press the shim stack down against the spring force and over the collar of the tap rebound. D07965-10 – Mount piston with the piston ring. Guideline of piston from above View...
Page 37 FORK, TRIPLE CLAMP 6 – Mount and tighten gasket support Guideline Gasket support M24.5x1 46 Nm (33.9 lbf ft) on cartridge Loctite ® 243™ D07952-11 – Unclamp the cartridge, turn it round, and clamp it on the flat surface of the pressure vessel. Guideline Use soft jaws.
Page 38 6 FORK, TRIPLE CLAMP – Position spring with the preload spacer(s). D07949-11 – Pull the spring down and then pull the piston rod up slightly so that the the spring seat can be mounted. Info The piston rod may slip down during this step and must be pulled up again.
Page 39 FORK, TRIPLE CLAMP 6 – Push on support ring – Sand edges of the sliding bushings with 600 grit sandpaper; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) ( p. 315) – Push on lower sliding bushing –...
Page 40 6 FORK, TRIPLE CLAMP – Slide the cartridge into the inside fork tube. D07934-10 – Lightly lubricate O-ring on the rebound adjuster. Lubricant (T159) ( p. 316) – Mount and tighten the rebound adjuster. Guideline Rebound adjuster on M20x1 40 Nm (29.5 lbf ft) the axle clamp –...
Page 41 FORK, TRIPLE CLAMP 6 Guideline Screw, compression M4x0.5 2 Nm (1.5 lbf ft) adjuster Condition Value not determined on removal: – Turn compression adjuster and rebound adjuster clockwise all the way. – Turn counterclockwise by the number of clicks correspond- ing to the fork type.
Page 42 6 FORK, TRIPLE CLAMP Main work – Loosen screw – Remove screw – Take off the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage. Do not kink the cables or lines. W00353-10 –...
Page 43 FORK, TRIPLE CLAMP 6 – Position the fork legs. Bleeder screws are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp. The pressure and rebound damping is located in the left and right fork leg.
Page 44 6 FORK, TRIPLE CLAMP Finishing work – Mount the handlebar cushion. – Install front fender. ( p. 108) – Install the front wheel. ( p. 116) – Install the headlight mask with the headlight. ( p. 109) – Check the wiring harness, cables, and brake and clutch lines for freedom of movement and correct routing.
Page 45 FORK, TRIPLE CLAMP 6 – Remove upper bearing ring with special tool Tool bracket (58429089000) ( p. 321) Pressing tool (58429092000) ( p. 322) R02804-10 – Remove lower steering head bearing – Remove the seal ring. – Grease and mount the new seal ring. –...
Page 46 6 FORK, TRIPLE CLAMP Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...
Page 47 FORK, TRIPLE CLAMP 6 – Remove the motorcycle from the lift stand. ( p. 13)
Page 48: Handlebar, Controls
7 HANDLEBAR, CONTROLS Handlebar position (All standard models) 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. W00321-10 (All special models) The holes on the handlebar support are placed at a distance from the center.
Page 49: Table Of Contents
HANDLEBAR, CONTROLS 7 (All standard models) – Remove screws . Take off the handlebar clamp. Take off the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables or lines. –...
Page 50: Info
7 HANDLEBAR, CONTROLS Info Make sure the cables and wiring are positioned cor- rectly. – 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. Adjusting the basic position of the clutch lever –...
Page 51 HANDLEBAR, CONTROLS 7 – Check that screw is firmly seated. Guideline Screw, fixed 5 Nm (3.7 lbf ft) grip Loctite ® 243™ Diamond must be positioned visibly as shown in the fig- ure. W00325-10 Checking the throttle cable routing Warning Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor- rectly.
Page 52: Info
7 HANDLEBAR, CONTROLS 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 53 HANDLEBAR, CONTROLS 7 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 54 7 HANDLEBAR, CONTROLS – 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 slowly.
Page 55 FRAME 8 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 Changing the footrests Preparatory work –...
Page 56 8 FRAME – Position spring as shown. The spring engages in area D08172-10 – Apply pressure to the spring with your thumb. – Mount pin B06183-10 – Mount the washer and splint – Repeat these steps on the opposite side. B06182-10 Finishing work –...
Page 57 FRAME 8 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. S05536-11 Installing the frame protector –...
Page 58 9 SHOCK ABSORBER, LINK FORK Adjusting the high-speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...
Page 59 SHOCK ABSORBER, LINK FORK 9 Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen.
Page 60 9 SHOCK ABSORBER, LINK FORK Main work – Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090100) Pin, sag scale (00029990010) – Note the value as dimension 402415-10 Finishing work –...
Page 61 SHOCK ABSORBER, LINK FORK 9 Checking the rider sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 57) – With another person holding the motorcycle, the rider, wear- ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
Page 62 9 SHOCK ABSORBER, LINK FORK Main work – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (90129051000) ( p. 325) Info If the spring cannot be fully released, the spring must be removed to accurately measure the spring length.
Page 63 SHOCK ABSORBER, LINK FORK 9 Main work – Select and mount a suitable spring. Guideline Spring rate Weight of rider: 65 … 66 N/mm (377 lb/in) 75 kg (143 … 165 lb.) Weight of rider: 75 … 69 N/mm (394 lb/in) 85 kg (165 …...
Page 64 9 SHOCK ABSORBER, LINK FORK – Remove screw and lower the rear wheel with the link fork as far as possible without blocking the rear wheel. Secure the rear wheel in this position. – Remove screw , push splash protector to the side, and remove the shock absorber.
Page 65 SHOCK ABSORBER, LINK FORK 9 Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Fit and tighten screws Guideline Remaining screws, EJOT PT ® 2 Nm (1.5 lbf ft) chassis K60x25‑Z Finishing work – Install the main silencer. ( p.
Page 66 9 SHOCK ABSORBER, LINK FORK 9.12 Removing the spring Condition The shock absorber has been removed. – Clamp the shock absorber into the vise. Guideline Use soft jaws. – Measure and note the spring length while the spring is under tension.
Page 67 SHOCK ABSORBER, LINK FORK 9 9.13 Disassembling the damper Preparatory work – Remove the spring. ( p. 64) Main work – Make a note of the present state of compression damping and rebound damping – Open the adjusters of the compression and rebound damping completely.
Page 68 9 SHOCK ABSORBER, LINK FORK – Remove the piston rod. Z03171-10 – Remove adjusting ring with the clamping ring. – Drain the oil. Info Place a collecting container underneath. Z03180-10 – Remove compression adjuster using the special tool. Remove the spring and piston. Socket (T18004) ( p.
Page 69 SHOCK ABSORBER, LINK FORK 9 – Remove compression shim stack Info Guide the compression shim stack onto a screwdriver and put them aside together. – Heat up support in area Guideline 50 °C (122 °F) Z03174-10 – Remove holder. – Remove rebound shim stack and washer.
Page 70 9 SHOCK ABSORBER, LINK FORK – Measure the inside diameter on both ends and in the middle of the damper cartridge. Damper cartridge ≤ 46.08 mm (≤ 1.8142 in) Diameter » If the measured value is greater than the specified value: –...
Page 71 SHOCK ABSORBER, LINK FORK 9 – Clamp the shock absorber into the vise. Guideline Use soft jaws. – Remove both collar bushings of the heim joint with a spe- cial tool. Drift (T120) ( p. 330) Z03196-10 – Press the heim joint against a lock ring using the special tool. Pressing tool (T1207S) ( p.
Page 72 9 SHOCK ABSORBER, LINK FORK – Position both collar bushings and press in. Info Always use new collar bushings. Z03201-10 9.17 Assembling the piston rod – Clamp the piston rod with the fork in a bench vise. Guideline Use soft jaws. –...
Page 73: Nm (29.5 Lbf Ft)
SHOCK ABSORBER, LINK FORK 9 – Mount rebound shim stack with the smaller washers facing upward. – Mount and tighten support Guideline Piston rod M12x1 40 Nm (29.5 lbf ft) holder Loctite ® 2701™ Z03189-10 – Mount compression shim stack with the smaller washers facing downward.
Page 74 9 SHOCK ABSORBER, LINK FORK – Clamp the damper in a bench vise. Guideline Use soft jaws. – Mount adjusting ring with the clamping ring. Info The adjusting ring cannot be mounted after the piston rod has been mounted. Z03195-10 –...
Page 75 SHOCK ABSORBER, LINK FORK 9 – Turn counterclockwise by the number of turns correspond- ing to the shock absorber type. Guideline Highspeed compression damping Comfort 2.5 turns Standard 2 turns Sport 1.5 turns – Turn adjusting screw clockwise up to the last percepti- ble click.
Page 76 9 SHOCK ABSORBER, LINK FORK – Clamp the damper as shown. Guideline Use soft jaws. Info The filling port must be located at the highest position. The piston rod moves in and out during filling; do not immobilize it by holding it with your hand. Z02334-10 –...
Page 77 SHOCK ABSORBER, LINK FORK 9 – When the pressure gauge reaches the specified value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 –...
Page 78 9 SHOCK ABSORBER, LINK FORK – When the pressure gauge reaches the specified value, turn control lever Damper to Vacuum. Guideline 3 bar The pressure gauge drops to the required value. 0 bar – When the pressure gauge reaches the required value, activate the On/Off switch.
Page 79 SHOCK ABSORBER, LINK FORK 9 – Secure the special tool in the vise. Filling tool (T170S1) ( p. 333) Filling adapter (T18001) ( p. 334) – Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen –...
Page 80 9 SHOCK ABSORBER, LINK FORK – Measure the total spring length while the spring is not under tension. – Position spring Guideline Spring rate Weight of rider: 65 … 66 N/mm (377 lb/in) 75 kg (143 … 165 lb.) Weight of rider: 75 … 69 N/mm (394 lb/in) 85 kg (165 …...
Page 81 SHOCK ABSORBER, LINK FORK 9 9.22 Checking the link fork – Check the link fork for damage, cracks, and deformation. » If the link fork shows signs of damage, cracks, or deforma- tion: – Change the link fork. Guideline Repairs on the link fork are not permitted. W00309-10 9.23 Checking the shock absorber heim joint for play...
Page 82 9 SHOCK ABSORBER, LINK FORK 9.25 Removing the link fork Preparatory work – Raise the motorcycle with a lift stand. ( p. 13) – Remove the rear wheel. ( p. 119) – Remove the frame protector. ( p. 55) Main work –...
Page 83: Loctite
SHOCK ABSORBER, LINK FORK 9 – Remove nut – Remove the swingarm pivot. – Take off the link fork. B06186-10 9.26 Installing the link fork Main work – Position the link fork. Mount the swingarm pivot. – Mount and tighten nut Guideline Nut, fork pivot M16x1.5...
Page 84 9 SHOCK ABSORBER, LINK FORK – Position the brake line in the guide. B06185-10 Finishing work – Install the rear wheel. ( p. 120) – Check the chain tension. ( p. 125) – Remove the motorcycle from the lift stand. ( p.
Page 85 SHOCK ABSORBER, LINK FORK 9 – Remove bushing R02758-10 – Remove radial shaft seal rings using a suitable tool. – Remove stop disks – Press out bearing using a suitable tool. – Using a suitable tool, press in new bearing –...
Page 86 9 SHOCK ABSORBER, LINK FORK Right fork bearing – Remove collar bushings R02760-10 – Remove bushing R02761-10 – Remove radial shaft seal rings using a suitable tool. – Press out bearing using a suitable tool. – Using a suitable tool, press in new bearing –...
Page 87 SHOCK ABSORBER, LINK FORK 9 – Grease the radial shaft seal rings. Long-life grease ( p. 316) – Position the collar bushings with the shoulder facing inward. R02764-10 Finishing work – Install the link fork. ( p. 81) – Install the rear wheel. ( p.
Page 88: Exhaust System
10 EXHAUST SYSTEM 10.1 Removing 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. – Remove screws – Pull off the main silencer with exhaust sleeve and the spring ring from the manifold.
Page 89 EXHAUST SYSTEM 10 – Disconnect plug-in connector of the lambda sensor. – Expose the cable. B06175-10 – Remove springs Spring hook (50305017000C1) ( p. 329) B06176-10 – Remove screw – Take off the manifold in a forward direction. B06177-10 (All EU models apart from EU) –...
Page 90 10 EXHAUST SYSTEM – Remove screw – Take off the manifold in a forward direction. B06173-10 10.4 Installing the manifold Main work (All EU models) – Position the manifold and mount springs Spring hook (50305017000C1) ( p. 329) B06178-10 – Mount and tighten screw Guideline Remaining screws,...
Page 91 EXHAUST SYSTEM 10 (All EU models apart from EU) – Position the manifold and mount springs Spring hook (50305017000C1) ( p. 329) B06171-10 – Mount screw , but do not tighten it yet. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis B06173-11 –...
Page 92 10 EXHAUST SYSTEM Main work – Remove screws . Pull out inner tube with O-ring – Pull glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for dam- age. – Mount new glass fiber yarn filling on the inner tube.
Page 93: Air Filter
AIR FILTER 11 11.1 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw S05540-10 – Pull off the air filter box cover in area and push it sideways and forward. Take off the air filter box cover. S05541-10 11.2 Installing the air filter box cover...
Page 94 11 AIR FILTER 11.3 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.
Page 95 AIR FILTER 11 11.5 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Page 96: Fuel Tank, Seat, Trim
12 FUEL TANK, SEAT, TRIM 12.1 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
Page 97 FUEL TANK, SEAT, TRIM 12 12.3 Removing the seat – Remove screw W00301-10 – Pull seat toward the fuel tank and lift it off. W00311-10 12.4 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.
Page 98 12 FUEL TANK, SEAT, TRIM 12.5 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
Page 99 FUEL TANK, SEAT, TRIM 12 – Remove screw with the rubber bushing. S05377-10 – 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.
Page 100 12 FUEL TANK, SEAT, TRIM Main work – Check the throttle cable routing. ( p. 49) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged.
Page 101 FUEL TANK, SEAT, TRIM 12 Finishing work – Mount the seat. ( p. 95) 12.7 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
Page 102 12 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
Page 103 FUEL TANK, SEAT, TRIM 12 Info Remaining fuel may flow out of the fuel hose. – Mount wash cap set Wash cap set (81212016100) (All BR/CN/XC-W models) – Clean quick release coupling thoroughly with com- pressed air. Info Under no circumstances should dirt enter into the fuel line.
Page 104: Nm (29.5 Lbf Ft)
12 FUEL TANK, SEAT, TRIM – Position the fuel pump. The connector and the fuel line face the rear. – Thread the fuel line downwards. – Mount and tighten screws Guideline EJOT PT Screw, fuel pump ® 2.5 Nm K60x30 Z (1.84 lbf ft) –...
Page 105 FUEL TANK, SEAT, TRIM 12 12.9 Changing the fuel pump 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 106 12 FUEL TANK, SEAT, TRIM (All BR/CN/XC-W models) – Clean quick release coupling thoroughly with com- pressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! – Disconnect the quick release coupling. D08177-10 Info Remaining fuel may flow out of the fuel hose.
Page 107 FUEL TANK, SEAT, TRIM 12 (All EU/ASEAN models) – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –...
Page 108 12 FUEL TANK, SEAT, TRIM 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 109 FUEL TANK, SEAT, TRIM 12 – Select "Actuator test" > "Fuel pump". Guideline Maximum duration of the 3 min actuator test – Check the fuel pressure with the fuel tank filler cap closed. Fuel pressure When the fuel pump is 3.3 …...
Page 110: Mask, Fender
13 MASK, FENDER 13.1 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 109) Main work – Remove screws V00340-10 – Remove screws . Take off front fender. V00341-10 13.2 Installing front fender Main work –...
Page 111 MASK, FENDER 13 13.3 Removing the headlight mask with the headlight – Release screws – Slide the headlight mask up and swing it forward. – Disconnect the brake line at the headlight mask. W00349-10 (All EXC models) – Detach plug-in connectors and take off the headlight mask with the headlight.
Page 112 13 MASK, FENDER – Position the brake line in the brake line guide. – Position the headlight mask. The holding lugs engage in the fender. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis W00349-11 Finishing work –...
Page 113 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 114 DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.
Page 115 WHEELS 14 – Check the front and rear brake disc thickness at multiple points for the dimension Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings. Brake discs - wear limit (All standard models) front 2.5 mm (0.098 in) 400257-10...
Page 116 14 WHEELS – Check for lateral and radial run-out of the rims. Lateral runout Outside the rim joint < 1.8 mm (< 0.071 in) Radial runout Outside the rim joint < 1.8 mm (< 0.071 in) » If the measured value is greater than the specified value: –...
Page 117 WHEELS 14 14.7 Front wheel 14.7.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 13) 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...
Page 118 14 WHEELS (All HARDENDURO models) – Remove spacer and brake disc guard H01890-10 14.7.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. –...
Page 119: Loctite
WHEELS 14 – 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 120 14 WHEELS (All special models) – Remove screws . Take off the brake disc. – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. – Mount and tighten screws Guideline Screw, front 14 Nm (10.3 lbf ft) brake disc Loctite...
Page 121 WHEELS 14 – Clean, grease, and mount spacing tube Long-life grease ( p. 316) – Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer bearing race, otherwise the bearing will be damaged when it is pressed in.
Page 122 14 WHEELS – 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 14.8.2 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
Page 123 WHEELS 14 – Position chain adjuster . Mount nut , but do not tighten it yet. – Make sure that chain adjusters are fitted correctly on adjusting screws – Check the chain tension. ( p. 125) – Tighten nut Guideline Nut, wheel spindle, M22x1.5 80 Nm (59 lbf ft)
Page 124 14 WHEELS Finishing work – Install the rear wheel. ( p. 120) – Remove the motorcycle from the lift stand. ( p. 13) 14.8.4 Changing the rear wheel bearing Preparatory work – Raise the motorcycle with a lift stand. ( p.
Page 125 WHEELS 14 – Press new bearing all the way in from the outside to the inside. Info Only press the bearing in via the outer bearing race, otherwise the bearing will be damaged when it is pressed in. Z00155-10 – Mount lock ring The lock ring engages audibly.
Page 126 14 WHEELS 14.8.5 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 124) 400678-01 14.8.6 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...
Page 127 WHEELS 14 14.8.7 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 128 14 WHEELS – 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 129 WHEELS 14 – 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 130 14 WHEELS 14.8.9 Adjusting 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 131 WHEELS 14 Main work – Remove screw – Remove screw – Take the engine sprocket cover off to the front. B06187-10 – Have an assistant operate the rear brake. – Remove screw with washer. B06188-10 – Remove connecting link of the chain. Info Cover the components to protect them against damage.
Page 132 14 WHEELS (All special models) – Remove fittings . Take off the rear sprocket. – Position the new rear sprocket. Mount and tighten the fit- tings. Guideline Nut, rear 35 Nm (25.8 lbf ft) sprocket screw Loctite ® 2701™ D08242-10 –...
Page 133 WHEELS 14 – Remove the motorcycle from the lift stand. ( p. 13)
Page 134: Wiring Harness, Battery
15 WIRING HARNESS, BATTERY 15.1 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all electrical power consumers of the vehicle. Preparatory work –...
Page 135 WIRING HARNESS, BATTERY 15 15.3 Connecting the negative cable of the 12-V battery Main work – Connect negative cable of the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) D08168-10 Finishing work – Mount the seat. ( p.
Page 136 15 WIRING HARNESS, BATTERY – Pull back positive terminal cover and disconnect positive cable from the 12-V battery. – Remove screw W00357-10 – Pull up battery holding bracket and remove the 12-V bat- tery to the rear. Info Pay attention to the wiring harness. W00358-10 15.5 Installing the 12-V battery...
Page 137 WIRING HARNESS, BATTERY 15 – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) – Connect negative cable to the 12 V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disks must be mounted under screws cable sockets with the claws toward the battery termi-...
Page 138 15 WIRING HARNESS, BATTERY Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, or charging time is exceeded, the 12-V battery will be destroyed.
Page 139 WIRING HARNESS, BATTERY 15 Main work – Carry out start procedure. ( p. 13) – Measure the voltage between the specified points. Measuring point plus (+) – Measuring point Ground (−) Charging voltage 5,000 rpm 13.5 … 15.0 V » If the displayed value is less than the specified value: –...
Page 140 15 WIRING HARNESS, BATTERY 15.9 Checking the starter relay Preparatory work – Remove the seat. ( p. 95) – Remove the fuel tank. ( p. 96) – Disconnect the negative cable of the 12-V battery. ( p. 132) Main work –...
Page 141 » If the wiring harness is damaged: – Change the wiring harness. Info Repair of the wiring harness is not H05465-10 recommended by KTM. 15.11 Diagnostics connector Diagnostics connector is located under the seat below the engine control unit. H00933-12 15.12...
Page 142: Brake System
16 BRAKE SYSTEM 16.1 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. – Check the brake linings for lining thickness ≥...
Page 143 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 144 16 BRAKE SYSTEM – Insert the new brake linings, insert the pin, and mount the cot- ter pins. Info Always change the brake linings in pairs. – Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.
Page 145 BRAKE SYSTEM 16 16.4 Adjusting the free travel of the handbrake lever – Check the free travel of the hand brake lever. ( p. 142) – Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel.
Page 146 16 BRAKE SYSTEM 16.6 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
Page 147 BRAKE SYSTEM 16 Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane – Add brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 (...
Page 148 16 BRAKE SYSTEM Info Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Cover the painted parts. – Remove screws – Take off cover with membrane.
Page 149 BRAKE SYSTEM 16 16.8 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. – Check the brake linings for lining thickness ≥...
Page 150 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 151 BRAKE SYSTEM 16 – Insert the new brake linings, insert the pin, and mount the cot- ter pins. Info Always change the brake linings in pairs. – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.
Page 152 16 BRAKE SYSTEM 16.11 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
Page 153 BRAKE SYSTEM 16 16.12 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
Page 154 16 BRAKE SYSTEM 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 Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. Preparatory work –...
Page 155 BRAKE SYSTEM 16 Warning Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
Page 156 16 BRAKE SYSTEM – Stand the vehicle upright. – Correct the brake fluid to marking Brake fluid DOT 4 / DOT 5.1 ( p. 314) – Mount and tighten screw cap with the membrane and O- ring. Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
Page 157: Lighting System, Instruments
LIGHTING SYSTEM, INSTRUMENTS 17 17.1 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 158 17 LIGHTING SYSTEM, INSTRUMENTS Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze orange cap in the area of the holding lugs and take it off. –...
Page 159 LIGHTING SYSTEM, INSTRUMENTS 17 17.4 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 156) 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 160 17 LIGHTING SYSTEM, INSTRUMENTS Finishing work – Install the headlight mask with the headlight. ( p. 109) – Check the headlight setting. ( p. 156) – Set kilometers or miles. ( p. 158) – Adjust combination instrument function. ( p. 159) –...
Page 161 LIGHTING SYSTEM, INSTRUMENTS 17 – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu is displayed and the active functions are shown. – Repeatedly press the button briefly until Km/h/Mph flashes.
Page 162 17 LIGHTING SYSTEM, INSTRUMENTS 17.10 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. –...
Page 163 LIGHTING SYSTEM, INSTRUMENTS 17 Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. Finishing work – Plug in combination instrument connector. –...
Page 164 18 ENGINE 18.1 Removing the engine Preparatory work (All XC-W and special models) – Remove the engine guard. ( p. 55) – Raise the motorcycle with a lift stand. ( p. 13) – Remove the frame protector. ( p. 55) –...
Page 165 ENGINE 18 – Push hose clip back and pull the hose off the engine. – Pull the fuel vapor valve off of the holder and remove it. B06202-10 – Unplug connector on the brake light switch. B06200-10 – Push back hose clamp –...
Page 166 18 ENGINE – Loosen hose clip – Lift up the subframe slightly. – Take off hose clip B06204-10 – Pivot the subframe up and secure it. Z01417-10 – Remove screw – Remove screw – Take off the engine sprocket cover. B06205-10 –...
Page 167 ENGINE 18 – Remove connecting link of the chain. Info Cover the components to protect them against damage. – Take off the chain. B06208-10 – Remove screw with washer. – Take off the engine sprocket. B06207-10 – Disconnect spark plug connector B06209-10 –...
Page 168 18 ENGINE – Remove the cable ties and expose the cable. B06212-10 – Unplug connector – Disconnect plug-in connector – Disconnect plug-in connector – Expose the cable. B06213-10 – Remove spring – Push back protection cap and remove the nut. –...
Page 169 ENGINE 18 (All BR/CN/XC-W models) – Remove screws – Remove screws – Take off the engine braces. B06216-10 – Loosen hose clip – Pull the throttle valve body out of the intake flange toward the rear and hang it to one side. B06217-10 –...
Page 170 18 ENGINE 18.2 Installing the engine Main work – Position the engine in the frame. Info The help of an assistant is useful in this step. Make sure that the motorcycle is sufficiently secured against falling over. Cover the components to protect them against damage. –...
Page 171 ENGINE 18 Guideline Screw, engine M8x15 25 Nm (18.4 lbf ft) brace Loctite ® 2701™ – Tighten screws and nut Guideline Engine bracket 60 Nm screw (44.3 lbf ft) Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) (All BR/CN/XC-W models) –...
Page 172 18 ENGINE – Plug in connector – Route the cable without tension and join plug-in connector – Route the cable without tension and join plug-in connector B06213-11 – Route the cables without tension and secure with the cable ties. B06212-10 –...
Page 173 ENGINE 18 – Plug in spark plug connector B06209-11 – Slide on the engine sprocket with the collar facing the engine. – Mount screw with washer, but do not tighten yet. Guideline Screw, drive 60 Nm (44.3 lbf ft) chain engine Loctite ®...
Page 174 18 ENGINE – Position the engine sprocket cover. – Mount and tighten screw Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder – Mount and tighten screw Guideline Screw, engine 15 Nm (11.1 lbf ft) B06205-11 sprocket cover – Remove the locking piece and position the subframe.
Page 175 ENGINE 18 – Mount fuel vapor valve on the holder. Info Make sure the cables and wiring are routed cor- rectly. – Plug the hose into the engine and position hose clip B06202-11 – Plug in connector B06222-11 – Plug in hose piece B06221-11 –...
Page 176 Clear the fault memory using the KTM diagnostics tool. – Go for a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leaks. – Check the gear oil level. ( p.
Page 177 ENGINE 18 – Loosen screws in a crisscross pattern and remove them. – Take off the cylinder head. Info The cylinder head consists of two parts; the com- bustion chamber liner and the cylinder head cover. E03373-10 – Remove O-rings E03268-10 Removing the cylinder –...
Page 178 18 ENGINE – Remove screws – Take off both covers of the exhaust control with the gas- kets. E03271-10 – Remove nuts Info Raise the cylinder slightly to be able to remove the front nuts. – Carefully slide the cylinder up and take it off. E03272-10 –...
Page 179 ENGINE 18 18.3.3 Draining the gear oil – Remove gear oil drain plug with the magnet and seal ring. – Let the gear oil drain fully. E03283-10 18.3.4 Disassembling the alternator side Preparatory work – Clamp the engine into the engine work stand. ( p.
Page 180 18 ENGINE – Take off Bendix E03280-10 – Pull the rubber grommet out of the engine case. – Remove screws – Take off the crankshaft speed sensor. E03281-10 18.3.5 Dismantling the clutch side Preparatory work – Clamp the engine into the engine work stand. ( p.
Page 181 ENGINE 18 – Remove screws – Take off the clutch cover with the gasket. Info Ensure that the cylindrical pins remain in place. E03286-10 Removing the clutch discs – Loosen screws in an incremental crisscross pattern and remove them. – Take off spring retainer –...
Page 182 18 ENGINE – Hold the inner clutch hub with special tool . Loosen Holding wrench (59029003100) ( p. 322) Alternative 1 Holding wrench (51129003000) ( p. 320) – Remove the nut with the wedge lock washer. E03291-10 – Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub.
Page 183 ENGINE 18 – Remove balancer shaft drive wheel E03296-10 – Remove woodruff key E03297-10 Removing the shift shaft, shift drum locating unit and locking lever – Remove screw with washer. – Take off locking lever with the sleeve and spring. E03298-10 –...
Page 184 18 ENGINE – Disassemble the alternator side. ( p. 177) – Drain the gear oil. ( p. 177) – Dismantle the clutch side. ( p. 178) Removing the spacer, balancer shaft and lock ring – Remove spacer E03301-10 – Take off O-ring E03302-10 –...
Page 185 ENGINE 18 – Remove reed valve housing – Take off the gasket. E03306-10 Removing the starter motor – Remove screw – Take off cover E03307-10 – Remove screws – Take off the starter motor. E03308-10 18.3.7 Dismantling the engine case Preparatory work –...
Page 186 18 ENGINE Removing shift rails, shift drum and shift forks – Remove shift rail with the springs. – Remove shift rail with the springs. E03310-10 – Tilt shift forks to the side. – Remove shift drum E03311-10 – Remove shift forks Info Do not misplace the shift rollers.
Page 187 ENGINE 18 – Remove O-ring E03316-10 – Remove distance sleeve E03315-10 18.4 Working on individual parts 18.4.1 Working on the right section of the engine case – Remove all dowels. – Remove radial shaft seal ring of the crankshaft. – Remove lock ring –...
Page 188 18 ENGINE Info When pressing in, ensure that the section of the engine case lies flat in order to prevent damage. Only press the bearings in using the outer bearing race; otherwise, the bearings will be damaged when they are pressed in.
Page 189 ENGINE 18 – Blow out lubrication bore with compressed air and check that it is clear. E03320-10 – Insert the new cold bearings in the bearing seats of the heated section of the engine case; if necessary, use a suitable man- drel to push them all the way in and make them flush.
Page 190 18 ENGINE 18.4.4 Installing the crankshaft bearing inner race – Fixate the crankshaft in the vice with special tool Guideline Use soft jaws. Separator plate (54829009000) ( p. 320) – Heat the crankshaft bearing inner race in special tool mount together. Guideline 312224-10 120 °C (248 °F)
Page 191 ENGINE 18 – Mount new bearing with washers and connecting Info Thoroughly oil the bearing. 312220-10 – Position special tool on the press. Crankshaft pressing tool (75029047000) ( p. 324) Insert for crankshaft pressing tool (54829108000) p. 321) – Insert the crankweb with the connecting rod and bearing. Posi- tion the second crankweb.
Page 192 18 ENGINE 18.4.6 Checking the crankshaft run-out at the bearing pin – Position the crankshaft on a roller block. – Turn the crankshaft slowly. – Check the crankshaft run-out on both bearing pins. ≤ 0.03 mm (≤ 0.0012 in) Crankshaft - run-out at bear- ing pin »...
Page 193 ENGINE 18 – Position special tool Retaining bracket (A44029065000) ( p. 329) – Remove screw with washer. – Remove screw – Take off the special tool. – Take off control flap lever E03360-10 – Take off right control gate E03361-10 –...
Page 194 18 ENGINE – Remove screws – Take off the exhaust flange. E03365-10 – Remove control flap evenly from the grooves on both sides. Info If the control flap is tilted, the cylinder may be dam- aged. E03366-10 18.4.9 Checking the exhaust control Condition Exhaust control removed.
Page 195 ENGINE 18 – Check control flap for damage and wear. » If there is damage or wear: – Change the control flap. – Check idler shaft of the exhaust control for damage and wear. » If there is damage or wear: –...
Page 196 18 ENGINE – Mount and grease O-rings Long-life grease ( p. 316) E03368-10 – Mount left control shaft The control shaft with marking L is installed on the left. – Mount the retaining bracket. – Mount and tighten screw Guideline Screw, retain- 6 Nm (4.4 lbf ft) ing bracket of...
Page 197 ENGINE 18 Info The screw point of the retaining bracket may be in a different position. – Mount right control gate The inner clutch hub of the idler shaft engages correctly in the control gate. of the control shaft engages in guide of the right control gate when the control flap is closed.
Page 198 18 ENGINE 18.4.11 Checking/measuring the piston – Check the piston bearing surface for damage. » If the piston bearing surface is damaged: – Replace the piston and, if necessary, the cylinder. – Check that the piston rings move easily in the piston ring grooves.
Page 199 ENGINE 18 18.4.12 Checking the piston ring end gap – Remove the piston ring from the piston. – Place the piston ring in the cylinder and align with the piston. Guideline Below the upper edge of the 20 mm (0.79 in) cylinder –...
Page 200 18 ENGINE 18.4.14 Disassemble the reed valve housing – Remove screws 311407-10 – Remove the reed valve housing from the back plate. E03322-10 – Remove screws on both sides. – Take off stop plate on both sides. – Remove the outer reed valve on both sides.
Page 201 ENGINE 18 18.4.15 Checking the reed valve housing, reed valve and intake flange Condition Reed valve housing has been removed. – Check intake flange for damage and wear. » If there is damage or wear: – Change the intake flange. –...
Page 202 18 ENGINE – Position holding strip The holding lugs engage in the drilled holes. D06263-10 – Position the reed valve holders. D06264-10 – Mount screws and screw in all the way. Info Mount the screws at right angles to prevent damage. –...
Page 203 ENGINE 18 – Position the stop plates on both sides. – Mount screws on both sides and screw in all the way. – Loosen screws and tighten again. Guideline Screw, outer reed EJOT DELTA PT 1 Nm (0.7 lbf ft) paddles ®...
Page 204 18 ENGINE – Remove form washer E03333-10 – Remove water pump gear wheel E03334-10 – Remove radial shaft seal ring E03335-10 – Press out bearing toward the inside. E03336-10 – Remove radial shaft seal ring – Press the new radial shaft seal ring all the way in to the stop. E03337-10...
Page 205 ENGINE 18 – Press bearing all the way in to the stop from the inside. E03336-10 – Press in radial shaft seal ring flush. – Ensure that the bearing can turn freely and does not touch the radial shaft seal ring. E03335-10 –...
Page 206 18 ENGINE 18.4.18 Checking the clutch 304690-10 – Check clutch throw-out for damage and wear. » If there is damage or wear: – Change the clutch push rod. – Place the clutch push rod on a flat surface and check for run-out. »...
Page 207 ENGINE 18 » If there is damage or wear: – Change the clutch facing discs and the clutch basket. – Check needle bearing and collar bushing for damage and wear. » If there is damage or wear: – Change the needle bearing and collar bushing. –...
Page 208 18 ENGINE 18.4.20 Checking the shift mechanism E03343-10 – Check shift forks on plate for damage and wear (visual check). » If there is damage or wear: – Change the shift fork. – Check shift grooves of shift drum for wear. »...
Page 209 ENGINE 18 » If the guide pin is loose and/or worn: – Change the shift shaft sliding plate. – Preassemble the shift shaft. ( p. 205) – Check clearance between the shift shaft sliding plate and the shift quadrant. Shift shaft - sliding 0.40 …...
Page 210 18 ENGINE Guideline Use soft jaws. E03461-10 – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk – Remove fifth-gear sliding gear – Remove lock ring – Remove stop disk – Remove third-gear idler gear and needle bearing –...
Page 211 ENGINE 18 E03463-10 – Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearings. – Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –...
Page 212 18 ENGINE – Use new lock rings in every repair. 18.4.24 Assembling the main shaft Info Use new lock rings with every repair. Preparatory work – Check the transmission. ( p. 208) – Carefully lubricate all parts before assembling. Main work –...
Page 213 ENGINE 18 Preparatory work – Check the transmission. ( p. 208) – Carefully lubricate all parts before assembling. Main work – Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. E03461-11 – Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar fac-...
Page 214 18 ENGINE 18.4.26 Checking the electric starter drive – Check the gear teeth of rotor for damage and wear. » If there is damage or wear: – Change the rotor. – Check the gear teeth and bearing of the Bendix for smooth operation, damage, and wear.
Page 215 ENGINE 18 – Oil all bearings. Engine oil (15W/50) ( p. 314) – Assemble the two transmission shafts and slide them into the bearing seats together. E03313-11 Installing the shift fork, shift drum and shift rails – Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft.
Page 216 18 ENGINE left engine case, assembling – Clean and degrease the sealing surface. – Thinly coat the sealing surface of the right section of the engine case with sealing compound. Loctite ® 5910 – Check that dowels are seated correctly. E03345-10 –...
Page 217 ENGINE 18 – Position cover – Mount and tighten screw Guideline Screw, cover, 8 Nm (5.9 lbf ft) starter motor E03307-11 Installing the reed valve housing – Position the gasket. – Position reed valve housing in the engine case open- ing.
Page 218 18 ENGINE – Before mounting, grease spacer in area and O- ring Long-life grease ( p. 316) – Position the O-ring in the cut-out of the spacer. E03347-10 – Grease the radial shaft seal ring. Long-life grease ( p. 316) –...
Page 219 ENGINE 18 – Ensure that the woodruff key is seated correctly. – Degrease the cone. – Mount the rotor and hold it with special tool Holding wrench (A44029012000) ( p. 329) – Mount and tighten nut with washer. Guideline Nut, rotor M12x1 60 Nm (44.3 lbf ft)
Page 220 18 ENGINE – Position locking lever with sleeve and spring. Guideline Ensure that the spring of the locking lever engages cor- rectly in the cut-out of the housing. – Mount screw with the washer and screw in approx. 2 full turns, but do not tighten it fully. Guideline Screw, locking 6 Nm (4.4 lbf ft)
Page 221 ENGINE 18 Installing the clutch basket – Mount collar bushing – Oil and mount needle bearings Engine oil (15W/50) ( p. 314) E03293-11 – Slide clutch basket onto the gearbox main shaft. – Slide on washer and inner clutch hub Guideline Teeth of the washer must be aligned with drill...
Page 222 18 ENGINE Info LH thread! – Crank the engine and check for smooth operation. Installing the clutch discs – Thoroughly oil the clutch facing discs. – Mount intermediate clutch disc with marking S. Guideline Thickness of intermediate 1.0 mm (0.039 in) clutch disc –...
Page 223 ENGINE 18 – Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (79129941000) ( p. 324) Spring washer distortion 0 … 0.10 mm (0 … 0.0039 in) » If the specified value is not reached: –...
Page 224 18 ENGINE – Position the water pump cover with the gasket. – Mount and tighten screws Guideline Bleeder screw, M6x25 8 Nm (5.9 lbf ft) water pump cover – Mount and tighten screws Guideline Screw, water pump M6x60 10 Nm (7.4 lbf ft) E03285-11 cover, long –...
Page 225 ENGINE 18 – Position the piston ring locks in the 6 o'clock or 12 o'clock position. – Ensure that the piston ring lock is in the correct position on both sides. – Remove the cloth. 302973-10 Installing the cylinder – Place new cylinder base gasket in position.
Page 226 18 ENGINE (All 250 models) – Apply special tool to the cylinder. Setting gauge (54829001100) ( p. 320) The cut-out faces downward. – Position the piston at top dead center. – Check the X-distance using the special tool. Feeler gauge (79129941000) ( p.
Page 227 ENGINE 18 – Counterhold screw and loosen nut E03359-10 – Adjust the Z-distance using the depth micrometer. Guideline Z distance (height of con- 50.0 mm (1.969 in) trol flap) (All 250 models) Z distance (height of con- 50.0 mm (1.969 in) trol flap) (All 300 models) –...
Page 228 18 ENGINE – Position actuator – Mount and tighten screws Guideline Screw, actu- 5 Nm (3.7 lbf ft) ator, exhaust Loctite ® 243™ control E03270-11 – Position cover – Mount and tighten screw Guideline Screw, cover, 5 Nm (3.7 lbf ft) actuator, Loctite ®...
Page 229 ENGINE 18 – Mount and tighten spark plug Guideline Spark plug M14x1.25 25 Nm (18.4 lbf ft) E03466-11 18.5.6 Gear oil drain plug, installing – Mount and tighten gear oil drain plug with the magnet and a new seal ring. Guideline Gear oil drain plug M12x1.5...
Page 230 19 CLUTCH 19.1 Checking/correcting the fluid level of hydraulic clutch Warning Skin irritation Brake fluid is a harmful substance. – 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 231 CLUTCH 19 19.2 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid is a harmful substance. – 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 232 19 CLUTCH – 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. 19.3 Checking the clutch Main work – Drain the fuel from the fuel tank into a suitable container. –...
Page 233 CLUTCH 19 – Take off spring washer G05832-10 – Take off pretension ring G05833-10 – Take off clutch pressure cap G05834-10 – Take off clutch throw-out with clutch push rod G05835-10 – Remove sleeves G05836-10...
Page 234 19 CLUTCH – Remove clutch discs completely. G05837-10 – Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) ( p. 320) – Remove the nut with the wedge lock washers. G05838-10 – Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub.
Page 235 CLUTCH 19 D02006-11 – Check clutch throw-out for damage and wear. » If there is damage or wear: – Change the clutch throw-out. – Place the clutch push rod on a flat surface and check for run-out. » If there is run-out: –...
Page 236 19 CLUTCH – Check needle bearings and collar bushing for damage and wear. » If there is damage or wear: – Change the needle bearings and collar bushing. – Check intermediate clutch discs for damage and wear. » If the intermediate clutch discs are not level and are pitted: –...
Page 237 CLUTCH 19 – Mount sleeves D08245-10 – Thoroughly oil the clutch facing discs. – with marking S. Mount intermediate clutch disc Guideline Thickness of intermediate 1.0 mm (0.039 in) clutch disc – Alternately place the clutch facing and 7 intermediate discs into the clutch basket.
Page 238 19 CLUTCH – Mount pretension ring with marking Top facing up. G05833-10 – Position spring washer G05832-10 – Position spring retainer with marking 1. – Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) retainer G05841-10 –...
Page 239 CLUTCH 19 Spring washer distortion 0 … 0.10 mm (0 … 0.0039 in) » If the specified value is not reached: – Change the clutch facing discs. – Position the clutch cover with the gasket. – Mount and tighten screws Guideline Screw, outer clutch 8 Nm (5.9 lbf ft)
Page 240: Water Pump, Cooling System
20 WATER PUMP, COOLING SYSTEM 20.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
Page 241 WATER PUMP, COOLING SYSTEM 20 20.3 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 242 20 WATER PUMP, COOLING SYSTEM 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 243 WATER PUMP, COOLING SYSTEM 20 – 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. 314) 400243-10 – Remove screw and wait until coolant emerges without bub- bles.
Page 244 20 WATER PUMP, COOLING SYSTEM 20.6 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 245 WATER PUMP, COOLING SYSTEM 20 – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant ( p. 314) 400243-10 – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...
Page 246 20 WATER PUMP, COOLING SYSTEM – Remove screws – Remove radiator shield on both sides. B06163-10 – Release hose clips – Pull off the radiator hoses. B06164-10 – Remove hose clips – Detach radiator and remove to the side. B06165-10 –...
Page 247 WATER PUMP, COOLING SYSTEM 20 – Remove coolant pipe B06167-10 – Pull off connecting piece to the side and remove. B06168-10 – Mount new connecting piece in the frame. B06168-11 – Mount and new coolant pipe with new O-ring tighten. Guideline Screw-in fitting, M24x1.5...
Page 248 20 WATER PUMP, COOLING SYSTEM – Mount the radiator hose. – Position and tighten hose clips – Plug in connector and mount the protection cap. B06166-10 – Detach the radiator and position. – Ensure that the cable guides in area are correctly hooked into the radiator.
Page 249 WATER PUMP, COOLING SYSTEM 20 – Slip overflow hose into the hose guide. B06162-10 (All special models) – Plug in connector – Mount the cable ties. B06161-10 Finishing work – Install the fuel tank. ( p. 97) – Mount the seat. ( p.
Page 250: Throttle Valve Body
21 THROTTLE VALVE BODY 21.1 Programming ambient air pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space. Info If the vehicle is ridden with the engine running at various heights above sea level, the ambient pressure is programmed on an ongoing basis.
Page 251 THROTTLE VALVE BODY 21 (All EU/ASEAN models) – Unplug hose piece B06192-10 – Unplug connector – Pull fuel vapor valve off the holder and hang it to the side. B06193-10 – Loosen hose clip B06194-10 – Loosen screw – Remove screw –...
Page 252 21 THROTTLE VALVE BODY – Push back sleeve – Remove screws and half-shells – Detach the throttle cables and take off the grip tube. B06103-10 – Remove screws – Take off the cover. B06196-10 – Unplug connector B06197-10 – Loosen hose clip –...
Page 253 THROTTLE VALVE BODY 21 – Remove screw – Remove the cover. B06108-10 – Push back sleeves – Loosen nuts. – Detach and remove throttle cables – Attach throttle cables to the new throttle valve body and route them correctly. Throttle cable of the opening cable is hooked in on the left.
Page 254 21 THROTTLE VALVE BODY – Plug in connector B06197-10 – Position the cover. – Mount and tighten screws Guideline Screw, throttle valve 2.6 Nm body cover (1.92 lbf ft) B06196-10 – Clean the outside of the handlebar and the inside of the grip tube.
Page 255 THROTTLE VALVE BODY 21 Guideline Screw, sub- 35 Nm (25.8 lbf ft) frame, top Loctite ® 243™ – Repeat these steps on the opposite side. – Position and tighten hose clip B06194-10 (All EU/ASEAN models) – Mount fuel vapor valve on the holder. Info Make sure the cables and wiring are routed cor- rectly.
Page 256 If the displayed value of Drosselklappensensor Spannung does not match the value of Angepasste voll- ständig geschlossene Drosselklappenstellung: – Perform the basic setting of the throttle valve with the KTM diagnostics tool. ( p. 256) – Adjust the idle speed. ( p. 256) –...
Page 257 THROTTLE VALVE BODY 21 21.4 Adjusting the basic throttle position sensor setting Condition The diagnostics tool is connected and running. Preparatory work – Remove the seat. ( p. 95) – Remove the fuel tank. ( p. 96) Main work – Remove screw and take off cover –...
Page 258 2.6 Nm body cover (1.92 lbf ft) E03467-10 21.5 Performing the basic setting of the throttle valve with the KTM diagnostics tool Condition The diagnostics tool is connected and running. – Perform "Engine control unit" > "Control unit functions" >...
Page 259 THROTTLE VALVE BODY 21 – Select "Engine control unit" > "Measured values" > "Throttle valve position". – Adjust the opening angle of the throttle valve by turning idle speed adjusting screw Info Turning counterclockwise decreases the opening angle of the throttle valve. Turning clockwise increases the opening angle of the throttle valve.
Page 260 21 THROTTLE VALVE BODY – Check the measured value from "throttle valve position" again and adjust if necessary. – Pull out the cold start button. 21.8 Cold start button The cold start button is fitted to the bottom of the throttle valve body.
Page 261: Exhaust Control
EXHAUST CONTROL 22 22.1 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 262 Info The instructions must be followed precisely. » If the specified value is reached: – Clear the fault memory using the KTM diagnostics tool. – Take a test ride. H02627-01 – Read out the fault memory using the KTM diagnostics...
Page 263: Lubrication System
LUBRICATION SYSTEM 23 23.1 Changing the gear oil Warning Danger of scalding Engine and gear oil get hot when the motorcycle is operated. – Wear suitable protective clothing and safety gloves. – In the event of scalding, rinse the area affected immediately with lukewarm water. Note Environmental hazard Hazardous substances cause environmental damage.
Page 264 23 LUBRICATION SYSTEM 23.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove gear oil level monitoring screw –...
Page 265 LUBRICATION SYSTEM 23 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 266 23 LUBRICATION SYSTEM 23.6 Adding 2-stroke oil Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
Page 267 LUBRICATION SYSTEM 23 – Check 2-stroke oil level. ( p. 263) Main work – Pull diagnostics connector off the holder. I00451-10 – Put throttle grip into full throttle position and secure. I00452-10 – Plug in wake-up connector for priming the oil pump to the diagnostics connector The combination instrument lighting is activated.
Page 268 23 LUBRICATION SYSTEM 23.9 Cleaning the oil screen in the oil tank 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. Preparatory work –...
Page 269 LUBRICATION SYSTEM 23 – Open hose clamp using a screwdriver. – Pull off the angle piece and collect the 2-stroke oil in a suit- able container. I00460-10 – Remove oil screen and clean it. – Check the oil screen for damage. »...
Page 270 23 LUBRICATION SYSTEM – Mount fuel vapor valve I00457-10 – Mount and tighten screws Guideline Screw, sub- 30 Nm (22.1 lbf ft) frame bottom Loctite ® 2701™ – Remove screws – Mount and tighten screws Guideline Screw, sub- 35 Nm (25.8 lbf ft) I00456-10 frame, top Loctite...
Page 271 LUBRICATION SYSTEM 23 Main work – Remove screws B06089-10 – Push back hose clamp – Pull the hose off the reed valve housing. Info Residual oil may escape from the hose. B06096-10 – Unplug connector B06091-10 – Push back hose clamp B06092-10 –...
Page 272 23 LUBRICATION SYSTEM – Open hose clamp using a screwdriver and pull off the angle piece. B06094-10 – Remove oil screen and clean it. – Check the oil screen for damage. » If the oil screen is damaged: – Change the oil screen. B06097-10 –...
Page 273 LUBRICATION SYSTEM 23 – Plug in connector B06091-10 – Mount hose on the reed valve housing. – Position hose clamp B06096-10 – Position the oil tank. – Mount and tighten screws Guideline Screw, oil tank on 5 Nm (3.7 lbf ft) frame B06089-10 Finishing work...
Page 274: Ignition System
24 IGNITION SYSTEM 24.1 Checking the ignition system Warning Risk of injury The ignition system is under high voltage. – Do not touch any affected metal parts or the ends of the connection cables during and immediately after the measurement. Preparatory work –...
Page 275 IGNITION SYSTEM 24 – Mount the spark plug connector on the ignition wire again. Mount the spark plug in the spark plug connector. Hold the spark plug to ground. – Press the start button. Info Do not open the throttle. –...
Page 276 24 IGNITION SYSTEM Alternator – checking the stator winding 24.4 Condition The stator is disconnected. Preparatory work – Remove the seat. ( p. 95) Main work Stator winding measurement I - check the resistance. – Measure the resistance between the specified points. Stator, connector EZ pin 1 –...
Page 277 IGNITION SYSTEM 24 24.5 Checking the crankshaft speed sensor Condition Crankshaft speed sensor is disconnected. – Measure the resistance between the specified points. Crankshaft speed sensor, connector AT pin 1 – Crankshaft speed sensor, connector AT pin 2 Crankshaft speed sensor 80 …...
Page 278 24 IGNITION SYSTEM 24.6 Changing the spark plug Preparatory work – Remove the seat. ( p. 95) – Remove the fuel tank. ( p. 96) Main work – Disconnect spark plug connector B06179-10 – Remove spark plug using a suitable tool. –...
Page 279 IGNITION SYSTEM 24 Main work – Disconnect spark plug connector B06179-10 – Remove spark plug using a suitable tool. – Mount and tighten the new spark plug using a suitable tool. Guideline Spark plug M14x1.25 25 Nm (18.4 lbf ft) B06180-10 –...
Page 280 24 IGNITION SYSTEM 24.8 Removing the stator Condition The alternator cover has been removed. – Remove screws – Remove cable retainer plate from the alternator cover. – Remove the stator together with the rubber grommet from the alternator cover. E03372-10 24.9 Installing the stator –...
Page 281: Electric Starter System
ELECTRIC STARTER SYSTEM 25 25.1 Checking the starter motor Condition The starter motor has been removed. – Connect negative cable of a 12-V power supply to the housing of the starter motor. Connect positive cable of the power sup- ply briefly with the connector of the starter motor. »...
Page 282: Technical Specifications
26 TECHNICAL SPECIFICATIONS 26.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement (All 250 models) 249 cm³ (15.19 cu in) Displacement (All 300 models) 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole (All 250 models) 66.4 mm (2.614 in) Hole (All 300 models) 72 mm (2.83 in)
Page 283 TECHNICAL SPECIFICATIONS 26 Piston/cylinder - mounting clearance (All 250 models) New condition 0.050 … 0.074 mm (0.00197 … 0.00291 in) Wear limit 0.10 mm (0.0039 in) Piston/cylinder - mounting clearance (All 300 models) New condition 0.066 … 0.088 mm (0.0026 … 0.00346 in) Wear limit 0.10 mm (0.0039 in) Piston ring end gap (All 250 models)
Page 284 26 TECHNICAL SPECIFICATIONS Screw, alternator cover 8 Nm (5.9 lbf ft) Screw, clutch cover 10 Nm (7.4 lbf ft) Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) Screw, clutch cover M6x60 10 Nm (7.4 lbf ft) Screw, cover, starter motor 8 Nm (5.9 lbf ft) Screw, engine case M6x45...
Page 285 TECHNICAL SPECIFICATIONS 26 Fuel reserve, approx. 1.5 l (1.6 qt.) 26.5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XPLOR CC Shock absorber WP PDS Suspension travel front 300 mm (11.81 in) Suspension travel rear 310 mm (12.2 in) Fork offset 22 mm (0.87 in)
Page 286 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 26.8 Fork Fork article number...
Page 287 TECHNICAL SPECIFICATIONS 26 Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.6 N/mm (26.3 lb/in) Fork length 940 mm (37.01 in) Oil capacity, cartridge 175 ml (5.92 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 315) Oil capacity, external mechanism 390 ml (13.19 fl.
Page 288 26 TECHNICAL SPECIFICATIONS Screw, oil fill level sensor EJOT PT ® 50x18 T25 7 Nm (5.2 lbf ft) Screw, oil pump holder on oil tank EJOTDELTA PT 45x12-Z 0.7 Nm (0.52 lbf ft) Screw, pressure regulator EJOT PT ® K60x25‑Z 2.3 Nm (1.7 lbf ft) Screw, radiator hoses clip 2.4 Nm (1.77 lbf ft)
Page 289 TECHNICAL SPECIFICATIONS 26 Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, seat fixing 8 Nm (5.9 lbf ft) Screw, silent block on frame 6 Nm (4.4 lbf ft) Screw, throttle grip 5 Nm (3.7 lbf ft) Fuel connection on fuel pump 15 Nm (11.1 lbf ft) Nut, foot brake lever...
Page 290 26 TECHNICAL SPECIFICATIONS 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 15 Nm (11.1 lbf ft) Screw, bottom shock absorber...
Page 291: Cleaning, Care
CLEANING, CARE 27 27.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
Page 292 27 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. 317) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Page 293 – 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. 13) – Cover the vehicle with a tarp or a similar cover that is perme-...
Page 294 28 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 295: Service Schedule
Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
Page 296 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 297 SERVICE SCHEDULE 29...
Page 298: Wiring Diagram
30 WIRING DIAGRAM 30.1 Page 1 of 5 (All EXC models) Y02965-01...
Page 299 WIRING DIAGRAM 30 Components: Vehicle system control unit Engine control unit 12-V battery Alternator Starter relay with main fuse Starter motor Fuel pump Radiator fan (if installed) Combination switch, right Voltage regulator...
Page 300 30 WIRING DIAGRAM 30.2 Page 2 of 5 (All EXC models) Y02966-01...
Page 301 WIRING DIAGRAM 30 Components: Vehicle system control unit Engine control unit Oil level sensor Front brake light switch Rear brake light switch Headlight unit Oil pump Horn Oil level warning lamp Brake/tail light Combination switch, left...
Page 302 30 WIRING DIAGRAM 30.3 Page 3 of 5 (All EXC models) Y02967-01...
Page 303 WIRING DIAGRAM 30 Components: Vehicle system control unit License plate lamp Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Combination switch, left...
Page 304 30 WIRING DIAGRAM 30.4 Page 4 of 5 (All EXC models) Y02968-01...
Page 305 WIRING DIAGRAM 30 Components: Engine control unit Connectivity Unit (if installed) Fuel level sensor Front wheel speed sensor M51/1 Injection valve 1, cylinder 1 M51/2 Injection valve 2, cylinder 1 Combination instrument Brake/tail light Terminating resistor (if installed) Map Select switch (if installed) X295 Diagnostics connector...
Page 306 30 WIRING DIAGRAM 30.5 Page 5 of 5 (All EXC models) Y02969-01...
Page 307 WIRING DIAGRAM 30 Components: Engine control unit Intake air temperature sensor Ambient air pressure sensor Coolant temperature sensor Tilt sensor Crankshaft speed sensor Induction manifold pressure sensor Throttle valve position sensor Lambda sensor (if installed) Fuel vapor valve Ignition coil Cable colors: Black Brown...
Page 308 30 WIRING DIAGRAM 30.6 Page 1 of 4 (All XC‑W models) Y03001-01...
Page 309 WIRING DIAGRAM 30 Components: Vehicle system control unit Engine control unit 12-V battery Alternator Starter relay with main fuse Starter motor Fuel pump Combination switch, right Voltage regulator...
Page 310 30 WIRING DIAGRAM 30.7 Page 2 of 4 (All XC‑W models) Y03002-01...
Page 311 WIRING DIAGRAM 30 Components: Vehicle system control unit Engine control unit Oil level sensor Headlight unit Radiator fan (if installed) Oil pump Oil level warning lamp Tail light Light switch...
Page 312 30 WIRING DIAGRAM 30.8 Page 3 of 4 (All XC‑W models) Y03003-01...
Page 313 WIRING DIAGRAM 30 Components: Engine control unit Connectivity Unit (if installed) Fuel level sensor Front wheel speed sensor Exhaust control actuator M51/1 Injection valve 1, cylinder 1 M51/2 Injection valve 2, cylinder 1 Combination instrument Terminating resistor (if installed) Map Select switch (if installed) X295 Diagnostics connector...
Page 314 30 WIRING DIAGRAM 30.9 Page 4 of 4 (All XC‑W models) Y03004-01...
Page 315 WIRING DIAGRAM 30 Components: Engine control unit Intake air temperature sensor Ambient air pressure sensor Coolant temperature Tilt sensor Crankshaft speed sensor Induction manifold pressure sensor Throttle valve position sensor Ignition coil Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet...
Page 316 31 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
Page 317 SUBSTANCES 31 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 335) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Page 318: Auxiliary Substances
32 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
Page 319 AUXILIARY SUBSTANCES 32 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Off-road chain spray Recommended supplier MOTOREX ® – Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX ® – Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier MOTOREX ®...
Page 320: Special Tools
33 SPECIAL TOOLS Cable connector unlocking kit Art. no.: 00029014000 H02257-01 Diagnostics adapter cable Art. no.: 00029094033 Feature Length approx. 25.8 cm (10.16 in) 501448-01 Break out box Art. no.: 00029095001 H01895-01 Adapter and template M3C Art. no.: 00029095013 H02568-01...
Page 321 SPECIAL TOOLS 33 EU battery charger XCharge‑professional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16 A Power cable length 5 m (16 ft) approx. Charger cable length 5 m (16 ft) H01065-01 approx. US battery charger XCharge‑professional Art.
Page 322 33 SPECIAL TOOLS Syringe Art. no.: 50329050000 500689-01 Holding wrench Art. no.: 51129003000 H00575-01 Setting gauge Art. no.: 54829001100 H00583-01 Separator plate Art. no.: 54829009000 H00584-01...
Page 323 SPECIAL TOOLS 33 Insert for crankshaft pressing tool Art. no.: 54829108000 H00994-01 Holder and fitting for work stand Art. no.: 55429002000 H01175-01 Puller Art. no.: 58429037043 Feature Inside diameter 43.9 mm (1.728 in) H00598-01 Tool bracket Art. no.: 58429089000 H00603-01...
Page 324 33 SPECIAL TOOLS Pressing tool Art. no.: 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 H00605-01 Torque wrench kit Art. no.: 58429094000 Feature Torque 3 … 15 Nm (2.2 … 11.1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in) Open ended bit 5.5 mm (0.217 in)
Page 325 SPECIAL TOOLS 33 Hose clamp pliers Art. no.: 60029057000 H00650-01 Testing hose Art. no.: 61029093000 H00659-01 Pressure testing tool Art. no.: 61029094000 H00660-01 Engine work stand Art. no.: 61229001000 H00662-01...
Page 326 33 SPECIAL TOOLS Crankshaft pressing tool Art. no.: 75029047000 H00714-01 Lift stand Art. no.: 78129955100 Feature Height 315 … 425 mm (12.4 … 16.73 in) ≤ 150 kg (≤ 331 lb.) Load H00980-01 Feeler gauge Art. no.: 79129941000 Feature 20 pieces 0.05 …...
Page 327 SPECIAL TOOLS 33 Gear segment Art. no.: 80029004000 H00813-01 Hook wrench Art. no.: 90129051000 H00831-01 Diagnostics tablet Art. no.: 00029XC2001 H02645-01 Hand strap Art. no.: 00029XC2002 H02883-01...
Page 328 33 SPECIAL TOOLS Battery charger Art. no.: 00029XC2003 H02882-01 Art. no.: 00029XC2004 H02646-01 VCI attachment Art. no.: 00029XC2005 H03078-01 Protective film Art. no.: 00029XC2006 500361-01...
Page 329 SPECIAL TOOLS 33 Diagnostics cable extension Art. no.: 00029XC2007 Feature Length approx. 1.15 m (3.77 ft) H02880-01 USB cable Art. no.: 00029XC2008 Feature Length approx. 5 m (16 ft) H02879-01 12-V power supply cable Art. no.: 00029XC2009 H02881-01 RideRecorder trigger Art.
Page 330 33 SPECIAL TOOLS Case Art. no.: 00029XC2011 H03082-01 Docking station Art. no.: 00029XC2012 H03077-01 Wall attachment Art. no.: 00029XC2013 H03080-01 Battery Art. no.: 00029XC2014 H03079-01...
Page 331 SPECIAL TOOLS 33 Input stylus Art. no.: 00029XC2015 H03083-01 Spring hook Art. no.: 50305017000C1 500454-01 Holding wrench Art. no.: A44029012000 502386-01 Retaining bracket Art. no.: A44029065000 502587-01...
Page 332 33 SPECIAL TOOLS Depth micrometer Art. no.: T107S H00842-01 Drift Art. no.: T120 Feature Diameter 8 mm (0.31 in) H00844-01 Pressing tool Art. no.: T1206 Feature Diameter 15 … 30 mm (0.59 … 1.18 in) H00880-01 Pressing tool Art. no.: T1207S H00881-01...
Page 333 SPECIAL TOOLS 33 Vacuum pump Art. no.: T1240S H00890-01 Protecting sleeve Art. no.: T1401 Feature Diameter 48 mm (1.89 in) H00894-01 Clamping stand Art. no.: T14015S Feature Diameter 27 mm (1.06 in) H01035-01 Clamping stand Art. no.: T14016S Feature Diameter 12 mm (0.47 in) H01036-01...
Page 334 33 SPECIAL TOOLS Ring wrench Art. no.: T14017 Feature Hexagonal part 50 mm (1.97 in) H00904-01 Calibrating unit Art. no.: T14021 Feature Diameter 12 mm (0.47 in) H00908-01 Clamping stand Art. no.: T1403S Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) H00896-01 Mounting tool...
Page 335 SPECIAL TOOLS 33 Pressing tool Art. no.: T14076 Feature Diameter 11.95 … 14 mm (0.4705 … 0.55 in) T04207-10 Special socket Art. no.: T14084 Feature Drive 1/2 in Diameter 24 mm (0.94 in) H01518-01 Mounting sleeve Art. no.: T1554 Feature Diameter 18 mm (0.71 in) H00903-01...
Page 336 33 SPECIAL TOOLS Filling adapter Art. no.: T18001 Z02292-10 Socket Art. no.: T18004 Feature Drive 1/2 in Z02290-10 Clamping stand Art. no.: T531S Feature Diameter 38 mm (1.5 in) H02439-01...
Page 337 STANDARDS 34 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
Page 338: List Of Abbreviations
35 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
Page 339 INDEX Brake lining retainers INDEX of front brake, checking ....140 of rear brake, checking ....147 12-V battery charging .
Page 340 INDEX Coolant level intake flange, checking ....199 checking ..... . 238-239 reed valve housing, checking .
Page 341 INDEX shift shaft, shift drum locating unit and locking Fuel pressure lever, removing ..... 178 checking ......105 spacer and balancer shaft, removing .
Page 342 INDEX Ignition system Pressure stage unit checking ......272 assembling ......31 disassembling .
Page 343 INDEX Spark plug changing ......276 Vehicle identification number ....11 Spark plug and spark plug connector changing .

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KTM 250 EXC EU Repair Manual

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