Page 1 REPAIRMANUAL2004-2010 BEDIENUNGSANLEITUNGEN REPARATURANLEITUNG FEDERBEIN GABEL OWNER’S MANUAL REPAIR MANUAL SHOCK ABSORBER FORK MANUALE O’USO MANUALE DI REPARAZIONE AMMORTIZZATORE FORCELLA MANUEL D’UTILISATION MANUEL DE REPARATION AMMORTISSEUR FOURCHE MANUAL DE INSTRUCCIONES MANUAL DE REPARACION AMORTIGUADOR HORQUILLA...
Page 2 OWNERSMANUAL2010 250 SX 250/300 XC, XC-W,EXC,EXC SixDays...
Page 3 OWNER'S MANUAL 2010 125 SX 150 SX 250 SX Art. no. 3211480en...
Page 4: Table Of Contents
Important maintenance work to be carried out by an Checking the free play of the foot brake lever ....46 authorized KTM workshop (as additional order)....24 Important checks and maintenance work to be carried Adjusting the basic position of the foot brake lever ..
Page 5 TABLE OF CONTENTS Ignition curve plug connection ........54 Carburetor - basic setting for sandy surfaces (150 SX) ..82 Changing the ignition curve ..........55 Carburetor configuration (150 SX)........83 Engine characteristic - auxiliary spring (250 SX)....55 250 SX................. 84 Carburetor - basic setting for sandy surfaces (250 SX) ..
Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
Page 7: Important Information
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
Page 8 IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob- lems and conflicts do not have to occur.
Page 9: View Of Vehicle
VIEW OF VEHICLE View of the vehicle from the left front (example) B00010-10 Hand brake lever Short circuit button Clutch lever Air filter box lid Fuel tap Choke button Shift lever Chain guide...
Page 10: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) B00014-10 Shock absorber rebound adjustment Level viewer for brake fluid, rear Fork rebound adjustment Foot brake lever Kickstarter Shock absorber compression adjustment Throttle grip Fork compression adjustment Filler cap...
Page 11: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head.  B00015-10 Type label The type label is fixed to the front of the steering head.  400284-10 Engine number The engine number is stamped on the left side of the engine under the engine ...
Page 12: Controls
CONTROLS Clutch lever (125 SX, 150 SX) The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. B00001-10 (250 SX) The clutch lever is fitted on the left side of the handlebar. ...
Page 13: Fuel Tap
CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the car-  buretor. Possible states Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. •...
Page 14: Shift Lever
CONTROLS Shift lever Shift lever is mounted on the left side of the engine.  B00005-10 (125 SX, 150 SX) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. B00005-12 (250 SX) The gear positions can be seen in the photograph.
Page 15: Plug-In Stand
CONTROLS Plug-in stand 5.12 Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. To park the motorcycle, insert plug-in stand into the left side of the wheel spindle. ...
Page 16: Operation
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
Page 17: General Tips And Hints On Putting Into Operation
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) – Check the spoke tension. ( p.
Page 18: Preparations For Riding On Wet Sand
Sand cover for air filter (59006022000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600871-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 96) –...
Page 19: Preparations For Riding On Wet And Muddy Surfaces
Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 96) –...
Page 20: Preparations For Riding At High Temperatures And Riding Slowly
Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop.
Page 21: Riding Instructions
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the gear oil level. ( p.
Page 22: Starting Up
Do not change into a low gear at high engine speed. The engine overspeeds and the rear wheel can block. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.
Page 23: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components get very hot when the vehicle is in use. –...
Page 24 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 8 l (2.1 US gal) Super unleaded gasoline, mixed with capacity, approx. 2-stroke engine oil (1:40) ( p.
Page 25: Service Schedule
SERVICE SCHEDULE Important maintenance work that must be done in an authorized KTM workshop S10N S20A S40A Engine Check the gear oil level. ( p. 68) • • • • Change the gear oil. p. 69) Check spark plug and replace if required.
Page 26: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop (as additional order) S10A S20N S20A S30A S40A S80A • Check/set the carburetor components. Check the intake diaphragm. • • • Check the clutch lining discs.
Page 27 SERVICE SCHEDULE NB1A Check the coolant level. ( p. 59) • Empty the carburetor float chamber. p. 68) • Check all controls for smooth operation. • Check braking. • Check all screws, nuts and hose clamps regularly for tightness. • NB1A: Depending on conditions of use according to requirements.
Page 28: Maintenance Work On Chassis And Engine
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.
Page 29: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.
Page 30: Adjusting The Rebound Damping Of The Shock Absorber
Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.
Page 31: Checking The Static Sag Of The Shock Absorber
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Page 32: Adjusting The Riding Sag
MAINTENANCE WORK ON CHASSIS AND ENGINE – Unscrew screw  – Turn adjusting ring until the spring is no longer under tension.  Combination wrench (50329080000) Hook wrench (T106S) – Measure the overall spring length when not under tension. – Tighten the spring by turning adjusting ring to measurement ...
Page 33: Installing The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the shock absorber 9.14 – Push splash protector to the side and position the shock absorber. Mount and  tighten screw  Guideline Screw, top shock absorber 80 Nm Loctite ® 243™ (59 lbf ft) –...
Page 34: Adjusting The Rebound Damping Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping, turn counterclockwise to reduce damp- ing. Adjusting the rebound damping of the fork 9.17 Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection covers ...
Page 35: Loosening The Fork Protection
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden for a lengthy period with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.
Page 36: Adjusting The Play Of The Steering Head Bearing
MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...
Page 37: Installing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fork legs 9.25 – Position the fork legs. Info The topmost milled groove in the fork leg must be flush to the upper edge of the upper triple clamp. Position bleeder screws toward the front.
Page 38: Removing The Lower Triple Clamp
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp 9.28 – Remove the fork legs. p. 34) – Remove the start number plate. ( p. 37) – Remove the front fender. ( p. 37) – Remove screws and hang the CDI control unit to the side. ...
Page 39: Greasing The Steering Head Bearing
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw  Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly.
Page 40: Installing The Start Number Plate
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the start number plate 9.34 – Position the start number plate. Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Ensure that the holding lugs engage in the fender. –...
Page 41: Checking The Play In The Throttle Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 9.37 – Move the handlebar to the straight-ahead position. – Push back bellows  – Pull back the throttle cable casing until you sense a resistance. – Now check throttle cable play ...
Page 42: Checking The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 96) Off-road chain spray ( p. 96) 400725-01 Checking the chain tension 9.41 Warning Danger of accidents Danger caused by incorrect chain tension. –...
Page 43: Adjusting The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE – Shift gear to neutral. – Pull on the upper part of the chain with the specified weight  Guideline 0 0 A Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section.
Page 44: Adjusting The Chain Guide
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...
Page 45: Checking The Free Travel Of The Hand Brake Lever
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Page 46: Adding Front Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 47: Removing The Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
Page 48: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 49: Adjusting The Basic Position Of The Foot Brake Lever
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Page 50: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 51: Removing The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
Page 52: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 53: Installing The Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.
Page 54: Removing The Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 9.65 – Jack up the motorcycle. ( p. 26) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
Page 55: Checking The Tire Condition
DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires are changed at the latest after 5 years, regardless of the actual state of wear. »...
Page 56: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
Page 57: Changing The Ignition Curve
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the ignition curve 9.71 Change the ignition curve from Performance to Soft. – Disconnect plug connection . (Figure B00029-10 p. 54)  Soft – better rideability Change the ignition curve from Soft to Performance. –...
Page 58: Removing The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the O-ring in the locking cap. – Position the locking cap. – Mount and tighten the screws. Guideline Remaining screws, engine 6 Nm (4.4 lbf ft) Removing the seat 9.74 – Remove screw .
Page 59: Installing The Fuel Tank
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw with the collar sleeve.  – Remove the tube from the fuel tank vent line. B00033-10 – Pull both spoilers sideways off of radiator bracket and lift off the fuel tank. ...
Page 60: Cooling System
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws with the collar sleeve.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the fuel hose. – Mount the seat. ( p. 56) B00031-11 Cooling system 9.78 (125 SX, 150 SX) Water pump...
Page 61: Checking The Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Correct the coolant level. Alternative 1 Coolant ( p. 94) Alternative 2 Coolant (mixed ready to use) ( p. 94) – Mount the radiator cap. Checking the coolant level 9.80 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...
Page 62: Refilling With Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE (125 SX, 150 SX) – Remove screw . Remove radiator cap   – Completely drain the coolant. – Mount screw with a new seal ring and tighten it.  Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft)
Page 63: Removing The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the main silencer 9.83 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws ...
Page 64: Removing The Glass Fiber Yarn Filling Of The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the glass fiber yarn filling of the main silencer 9.87 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. –...
Page 65: Removing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 9.91 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 66: Adjusting The Basic Position Of The Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Oil the dry air filter with a high quality filter oil. Oil for foam air filter ( p. 96) – Clean the air filter box. – Check the carburetor connection boot for damage and tightness. –...
Page 67: Changing The Hydraulic Clutch Fluid
MAINTENANCE WORK ON CHASSIS AND ENGINE » If the level of the fluid does not meet specifications: – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( p. 94) – Position the cover with the membrane. Mount and tighten the screws. Changing the hydraulic clutch fluid 9.96 Warning...
Page 68: Checking The Basic Position Of The Shift Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Inject the liquid into the system until it escapes from hole of the master  cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –...
Page 69: Carburetor - Adjusting The Idle Speed
MAINTENANCE WORK ON CHASSIS AND ENGINE (250 SX) Altitude above sea level 500 m (1,640 ft) Ambient temperature 20 °C (68 °F) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 95) The idle speed is adjusted with adjustment screw ...
Page 70: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust to the point between these two positions with the highest idle speed. Info If there is a large engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.
Page 71: Changing The Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE (125 SX, 150 SX) – Remove gear oil level check screw  – Check the gear oil level. A small amount of gear oil should flow out of the hole. » If no gear oil flows out: –...
Page 72: Refilling With Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place the motorcycle on a level surface. – Place a suitable container under the engine. (125 SX, 150 SX) – Remove the gear oil drain plug with magnet  – Remove the gear oil drain plug ...
Page 73 MAINTENANCE WORK ON CHASSIS AND ENGINE (125 SX, 150 SX) – Remove gear oil level check screw  B00049-10 (250 SX) – Remove gear oil level check screw  B00050-10 – Remove screw cap  – Add gear oil until it flows out of the hole of the gear oil level check screw. Engine oil (15W/50) ( p.
Page 74: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Go through the steps of starting the engine. p. 19) – Motorcycle was out of use for a long Empty the carburetor float chamber. time and there is old fuel in the float p.
Page 75 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Radiator fins very dirty Clean the radiator fins. – Foam formation in cooling system Drain the coolant. p. 59) – Refill with coolant. p. 60) – Damaged cylinder head or cylinder Check the cylinder head or cylinder head gas- head gasket ket.
Page 76: Cleaning
CLEANING Cleaning the motorcycle 11.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 77: Storage
Check the tire air pressure. ( p. 54) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 26) –...
Page 78: Technical Data - Engine
TECHNICAL DATA - ENGINE 125 SX 13.1 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing...
Page 79: Capacity - Gear Oil
TECHNICAL DATA - ENGINE Ignition Kokusan 2K-1 Ignition point (BTDC) 1.4 mm (0.055 in) Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kickstarter 250 SX 13.3 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³...
Page 80: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 125 SX, 150 SX 14.1 – Remaining screws, engine 6 Nm (4.4 lbf ft) – Screw, alternator cover 5 Nm (3.7 lbf ft) – Screw, exhaust control cover 5 Nm (3.7 lbf ft) ® Screw, ignition system/stator 6 Nm (4.4 lbf ft) Loctite...
Page 81: Nm (14.8 Lbf Ft)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –...
Page 82: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 125 SX 15.1 Carburetor type KEIHIN PWK 38S AG Carburetor identification number Needle position 3rd position from top Jet needle NOZI (NOZH, NOZJ) Main jet 182 (180, 185) Idling jet 42 (40, 45) Starting jet Idle air adjusting screw Open 1.5 turns Throttle slide...
Page 83: Carburetor Configuration (125 Sx)
TECHNICAL DATA - CARBURETOR Carburetor configuration (125 SX) 15.3 400709-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...
Page 84: Carburetor - Basic Setting For Sandy Surfaces (150 Sx)
TECHNICAL DATA - CARBURETOR 150 SX 15.4 Carburetor type KEIHIN PWK 38S AG Carburetor identification number Needle position 2nd position from top Jet needle NOZI (NOZH, NOZJ) Main jet 182 (180, 185) Idling jet 42 (40, 45) Starting jet Idle air adjusting screw Open 1.5 turns Throttle slide...
Page 85: Carburetor Configuration (150 Sx)
TECHNICAL DATA - CARBURETOR Carburetor configuration (150 SX) 15.6 400710-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...
Page 86: Carburetor - Basic Setting For Sandy Surfaces (250 Sx)
TECHNICAL DATA - CARBURETOR 250 SX 15.7 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0180 Needle position 3rd position from top Jet needle N1EI (N1EH) Main jet 158 (155, 160) Idling jet 42 (40) Starting jet Idle air adjusting screw Open 1.0 turn Throttle slide...
Page 87: Carburetor Configuration (250 Sx)
TECHNICAL DATA - CARBURETOR Carburetor configuration (250 SX) 15.9 400711-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...
Page 88: Technical Data - Chassis
80/100 - 21 51M TT 110/90 - 19 62M TT Bridgestone M59 Bridgestone M70 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 16.2 Total fuel tank capacity, 8 l (2.1 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) approx.
Page 89: Technical Data - Fork
TECHNICAL DATA - FORK 125 SX, 150 SX 17.1 Fork part number 14.18.7J.01 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s)
Page 90: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER 125 SX, 150 SX 18.1 Shock absorber part number 12.18.7J.01 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport...
Page 91 TECHNICAL DATA - SHOCK ABSORBER Shock absorber oil ( p. 95) SAE 2.5...
Page 92: Technical Data - Tightening Torques For Chassis
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) – Remaining nuts, chassis 15 Nm (11.1 lbf ft) –...
Page 94: Wiring Diagram
WIRING DIAGRAM Wiring diagram 20.1 re-wh re-bl B00059-10...
Page 95 WIRING DIAGRAM Components CDI controller Generator Pulse generator Ignition coil Plug-in connector, ignition curve Short circuit button Cable colors Green gr-bl Gray-black Gray Black ye-bl Yellow-black bu-wh Blue-white re-wh Red-white re-bl Red-black Brown...
Page 96 – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
Page 97: Substances
SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) according to – SAE ( p. 98) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) according to –...
Page 98: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –...
Page 99 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
Page 100: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.
Page 101: Index
INDEX Compression damping INDEX fork, adjusting ......31 Accessories ........5 Compression damping, high-speed Air filter shock absorber, adjusting...
Page 102 INDEX removing ....... . . 50 removing ....... . . 52 Fuel tank Rebound damping installing .
Page 103 INDEX Use definition ....... . . 5 View of vehicle right rear .
Page 104 OWNER'S MANUAL 2010 125 EXC EU 125 EXC SIX DAYS EU 150 XC USA 200 EXC EU 200 EXC AUS 200 XC‑W USA 250 EXC EU 250 EXC SIX DAYS EU 250 EXC AUS 250 XC EU/USA 250 XC‑W USA 300 EXC EU 300 EXC SIX DAYS EU 300 EXC AUS...
Page 105: Adjusting The Spring Preload Of The Shock Absorber Adjusting The Riding Sag X
300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC) ... 13 Important maintenance work to be carried out by an Electric starter button (250/300 EXC AUS)...... 13 authorized KTM workshop (as additional order)....36 Light switch (EXC, EXC SIX DAYS) ........14 Important checks and maintenance work to be carried Light switch (XC-W) ............
Page 106: Adjusting The Basic Position Of The Foot Brake Lever Checking The Rear Brake Fluid Level
TABLE OF CONTENTS Removing the headlight mask with the headlight (EXC, Cooling system .............. 76 EXC SIX DAYS) ............. 52 Checking the antifreeze and coolant level ......77 Refitting the headlight mask with the headlight (EXC, Checking the coolant level..........77 EXC SIX DAYS) .............
Page 107 TABLE OF CONTENTS 300 XC EU/USA, 300 XC‑W USA........103 Carburetor configuration (125 EXC EU, 125 EXC SIX DAYS EU) .......... 104 Carburetor configuration (150 XC USA) ....105 Carburetor configuration (All 200 models) ....106 Carburetor configuration (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC‑W USA) .............
Page 108: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
Page 109: Important Information
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
Page 110 IMPORTANT INFORMATION Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. –...
Page 111: View Of Vehicle
VIEW OF VEHICLE View of the vehicle from the left front (example) B00077-10 Hand brake lever Short circuit button Clutch lever Air filter box lid Fuel tap Shift lever Chain guide Side stand...
Page 112: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) B00076-10 Shock absorber rebound adjustment Level viewer for brake fluid, rear Foot brake lever Kickstarter Bleeder screw, fork leg Throttle grip Chassis number Filler cap...
Page 113: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head.  B00015-10 Type label The type label is fixed to the front of the steering head.  400284-10 Key number (EXC, EXC SIX DAYS) The key number is stamped on the key strap.
Page 114: Shock Absorber Part Number
LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above  the adjusting ring on the engine side. 500083-10...
Page 115: Controls
CONTROLS Clutch lever (All 125/150/200 models) The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. B00001-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. ...
Page 116: Short Circuit Button (Xc-W/Xc)
CONTROLS Short circuit button (XC‑W/XC) Short circuit button is fitted on the left side of the handlebar.  Possible states in basic position – In this position, the ignition circuit is • Short circuit button closed, and the engine can be started. pressed –...
Page 117: Light Switch (Exc, Exc Six Days)
CONTROLS Light switch (EXC, EXC SIX DAYS) 5.10 The light switch is fitted on the left side of the handlebar.  Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on –...
Page 118: Controls (All Exc/Xc-W Models)
CONTROLS (ALL EXC/XC-W MODELS) Speedometer – Press the key to change the display mode or change to one of the setup menus. – Press the button to control different functions. – Press the button to control different functions. Info In its condition at delivery, the display mode SPEED/H and SPEED/ODO is acti- vated.
Page 119: Setting The Clock
CONTROLS (ALL EXC/XC-W MODELS) – Press the button for 3 - 5 seconds. The settings are stored and the setup menu is closed. Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the setup menu closed.
Page 120: Querying The Lap Time
CONTROLS (ALL EXC/XC-W MODELS) Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the setup menu closed. Querying the lap time Info This function can be called only if lap times are measured. Condition The motorcycle is stationary.
Page 121: Display Mode Speed/Clk (Clock)
CONTROLS (ALL EXC/XC-W MODELS) Display mode SPEED/CLK (clock) 6.10 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button .
Page 122: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS (ALL EXC/XC-W MODELS) Press the button Next display mode briefly. Display mode SPEED/TR2 (trip master 2) 6.14 – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .
Page 123: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS (ALL EXC/XC-W MODELS) Display mode SPEED/S1 (stop watch 1) 6.17 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.
Page 124 CONTROLS (ALL EXC/XC-W MODELS) Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary vated Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...
Page 125: Controls
CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. Tap handle on the fuel tap is used to open or close the supply of fuel to the carbure-  tor. Possible states Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. •...
Page 126: Choke (Exc Eu, Exc Six Days)
CONTROLS Choke (EXC EU, EXC SIX DAYS) The choke lever is fitted on the left side of the handlebar.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.
Page 127: Foot Brake Lever
CONTROLS Foot brake lever Foot brake lever is located in front of the right footrest.  The foot brake lever is used to activate the rear brake. B00007-10 Side stand Note Danger of damage The parked vehicle may roll away or fall over. –...
Page 128: Unlocking The Steering (Exc, Exc Six Days)
CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible.
Page 129 When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
Page 130: General Tips And Hints On Putting Into Operation
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution.
Page 131: Preparations For Riding On Wet Sand
Sand cover for air filter (59006022000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600871-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 132) –...
Page 132: Preparations For Riding On Wet And Muddy Surfaces
Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 132) –...
Page 133: Preparations For Riding At High Temperatures And Riding Slowly
Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop.
Page 134: Riding Instructions
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the gear oil level. ( p.
Page 135: Starting Up
Do not change into a low gear at high engine speed. The engine overspeeds and the rear wheel can block. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.
Page 136: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components get very hot when the vehicle is in use. –...
Page 137 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 9.5 l Super unleaded gasoline, mixed with capacity, approx. (2.51 US gal) 2-stroke engine oil (1:60) ( p.
Page 138: Service Schedule
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop 10.1 S10N S20A S40A Engine Check the gear oil level. ( p. 88) • • • • Change the gear oil. p. 88) Check spark plug and replace if required.
Page 139: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)
SERVICE SCHEDULE S20A: every 20 operating hours S40A: every 40 operating hours/after every race Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 10.2 Competition use Hobby use S10A S20N S30A S10A S20A S40A...
Page 140: Important Checks And Maintenance Work To Be Carried Out By The Rider
SERVICE SCHEDULE Competition use Hobby use S10A S20N S30A S10A S20A S40A S80A S20A S40A S60A S80A Check exhaust con- trol for functioning • • • • • • • • and smooth opera- tion, clean. Change the crankshaft main •...
Page 141: Maintenance Work On Chassis And Engine
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.
Page 142: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.
Page 143: Adjusting The Rebound Damping Of The Shock Absorber
11.7 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise with a screwdriver to the last click.
Page 144: Measuring The Sag Of The Unloaded Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE (250/300 XC) Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Measuring the sag of the unloaded rear wheel 11.8 –...
Page 145: Checking The Riding Sag Of The Shock Absorber
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Page 146: Adjusting The Riding Sag
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw  Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) –...
Page 147: Installing The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the shock absorber 11.14 – Push splash protector to the side and position the shock absorber. Mount and  tighten screw  Guideline Screw, top shock absorber 80 Nm Loctite ® 243™ (59 lbf ft) –...
Page 148: Adjusting The Rebound Damping Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. – Mount protection covers  (XC) – Turn adjusting screws clockwise all the way.  Info Adjusting screws are located at the top end of the fork legs. ...
Page 149: Adjusting The Spring Preload Of The Fork (Exc, Exc Six Days, Xc-W)
MAINTENANCE WORK ON CHASSIS AND ENGINE (XC) – Remove protection covers  – Turn adjusting screws clockwise all the way.  Info Adjusting screws are located at the bottom end of the fork legs.  Make the same adjustment on both fork legs. –...
Page 150: Bleeding The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding the fork legs 11.19 – Jack up the motorcycle. ( p. 38) – Remove bleeder screws briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. –...
Page 151: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden for a lengthy period with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.
Page 152: Removing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw  Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) (EXC SIX DAYS, XC‑W) – Loosen screws . Remove screw   – Loosen and retighten screw ...
Page 153: Installing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE (XC) – Loosen screws . Remove the fork leg on the left.  – Loosen screws . Remove the fork leg on the right.  B00021-10 Installing the fork legs 11.26 – Position the fork legs. Info The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp.
Page 154: Removing The Fork Protector
MAINTENANCE WORK ON CHASSIS AND ENGINE (XC) – Position the brake line. Put on the clamp and mount and tighten screws  – Install the front wheel. p. 67) Removing the fork protector 11.27 – Remove the fork legs. p. 49) –...
Page 155: Removing The Headlight Mask With The Headlight (Exc, Exc Six Days)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the headlight mask with the headlight (EXC, EXC SIX DAYS) 11.31 – Switch off all power consumers. – Remove screw and take off the clamp.  – Release rubber band . Slide the headlight mask up and swing it forward. ...
Page 156: Installing The Start Number Plate (Xc-W/Xc)
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the start number plate (XC‑W/XC) 11.34 – Position the start number plate. Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Ensure that the holding lugs engage in the fender. –...
Page 157: Checking The Play In The Throttle Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 11.37 – Move the handlebar to the straight-ahead position. – Push back bellows  – Pull back the throttle cable casing until you sense a resistance. – Now check throttle cable play ...
Page 158: Checking The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 132) Off-road chain spray ( p. 132) 400725-01 Checking the chain tension 11.41 Warning Danger of accidents Danger caused by incorrect chain tension. –...
Page 159: Adjusting The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE – Shift gear to neutral. – Pull on the upper part of the chain with the specified weight  Guideline 0 0 A Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section.
Page 160: Adjusting The Chain Guide
MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws to the left and right.  Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn adjusting screws on the left and right so that the markings on the left ...
Page 161: Checking The Brake Discs
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...
Page 162: Adjusting The Basic Position Of The Hand Brake Lever (Xc-W/Xc)
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Page 163: Adding Front Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 164: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
Page 165: Checking The Free Travel Of The Foot Brake Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove locking split pins , withdraw bolt , and take out the brake linings.   – Clean the brake caliper and brake caliper support. 100396-10 – Check that leaf spring in the brake caliper and sliding plate in the brake ...
Page 166: Adjusting The Basic Position Of The Foot Brake Lever
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Page 167: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 168: Removing The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
Page 169: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 170: Installing The Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.
Page 171: Removing The Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 11.64 – Jack up the motorcycle. ( p. 38) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
Page 172: Checking The Tire Condition
DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires are changed at the latest after 5 years, regardless of the actual state of wear. »...
Page 173: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
Page 174: Engine Characteristic - Auxiliary Spring (All 250/300 Models)
MAINTENANCE WORK ON CHASSIS AND ENGINE Engine characteristic - auxiliary spring (All 250/300 models) 11.69 The auxiliary spring is located on the right side of the engine below the water pump cover. Possible states Auxiliary spring with yellow marking – Auxiliary spring mounted at the factory with •...
Page 175: Removing The Battery (250 Exc Aus/Xc-W/Xc, All 300 Models)
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 176: Removing A Fuse (250 Exc Aus/Xc-W/Xc, All 300 Models)
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
Page 177: Checking The Headlight Setting (Exc, Exc Six Days)
MAINTENANCE WORK ON CHASSIS AND ENGINE – Refit the fuse. Fuse (58011109110) Info A reserve fuse is located in the starter relay.  Replace a burned-out fuse only by an equivalent fuse.  – Replace the protection cover. – Install the air filter box lid. ( p.
Page 178: Mounting The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 11.79 – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. – Make sure that the seat is correctly locked in. –...
Page 179: Installing The Fuel Tank
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 11.81 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
Page 180: Checking The Antifreeze And Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE (All 250/300 models) Water pump in the engine circulates the coolant.  The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified ...
Page 181: Draining The Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in)  » If the level of the coolant does not meet specifications: –...
Page 182: Refilling With Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE Refilling with coolant 11.86 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor.
Page 183: Removing The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the main silencer 11.87 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws ...
Page 184: Installing The Glass Fiber Yarn Filling Of The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the glass fiber yarn filling of the main silencer 11.91 – Slide the glass fiber yarn filling over the inner tube. 0 0 4  0 0 3 – Slide the outer tube over the glass fiber yarn filling.
Page 185: Installing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE – Detach air filter holder at the bottom and swing it to one side. Remove the air  filter with the air filter support. – Remove the air filter from the air filter support. B00039-10 Installing the air filter 11.96...
Page 186: Adjusting The Basic Position Of The Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the basic position of the clutch lever 11.98 (All 125/150/200 models) – Adjust the basic setting of the clutch lever to your hand size by turning adjust- ing screw  Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar.
Page 187: Changing The Hydraulic Clutch Fluid
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the hydraulic clutch fluid 11.100 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (All 125/150/200 models) –...
Page 188: Checking The Basic Position Of The Shift Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Inject the liquid into the system until it escapes from hole of the master  cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –...
Page 189: Carburetor - Adjusting The Idle Speed
MAINTENANCE WORK ON CHASSIS AND ENGINE Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) ( p. 131) (EXC, EXC SIX DAYS, XC-W, 250/300 XC) Altitude above sea level 500 m (1,640 ft) Ambient temperature 20 °C (68 °F) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p.
Page 190: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
Page 191: Checking The Gear Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a cloth beneath the carburetor to soak up emerging fuel. – Remove plug  – Completely drain the fuel. – Mount and tighten the plug. B00047-10 Checking the gear oil level 11.106 Info The gear oil level must be checked when the engine is cold.
Page 192: Draining The Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the gear oil 11.108 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 193: Adding Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – Start the engine and check that it is oil-tight. – Check the gear oil level. ( p. 88) Adding gear oil 11.110 Info Too little gear oil or poor-quality oil results in premature wear of the transmission. The gear oil must be added when the engine is cold.
Page 194: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 31) (250 EXC AUS/XC‑W/XC, – Battery discharged Recharge the battery. p. 72) all 300 models) –...
Page 195 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Lack of fuel Turn handle of the fuel tap to the ON posi-  carburetor tion. – Refuel. ( p. 33) – Engine takes in bad air Check the intake flange and carburetor for tightness.
Page 196: Cleaning
CLEANING Cleaning the motorcycle 13.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 197: Storage
Storage temperature of battery without direct sunlight 0… 35 °C (32… 95 °F) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 38) –...
Page 198: Technical Data - Engine
TECHNICAL DATA - ENGINE 125 EXC EU, 125 EXC SIX DAYS EU 15.1 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing...
Page 199: All 200 Models
TECHNICAL DATA - ENGINE Ignition Kokusan 2K-3 Ignition point (BTDC) 1.4 mm (0.055 in) Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kickstarter All 200 models 15.3 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 193 cm³...
Page 200: All 300 Models
TECHNICAL DATA - ENGINE Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydraulically activated Gearbox 5-gear, claw shifted Transmission ratio (250 XC EU/USA) 1st gear 14:30 2nd gear 16:26 3rd gear 18:24 4th gear 21:24 5th gear 22:21 Transmission ratio (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC‑W USA) 1st gear 14:30 2nd gear...
Page 201: Capacity - Gear Oil
TECHNICAL DATA - ENGINE 4th gear 20:20 5th gear 29:23 Ignition Kokusan E Ignition point (BTDC) 1.9 mm (0.075 in) Spark plug NGK BR 7 ES Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kickstarter and electric starter Capacity - gear oil 15.6 Gear oil...
Page 202: Nut, Rotor M12X1
TECHNICAL DATA - ENGINE TIGHTENING TORQUES All 125/150/200 models 16.1 – Remaining screws, engine 6 Nm (4.4 lbf ft) – Screw, alternator cover 5 Nm (3.7 lbf ft) – Screw, exhaust control cover 5 Nm (3.7 lbf ft) ® Screw, ignition system/stator 6 Nm (4.4 lbf ft) Loctite ®...
Page 203: Nm (73.8 Lbf Ft) Loctite
TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Nuts, cylinder base 35 Nm (25.8 lbf ft) – Remaining screws, engine 45 Nm (33.2 lbf ft) – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.3 lbf ft) –...
Page 204: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 125 EXC EU, 125 EXC SIX DAYS EU 17.1 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0191 Needle position 5th position from top Jet needle N84I (NOZE / NOZF) Main jet 140 (168 / 170 / 172) Idling jet 38x38 (45 / 48) Starting jet...
Page 205: 200 Xc-W Usa
TECHNICAL DATA - CARBURETOR 200 XC‑W USA 17.5 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0200 Needle position 4th position from top Jet needle NOZH (NOZG) Main jet 162 (160 / 165) Idling jet Starting jet Idle air adjusting screw Open 1 turn Throttle slide...
Page 206: 250 Xc-W Usa
TECHNICAL DATA - CARBURETOR 250 XC‑W USA 17.9 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0230 Needle position 4th position from top Jet needle N8RW (N8RH / N8RJ) Main jet 165 (162) Idling jet Starting jet Idle air adjusting screw Open 1 turn Throttle slide...
Page 207: Carburetor Configuration (125 Exc Eu, 125 Exc Six Days Eu)
TECHNICAL DATA - CARBURETOR Carburetor configuration (125 EXC EU, 125 EXC SIX DAYS EU) 17.13 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 400748-01 M/FT ASL Sea level...
Page 208: Carburetor Configuration (150 Xc Usa)
TECHNICAL DATA - CARBURETOR Carburetor configuration (150 XC USA) 17.14 400710-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces!
Page 209: Carburetor Configuration (All 200 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 200 models) 17.15 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 400749-01 M/FT ASL Sea level...
Page 210: Carburetor Configuration (250 Exc Eu, 250 Exc Six Days Eu, 250 Exc Aus, 250 Xc-W Usa)
TECHNICAL DATA - CARBURETOR Carburetor configuration (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC‑W USA) 17.16 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only.
Page 211: Carburetor Configuration (250 Xc Eu/Usa)
TECHNICAL DATA - CARBURETOR Carburetor configuration (250 XC EU/USA) 17.17 400750-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces!
Page 212: Carburetor Configuration (All 300 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 300 models) 17.18 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 400752-01 M/FT ASL Sea level...
Page 213: General Carburetor Configuration
TECHNICAL DATA - CARBURETOR General carburetor configuration 17.19 1... 5 Needle position from above The five needle positions are shown here. 0 0 1 The carburetor configuration depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4 0 0 5 B00075-10...
Page 214: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork (EXC, EXC SIX DAYS, XC-W) WP Suspension Up Side Down 4860 MXMA PA Fork (XC) WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 300 mm (11.81 in) Rear...
Page 215: Lighting Equipment
80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 18.3 Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) approx.
Page 216: Technical Data - Fork
TECHNICAL DATA - FORK All 125/200 models 19.1 Fork part number 14.18.7J.02 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s)
Page 217: All 250/300 Exc/Xc-W Models
TECHNICAL DATA - FORK All 250/300 EXC/XC-W models 19.3 Fork part number 14.18.7J.04 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s)
Page 218: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER All 125/200 models 20.1 Shock absorber part number 12.18.7J.02 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns...
Page 219: All 250/300 Exc/Xc-W Models
TECHNICAL DATA - SHOCK ABSORBER Shock absorber oil ( p. 131) SAE 2.5 All 250/300 EXC/XC-W models 20.3 Shock absorber part number 12.18.7J.04 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort...
Page 220 TECHNICAL DATA - SHOCK ABSORBER Riding sag 107 mm (4.21 in) Fitted length 411 mm (16.18 in) Shock absorber oil ( p. 131) SAE 2.5...
Page 221: Technical Data - Tightening Torques For Chassis
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, spoiler on fuel tank (XC‑W/XC) M5x12 1.5 Nm (1.11 lbf ft) – Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) –...
Page 223: Wiring Diagram
WIRING DIAGRAM...
Page 224: Wiring Diagram (125 Exc Eu, 125 Exc Six Days Eu, 200 Exc Eu, 200 Exc Aus, 250 Exc Eu, 250 Exc Six Days Eu)
WIRING DIAGRAM Wiring diagram (125 EXC EU, 125 EXC SIX DAYS EU, 200 EXC EU, 200 EXC AUS, 250 EXC EU, 22.1 250 EXC SIX DAYS EU) CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 AK1/2 CW3/2 DG/4 CW2/2 AH1/2 CX3/2 CX2/2 BP/4 ye-bl BA/1...
Page 225 WIRING DIAGRAM Components CDI controller Wheel speed sensor Alternator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay Ignition pulse generator...
Page 226 WIRING DIAGRAM...
Page 227: Wiring Diagram (250/300 Exc Aus, 300 Exc Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM Wiring diagram (250/300 EXC AUS, 300 EXC EU, 300 EXC SIX DAYS EU) 22.2 CX/2 CZ/3 D DB/4 CW/2 CY/3 D DA/4 AK1/2 D DG/4 CW2/2 CW3/2 AH1/2 CX2/2 CX3/2 BP/4 ye-bl bu bu-wh ye-r -re ye-r -re ye-r -re or or or or...
Page 228 WIRING DIAGRAM Components CDI controller Wheel speed sensor Battery Alternator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay...
Page 229: Wiring Diagram (150 Xc Usa, 200 Xc-W Usa)
WIRING DIAGRAM Wiring diagram (150 XC USA, 200 XC‑W USA) 22.3 bu-wh bu-wh ye-bl ye-bl re-wh re-bl re-bl re-wh B00086-10...
Page 230 WIRING DIAGRAM Components CDI controller Wheel speed sensor (XC-W) Alternator Ignition pulse generator Ignition coil Voltage regulator/rectifier Speedometer (XC-W) Tripmaster switch (optional) Light switch (XC-W) Short circuit button Ignition curve plug connection Cable colors Black bl-wh Black-white Brown Blue bu-wh Blue-white Green Gray...
Page 231: Wiring Diagram (250/300 Xc-W, 250/300 Xc)
WIRING DIAGRAM Wiring diagram (250/300 XC‑W, 250/300 XC) 22.4 bu-wh ye-bl bu-wh ye-bl re-wh re-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re B00087-10...
Page 232 WIRING DIAGRAM Components CDI controller Wheel speed sensor Battery Alternator Starter relay with main fuse Ignition pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer (XC-W) Tripmaster switch (optional) Light switch (XC-W) Short circuit button Electric starter button Ignition curve plug connection Cable colors Black bl-wh...
Page 233 – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
Page 234: Substances
SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 134) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) According to –...
Page 235: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –...
Page 236 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
Page 237: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.
Page 238: Index
INDEX Compression damping INDEX fork, adjusting ......44 Accessories ........6 Compression damping, high-speed Air filter shock absorber, adjusting...
Page 239 INDEX Front wheel installing ....... . . 67 Putting into operation removing .
Page 240 INDEX Technical data carburetor ......101-110 chassis ......111-112 chassis tightening torques .
Page 241 REPAIRMANUAL2004-2010 250/300 SX, SXS, MXC, EXC EXC-E, EXC SIX DAYS, EXC-E SIX DAYS, XC, XC-W REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE REPARATION MANUAL DE REPARACION...
Page 242 1 SERVICE-INFORMATION 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAM...
Page 243 GENERAL INFORMATION INDEX SPECIAL TOOLS - ENGINE .........2-2 CHECKING THE SETTING OF THE TVC SYSTEM .
Page 244 SPECIAL TOOLS - ENGINE 250 / 300 Fig. Part no. Description 560.12.001.000 Universal engine work stand 548.29.001.000 Adjusting plate "dimension X" 546.29.003.000 Clutch holder 560.12.004.000 Gear wheel segment 546.29.009.044 Magneto extractor M 27x1 580.12.009.000 Magneto extractor (electric starter) 510.12.011.000 Circlip pliers 510.12.016.000 Protection cap 546.29.012.100...
Page 245 Make sure you do not turn the dolly screw since as will impair the engine characteristic. NOTE: If you prefer a smoother engine power application, you can mount a different ignition rotor and a different exhaust. Ask your KTM dealer for more information.
Page 246 – Correct the oil level with the master cylinder in a horizontal position to 4 mm under the upper edge. – Mount the rubber boot and cover with the screws CAUTION – KTM USES BIODEGRADABLE HYDRAULIC MINERAL OIL TO ACTUATE THE 2005 HYDRAULIC CLUTCH UP TO THE MODEL...
Page 247 Bleeding the hydraulic clutch (as of model 2006) – Turn the handlebar until the master cylinder is in a horizontal position. – Remove the screws , the cover and the rubber boot – Fill the bleeder syringe 503.29.050.000 with a suitable fluid (as of modell 2006 - brake fluid DOT 5.1).
Page 248 Changing the front brake fluid – Move the hand brake cylinder into a horizontal position. – Disassemble the cover together with the rubber boot from the brake fluid reservoir. – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
Page 249 Changing the rear brake fluid – Move the vehicle into a vertical position. – Disassemble the screw cap together with the rubber boot from the brake fluid reservoir. – Use a syringe to extract the used brake fluid and fill with fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
Page 250 REMOVING AND REFITTING ENGINE INDEX REMOVING THE ENGINE ......... .3-2 REFITTING THE ENGINE .
Page 251 Removing the engine NOTE: The cylinder head and the cylinder can be dismounted even if the engine remains mounted. Likewise, work on the clutch, primary drive, gearshift mechanism, and ignition system can also be carried out. – Clean the motorcycle thoroughly. –...
Page 252 – Loosen both hose clamps, and pull the caburetor out of the carburetor connection boot and intake flange. – Remove the engine fastening screw – Remove the cable ties and loose the ignition cable from the frame. – Remove the engine fastening screw –...
Page 253 Refitting the engine – Lift the engine into the frame and move it into the correct position. – Slightly grease the two engine fixing screws and mount but do not tighten yet. – Slightly grease the swing arm pivot, mount the hexagon nut tighten to 100 Nm.
Page 254 – Mount the chain. WARNING HEN MOUNTING THE CHAIN JOINT MAKE SURE THAT THE CLOSED SIDE OF THE RETAINER POINTS IN THE RUNNING DIRECTION – Mount the clutch slave cylinder together with the chain guard and tighten the three screws to 10 Nm. –...
Page 255 Filling up the cooling liquid: – Make sure that the drain screw is fastened. – Pour approx. 0.50 litres (0.13 US gallons) of coolant into the system. Coolant: 50% anti freeze : 50% pure water, at least -25 °C – Remove the screw on the right radiator and tilt the motorcycle to the right approx.
Page 256 DISASSEMBLING THE ENGINE INDEX PREPARATION ..........4-2 DRAINING THE GEAR OIL .
Page 257 Preparation – Clean the engine thoroughly. – Clamp the engine into the workstand. – Remove the kickstarter. Draining the gear oil NOTE: The transmission oil should already be drained when the engine is dismounted. Otherwise, the transmission oil will leak out of the drive shaft following the removal of the slave cylinder of the clutch.
Page 258 Removing electric starter motor (with electric starter) – Remove the 2 screws and pull off the electric starter. Dismounting the cylinder head, cylinder and piston – Unscrew the 6 collar bolts and remove the cylinder head and the two O-rings. –...
Page 259 – Remove the 4 collar nuts on cylinder base and remove the cylinder. – Remove the cylinder base gasket. – Cover the crankcase. – Place piston on a wooden jig and remove both piston pin locking pins. – Expel the piston pin from the piston without exerting undue force. Use a suitable mandrel if necessary.
Page 260 Dismounting the primary drive – Block the primary gear with the gear wheel segment 560.12.004.000 (see illustration). – Undo the hexagon nut (LH thread) and remove it together with the detent edged ring. – Release the lock washer of the inner clutch hub. –...
Page 261 – Loosen the AH bolt and remove the shift lock. NOTE: Disassemble locating lever only if the engine case must be replaced. – Remove bolt and the locking lever with the spring and bush. Dismounting the ignition cover (without electric starter) –...
Page 262 – Undo the 3 bolts and remove the stator together with the base plate. Removing starter drive cover (with electric starter) – Loosen the 2 screws and remove the ignition outer cover with its gasket. – Take off the layshaft with the crown wheel. Removing ignition cover (with electric starter) –...
Page 263 Dismounting the reed valve housing – Remove the 4 collar bolts – Remove the reed valve housing with the intake flange or rubber sleeve. Parting the engine housing halves – Face ignition-gear upwards and remove all 12 housing bolts. – Loosen the 2 engine fixtures on the engine work stand. –...
Page 264 – Remove the pressure spring from the engine case. – Pull the drive shaft together with the countershaft out of the bearing seats. – Remove 1st-gear idler gear with the needle cage and the two stop discs from the engine case. Dismounting the crankshaft –...
Page 265 SERVICING INDIVIDUAL COMPONENTS INDEX SERVICING THE RIGHT ENGINE HOUSING HALF ......5-2 SERVICING THE LEFT ENGINE HOUSING HALF ......5-3 CRANKSHAFT .
Page 266 Servicing the right engine housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. The bearings usually fall out of their seat of their own accord by knocking the housinq half on a plane piece of wood when the housing has a temperature of 150°...
Page 267 Servicing the left engine housing half – Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C. The bearings usually fall out of their seat of their own accord by knocking the housinq half on a plane piece of wood when the housing has a temperature of 150°...
Page 268 Crankshaft – When replacing the roller bearing, the inner crankshaft ring must also be renewed. – Heat special tool 584.29.037.043 on a heating pad up to approx. 150°C and slip it on the inner ring immediately. Press the special tool together tightly to obtain a good heat transfer and pull the inner ring off the crankshaft.
Page 269 Measuring pistons and cylinders, establishing the piston mounting clearance 10mm – Measure the cylinder diameter approx. 10 mm below the top of the cylinder edge. – Check the diameter in several corresponding places to see if the cylinder has worn oval. –...
Page 270 Cylinder exhaust control system Dismantle and clean all the exhaust control components, check for signs of wear and damage. Control rollers - Check the clearance of the bearings. Remove oil-derived deposits. Check the toothing of the control rollers for signs of wear. Gear segments - Check the toothing of the gear segments and control rollers for signs of wear.
Page 271 – Mount and grease the O-rings (15x1.50 mm) on the control flap and grease. – Slightly grease the bearing sleeves and plug them on the control flap. – Mount the toothed segments (the toothed segment with the cylindrical pin has to be mounted on the right side). –...
Page 272 LOCTITE 243 LOCTITE 243 Exhaust control, clutch cover – Remove bolts , the spring insert , the control spring and the auxiliary spring from the clutch cover. – Remove bolt with the rocker arm and the control lever – Take off the water pump cover, remove the allen head bolt take off the water pump wheel –...
Page 273 Reed valve housing (250 SX/SXS) 250 SX/SXS NOTE: Reed paddles gradually lose tension through operation, resulting in power loss. Damaged or worn reed paddles must be replaced. Intake flange Check for firm mounting and for signs of damage. Reed valve housing (EXC/EXC SIX DAYS/MXC/XC/XC-W) EXC/EXC SIX DAYS/MXC/XC/XC-W NOTE: Reed paddles gradually lose tension through operation,...
Page 274 5-10 13.5 mm LOCTITE 242 Clutch Thrust bearing check for wear Push rod Check for wear. Minimum length: 192 mm (new: 192.50 mm) Clutch springs New spring length 42 mm / 1.69 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable. 9 Lining discs Minimum thickness 2.60 mm (0.102 in) / new disc 2.70 mm (0.106 in).
Page 275 5-11 Replace outer clutch hub – Drill open the clutch rivets in area of retaining bracket remove parts. NOTE: Check the 8 absorbing elements bn for signs of mechanical damage, replace all 8 where applicable. CAUTION HE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED DIRECTLY ON THE PRIMARY GEAR CROWN THE PARTS MUST BE HELD IN...
Page 276 5-12 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 Shift mechanism Shift forks Check the shift fork blades and shift roller driving pin for signs of wear. 0.40 - 0.80 Shift roller Check the shift grooves for wear. Check the position of shift roller in grooved ball bearings Slide plate Check the slide plate at meshing points for wear.
Page 277 5-13 Transmission Secure the mainshaft or countershaft in the vice (using soft jaw-covers). Remove the gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels –...
Page 278 5-14 Transmission Secure the mainshaft or countershaft in the vice (using soft jaw-covers). Remove the gears and check the following for wear: – Needle bearing – Mainshaft and countershaft pivot points including idler gears – Shift dogs and gear wheels –...
Page 279 5-15 LOCTITE 243 LOCTITE 243 Checking the kickstarter for wear Take all the components off the kickstarter shaft and clean them. Kickstarter gear Check the toothing for wear and the bearing for clearance. Kickstarter idler gear Check the bearing for clearance and seizing marks. Check the toothing for wear.
Page 280 5-16 Checking the electric starter motor for wear – Check Bendix for smooth operation and signs of wear. – Check the sprocket of the electric starter for wear and radial clearance. – Replace O-ring of the electric starter. – Replace gasket –...
Page 281 ASSEMBLING THE ENGINE INDEX CRANKSHAFT ..........6-2 TRANSMISSION .
Page 282 – Secure the right-hand housing half in the engine work stand. Crankshaft – Insert the crankshaft from above through the grooved ball bearing and push carefully as far as it will go. CAUTION HEN PUSHING IN THE CRANKSHAFT MAKE SURE THE CONROD IS FACING THE CYLINDER NOTE: To make it easier to mount the crankshaft, heat the crankshaft bearing with a hot air blower.
Page 283 – Fix the 3 pressure springs with ample amounts of grease in the gearshift rails. NOTE: The bottom of the longer gearshift rail does not have a spring. – Oil the gearshift rails and insert them into the gearshift forks (short gearshift rail toward drive shaft).
Page 284 Mounting the shift mechanism – Slip the disc , the locking lever , the locking spring sleeve and the locking lever spring onto the bolt (M5x20). – Apply Loctite 243 to the thread of the screw and mount all parts at one time.
Page 285 Mounting the primary drive and clutch – Grease the crankshaft seal ring. – Put the oiled O-ring (25x1.50 mm) onto the crankshaft and mount the distance bushing with the chamfer facing the crank web. – Place primary gear onto crankshaft with the collar downwards. –...
Page 286 Mounting the clutch discs and pressure cap – Oil the thrust bearing , and slide it over the drive shaft. – Oil the lining discs before mounting. – Beginning with one lining disc, mount alternately 9 lining discs (= 2.70 mm / 0.10 in) and 8 intermediate discs (= 1.20 mm / 0.047 in), with a lining disc forming the final layer upwards.
Page 287 Mounting the piston and cylinder – Before assembly, oil all parts thoroughly at the sliding points. – Insert the needle bearing in the conrod eye, attach the piston (the arrow on the base of the piston should point towards the exhaust port) and mount the piston pin.
Page 288 Adjusting the control flap (dimension “Z”) control NOTE: Dimension “Z“ is the distance from the lower edge of the control flap flap to the upper edge of the cylinder, as measured in the centre of the exhaust port. 250/300 model 2004/2005 Dimension “Z“...
Page 289 Mounting the steering covers – Mount the right control cover including the gasket and fasten with 3 bolts. – Place the gasket in position and fix the left-hand steering cover on the cylinder. Mounting the cylinder head – Clean the cylinder and the cylinder head sealing surface, place the O-rings in the grooves.
Page 290 6-10 Mounting the engine sprocket – Lubricate O-ring with oil and slide over the counter shaft. – Slide the distance bushing over the countershaft so that the O-ring rests in bevel and the dust lip on the shaft seal ring does not slip inside.
Page 291 6-11 Mounting the ignition cover (without electric starter) – Put on a new gasket, and fix the ignition cover by means of the 4 bolts. Mounting the ignition system (with electric starter) – Push the rotor on to the crankshaft. –...
Page 292 6-12 Fitting the push rod – Fit the push rod Mounting the starting lever and shift lever – Mount the kickstarter. Secure the kickstarter screw with Loctite 243 and tighten to 25 Nm. – Mount the shift lever. Secure the screw on the shift lever with Loctite 243 and tighten to 14 Nm.
Page 293 ELECTRICAL INDEX IGNITION COIL ..........7-2 CDI UNIT .
Page 294: Ignition Coil
Ignition coil – Disconnect all cables and remove the spark plug connector. – Use an ohmmeter to measure the following values. NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values.
Page 295 Checking the capacitor – Discharge the capacitor by bridging the two connections with a cable bridge and dismount it. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor is made with a test lamp –...
Page 296 Check the stator and pulse generator Use an ohmmeter to perform the following measurements: Kokusan 2K-1 Ignition Measure Cable colors Resistance 100 Ω ±15% 2K-1 Pulser coil red - green Exciter black/red - red/white 24 Ω ±15% 2K-2 Pulser coil red - green 100 Ω...
Page 297 STATIC IGNITION VALUES 250 SX, 250-300 EXC/MXC (KOKUSAN 2K-1, 2K-3) 2004 Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroded condition and connectors tightly connected – spark plug unscrewed and spark plug connector attached to ground –...
Page 298 high/low beam switch horn switch stop button flasher switch handle bar switch flasher relay horn regulator-rectifier ye-re br-bl ye-re capacitor ye-re rear brake switch speed sensor right rear flasher wh-gn gn-wh right front flasher ye-bl ye-bl left rear flasher pick up generator ignition coil left front flasher...
Page 299 STATIC GENERATOR VALUES 250-300 MXC/EXC (KOKUSAN 2K-3) 2004 Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroded condition and connectors tightly connected – light switch turned off – kick the kick starter forcefully at least 5 times for each measurement Static generator values 250-300 MXC/EXC (except 250 EXC USA) Check the generator output...
Page 300 high/low beam switch horn switch stop button flasher switch handle bar switch flasher relay horn regulator-rectifier ye-re br-bl ye-re capacitor ye-re rear brake switch speed sensor right rear flasher wh-gn gn-wh right front flasher ye-bl ye-bl left rear flasher generator pick up ignition coil left front flasher...
Page 301 STATIC IGNITION AND GENERATOR VALUES 250 EXC USA (KOKUSAN 2K-2) 2004 Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroded condition and connectors tightly connected – spark plug unscrewed and spark plug connector attached to ground –...
Page 302 light switch stop switch handle bar switch regulator-rectifier speed sensor ye-bl ye-bl pick up generator ignition coil EXC-USA 250 2004 wiring diagramm 22.05.2003 main harness 523.11.075.000...
Page 303 7-11 STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC (KOKUSAN 2K-1, 2K-3) 2005 250 SX/SXS, 250/300 EXC/EXC SIX DAYS, 300 XC/XC-W (KOKUSAN 2K-1, 2K-3) 2006 Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroded condition and connectors tightly connected –...
Page 305 7-13 STATIC GENERATOR VALUES 250/300 MXC/EXC (KOKUSAN 2K-3) 2005 250/300 EXC/EXC SIX DAYS, 300 XC-W (KOKUSAN 2K-3) 2006 Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroded condition and connectors tightly connected –...
Page 307 7-15 STATIC IGNITION AND GENERATOR VALUES 250 EXC USA (KOKUSAN 2K-2) 2005 250 XC/XC-W (KOKUSAN 2K-2) 2006 Measuring conditions: – cold engine – seat and tank removed – all connectors and the ground connection in a non-corroded condition and connectors tightly connected –...
Page 309 7-17 STATIC IGNITION VALUES 250/300 EXC-E FROM 2007 Measuring conditions: – Engine cold – Seat and tank removed – All plug contacts and the ground connections in corrosion-free condition, plugs firmly connected – Spark plug screwed out and fixed, with spark plug cap on, to ground –...
Page 310 c t i c t i n i l r - r i f i t e r - l b - l b - l i o...
Page 311 7-19 STATIC GENERATOR VALUES 250/300 EXC-E FROM 2007 Measuring conditions: – Engine cold – Seat and tank removed – All plug contacts and the ground connections in corrosion-free condition, plugs firmly connected – Spark plug screwed out and fixed, with spark plug cap on, to ground –...
Page 312 c t i c t i n i l r - r i f i t e r - l b - l b - l i o...
Page 313 7-21 DYNAMIC GENERATOR VALUES 250/300 EXC-E FROM 2007 Measuring conditions: – Seat, side fairing and side cover (left) removed – All plug contacts and the ground connections in corrosion-free condition, plugs firmly connected – Battery strong enough to start, but not fully charged (if the battery is fully charged, start the engine a few times!) –...
Page 314 FUEL SYSTEM INDEX OPERATING RANGES OF THE CARBURETOR ......8-2 CARBURETOR ADJUSTMENT ........8-3 DISMOUNTING AND INSTALLING THE CARBURETOR .
Page 315 OPERATING RANGES OF THE CARBURETOR main jet jet needle jet needle idle jet throttle valve air control screw idle adjusting screw mixture too lean: not enough fuel in proportion to air mixture too rich: too much fuel in proportion to air Idling range Operation with closed throttle valve.
Page 316 Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95/98). Mixing ratio 2-stroke motor oil : super fuel 1:40 - 1:60.
Page 317 CARBURETOR KEIHIN PWK 36S AG, PWK 38S AG DESIGNATION: 1 Jet needle 5 Idle adjusting screw 9 Float 2 Main jet 6 Air control screw 10 Plug 3 Idling jet 7 Choke 11 Clamping spring 4 Throttle slide 8 Float needle...
Page 318 Dismounting and installing the carburetor NOTE: Before you start working on the carburetor, you should clean the motorcycle thoroughly. – Dismount the seat and the tank with the spoilers. – Loosen the 2 hose clamps and pull the carburetor out of the connection boot.
Page 319 Disassembling the carburetor NOTE: Before you start disassembling the carburetor, you should look for a clean workplace. It should offer you enough space to lay out all individual components of the carburetor in perfect order. – Dismount the carburetor and remove any coarse dirt. –...
Page 320 – Remove the nipple in the throttle slide to be able to remove the jet needle Checking the jet needle and throttle slide Jet needle: Check the jet needle for bending and wear. Throttle slide: Check for damage and wear. NOTE: engine vibrations subject the throttle slide, jet needle, float needle valve and needle jet to extreme wear.
Page 321 Assembling the carburetor – Insert the jet needle and clamping spring in the throttle side, screw on the nipple and tighten to 4Nm. – Mount the starting piston and actuate several times, checking for smooth operation. Also check whether the starting piston locks cor- rectly.
Page 322 – Mount all of the vent hoses and position the retaining brackets – Mount the float chamber together with the retaining brackets. Draining the carburetor float chamber – Close the fuel tap and place a cloth under the carburetor to catch any draining fuel.
Page 323 TROUBLE SHOOTING INDEX TROUBLE SHOOTING 250 / 300 ........9-2...
Page 324 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. TROUBLE CAUSE REMEDY...
Page 325 TROUBLE CAUSE REMEDY Engine lacks power Reed paddles tensionless Replace reed paddles or reed valve housing damaged, surface of reed valve housing damaged Wear Overhaul engine Electronical ignition timing faulty Check ignition system Engine does not rev high Carburetor overflows if level is Clean carburetor, if necessary replace float needle and adjusted too high, float needle adjust level...
Page 326 10-1 TECHNICAL SPECIFICATIONS INDEX MODEL 2004 ENGINE ........... . .10-2 CHASSIS .
Page 327 10-1B TECHNICAL SPECIFICATIONS INDEX MODEL 2010 ENGINE 250 SX ..........10-27 ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS .
Page 328 TECHNICAL SPECIFICATIONS – ENGINE 2004 ENGINE 250 SX/SXS 250 EXC 300 MXC/EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm 249 ccm 293.15 ccm Bore / stroke 66.4 / 72 mm 66.4 / 72 mm...
Page 329 10-3 TECHNICAL SPECIFICATIONS - CHASSIS 2004 CHASSIS 250 SX/SXS 300 MXC 250/300 EXC Frame Central chrome-moly-steel frame Fork White Power – Upside down 48 MA Wheel travel front/rear 300/335 mm Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Front brake Disc brake with perforated brake disc Ø...
Page 330 ENGINE 250 SX/SXS 250 EXC/EXC SIX DAYS 300 MXC/EXC/EXC SIX DAYS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm 249 ccm 293.15 ccm Bore / stroke 66.4 / 72 mm 66.4 / 72 mm...
Page 331 10-5 TECHNICAL SPECIFICATIONS – CHASSIS 2005 CHASSIS 250 SX/SXS 300 MXC 250/300 EXC/SIX DAYS Frame Central chrome-moly-steel frame Fork White Power – Upside down 48 MA Wheel travel front/rear 300/335 mm Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Front brake Disc brake with perforated brake disc Ø...
Page 332 MOTOR 250 SX / SXS / XC 250 EXC / EXC SIX DAYS / XC-W Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm 249 ccm Bore / stroke 66.4 / 72 mm...
Page 333 ENGINE 300 EXC / EXC SIX DAYS / XC-W 300 XC Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 293.15 ccm 293.15 ccm Bore / stroke 72 / 72 mm...
Page 334 10-8 TECHNICAL SPECIFICATIONS - CHASSIS SX / SXS / EXC / EXC SIX DAYS 2006 CHASSIS 250 SX / SXS 250/300 EXC / EXC SIX DAYS Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 Fork offset (caster) SX - adjustable 18mm/20mm EXC - 20mm SXS - adjustable 17.5mm/20.5mm...
Page 335 10-9 TECHNICAL SPECIFICATIONS - CHASSIS XC / XC-W 2006 CHASSIS 250/300 XC-W 250/300 XC Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 Fork offset (caster) 20mm adjustable 18mm/20mm Wheel travel front/rear 300/335 mm Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm Front brake Disc brake with perforated brake disc Ø...
Page 336 10-10 TECHNICAL SPECIFICATIONS - ENGINE 250 SX 2007 ENGINE 250 SX Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 249 cm Bore / stroke 66,4 / 72 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91), mixed with high grade two stroke oil Oil / gasoline ratio 1:60 when using high grade, two- stroke oil (Motorex Cross Power 2T).
Page 337 10-11 TECHNICAL SPECIFICATIONS - CHASSIS 250 SX 2007 CHASSIS 250 SX Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 MXMA CC (Closed Cartridge Multi Adjuster) Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 DCC B07 Front brake Disc brake with carbon-steel brake disc Ø...
Page 338 250 XC 250 XC-W/EXC SIX DAYS/EXC 300 XC 300 XC-W/EXC SIX DAYS/EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm 293.15 ccm Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in) 72 / 72 mm (2.84 / 2.84 in)
Page 339 10-13 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 CHASSIS 250/300 XC/XC-W 250/300 EXC SIX DAYS 250/300 EXC (EXC ZA) Frame Central chrome-moly-steel frame Fork WP Suspension – 4860 MXMA (-PA; 250/300 XC/EXC SIX DAYS) Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP Suspension –...
Page 340 10-14 STANDARD ADJUSTMENT – FORK 250/300 EXC/XC-W STANDARD ADJUSTMENT – SHOCK ABSORBER 250/300 EXC/XC-W WP 4860 MXMA WP 5018 PDS MCC 14187C04 12187C04 Compression adjuster Compression adjuster Rebound adjuster Rebound adjuster Spring 4,2 N/mm Spring 76-250 Spring preload 5 mm Air chamber length 110 mm Fork oil...
Page 341 10-15 TECHNICAL SPECIFICATIONS - ENGINE 250 SX 2008 ENGINE 250 SX Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 249 ccm Bore / stroke 66.4 / 72 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91), mixed with high grade two stroke oil Oil / gasoline ratio 1:60 when using high grade, two- stroke oil (Motorex Cross Power 2T).
Page 342 250 EXC 250 XC-W USA 250 EXC SIX DAYS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in)
Page 343 300 XC 300 EXC-E 300 EXC-E SIX DAYS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 293 ccm Bore / stroke 72 / 72 mm (2.84 / 2.84 in) Fuel...
Page 344: Sae
10-18 TECHNICAL SPECIFICATIONS - CHASSIS 250 SX 2008 CHASSIS 250 SX Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 MXMA CC (Multi Adjuster Closed Cartridge) Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 DCC (Progressive Damping System) Front brake Disc brake with carbon-steel brake disc Ø...
Page 345 10-19 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC SIX DAYS/EXC 2008 TECHNICAL SPECIFICATIONS - CHASSIS 250 XC/XC-W/EXC SIX DAYS/EXC 2008 CHASSIS 250 XC/XC-W/EXC/EXC SIX DAYS 300 XC/XC-W/EXC-E/EXC-E SIX DAYS Frame Central chrome-moly-steel frame Fork 250/300 XC WP Suspension – 4860 MXMA CC (Closed Cartridge) 250 XC-W/EXC/EXC Six Days WP Suspension –...
Page 346: Spring
10-20 STANDARD ADJUSTMENT – FORK 250/300 XC-W/EXC/EXC-E 250/300 EXC-E EXC-E SIX DAYS 250/300 XC WP 4860 MXMA PA WP 4860 MXMA PA WP 4860 MXMA CC 14.18.7D.04 14.18.7D.34 14.18.7D.28 Compression adjuster 22 clicks 24 clicks 20 clicks Rebound adjuster 20 clicks 22 clicks 21 clicks Spring...
Page 347 10-21 TECHNICAL SPECIFICATIONS - ENGINE 250 SX 2009 ENGINE 250 SX Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 249 ccm Bore / stroke 66.4 / 72 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91), mixed with high grade two stroke oil Oil / gasoline ratio 1:60 when using high grade, two- stroke oil (Motorex Cross Power 2T).
Page 348 250 XC 250 EXC SIX DAYS 250 EXC AUS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in)
Page 349 300 XC 300 EXC 300 EXC SIX DAYS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 293 ccm Bore / stroke 72 / 72 mm (2.84 / 2.84 in) Fuel...
Page 350 10-24 TECHNICAL SPECIFICATIONS - CHASSIS 250 SX 2009 CHASSIS 250 SX Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 MXMA CC (Multi Adjuster Closed Cartridge) Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 DCC (Progressive Damping System) Front brake Disc brake with carbon-steel brake disc Ø...
Page 351 250 EXC EU/EXC Six Days 100.8 kg (222.5 lbs) 300 XC 100.4 kg (221.6 lbs) 300 XC-W 100.6 kg (222 lbs) 300 EXC/EXC Six Days 103.1 kg (227.6 lbs) * further tire releases are available on the Internet at www.ktm.com...
Page 352 10-26 STANDARD ADJUSTMENT – FORK 250/300 XC-W/EXC/EXC SIXDAYS 250/300 XC WP 4860 MXMA PA WP 4860 MXMA CC 14.18.7E.04 14.18.7E.28 Compression adjuster 22 clicks 15 clicks Rebound adjuster 22 clicks 21 clicks Spring 432.505.00.042W 432.485.00.044W Preload Adjuster 2 turns – Air chamber length 110 mm (4.3 in) –...
Page 353 10-27 TECHNICAL SPECIFICATIONS - ENGINE 250 SX 2010 ENGINE Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 249 ccm Bore / stroke 66.4 / 72 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91), mixed with high grade two stroke oil Oil / gasoline ratio 1:60 when using high grade, two- stroke oil (Motorex Cross Power 2T).
Page 354 250 XC 250 EXC SIX DAYS 250 EXC AUS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 249 ccm Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in)
Page 355 300 XC 300 EXC 300 EXC SIX DAYS Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 293 ccm Bore / stroke 72 / 72 mm (2.84 / 2.84 in) Fuel...
Page 356 10-30 TECHNICAL SPECIFICATIONS - CHASSIS 250 SX 2010 CHASSIS 250 SX Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 MXMA CC (Multi Adjuster Closed Cartridge) Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 DCC (Progressive Damping System) Front brake Disc brake with carbon-steel brake disc Ø...
Page 357 250 XC-W USA 101.8 kg 250 EXC AUS 100.8 kg 250 EXC EU/EXC Six Days 100.8 kg 300 XC 98 kg 300 XC-W 100.4 kg 300 EXC/EXC Six Days 103.1 kg * further tire releases are available on the Internet at www.ktm.com...
Page 358: Spring Preload
10-32 STANDARD ADJUSTMENT – FORK 250/300 XC-W/EXC/EXC SIXDAYS 250/300 XC WP 4860 MXMA PA WP 4860 MXMA CC 14.18.7J.04 14.18.7J.28 Compression adjuster 22 clicks 12 clicks Rebound adjuster 20 clicks 12 clicks Spring 432.505.00.042W 432.485.00.044W Preload Adjuster 2 turns – Air chamber length 110 mm –...
Page 359 10-33 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head 27 Nm Nuts-cylinder base M 10 35 Nm Flywheel collar nut M 12x1 60 Nm Exhaust control - retaining bracket Loctite 243 + 7 Nm Exhaust control - control flap Loctite 243 + 10 Nm Exhaust control - lever for control segment Loctite 243 + 6 Nm Shift roller - bearing retaining bracket...
Page 360 10-34 TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle M24x1.5 45 Nm Brake caliper, front Loctite 243 + 25 Nm Brake disks up to model 2005 Loctite 243 + 10 Nm Brake disks as of model 2006 Loctite 243 + 14 Nm Clamping screws, upper fork bridge model 2004 Loctite 243 + 20 Nm Clamping screws, lower fork bridge model 2004...
Page 361 KTM 250, 300 MXC/EXC EUR/USA 2004 KEIHIN PWK S36 AG VERGASERREGULIERUNG CARBURETOR SETTING MEERESHÖHE TEMPERATUR -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C ALTITUDE -2°F to 20°F 19°F to 41°F 42°F to 60°F...
Page 362 Repair manual KTM 250 / 300 Art.- No. 3.206.088-E KTM 250 SX / SXS EUR/USA 2004 KEIHIN PWK S38 AG VERGASERREGULIERUNG CARBURETOR SETTING MEERESHÖHE TEMPERATUR -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C...
Page 363 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 364 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 365 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 366 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 367 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 368 10-42 VERGASERREGULIERUNG 250 SX 2007 CARBURETOR SETTING KEIHIN PWK-S 36 AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C ALTITUDE TEMPERATURE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F...
Page 369 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 370 EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car- buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 371 10-45 VERGASERREGULIERUNG 250 SX 2008 CARBURETOR SETTING KEIHIN PWK-S 36 AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C ALTITUDE TEMPERATURE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F...
Page 372 10-46 VERGASERREGULIERUNG 250 XC 2008 CARBURETOR SETTING KEIHIN PWK 36S AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C ALTITUDE TEMPERATURE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F...
Page 373 EXC/EXC-E models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 374 EXC/EXC-E models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 375 10-49 VERGASERREGULIERUNG 250 SX 2009/2010 CARBURETOR SETTING KEIHIN PWK-S 36 AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C ALTITUDE TEMPERATURE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F...
Page 376 EEXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 377 EXC/EXC-E models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 378 EXC/EXC-E models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the carburetor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON...
Page 379 11-1 PERIODIC MAINTENANCE SCHEDULE INDEX MODEL 2004 / 2005 ......... . .11-2 MODEL 2006 .
Page 380 IF MOTORCYCLE IS USED FOR COMPETITION THE 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!
Page 381 11-3 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary...
Page 382 11-4 RECOMMENDED INSPECTION OF THE 250/300 ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) hours hours hours hours hours hours Check the reed-type intake valve for wear Check the clutch shoes for wear...
Page 383 Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!
Page 384 11-6 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER Clean and adjust carburetor Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs Check the cylinder and piston for wear Check function of exhaust control Check piston pin bearing Replace the crankshaft main bearings...
Page 385 Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!
Page 386 11-8 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs...
Page 387 Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!
Page 388 11-10 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear...
Page 389 Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!
Page 390 11-12 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs...
Page 391 Clean and lubricate chain, clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!
Page 392 11-14 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs...
Page 393 11-15 PERIODIC MAINTENANCE SCHEDULE 2010 250 SX...
Page 394 11-16...
Page 395 11-17 250/300 XC/XC-W/EXC/EXC SIX DAYS PERIODIC MAINTENANCE SCHEDULE 2010 250/300 EXC-E/EXC-E SIX DAYS...
Page 396 11-18...
Page 397 11-19...
Page 398 12-1 WIRING DIAGRAM INDEX MODEL 2004 250/300 EXC ..........12-2 250/300 EXC-USA .
Page 399 12-1B WIRING DIAGRAM INDEX MODEL 2008/2009 250 EXC / EXC SIX DAYS ........12-32 250/300 XC / 250 XC-W .
Page 400 high/low beam switch horn switch stop button flasher switch handle bar switch flasher relay horn regulator-rectifier ye-re br-bl ye-re capacitor ye-re rear brake switch speed sensor right rear flasher wh-gn gn-wh right front flasher ye-bl ye-bl left rear flasher generator pick up ignition coil left front flasher...
Page 401 high/low beam switch capacitor horn switch stop button C_AL/2 C_BC/6 C_BF3/1 C_AC/6 C_AT/2 C_BA3/1 regulator-rectifier ye-re page 3/6 ye-bl ye-bl pick up generator ignition coil CDI - charging circuit EXC 250-300 2004...
Page 402 headlight headlight high/low beam switch horn switch stop button handle bar switch driving light lamp C_BC/6 C_AC/6 C_BW/3 ye-re horn ye-re br-bl gn-wh speed sensor page 2/6 C_AJ/3 gn-wh C_BG/3 rear light/brakelight EXC 250-300 2004 light system-instruments...
Page 403 flasher switch ye-re flasher control lamp C_BG/3 C_BT/3 ye-re ye-re C_BG1/3 C_AJ1/3 EXC 250-300 2004 turn indicator system...
Page 404 capacitor multi-func.-digital-speedometer regulator-rectifier flasher relay horn rear brake switch generator light switch front brake switch positive connection EXC 250-300 2004...
Page 405 right rear flasher left rear flasher C_AJ1/3 C_BG1/3 multi-func.-digital-speedometer horn switch right front flasher left front flasher capacitor position light headlight regulator driving light lamp rear light/brakelight ground connection EXC 250-300 2004...
Page 406 light switch stop switch handle bar switch regulator-rectifier speed sensor ye-bl ye-bl pick up generator ignition coil EXC-USA 250 2004 wiring diagramm 22.05.2003 main harness 523.11.075.000...
Page 407 stop button generator black yellow-black brown green blue-white pick up ignition coil SX 250 19.05.2003...
Page 408 EXC 250-300 2005 EXC SIX DAYS 250-300 05/06...
Page 409 EXC 250-300 2005 EXC SIX DAYS 250-300 05/06...
Page 410 EXC 250-300 2005 EXC SIX DAYS 250-300 05/06...
Page 411 EXC 250-300 2005 EXC SIX DAYS 250-300 05/06...
Page 412 EXC 250-300 2005 EXC SIX DAYS 250-300 05/06...
Page 413 EXC 250-300 2005 EXC SIX DAYS 250-300 05/06...
Page 414 EXC-USA 250 2005...
Page 415 g i l c t i r - r i f i t l b - l b - o i t l i o...
Page 417 c t i c t i c t i c t i r - r i f i t e r - l b - r e r - t i c e r - c t i l b - l b - o i t l i o...
Page 418 c t i t i c c t i r - r i f i t e r - l b - l b - o i t l i o EXC 250-300 2006 c r i t i u...
Page 419 g i l c t i c t i c t i g i l e r - e r - l b - r - n g - n g g i l g i l EXC 250-300 2006 g i l...
Page 420 c t i e r - e r - e r - EXC 250-300 2006...
Page 421 t i c - i t l a t i r - r i f i t a l f g i l EXC 250-300 2006 i t i o i t...
Page 422 a l f a l f - i t l a t i a l f f e l a l f t i c - l b o i t g i l g i l t a l v i r g i l g i l...
Page 423 g i l c t i c t i c t i r - r i f i t l b - l b - o i t l i o XC-W 250 2006 2006...
Page 424 g i l c t i c t i c t i r - r i f i t l b - l b - o i t l i o 2006...
Page 425 a l b o l l a l b o r b - e u e t i o i t l i o 250 SX/SXS/XC 300 XC 2006...
Page 426 c t i c t i c t i c t i r - r i f i t e r - e r - e r - l b - r t i c c t i l b - l b - l b - r o i t...
Page 427 c t i c t i r - r i f i t l b - l b - l b - r o i t l i o XC-W 250 2007...
Page 428 c t i c t i r - r i f i t l b - l b - l b - r o i t l i o...
Page 429 a l b o l l a l b - y e a l b y e r o r b - e u e t i t i n l i o SX 250 2007...
Page 430 250 EXC / EXC Six Days EU/ AUS 2008/2009...
Page 431 250/300 XC USA 2008 250 CX-W ZA 2008/2009...
Page 432 250 XC-W USA 2008/09 300 XC-W USA/ZA 2008/09...
Page 433 300 EXC-E/EXC-E SixDays EU / AUS 2008/2009...
Page 434 a l b o l l a l b - y e a l b y e r o r b u l b e t i o i t l i o SX 250 2007-2009...
Page 435 12-37 CABLE COLOURS bl. black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple...
Page 436 12-38 g i l c t i c t i c t i c t i c t i...
Page 437 250 SX 2010...
Page 438 12-40...
Page 439 250 EXC EU 2010...
Page 440 12-42...
Page 441 250/300 EXC 2010...
Page 442 12-44...
Page 443 250/300 XC/XC-W 2010...
Page 444 12-46...
Page 445 REPAIRMANUAL2004-2010 >2004 2005<...
Page 446 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Shock absorber 5018 PDS 2003 Introduction Exploded view Disassembly shock absorber Disassembly tube side Disassembly MCC Assembling MCC Assembling Tube side Disassembly piston-rod side Diassembly adaptor DU-bush Assembling adaptor DU-bush Assembling piston-rod side Assembling shock absorber Bleeding...
Page 447 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Introduction General notice Pay attention to the following notes, when you are working with WP suspension products as described in this workshop manual: Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.
Page 448: Exploded View
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Exploded view...
Page 449 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly Shock absorber Take note of the rebound (REB) position. Fully closed is turning the adjustment screw (“ ”) clockwise. MCC = Mono Compression Control Take note of the compression (COM) position.
Page 450 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Take note of the compression High-Speed position. Fully closed is turning the hexagonal (size 17) screw clockwise. Measure the length of the spring. Spring preload. Unscrew the Allen bolt (size 4). We r k p l a a t s h a n d b o e k...
Page 451 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Release the spring preload with open spanner T106. Screw the screw retainer against the lock retainer. Disassemble the spring retainer and springring. We r k p l a a t s h a n d b o e k...
Page 452 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the washer. Remove the spring. Pay attention to the assembling direction!!! Remove the second washer. We r k p l a a t s h a n d b o e k...
Page 453 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Spring with washers, spring retainer and springring. We r k p l a a t s h a n d b o e k...
Page 454 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassemble the rubber cap. Unscrew slowly the nitrogen plug (size 4) to release the pressure. Nitrogen plug with O-ring. We r k p l a a t s h a n d b o e k...
Page 455 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tap the cap from the tube. 1. Place disassembling bush T1216 on the adaptor DU-bush. We r k p l a a t s h a n d b o e k...
Page 456 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push the adaptor DU-bush downwards. Disassemble the springring out of the tube. Springring. We r k p l a a t s h a n d b o e k...
Page 457 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Pull carefully but firmly the piston-rod “complete” out of the tube. Push with depth-stop T107S the separation piston downwards. We r k p l a a t s h a n d b o e k...
Page 458 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly tube-side Drain the oil out the tube. Clamp the tube side in the vice. Remove the springring out of the groove and slide it a little bit downwards. We r k p l a a t s h a n d b o e k...
Page 459 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Slide the guiding bush downwards. Remove the upper springring. Remove the guiding bush. Pay attention to the assembling direction!!! We r k p l a a t s h a n d b o e k...
Page 460 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the springring. Spring guiding bush with the two springrings. We r k p l a a t s h a n d b o e k...
Page 461 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the screw-retainer of the tube. Screw-retainer with the Allen bolt. We r k p l a a t s h a n d b o e k...
Page 462 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Unscrew the screw-cap of the MCC (size 24) (DCC also size 24) Remove the screw-cap. Remove the washer inside the screw- cap, or on top of the spring inside the bottom.
Page 463 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the spring. Pull the damping holder “cpl” out of the bottom. Srew-cap with adjustment needle, spring and the MCC damping holder “cpl”. We r k p l a a t s h a n d b o e k...
Page 464 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Heat the lock retainer. Unscrew the lock retainer with open spanner T1233. Screw the lock retainer of the bottom. We r k p l a a t s h a n d b o e k...
Page 465 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Heat the bottom near the tube. Use slide-spanner T146 with bush T1201. Unscrew the tube. We r k p l a a t s h a n d b o e k...
Page 466 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Screw the tube out of the bottom. Screw the lock retainer of the tube. Tube with lock retainer. We r k p l a a t s h a n d b o e k...
Page 467 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassemble the O-ring out of the groove inside the bottom. Place dis- / assembling tool T145S on top of the screw-cap Place pin spanner T125S onto T145S. We r k p l a a t s h a n d b o e k...
Page 468 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Heat the reservoir near the bottom. Unscrew the screw-cap. Turn the reservoir from the bottom. We r k p l a a t s h a n d b o e k...
Page 469 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the O-ring. Bottom “cpl” with both O-rings. We r k p l a a t s h a n d b o e k...
Page 470 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Pay attention to the assembling direction!!! Push the separation piston out of the reservoir. Separation piston. Disassemble the O-ring. We r k p l a a t s h a n d b o e k...
Page 471 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Separation piston, piston ring and O-ring. We r k p l a a t s h a n d b o e k...
Page 472 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Clamp the bottom in the vice. Use disassembling tool T120 for disassembling the adaptor bushes. Tap the adaptor bush out of the heim- joint. We r k p l a a t s h a n d b o e k...
Page 473 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the seal. Disassemble the springring. Tap the other adaptor bush out of the heim-joint. We r k p l a a t s h a n d b o e k...
Page 474 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Use Dis- / assembling tool T1207S for disassembling the heim-joint. Press the heim-joint out of the bottom at the side were the springring is removed. Adaptor bushes, seals, springrings and heim-joint.
Page 475 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Replace one springring. Assemble the heim-joint with the bevelled edge into the direction of the bottom with assembling tool T1206. Press the heim-joint into the bottom with support of the vice. We r k p l a a t s h a n d b o e k...
Page 476 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Press with T1207(A) the heim-joint against the springring. Assemble the springring into the groove. Replace the seals. We r k p l a a t s h a n d b o e k...
Page 477 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Assemble the adaptor bushes with support of T1206. We r k p l a a t s h a n d b o e k...
Page 478: Disassembly Mcc
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly MCC There is a separated workshop manual for the DCC. ----------------------------------------------------- Damping holder MCC. Remove the disk. Pay attention to the assembling direction!!! Clamp the damping holder with clamping block T1202S.
Page 479 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Unscrew the nut (size 10). Turn the nut of. Remove the piston with check-valve. We r k p l a a t s h a n d b o e k...
Page 480 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Piston with the check-valve side. Compression side. Damping holder with shims (setting). We r k p l a a t s h a n d b o e k...
Page 481 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the shims of the damping holder. Pay attention to the assembling order and direction!!! - Nut M6 - piston with check-valve - setting (shims) - damping holder - disk. We r k p l a a t s h a n d b o e k...
Page 482 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the O-ring of the screw-cap. Turn clockwise the adjustment needle out of the screw-cap. Adjustment needle “complete”. We r k p l a a t s h a n d b o e k...
Page 483 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling - Steel ball - spring - adjustment needle with O-ring - screw-cap - O-ring We r k p l a a t s h a n d b o e k...
Page 484: Assembling Mcc
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling MCC Assemble the spring and steel ball, and grease, also the O-ring, these with water proof grease T159. Assemble the O-ring. Assemble the needle. We r k p l a a t s h a n d b o e k...
Page 485 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the needle fully open. Replace the setting and piston with the check-valve Wet the thread of the nut with Loctite 2701 (T132) and turn the nut on the holder.
Page 486 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tighten the nut to a torque of 6Nm. Replace the disk. We r k p l a a t s h a n d b o e k...
Page 487: Assembling Tube Side
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling tube side Assemble the O-ring on the bottom. Assemble the O-ring inside the bottom. Grease the O-ring groove of the separation piston with O-ring grease T158. We r k p l a a t s h a n d b o e k...
Page 488 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the O-ring. Grease the O-ring with T158. Pay attention to the groove of the nitrogen reservoir. We r k p l a a t s h a n d b o e k “groove”.
Page 489 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Assemble the separation piston and piston ring with the hollow surface into the reservoir at the groove side. Push the separation piston into the reservoir. We r k p l a a t s h a n d b o e k...
Page 490 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Wet the thread of the bottom with T132. Wet the thread of the reservoir with T132 on both sides. Wet the thread of the screw-cap. We r k p l a a t s h a n d b o e k...
Page 491 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the reservoir with screw-cap on the bottom. Tighten the reservoir wit T125S and T145S. Wet the thread inside the bottom with T132. We r k p l a a t s h a n d b o e k...
Page 492 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the lock retainer as far as possible onto the tube. Wet the thread of the tube with T132. Turn the tube into the bottom. We r k p l a a t s h a n d b o e k...
Page 493 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tighten the tube with T146 and T1201. Screw the lock retainer against the bottom and tighten it with T1233. Turn the screw spring retainer onto the tube and... We r k p l a a t s h a n d b o e k...
Page 494 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling ...completely downwards. Assemble the springring passed the groove of the tube. Slide the spring guide onto the tube. We r k p l a a t s h a n d b o e k...
Page 495 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the first springring into the groove. Slide the guiding bush over the springring. Assemble the second springring. We r k p l a a t s h a n d b o e k...
Page 496 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Wet the O-ring of the piston MCC with T158. Assemble the damping holder MCC “cpl” into the housing of the bottom. Assemble the spring. We r k p l a a t s h a n d b o e k...
Page 497 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Place the ring into the screw-cap. Turn the screw-cap into the bottom. Tighten the screw-cap. We r k p l a a t s h a n d b o e k...
Page 498: Disassembly Piston-Rod Side
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly piston-rod side Clamp the piston-rod “cpl” in the vice. Unscrew the nut (size 22) We r k p l a a t s h a n d b o e k...
Page 499 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn off the nut. Place a screwdriver on top of the piston- rod and lift the entire assembly onto the screwdriver. - Rebound bush plane - compression setting 1 (shims) - piston 1 - rebound setting 1 (shims) - intermediate bush...
Page 500 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the adaptor DU-bush. Remove the cap. Remove the bump rubber. We r k p l a a t s h a n d b o e k...
Page 501 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Clamp the mounting-fork in the vice. Unscrew the screw-cap of the rebound adjustment (size 15). Turn the screw-cap out of the mounting- fork. We r k p l a a t s h a n d b o e k...
Page 502 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Turn the rebound adjustment needle anti clockwise out of the mounting-fork. Rebound adjustment needle with the screw-cap. We r k p l a a t s h a n d b o e k...
Page 503 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling 1. Push the rubber plug out of the mounting-fork. Push with an pin (d2) on top of the piston- rod the rebound needle out of the piston- rod. We r k p l a a t s h a n d b o e k...
Page 504 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Take the rebound needle out. Rebound needle. Clamp the mounting-fork in the vice and unscrew the locking nut (size 24). We r k p l a a t s h a n d b o e k...
Page 505 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Clamp the piston-rod in clamping block T1202S. Heat de mounting-fork. Unscrew the mounting-fork. We r k p l a a t s h a n d b o e k...
Page 506 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the mounting-fork of the piston-rod. Turn the nut of the piston-rod. Push with een Allenkey (size 5) the rebound tube out of the piston-rod. We r k p l a a t s h a n d b o e k...
Page 507 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Piston-rod and rebound tube “cpl”. We r k p l a a t s h a n d b o e k...
Page 508 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Disassembly adaptor DU-bush Adaptor DU-bush. 1. Lift the rebound spring out of the adaptor. We r k p l a a t s h a n d b o e k...
Page 509 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Remove the steel washer. Pay attention to the back-up ring in the washer. Remove the quad ring. Remove the second back-up ring. We r k p l a a t s h a n d b o e k...
Page 510 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Lift the dirt scraper out of the adaptor. Disassemble the O-ring. Dis- / assembling tool T1504, adaptor and support bush T1209. We r k p l a a t s h a n d b o e k...
Page 511 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Press the DU-bush out of the adaptor. We r k p l a a t s h a n d b o e k...
Page 512: Assembling Adaptor Du-Bush
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling adaptor DU-bush Press the DU-bush into the adaptor with T1504 and T1209. Calibrate the DU-bush with the calibration thorn T1205. Important: wet the thorn with oil before the calibration. Press the dirt scraper into the adaptor with assembling bush T1204.
Page 513 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the first the back-up ring and then the quad ring into the adaptor. Replace the steel disk with the back-up ring. Assemble the rebound spring with support of T1209. We r k p l a a t s h a n d b o e k...
Page 514 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the O-ring. Grease the O-ring with T158. We r k p l a a t s h a n d b o e k...
Page 515: Assembling Piston-Rod Side
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling piston-rod side Turn the lock nut on the piston-rod. Grease the O-ring of the rebound tube with T158. Assemble the tube into the piston-rod. We r k p l a a t s h a n d b o e k...
Page 516 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Wet the thread of the piston-rod with T132. Turn the mounting-fork on the piston- rod. Tighten the mounting-fork. We r k p l a a t s h a n d b o e k...
Page 517 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the lock nut against the mounting- fork. Tighten the nut. 1. Place assembling tool T1215 on top of the piston-rod. We r k p l a a t s h a n d b o e k...
Page 518 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the bump rubber. Replace the cap. We r k p l a a t s h a n d b o e k...
Page 519 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Replace carefully the adaptor DU-bush. Replace the entire damping package. Pay attention to the first shim, this one must be centered on the ring. We r k p l a a t s h a n d b o e k...
Page 520 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Grease the thread of the piston-rod with a little bit of T158. Turn the nut on the piston-rod. Turn the nut just so far so that the pistons can still be turned. We r k p l a a t s h a n d b o e k...
Page 521 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Place the center sleeve T1214..over both pistons and adaptor DU-bush. Place T107S through T1214, intermediate bush and piston rod. We r k p l a a t s h a n d b o e k...
Page 522 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Tighten the piston-rod nut to a torque of 40Nm. Check if you can lift the shim. Grease the O-ring of the rebound needle with T158. We r k p l a a t s h a n d b o e k...
Page 523 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the needle into the piston-rod. Push the needle further. Grease the O-ring and steel ball of the rebound adjustment needle with T159. We r k p l a a t s h a n d b o e k...
Page 524 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Screw the adjustment needle into the mounting-fork. Turn de rebound screw-cap into the mounting-fork. Tighten the screw-cap. We r k p l a a t s h a n d b o e k...
Page 525 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn the adjustment completely open. Push the needle downwards. Assemble the rubber plug. We r k p l a a t s h a n d b o e k...
Page 526: Assembling Shock Absorber
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling shock absorber Turn the compression adjustment fully open. (DCC High and Low-speed) Fill the tube with oil, just under the springring groove inside the tube. Place plunger T1210S into the tube. We r k p l a a t s h a n d b o e k...
Page 527 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push the plunger downwards. Push with T107S the separation piston in the reservoir as far as possible. Slide the O-ring of T107S against the screw-cap. We r k p l a a t s h a n d b o e k...
Page 528 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push again with T1210S. Push with T107S the separation piston..to the correct position, the O-ring of T107S must have a distance of about 10mm from the screw-cap. We r k p l a a t s h a n d b o e k...
Page 529 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Fill oil till 10mm under the groove. Close the compression adjustment. (DCC Low-speed) Push both pistons under the oil. We r k p l a a t s h a n d b o e k...
Page 530 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Open the compression adjustment. Push the adaptor DU-bush just under the O-ring groove. We r k p l a a t s h a n d b o e k...
Page 531 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the springring. Pull the piston-rod fully out. Tap the cap into the tube. We r k p l a a t s h a n d b o e k...
Page 532 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Bleeding Clamp “not too tight” the shock absorber in the vice like picture. 1. Unscrew the screw-cap and remove the entire MCC. We r k p l a a t s h a n d b o e k...
Page 533 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Turn adaptor T1502S of the air release bottle T144S into the MCC (DCC) housing of the bottom. Ensure that there is sufficient oil in the bottle. Hold the bottle up so that the oil wil flow into the shock absorber.
Page 534 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Push the piston rod slowly completely inwards. And out. Repeat those handlings several times. Cant the shock absorber several times. We r k p l a a t s h a n d b o e k...
Page 535 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Repeat all the handling till all air is out of the shock absorber. Push the separation piston to the correct position. Remove the adaptor. We r k p l a a t s h a n d b o e k...
Page 536 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the MCC (DCC). We r k p l a a t s h a n d b o e k...
Page 537: On Pressure With Nitrogen
Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling On pressure with nitrogen Turn the nitrogen plug with O-ring several turns into the screw-cap of the reservoir Nitrogen charging device T170S. We r k p l a a t s h a n d b o e k...
Page 538 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Place the shock absorber in T170S and open de tap for about 20 seconds. Close the nitrogen plug. Close the tap. We r k p l a a t s h a n d b o e k...
Page 539 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the rubber cap. We r k p l a a t s h a n d b o e k...
Page 540 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assembling spring Assemble the washer. Assemble the spring. We r k p l a a t s h a n d b o e k...
Page 541 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Assemble the second washer. Assemble the spring retainer. Assemble the springring. We r k p l a a t s h a n d b o e k...
Page 542 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Adjust the spring..to the correct preload. Tighten the bolt to a torque of 5Nm. We r k p l a a t s h a n d b o e k...
Page 543 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Adjustment Turn the mounting-fork to the correct position. Compression position (MCC)! Compression Low-speed position (DCC)! We r k p l a a t s h a n d b o e k...
Page 544 Workshop manual 5018 PDS 2003 Product Exploded View Disassembly & Assembling Compression High-Speed position (DCC)! Rebound position! We r k p l a a t s h a n d b o e k...
Page 545 REPAIRMANUAL2005- WP SHOCK ABSORBER 5018 DCC 5018 SXS 5018 SMR REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
Page 546 1 SPECIAL TOOLS 2 GENERAL INFORMATION 3 DISASSEMBLING AND ASSEMBLING THE SHOCK ABSORBER 4 MANUAL FOR VACUUM FILLING DEVICE...
Page 547 SPECIAL TOOLS INDEX T 107S DEPTH STOP ..........1-2 T 120 DISMOUNTING/MOUNTING TOOL .
Page 548 T 107S Depth Stop T 120 Dismounting/mounting tool T 125S Pin wrench T 132 Loctite 2701 T 145S Dismounting/mounting tool...
Page 549 T 146 Dismounting/mounting tool T 152 Lubricant T 158 O-Ring Grease T 159 Water-resistant grease T 170S1 Nitrogen Filling Device...
Page 550 T 625 Lubricant T 1201 Bushing T 1202S Clamping Blocks T 1204 Mounting tool for dust boot T 1205 Calibration pin...
Page 551 T 1206 Mounting tool T 1207S Dismounting/mounting tool (A+B) T 1208 Dismounting/mounting tool T 1209 Dismounting/mounting tool T 1214 Centering bushing...
Page 552 T 1215 Mounting tool T 1216 Dismounting/mounting tool T 1218 Adjusting wrench T 1233 Hook Wrench T 1240S Vacuum filling device...
Page 553 T 14031 Dismounting/mounting tool...
Page 554 RECOMMENDED PERIODIC MAINTENANCE INTERVALS PDS 5018 DCC 2006/07 ......SEE KTM-REPAIR MANUAL PDS 5018 SXS/SMR 2005-2007 ........2-16...
Page 555 Exploded view PDS 5018 DCC 2006 Reparatur-Kit Repair-Kit Parts with...
Page 556 Seal ring D=25 Shim 16x40x0.20 Lock ring Shim 16x42x0.20 Bearing Shim 16x44x0.20 Bleeder screw Shim 16x28x0.25 O-ring 48x2 Shim 16x30x0.25 WP Caution (PDS KTM) Shim 16x32x0.25 Reservoir Shim 16x34x0.25 O-ring 41x5 Shim 16x36x0.25 Dividing piston Shim 16x38x0.25 Piston ring 3.9x1.5x156 Shim 16x44x0.25 Reservoir cap Shim 16x40x0.25...
Page 557 Exploded view PDS 5018 DCC 2007 Reparatur-Kit Repair-Kit Teile mit Parts with SIEHE SETTING LISTE SEE SETTING LIST SIEHE SETTING LISTE SEE SETTING LIST SIEHE SETTING LISTE SEE SETTING LIST SIEHE SETTING LISTE SEE SETTING LIST SIEHE SETTING LISTE SEE SETTING LIST...
Page 558 Upper shock absorber case DCC (dual compression control) Distance bushing Seal ring Lock ring Bearing Bleeder screw WP Caution (PDS KTM) O-ring Plug Rubber cap "Do not open" Circlip (not for SX) Spring guide (not for SX) Adjusting ring AH screw...
Page 559 Exploded view PDS 5018 SXS/SMR 2005/2006...
Page 560 Tube 5018.0467 Lock washer tube 5018.0241 Circlip 5018.0133 Spring guide 5018.0081 Circlip 5018.0133 DCC complete 5018.0213S6 Wp Caution (PDS Ktm) 5200.0041 Circlip Stainl.steel 5018.0126 Bleed plug 5018.0095 O-ring 5,28x1,78 4681.0893 Nitrogen plug 3612.0151 Interm. ring screw spring ret. 5018.0114 Interm. ring screw spring ret.
Page 561 Exploded view PDS 5018 SXS 2007...
Page 562 Pos. Part description Part number Pieces Mount 5018.0583S1 Adaptor 5018.0435S1 Shock absorber housing 5018.0581S1 Bump rubber 5018.0480 Reservoir cap 5018.0580 Rebound disc 5018.0516 Piston 5018.0197 O-ring 5018.0099 Piston ring 5018.0135 Support disc 5018.0578 Adaptor 5018.0510 Piston 5018.0446 O-ring 5018.0099 Piston ring 5018.0135 Piston rod nut 5018.0141...
Page 563 2-10 Setting list PDS 5018 BAVP Shock absorber 12.18.7A.10 and 12.18.7B.10 KTM 125 SXS 2005/2006 Compression damping piston 1 Item Part description Parts. No. Pieces Spacer plate 16x22x0,30 5018.0036 Spacer plate 16x24x0,25 5018.0031 Spacer plate 16x26x0,25 5018.0033 Shim 16x28x0,25 5018.0063 Shim 16x30x0,25 5018.0064...
Page 564 2-11 Setting list PDS 5018 BAVP Shock absorber 12.18.7A.11 KTM 250 SXS 2005 Compression damping piston 1 Item Part description Parts. No. Pieces Spacer plate 16x23x0,30 5018.0037 Spacer plate 16x24x0,30 5018.0038 Spacer plate 16x25x0,30 5018.0039 Spacer plate 16x26x0,25 5018.0033 Shim 16x28x0,25 5018.0063...
Page 565 2-12 Setting list PDS 5018 BAVP Shock absorber 12.18.7B.11 KTM 250 SXS/SXS-F 2006 Compression damping piston 1 Item Part description Parts. No. Pieces Spacer plate 16x23x0,30 5018.0037 Spacer plate 16x24x0,30 5018.0038 Spacer plate 16x25x0,30 5018.0039 Spacer plate 16x26x0,25 5018.0033 Shim 16x28x0,25 5018.0063...
Page 566 2-13 Setting list PDS 5018 BAVP Shock absorber 12.18.7A.12 KTM 450/540 SXS 2005 Compression damping piston 1 Item Part description Parts. No. Pieces Spacer plate 16x23x0,30 5018.0037 Spacer plate 16x24x0,30 5018.0038 Spacer plate 16x25x0,30 5018.0039 Spacer plate 16x26x0,25 5018.0033 Shim 16x28x0,25 5018.0063...
Page 567 2-14 Setting list PDS 5018 BAVP Shock absorber 12.18.7B.12 KTM 450/540 SXS 2006 Compression damping piston 1 Item Part description Parts. No. Pieces Spacer plate 16x23x0,30 5018.0037 Spacer plate 16x24x0,30 5018.0038 Spacer plate 16x25x0,30 5018.0039 Spacer plate 16x26x0,25 5018.0033 Shim 16x28x0,25 5018.0063...
Page 568 2-15 Setting list PDS 5018 BAVP Shock absorber 12.18.7B.15 KTM 450/560 SMR 2006 Compression damping piston 1 Item Part description Parts. No. Pieces Spacer plate 16x22x0,30 5018.0036 Shim 16x30x0,20 5018.0055 Shim 16x32x0,20 5018.0056 Shim 16x34x0,20 5018.0057 Shim 16x36x0,20 5018.0058 Shim 16x38x0,25 5018.0068...
Page 569 2-16 Adjusting the position of the compression and rebound damping Rebound damping: – Turn in the adjusting screw in a clockwise direction all the way to the stop. – Turn back the respective number of clicks in a counterclockwise direction. Compression damping, low speed: –...
Page 570 DISASSEMBLING AND ASSEMBLING THE SHOCK ABSORBER INDEX DISASSEMBLING THE SHOCK ABSORBER ......3-2 DISASSEMBLING THE TUBE SIDE .
Page 571 Disassembling the shock absorber – Unscrew the Allen bolt of the spring retainer (Size 5). – Place the shock absorber in the vice according to the picture. – Screw the spring retainer downwards. – Push the spring retainer downwards so that you are able to remove the springring –...
Page 572 – Remove the washer. – Remove the spring. – Remove the second washer – Lock washer – Spring – Spring retainer – O-Ring – Washers – Disassemble the rubber plug “do not open” out of the screw cap of the nitrogen reservoir. NOTE: the SXS/SMR shock absorber does not have a rubber cap.
Page 573 – Unscrew the oil filling plug for about two turns. (size 5) This wil help you later by removing the piston rod “complete” out of the shock absorber! – Tap the cap from the tube. – Place disassembling bush T 1216 on the adaptor and push the adaptor downwards.
Page 574 Disassembling the tube side – Drain the oil out of the tube. – Clamp the tube side in the vice according to the picture. – Remove the spring ring out of the groove and slide it downwards. – Slide the guiding bush downwards.
Page 575 All models accept SXS 2007: – Clamp the tube side in the vice according to the picture. – Unscrew the screw cap of the DCC out of the shock absorber housing (size 24). NOTE: DDC = Dual Compression Control. – Remove the screw cap –...
Page 576 – Heat the shock absorber housing near the tube. – Unscrew the lock ring several turns with T 1233 – Clean the tube with brake cleaner. – Heat the shock absorber housing near the tube. – Unscrew the tube out of the bottom with slide-spanner T 146 and bush T 1201.
Page 577 – Remove the O-ring inside the shock absorber housing out of the groove. NOTE: only when you want to disassemble the screw cap of the nitrogen reservoir – Heat the nitrogen reservoir near the screw cap. – Place T 145S on the screw cap.
Page 578 Disassembling adaptor bushes and heim joint – Clamp the shock absorber housing in the vice. – Use Disassembling tool T 120 for disassembling the adaptor bushes. – Tap the adaptor bush out of the heim joint. – Remove the seal –...
Page 579 3-10 – Press the heim joint against the springring. – Disassemble the springring – Press the heim joint out of the shock absorber housing. – Disassemble the other spring ring – Individual parts of the heim joint.
Page 580 3-11 Disassembling the nitrogen reservoir – Push the dividing piston out of the reservoir – Remove the piston ring – Remove the O-ring out of the groove of the separation piston. Assembling the nitrogen reservoir – Check the inner side of the nitrogen reservoir for scratches. –...
Page 581 3-12 Assembling the tube side – Clean the thread of the nitrogen reservoir. – Place the new O-ring in the groove of the shock absorber housing. – Assemble the O-ring inside the groove of the shock absorber housing. NOTE: the SXS/SMR shock absorber does not have the needle...
Page 582 3-13 Assembling adaptor bushes and heim joint – Place the spring ring in the shock absorber housing. – Assemble the heim joint with the bevelled edge into the direction of the shock absorber housing with assembling tool T 1206 – Press the heim joint into the shock absorber housing. –...
Page 583 3-14 – Assemble both seals – Assemble one adaptor bush with support of T 1206 in the heim joint. – Press the other adaptor bush with support of the vice in the heim joint. Mounting the reservoir – Wet the thread of the shock absorber housing with T 132. –...
Page 584 3-15 Inspection of the tube – Inspect the running surface of the tube. If necessarry polish the running surface with sandpaper 600. – Measure the inner diameter at both ends and in the center of the pipe. The maximum diameter is: 50,12mm Mounting the pipe –...
Page 585 3-16 – Screw the lock ring against the shock absorber housing and tighten it with T 1233. Mounting the DCC mechanism All models accept SXS 2007: – Wet the O-ring with T 158. – Place the DCC mechansm in the shock absorber housing. –...
Page 586 3-17 Filling the shock absorber body – Fill the tube till approximately 10 mm under the inner side spring ring groove of the tube. NOTE: only use the specified oil. Disassembling the piston rod (also applies to SXS 2007 but not to SXS up to 2006/SMR) –...
Page 587 3-18 – Remove the rebound disc – Rebound disc – Piston 1 – Piston 2 – Settings (rebound and compresion) – Piston rod tap – Piston rod nut – Piston ring(s) – O-ring(s)
Page 588 3-19 Disassembling the piston rod (for SXS up to 2006/SMR only) – Loosen the nut on the piston rod with a 17 mm wrench. – Remove the nut from the piston rod. – Remove the shims from the rebound NOTE: the lower large shim is centered with a smaller shim –...
Page 589 3-20 – Piston rod nut A/F 17 – Set of shims (rebound and compression damping) – Piston ("2") – Adapter – Piston rod nut A/F 22 – Rebound disk – Piston ("1") – Piston ring – O-ring – Slide the adaptor from the piston rod.
Page 590 3-21 – Clamp the piston rod in the vice according to the picture. – Unscrew the screw cap of the rebound adjustment. – Remove the screw cap – Turn anti clockwise the rebound adjustment screw out of the mounting fork.
Page 591 3-22 – Remove the rebound adjustment screw – Pay attention to the steel balls and spring – Parts of the rebound adjustment screw. – Push with a pin (size 2,5mm) the rebound adjustment needle through the mounting fork out of the piston rod. –...
Page 592 3-23 – Remove the seat - does not apply to SXS/SMR – Always assemble a new O-ring on the seat. NOTE: since only assemblies are available for shock absorbers starting with the 2007 model, no further disassembly is necessary. – Heat the lock nut of the piston rod/mounting fork. –...
Page 593 3-24 – Untighten the mounting fork. – Remove the mounting fork. – Brush the thread of the piston rod clean. – Unscrew the lock nut. – Remove the lock nut.
Page 594 3-25 – Disassemble the rebound adjustment tube - does not apply to SXS/SMR – Always assemble a new O-ring! – Rebound adjustment tube. Inspection of the piston rod – Replace the piston rod if you have inspect that the running surface of the.piston rod has scratches and or indentations.
Page 595 3-26 Assembling piston rod side – Clamp the piston rod in the clamping block T 1202S. – Apply the new O-ring of the rebound adjustment tube with T 158. NOTE: the shock absorber on SXS/SMR models does not have an adjusting pipe for the rebound damping.
Page 596 3-27 – Screw the lock nut on the piston rod. – Pay attention to the assembling direction! The rounded side 2 should face the center of the piston rod. – Screw the lock nut fully on the thread of the piston rod. –...
Page 597 3-28 – Screw the rebound adjustment needle in the mounting fork. – When you feel the clicks turn the rebound adjustment needle two turns further. – Assemble the screw cap of the rebound adjustment. – Tighten the screw cap. – Turn the rebound adjustment screw anti clockwise fully open.
Page 598 3-29 – Tighten the seat! (PDS 2006/07: AH 5 mm; SXS/SMR: A/F 13). – Place assembling tool T 1215 on top of the piston rod. – Assemble the bump rubber – Assemble the cap...
Page 599 3-30 Disassembling adaptor NOTE: only applies to models for which individual parts are available (see exploded view). – Lift the rebound rubber out of the adaptor – Remove the steel plate – Remove the back-up ring – Remove the quad ring –...
Page 600 3-31 Assembling adaptor – Press the bush into the adaptor with T 1208 (up to model 2006) or T14031 (model 2007 on) and T 1209. – Wet the calibration thorn with shock absorber oil! – Calibrate the bush with calibration thorn T 1205 with support of T 1209.
Page 601 3-32 – Grease the groove of the adaptor with T 158. – Assemble the O-ring – Grease the inside lip of the dirt scraper with T 625. – Put special tool T 1215 onto the piston rod. – Slide carefully the adaptor over the tool on the piston rod.
Page 602 3-33 – Polish the surface of both sides of the pistons on a flat plate with sandpaper 600. Pistons NOTE: – The "piston 1" and "piston 2" designations refer to assembling, i.e. the piston mounted on the piston rod first will be designated "piston 1".
Page 603 3-34 Continuing to assemble the piston rod (also applies to SXS 2007 but not to SXS up to 2006/SMR) – Assemble the rebound disc – Assemble the compression setting , mounting the shims with the smaller diameter first. – Place the piston (“piston 1”) –...
Page 604 3-35 – Screw the piston rod nut with the collar downwards on the piston rod tap. – Grease the O-ring of the adaptor with T 158. – Place center sleeve T 1214 over both pistons and push the adaptor in the center sleeve. –...
Page 605 3-36 Continuing to assemble the piston rod (applies to SXS up to 2006/SMR only) – Mount the rebound disk – Mount the set of shims for the compression – Mount the piston ("piston 1") – Mount the set of shims for the rebound damping –...
Page 606 3-37 – Grease again the O-ring of the adaptor with T 158. – Assemble the rubber plug into the mounting fork. Assembling the shock absorber – Assemble the piston rod “complete” into the tube. – Push the adaptor beyond the springring groove of the tube.
Page 607 3-38 – Assemble the spring ring first with the closed side into the groove. – Pull the piston rod “complete” fully out. – Tap the cap with a plastic hammer in the tube. Evacuating and filling the shock absorber CAUTION EFORE YOU START TO WORK WITH THE VACUUM FILLING DEVICE CAREFULLY READ...
Page 608 3-39 1. Ventilation/filling process – Move the control levers into the positions shown in the photo. NOTE: "External tank" control lever to "Closed", "Damper" "Vacuum" and "Oil reservoir" to "Vacuum". – Press the "On/Off" switch to start the ventilation process. NOTE: –...
Page 609 3-40 – Adjust the O-ring on the shaft of T 107S to 106mm. – Push the separation piston with T 107S to the correct position, the O-ring must have a distance for about 10 mm from the screw cap. – Unscrew the adapter from the opening in the shock absorber. –...
Page 610 3-41 On pressure with nitrogen – Nitrogen charging device T 170S1. Adjust the nitrogen gas pressure to 10 - 11 bar. – Place the shock absorber in the Nitrogen charging device and ensure that the Allen key is fitting in the nitrogen filling plug. –...
Page 611 3-42 – Remove the shock absorber out of the nitrogen charging device. – Place the rubber plug ‘do not open’. Assembling the spring – Place the washer – Place the spring. – Place the first washer – Assemble the (new) O-ring in the groove of the spring retainer –...
Page 612 3-43 – Adjust the spring to the correct spring preload as noticed before. – Tighten the Allen bolt of the screw retainer to a torque of 5 Nm. – Clean the nitrogen reservoir. – Assemble a new sticker. – Set the shock absorber in the correct mounting position. NOTE: adjustments of the rebound and compression damping should be on the same side.
Page 613 MANUAL FOR VACUUM-/FILLING DEVICE INDEX INTRODUCTION ..........4-2 SUPPLIED PARTS .
Page 614: Supplied Parts
Introduction The WP Suspension vacuum-filling device is designed specially for the filling of shock absorbers. The filling device enables you to fill a shock absorber with no air inside the shock absorber. The layout of the system was chosen to allow maximum flexibility for the filling of shock absorbers and to create a compact, lightweight construction.
Page 615 Overview of vacuum filling device – Control levers – Vacuum gauge (mbar) – Pressure gauge (bar) – Damper connector – Main power switch – Filling plug – Oil level indicator – Vacuum pump oil level indicator – Vacuum pump filling plug –...
Page 616: General Handling Information
General handling information CAUTION – O NLY PEOPLE WHO HAVE READ AND UNDERSTOOD THE MANUAL ARE ALLOWED TO OPERATE THE VACUUM FILLING DEVICE – T HE INSTRUCTIONS GIVEN IN THIS MANUAL MUST BE FOLLOWED CAREFULLY NY DEVIATION FROM THE INSTRUCTIONS COULD RESULT IN A DANGEROUS SITUATION FOR THE USER OF THE FILLING INSTALLATION EVIATION FROM THE INSTRUCTIONS MAY ALSO CAUSE A BAD VACUUM FILLING OF THE DAMPER...
Page 617: Before / During Transportation
– T HE PENETRATION OF DIRT INSIDE OF THE EXTERNAL TANK MUST BE AVOIDED AS MUCH AS POSSIBLE HE DIRT MAY CLOG UP THE FILTER IN THE LID OF THE EXTERNAL TANK CAUSING A MALFUNCTION OF THE VACUUM FILLING INSTALLATION –...
Page 618 Preparing vacuum filling device for use (after transportation) – Place the vacuum-filling device on a stabile flat and horizontally surface in the upright position. There has to be an undisturbed fresh airflow around the vacuum-filling device, to ensure sufficient cooling of the pump.
Page 619 – Fill the oil reservoir until the level indicator reaches max. level. Place back the filling plug using a torque wrench. The filling plug has to be fastened with a torque of 10 Nm. The vacuum-filling unit should always be in the upright position, to avoid oil spreading trough the entire system! This will cause serious damage to the vacuum filling device.
Page 620: Using The Filling Adapters
Using the filling adapters Filling adapter A – Screw the filling adapter into the filling hole of the damper. The nose of the filling adapter is able to rotate in relation to the rest of the filling adapter. Filling adapter B –...
Page 621 General preparation procedures The damper must be filled with as much oil as possible, when assembling. This operation minimizes the amount of air in the damper and allows the vacuum-filling device to give a good result. The damper will have a bad filling if this guideline is not followed! When vacuum filling, the damper should not have a spring on it.
Page 622 4-10 – The pressure can be adjusted by pulling up and turning the knob of the pressure regulator. For increasing pressure turn knob clockwise and for lowering pressure turn knob anti clockwise. – When the correct pressure has been set, press knob of pressure regulator down and release the pressure by moving lever Damper to the Vacuum position.
Page 623 4-11 – Now the main power can be turned on and the vacuum process will start. – First you will see the pressure gauge moving to a negative pressure. – As soon as the pressure reaches 25 mbar the vacuum gauge will also start moving to a lower pressure.
Page 624 4-12 – Now the vacuum will be released, and you will see the pressure rising on both gauges. – Shortly after this the vacuum gauges starts to run to a low pressure. This is happening because the pump is now working in a small volume witch includes the vacuum gauge.
Page 625 4-13 – Now you will see the pressure gauge moving to a negative pressure, as soon as the pressure reaches 25 mbar the vacuum gauge will also start moving to a lower pressure. – As soon as the vacuum gauge reaches the specified pressure(2nd cycle), in this example 8 mbar, the lever Oil reservoir should be moved to Pressure equalize.
Page 626 4-14 Filling procedure using the external tank – Remove the lid of the external tank and connect the damper to the quick release connecter under the lid. – The hook can be placed on several places on the lid, you might have to move the hook to another position in order to hang up a certain damper.
Page 627 4-15 – You also need to connect the damper connection to the external tank. – Put the control levers in the following positions. External tank Open Damper Vacuum Oil reservoir Vacuum – Now the main power can be turned on and the vacuum process will start.
Page 628 4-16 External tank Closed Damper Vacuum Oil reservoir Equalize pressure – Now the vacuum will be released, and you will see the pressure rising on both gauges. – Shortly after this the vacuum gauge starts to run to a low pressure. This is happening because the pump is now working in a small volume which includes the vacuum gauge.
Page 629 4-17 – When the pressure gauge reaches 0 bar, the lever Oil reservoir can be moved to Vacuum and the lever External tank must be moved to Open position, this will start the 2nd cycle of vacuum. External tank Open Damper Vacuum Oil reservoir...
Page 630 4-18 Filling procedure steering dampers CAUTION TEERING DAMPERS GENERALLY USE DIFFERENT OIL THAN NORMAL DAMPERS THIS REASON IT IS NECESSARY TO DRAIN AND CLEAN THE OIL RESERVOIR “ ” .M DESCRIBED IN MAINTENANCE AKE SURE THAT IT IS CLEAR TO EVERYONE THAT THE OIL RESERVOIR CONTAINS STEERING DAMPER OIL HERE MIGHT BE A SMALL AMOUNT OF OIL LEFT IN THE CONNECTOR UNDER THE LID OF THE EXTERNAL TANK...
Page 631 4-19 – Now the main power can be turned on and the vacuum process will start. – First you will see the pressure gauge moving to a negative pressure as soon as the vacuum gauge reaches the specified pressure, in this example 4 mbar as soon as the pressure reaches 25 mbar the vacuum gauge will also start moving to a lower pressure.
Page 632: Frequent Checks
4-20 – Now you will see the pressure gauge moving to a negative pressure, as soon as the pressure reaches 25 mbar the vacuum gauge will also start moving to a lower pressure. – As soon as the vacuum gauge reaches the specified pressure (2nd cycle), in this example 4 mbar the lever Oil reservoir should be moved to Equalize pressure.
Page 633 4-21 – Fill the oil reservoir until the level indicator reaches max. level. – Place back the filling plug using a torque wrench. The filling plug has to be fastened with a torque of 10 Nm. – Before the unit can be used, the oil in the oil reservoir should be put under vacuum in order to get rid of the air inside of the oil.
Page 634 4-22 – Remove the filling plug of the vacuum pump. – Fill up the vacuum pump with oil to the max. level on the level indicator. Only use Busch Vm22 vacuum pump oil! Place back the filling plug. Checking / cleaning oil separator –...
Page 635 4-23 Maintenance CAUTION URING MAINTENANCE VACUUM FILLING DEVICE SHOULD ALWAYS DISCONNECTED FROM BOTH AIR AND ELECTRICAL SUPPLY Maintenance vacuum pump – The vacuum pump oil must be changed after the first 100 hours of operation. Further oil changes depend on operating conditions. The oil must be changed after 500-2000 hours of operation, but at least semi-annually.
Page 636 4-24 – The fan cover should also be checked regularly for dirt. Spoiling the fan cover prevents cool air intake and may lead to overheating of the vacuum pump. Cleaning oil reservoir – The oil reservoir should be disassembled and cleaned at least every 6 months.
Page 637 4-25 – The oil reservoir can now be taken out of the frame trough the backside of the installation. Guide the damper connector pipe to avoid kink. – Place the oil reservoir on the front lid and remove the nuts from the rear lid using tool T103.
Page 638 4-26 – Replace the rear lid carefully. – Be sure that the front and rear lid are correctly lined up. – Screw the nuts on the treaded rod and tighten them with the adjustable pin spanner T103. – Hold the threaded rod while screwing the nuts, to avoid the rods from piercing the front sticker of the oil reservoir.
Page 639: Filling List
4-27 Spare parts Partnumber Exhaust filter vacuum pump T1254 O-ring oil reservoir T1253 Vacuum pump oil Vm22, 1 litre T1255 O-ring lid external tank T1258 Quick release hydraulic connector male T1262 Quick release hydraulic connector female T1263 Filling adapter A T1245S Filling adapter B T1246S...
Page 640: Short Operation Instruction For Vacuum Filling Unit
4-28 Short operation instruction for vacuum filling unit CAUTION F AT ANY TIME YOU FEEL UNCERTAIN OF THE VACUUM FILLING OF A DAMPER START OVER AGAIN TO ENSURE SAFETY Procedure without external tank Procedure using the external tank – Begin situation –...
Page 641 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Dual Compression Control Introduction Exploded view Disassembly DCC Assembling DCC...
Page 642 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Introduction General notice Pay attention to the following notes, when you are working with WP suspension products as described in this workshop manual: Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.
Page 643 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Exploded view...
Page 644 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Disassembly DCC DCC for the “OFF ROAD” shock absorbers. Hexagonal size 17 for the High-Speed compression adjustment. Adjusting screw for the Low-Speed compression adjustment.
Page 645 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling 1. Remove the screw-cap with the hexagonal high-speed adjustment. Turn clockwise the hexagonal adjustment part out of the screw-cap. (size 17)
Page 646 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling The hexagonal adjustment part out of the screw-cap. Remove the plate (backplate) from the spring. Remove the high-speed spring.
Page 647 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Clamp the mechanism in T1208S.
Page 648 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Unscrew the nut. (size 10) Turn the nut of the dampings adaptor. Remove the piston with check-valve mechanism.
Page 649 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Check-valve side. DCC piston side. Disassemble the O-ring.
Page 650 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Disassemble the entire dampings (shims) package. Pay attention to the assembling direction!!! Remove the disk. Pay attention to the assembling direction!!!
Page 651 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Remove the locking ring of the dampings adaptor. Clamp the mechanism not too tight in the clamping block in this position. Turn with the knob or screwdriver the Low-Speed compression fully inwards.
Page 652 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Remove the springring out of the dampings adaptor. Turn with the adjusting knob or screwdriver the Low-speed needle completely out.
Page 653 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Disassemble or pull the Low-Speed adjustment needle out. Pay attention to the spring and steel ball. Remove the steel ball and spring.
Page 654 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Remove the O-ring out of the groove of the screw-cap. Remove the O-ring out of the groove of the High-Speed hexagonal. Remove the O-ring inside.
Page 655 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling All parts of the DCC mechanism.
Page 656 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Assembly DCC Assemble the spring into the Low-Speed adjustment needle. Grease some T159 on top of the spring and also on the O-ring. Place the steel ball on the spring.
Page 657 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling 1. Assemble the Low-Speed adjustment needle dampings adaptor. Turn completely the needle inwards.
Page 658 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Assemble the springring into the groove of the dampings adaptor. Assemble the locking ring. Assemble the disk. Pay attention to the assembling direction!!!
Page 659 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Replace the entire DCC setting. Pay attention to the assembling direction!!! 1. Replace the piston with check-valve mechanism.
Page 660 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Wet the thread of the nut with T132. Tighten the nut to a torque of 4Nm. Assemble the spring of the High-Speed adjustment.
Page 661 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Replace the plate (backplate). High-Speed adjustment part with the assembled O-ring.
Page 662 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Assemble the O-ring inside the groove of the hexagonal High-speed adjustment part. Grease the O-ring with T159. Grease with T159 the O-ring inside.
Page 663 Workshop Manual Dual Compression Control Product Exploded View Disassembly & Assembling Assemble the O-ring into the groove of the screw-cap. Assemble the hexagonal into the screw-cap. Turn the hexagonal High-Speed adjustment part anti clock wise through the screw-cap of the DCC.
Page 664 REPAIRMANUAL2004-2010 WP 4860 MXMA Closed Cartridge Preload Adjuster WP 4357/4860 MXMA WP 4860 MXMA...
Page 665 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & assembling 12_016 Preload Adjuster PA Frontfork Introduction Exploded view 3 Disassembly Assembling...
Page 666 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Introduction General notice Pay attention to the following notes, when you are working with WP Suspension products as described in this workshop manual: Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.
Page 667 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & assembling Exploded view...
Page 668 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Disassembly Tur the preload adjuster to the left. (size 24) 12_017 Clamp spanner 24 in the vice. 12_018 Disassemble the springring. 12_019...
Page 669 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Screw the screw-cap to the right so that the spring washer is turning out of the screw-cap PA. 12_021 Remove the spring washer. Pay attention to the assembling direction!!! 12_022 Turn the plastic adjustment tube holder out of the screw-cap.
Page 670 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling 1. Remove the O-ring inside. 12_024 2. Remove the O-ring. 12_025 Unscrew the air release plug. 12_026...
Page 671 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Disassemble the adjusting knob from the screw-cap. Pay attention to the steel balls and spring!!! 12_027 Heat the steel nut. 12_028 Unscrew the nut (size 32) clockwise. 12_029...
Page 672 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling The nut. Pay attention to the assembling direction!!! 12_030 Push the holder rebound PA out of the screw-cap. 12_031 Remove the O-ring. 12_032...
Page 673 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling - springring - spring washer - O-rings - holder rebound adjustment tube - rebound adjusting knob with steel balls and spring - air release screw with O-ring 12_033/ - nut 12_034/ - holder rebound adjustment 12_035/...
Page 674 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Assembling Assemble a new O-ring. 12_037 Greasing the O-ring with T159. 12_038 Wet only the end of the thread with T132. 12_039...
Page 675 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Assemble the holder in the screw-cap. 12_040 Assemble the nut. Pay attention to the assembling direction!!! 12_041 Tighten the nut to a torque of 100Nm. 12_042...
Page 676 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Assemble the O-ring into the innerside of the holder. 12_043 Screw plastic holder adjustment tube into the holder. 12_044 Grease theO-ring adjustment tube with T159. 12_045...
Page 677 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Grease the steel balls with spring (T159) and assemble those in the adjustment knob. 12_046 Assemble the rebound adjusting knob. 12_048 Place spring washer. 12_049...
Page 678 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Turn the washer so that its fitting into the screw-cap. 12_050 Turn the spring washer past the springring groove. 12_051 Assemble the springring. 12_052...
Page 679 Workshop manual Preload Adjuster frontfork Product Exploded View Disassembly & Assembling Assemble the O-ring. 12_054 Assemble the air release screw with O-ring. 12_055 Turn the adjusting knob completely to the left. (open) 12_056...
Page 680: Mx Multi Adjuster
Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling 12_234 Frontfork 4860 MX Multi Adjuster 2003 Introduction Exploded view Disassembly forkleg Disassembly cartridge Disassembly compression holder Assembling compression holder Disassembly tap rebound Assembling tap rebound Assembling cartridge Assembling forkleg...
Page 681 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Introduction General notice: Pay attention to the following notes, when you are working with WP Suspension products as described in this workshop manual. Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.
Page 682 Workshop manual 4860 MXMA Product Exploded View Disassembly & assembling Exploded view...
Page 683: Disassembly Forkleg
Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly forkleg Note the rebound position by turning the knob to the right. 12_062 After removing the rubber cap. Note the compression position by turning the screw to the right. 12_063 Clamp the outer-tube in T1403S and unscrew the screw-cap PA with T103.
Page 684 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards... 12_067 ...and place open-end spanner (size 22) on the hydraulic stop. 12_068 Unscrew the screw-cap.
Page 685 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the screw-cap from the piston- rod. 12_070 Remove the preload spacers. 12_074 Pull the spring downwards and remove the spanner. 12_075...
Page 686 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the spring. 12_076 Remove the adjustment tube with the O-ring. 12_089...
Page 687 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Drain the oil out the forkleg. 12_094 Clamp the axle-clamp in the vice so that the forkleg is at an angle of ±45 degrees. 12_095 Unscrew the compression holder out of the axle-clamp.
Page 688 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove holder compression. Caution: oil iscoming out the cartridge. 12_097 Disassemble the cartridge out the forkleg. 12_098 Disassemble the dust-wiper. 12_099...
Page 689 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the circlip. 12_100 Heat the outer-tube near the oilseal. (not too hot) Heat the outer-tube at this level..
Page 690 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull with both hands the outer-tube from the inner-tube. Remove DU-bush inner-tube. 1. Remove DU-bush.
Page 691 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove DU-bush inner-tube. Remove DU-bush outer-tube.
Page 692 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove support ring. 12_105 Disassemble the oilseal. Pay attention to the assembling direction!!! 12_106...
Page 693 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the circlip. 12_107 Remove the dust wiper. 12_108...
Page 694 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Heat the axle-clamp. 12_111 Use T1404S... 12_112...
Page 695 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling ...and unscrew the inner-tube from the axle-clamp. 12_113 Remove the inner-tube. 1 2 - 1 1 4 Remove the O-ring out the groove of the axle-clamp. 12_115...
Page 696 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly cartridge 1. Clamp the tube with plug in the clamping-block (Tool T508S + T509). 12_116 12_117 12_118...
Page 697 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Unscrew the screw sleeve (size 22). 12_119 Turn the screw sleeve out of the tube. 12_120 Disassemble the piston-rod “complete”. Pay attention to the piston ring!!! 12_121...
Page 698 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the piston rod in T508S “not too tight” and unscrew the hydraulic stop from the piston-rod. 12_164 Remove the hydraulic stop. 12_165...
Page 699 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the screw sleeve with spring retainer. 12_167 Disassemble the DU-bush with T507 and press it out the screw sleeve with support of the vice. 12_168 - Spring retainer - screw sleeve - DU-bush 12_169...
Page 700 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly holder compression Clamp the compression holder in the vice and unscrew the check-valve nut. (size 17) Version with a locking: remove the locking with a file. 12_124 Remove the check-valve nut. 12_125 Remove the check-valve spring.
Page 701 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the check-valve shim. 12_127 Disassemble the compression piston with O-ring. Pay attention to the assembling direction!!! 12_128 Place a screwdriver on top of the holder and remove the entire shim packet. 12_129...
Page 702 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the O-ring. 12_130 Remove the copper washer. 12_131 - Holder compression - copper washer - O-ring - shims compression - piston compression with O- 12_132 ring - shim check-valve - spring check-valve - nut check-valve...
Page 703 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling holder compression Replace copper washer. 12_133 Assemble the O-ring. 12_134 Replace the entire shim packet. 12_135...
Page 704 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Replace piston. Pay attention to the assembling direction!!! 12_136 Replace shim check-valve. 12_137 Replace spring check-valve. Pay attention to the assembling direction!!! 12_138...
Page 705 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Wetting the thread of the nut with T132 and tighten it... 12_140 ...to a torque of 5Nm. 12_141 Check if the spring is correctly placed in the chamber of the nut. 12_142...
Page 706: Disassembly Tap Rebound
Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly tap rebound Clamp the piston-rod (at the level where the hydraulic stop is mounted) in T508S and unscrew the rebound tap. (Size 17) 12_143 Remove the rebound tap “complete”. 12_144/ 145/146 - posterize...
Page 707 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull the rebound needle with spring out of the tap rebound. 12_148 Check the O-ring. 12_149 Pay attention to the position of the triangular shims on the piston!!! Clamp the tap in the vice and unscrew the nut.
Page 708 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove the nut. Pay attention to the assembling direction!!! 12_151 Place a screwdriver on top of the tap and remove the entire shim packet. 12_152 Remove piston rebound. Pay attention to the assembling direction!!! 12_153...
Page 709 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Remove check-valve shims. 12_154 Remove spring check-valve. 12_155 - Rebound adjustment needle with O-ring - spring - tap rebound - spring check-valve 12_156 - shims check-valve - piston rebound - shims - nut M6x0.5...
Page 710: Assembling Tap Rebound
Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling tap rebound Assemble the spring and shims check- valve. 12_157 Assemble the piston rebound. Pay attention to the assembling direction!!! 12_158 Replace the shims. Pay attention to the position of the triangular shims on the piston!!! 12_159...
Page 711 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Wetting the thread of the nut with T132. Screw the nut on the tap... 12_160 ...tighten the nut to a torque of 5 Nm. 12_161 Grease the O-ring of the adjustment needle with T158.
Page 712 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Mount the needle with spring into the tap rebound. 12_163...
Page 713: Assembling Cartridge
Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling cartridge Press with T507 the DU-bush into the screw sleeve. 12_171 Clamp the piston-rod in T508S. At the level where the hydraulic stop is mounted. 12_172 Wetting the thread with T131. And screw the tap in the piston-rod.
Page 714 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Tighten the tap rebound. 12_174 Clamp the piston-rod “not too tight” in at the other side and replace the screw sleeve with spring retainer. 12_175 Screw the hydraulic stop “hand tight” to the end of the thread of the piston-rod.
Page 715 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the tube with plug in the clamping block (T508S and T509) and assemble the piston-rod “cpl.” into the tube. Guide the piston ring!!! 12_177 Before assembling wet the thread of the screw sleeve with T131.
Page 716: Assembling Forkleg
Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assembling forkleg Replace a new O-ring in the groove of the axle-clamp. 12_180 Wetting the thread of the axle-clamp with T132. 12_181 Wetting the thread of the inner-tube with T132. 12_182...
Page 717 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the inner-tube in the axle- clamp. 12_183 Screw very tight the inner-tube with T503S / T1404S. 12_184 Apply the dust wiper with T511. 1 4 _ 0 0 0 7...
Page 718 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Place T1401 over the inner-tube and assemble the dust wiper. 14_0008 Replace the circlip. 14_0011 Apply the innerside of the oilseal with T511 and the outerside with frontfork oil. 14_0010...
Page 719 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the oilseal. Pay attention to the assembling direction!!! 14_0012 Remove the tool and replace the support ring. 12_190...
Page 720 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Replace the DU-bush. Replace the tube. Replace the DU-bush.
Page 721 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Replace the DU-bush on the inner-tube. Slide carefully the outer-tube over the inner-tube.
Page 722 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble with T1402S the DU-bush - with the flat side- and... 12_194 ...tap or push it into the outer-tube. 12_195...
Page 723 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Use the other side of T1402S... 12_196 ...and tap the oilseal into the outer-tube. 12_197 Assemble the circlip into the groove of the outer-tube. Important: Check this very carefully!!! 12_198...
Page 724 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the dust wiper with T1402S. 12_199 Place the cartridge into the forkleg. Apply the O-ring of the compression piston with frontfork oil. 12_202...
Page 725 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the cartridge in the center of the axle-clamp and tighten the holder compression to a torque of 25Nm. 12_203 Assemble the adjustment tube with the O-ring into the piston-rod. 12_204...
Page 726 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Keep the outer-tube down and the piston- rod a little bit extended (like picture), fill the forkleg with oil till the edge of the outer-tube, wait a few moments, you will see air bubbles rising 12_206 The oil must stay above the 4 holes of the inner-tube, if necesarry fill some...
Page 727 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull the piston-rod out and assemble the spring. 12_211 Pull the spring downwards and place open-end spanner 22 on the hydraulic stop. 12_212 Replace first the steel washer on the spring, then the preload spacer(s).
Page 728 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Screw handtight the screw-cap on the piston-rod. Screw down the screw-cap, till the hydr. stop is against the screw-cap and tighten it to a torque of 25Nm.
Page 729 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Pull the spring downwards and remove the spanner. Tighten the screw-cap with T103. Position rebound!
Page 730 Workshop manual 4860 MXMA Product Exploded View Disassembly & Assembling Position compression! And replace the rubber cap. 12_226...
Page 731 REPAIRMANUAL2005- WP FORK 4860 MXMA CLOSED CARTRIDGE REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
Page 732 1 SPECIAL TOOLS 2 GENERAL INFORMATION 3 DISMOUNTING/MOUNTING THE FORK 4 DISASSEMBLING AND ASSEMBLING THE FORK...
Page 733 SPECIAL TOOLS INDEX T 103 PIN SPANNER ..........1-2 T 131 LOCTITE 243 .
Page 734 T 103 Pin spanner T 131 Loctite 243 T 132 Loctite 2701 T 137S Squeeze bottle T 158 O-Ring grease...
Page 735 T 159 Water proof grease T 511 Grease for seals T 605 T 1240S Vacuum filling device T 1401 Assembling tool for seal...
Page 736 T 1402S Assembling tool seal and DU-bush T 1403S Clamping-block 48/60 T 1404 Pin spanner inner-tube T 14.015S Clamping block 27 T 14.016S Clamping block 12...
Page 737 T 14.017 Spanner 50 T 14.018 Spanner screw-cap membrane holder T 14.019 Charging device tool T 14.020 Support tool dis-/assembling closed cartridge. T 14.021 Calibrate mandrel DU-bush...
Page 738 T 14.022 Dis-/assembling tool DU-bush T 14.023 Threaded bush T 14.024 Support bush T 14.025 Assembling tool oil seal screw sleeve T 14.029 Mounting bush...
Page 739 T 14.030 Adaptor T 14.033 Assembling tool...
Page 740 GENERAL INFORMATION INDEX EXPLODED VIEW SXS 2005 ........2-2 PART LIST SXS 2005 .
Page 741 Exploded view SXS 2005...
Page 742 O-ring N.B.R. 9.5x1.5 4860.0301. O-ring Viton 7x1.5 5018.0157. O-ring N.B.R. 4x1.5 5018.0222. Bush d10x3 4054.0497. Axle-clamp Ma brake KTM SXR “03 4860.0465. Axle-clamp MA ri KTM SXR “03 4860.0466. Oil seal d12xd22x9.5 4860.0471. Bolt with flange M 8x25 5060.0113. Holder adj. tube d4 L=18 4860.0271.
Page 743 Setting list 4860 MXMA Fork 14.18.7A.14 KTM 125 SXS 2005 Compression Part description Art. No. Shim 6x16x0.25 4054.0414. Backpl. 6x8.5x0.20 4054.0425. Shim 6x12x0.1 4054.0400. Shim 6x14x0.1 4054.0401. Shim 6x16x0.1 4054.0402. Shim 6x18x0.1 4054.0403. Shim 6x20x0.1 4860.0065. Shim 6x22x0.1 4860.0064. Shim 6x24x0.1 4860.0063.
Page 744 Setting list 4860 MXMA Fork 14.18.7A.15 KTM 250 SXS 2005 Compression Part description Art. No. Shim 6x16x0.25 4054.0414. Backpl 6x9.5x0.20 4054.0427. Shim 6x12x0.10 4054.0400. Shim 6x13x0.10 4860.0325 Shim 6x14x0.10 4054.0401. Shim 6x15x0.10 4860.0327. Shim 6x16x0.10 4054.0402. Shim 6x17x0.10 4860.0329. Shim 6x18x0.10 4054.0403.
Page 745 Setting list 4860 MXMA Fork 14.18.7A.16 KTM 450/540 SXS 2005 Compression Part description Art. No. Shim 6x16x0.25 4054.0414. Backpl 6x9.5x0.20 4054.0427. Shim 6x12x0.10 4054.0400. Shim 6x13x0.10 4860.0325 Shim 6x14x0.10 4054.0401. Shim 6x15x0.10 4860.0327. Shim 6x16x0.10 4054.0402. Shim 6x17x0.10 4860.0329. Shim 6x18x0.10 4054.0403.
Page 746 Exploded view SXS 2006...
Page 747 Part list SXS 2006 Pos. Part description Part number Pieces Dust stripper 4860.0400 Oil seal 4860.0347 Inner-tube 4860.0550 Hydr.stop 4860.0521 Support ring 4860.0013 DU-bush 4860.0429 DU-bush 4860.0428 Lock washer 4860.0070 Outer-tube 4860.0539E Check valve ring 4860.0513 O-ring 4860.0299 Shuttle valve spring 4860.0382 Piston rebound bleed 4860.0489...
Page 748 Setting list 4860 MXMA Fork 14.18.7B.14 KTM 125 SXS 2006 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x10x0.1 4054.1404 Shim 6x11x0.1 4860.0323 Shim 6x12x0.1 4054.0400 Shim 6x13x0.1 4860.0325 Shim 6x14x0.1 4054.0401 Shim 6x15x0.1 4860.0327 Shim 6x16x0.1 4054.0402 Shim 6x18x0.1...
Page 749 2-10 Setting list 4860 MXMA Fork 14.18.7B.15 KTM 250 SXS 2006 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x11x0.1 4860.0323 Shim 6x12x0.1 4054.0400 Shim 6x13x0.1 4860.0325 Shim 6x14x0.1 4054.0401 Shim 6x15x0.1 4860.0327 Shim 6x16x0.1 4054.0402 Shim 6x17x0.1 4860.0329...
Page 750 2-11 Setting list 4860 MXMA Fork 14.18.7B.16 KTM 450/540 SXS 2006 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x12x0.1 4054.0400 Shim 6x13x0.1 4860.0325 Shim 6x14x0.1 4054.0401 Shim 6x15x0.1 4860.0327 Shim 6x16x0.1 4054.0402 Shim 6x17x0.1 4860.0329 Shim 6x18x0.1 4054.0403...
Page 751 2-12 Exploded view SX 2007...
Page 752 2-13 Part list SX 2007 Pos. Part description Part number Pieces Dust stripper 4860.0400 Oil seal 4860.0399 Support ring 4860.0013 DU-bush 4860.0429 DU-bush 4860.0428 Lock washer 4860.0070 Outer-tube 4860.0492E Rebound support 4860.0576 O-ring 4860.0299 Shuttle valve spring 3548.0377 Piston rebound 4860.0575 4054.0486 Needle for rebound adjustment...
Page 753 2-14 Setting list 4860 MXMA Fork 14.18.7C.01 KTM 125 SX 2007 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x9,5x0.30 4054.0450 Shim 6x12x0.10 4054.0400 Shim 6x14x0.15 4054.0405 Shim 6x16x0.15 4054.0406 Shim 6x18x0.15 4054.0407 Shim 6x20x0.15 4860.0069 Shim 6x22x0.15 4860.0097...
Page 754 2-15 Setting list 4860 MXMA Fork 14.18.7C.03 KTM 250 SX/250 SX-F 2007 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x9,5x0.2 4054.0427 Shim 6x12x0.15 4054.0404 Shim 6x14x0.15 4054.0405 Shim 6x16x0.15 4054.0406 Shim 6x18x0.15 4054.0407 Shim 6x20x0.15 4860.0069 Shim 6x22x0.15 4860.0097...
Page 755 2-16 Setting list 4860 MXMA Fork 14.18.7C.05 KTM 450 SX-F 2007 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x10x0.2 4054.1403 Shim 6x12x0.15 4054.0404 Shim 6x14x0.15 4054.0405 Shim 6x16x0.15 4054.0406 Shim 6x18x0.15 4054.0407 Shim 6x20x0.15 4860.0069 Shim 6x22x0.15 4860.0097...
Page 756 2-17 Exploded view Fork SXS 2007...
Page 757 2-18 Part list Fork SXS 2007 Pos. Part description Part number Pieces Dust stripper 4860.0400 Oil seal 4860.0347 Support ring 4860.0013 DU-bush 4860.0429 DU-bush 4860.0428 Lock washer 4860.0070 Outer-tube 4860.0684 Piston rod tap rebound 4860.0576 O-ring 4860.0299 Shuttle valve spring 4860.0382 Piston rebound bleed 4860.0679...
Page 758 2-19 Setting list Fork 4860 MXMA CC 14.18.7C.14 Setting list Fork 4860 MXMA CC 14.18.7C.15 KTM 125 SXS 2007 KTM 250 SXS, 250 SXS-F 2007 Compression Compression Pos. Part description Part number Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x16x0.25...
Page 759 2-20 Setting list Fork 4860 MXMA CC 14.18.7C.16 KTM 450 SXS-F 2007 Compression Pos. Part description Part number Shim 6x16x0.25 4054.0414 Shim 6x13x0.10 4860.0325 Shim 6x14x0.10 4054.0401 Shim 6x15x0.10 4860.0327 Shim 6x16x0.10 4054.0402 Shim 6x17x0.10 4860.0329 Shim 6x18x0.10 4054.0403 Shim 6x19x0.10 4054.0403...
Page 760 – For the standard position see setting list. Position of the compression and rebound adjustment – Set the rebound position , see KTM-Owners manual. – Assemble the rubber cap. – Set the compression position , see KTM-Owners manual.
Page 761 2-22 Explanation of the spring preload – Total spring length without the spacers, see chapter inspection of the spring! – Spring length with spacers , see setting list. – Spring with the spacers. – The spring is assembled in the front fork leg. NOTE: the distance of “B”...
Page 762 2-23 Air release screw – Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! – Unscrew the air release screw of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork A 100 liter fuel consumption is equivalent to...
Page 763 DISMOUNTING/MOUNTING THE FORK INDEX DISMOUNTING THE FORK .........3-2 MOUNTING THE FORK .
Page 764 Dismounting the fork – Place your motorcycle on a stand. – Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual.
Page 765 Mounting the fork – Clean the innerside of the triple-clamps with brake cleaner. – Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! –...
Page 766 DISASSEMBLING/ASSEMBLING THE FORK INDEX DISASSEMBLING THE CARTRIDGE OUT OF THE FRONT FORK LEG ... . .4-2 INSPECTION OF THE SPRING ........4-6 DISASSEMBLING THE INNER-TUBE / OUTER-TUBE .
Page 767 Disassembling the cartridge out of the front fork leg – Place clamping block T1403S in the vice. – Clamp the outer-tube of the front fork leg in the clamping block at the level of the lower triple-clamp. – Place T14.017 on the screw-cap of the front fork leg.
Page 768 – Remove the front fork leg out of the vice and move the outer-tube downwards to the axle-clamp. – Drain the oil out of the front fork leg. – Only for replacing the spring or changing the spring preload! – Place the front fork leg in the vice according to the picture. –...
Page 769 – Push the cartridge downwards and place T14.020 over the piston-rod, just below the contra nut. (art. no. 4860.0459) NOTE: Do this with help of a second person. – Screw the rebound adjustment holder from the nut, (Size 19 and –...
Page 770 – Push the cartridge downwards and remove T14.020 – Remove the nut – Release the spring pressure on the cartridge slowly. – Remove the closed cartridge complete. – “The closed cartridge complete” SXS 2005/06. – “The closed cartridge complete” SX 2007...
Page 771 – Remove the spring with the spacer – Also remove the bushing on the lower end of the spring (2006 model). Inspection of the spring NOTE: Only for replacing the spring or changing the spring preload! – It is necessary to place the front fork leg according to the picture for about 5 minutes.
Page 772 – Slide the dust stripper downwards. – Remove the lock washer with a screwdriver. NOTE: The lock washer is on one side chamfered to disassemble it easier! – Heat the surface of the outer-tube near the oil seal to a temperature of ±...
Page 773 Inspection of the outer-tube – The outer-tube. – Inspect the outside surface of the outer-tube if there isn’t any damage because of (for example) stones. – Inspect the inside running surface of the outer-tube on scratches. – Also inspect the anodized coating of the running surface. –...
Page 774 – Measure the chamber for the DU-bush. The maximum diameter is: 52.15 mm – Measure the chamber for the oil seal. The maximum diameter is: 57.50 mm – Micrometer for measuring the diameter of the running surface of the outer-tube. –...
Page 775 4-10 – Place the inner-tube in the vice according to the picture. – Remove the DU-bush from the inner-tube. – Remove the outer-tube DU-bush – Remove the support ring...
Page 776 4-11 – Remove the oil seal – Remove the lock ring. – Remove the dust stripper – Dust stripper – Lock ring – Oil seal – Support ring – DU-bush outer-tube – DU-bush inner-tube...
Page 777 4-12 Inspection of the DU-bushes, support ring and seals – Replace the DU-bush of the inner-tube if the surface is feeling rough. NOTE: The best way to do this is to compare it with a new one! – Replace the DU-bush when you see through the surface a bronze color.
Page 778 4-13 – Always replace the dust stripper and oil seal with every service! See periodic service interval! – Unscrew both bolts out of the axle-clamp. – Heat the axle-clamp. NOTE: the inner tube and axle clamp come as a unit for SX models starting in 2007 and do not need to be disassembled.
Page 779 4-14 – Unscrew the inner-tube from the axle-clamp – Take the axle-clamp out of the vice. – Axle-clamp complete!
Page 780 4-15 Inspection of the inner-tube – Inner-tube. – Inspect the outside running surface of the inner-tube on scratches, wear and tear. NOTE: When the scratches are sharp and they are not to deep, polish them with “Scotch Brite” hand pad. –...
Page 781 4-16 – Measure the outside diameter of the inner-tube, rotate the inner- tube 180° and measure again. Repeat these measurements on several places of the inner-tube. The maximum diameter is: 48.005mm The minimum diameter is: 47.950mm – Clock gauge for measuring the straightness of the inner-tube. –...
Page 782 4-17 – Take the spacer out of the axle-clamp – Use air pressure to remove the O-ring out of the groove of the axleclamp. – Remove the hydraulic sleeve – Axle-clamp with components.
Page 783 4-18 Disassembling the closed cartridge – The closed cartridge complete. – Remove the rebound adjustment tube – Clamp the reservoir of the cartridge in the vice according to the position of the picture. – Hold the rebound adjusting screw and loosen the screw...
Page 784 4-19 Release the nitrogen gas pressure – Unscrew the Allen bolt that is nearist to the compression adjustment screw, (Size 3). – Remove the Allen bolt with the seal out of the screw-cap. – Model 2005: Allen bolt with the seal. –...
Page 785 4-20 – 2005: place T14.018 on the screw-cap. – 2006: place T103 on the screw-cap. – Loosen the screw-cap of the membrane holder. – Lift with a screw driver the screw-cap of the membrane holder out of the reservoir. – Take the membrane holder out of the reservoir.
Page 786 4-21 – Clamp the closed cartridge in the vice according to the picture! – Heat the screw sleeve – Loosen the screw sleeve, (Size 24) – Unsrew the screw sleeve out of the tube. – Pull the piston rod out of the tube.
Page 787 4-22 – The complete piston rod with the rebound setting - pay attention to the piston ring – Remove the tube (SXS) or guiding ring adapter (SX). – Remove the support ring and the lock ring (SX only). – Tube d35xD37.5 with guiding ring –...
Page 788 4-23 – Place clamping block T14.016 in the vice. NOTE: Place the piston rod in the vice according to the picture. – Remove the piston ring – Loosen the tap rebound , (Size 17). – Screw the tap rebound with needle and spring out of the piston rod. –...
Page 789 4-24 – Remove the steel washer – Remove the screw sleeve Inspection of the piston rod – Piston rod. – Replace the piston rod if you have inspect that the surface of the piston rod has scratches and or indentations. –...
Page 790 4-25 – Measure the diameter of the piston rod, rotate the piston rod 90° and measure the diameter again. – Repeat these measurements on several places of the piston rod. The maximum diameter is: 12.00 mm. The minimum diameter is: 11.92 mm. –...
Page 791 4-26 Disassembling the membrane holder – The membrane holder complete. – Screw the plug out of the membrane holder, (Size 4) - this plug is for factory production use! NOTE: starting in 2007 SX forks have the filling screw in this position which should be removed;...
Page 792 4-27 – Disassemble the spring ring NOTE: – Pay attention in which groove the springring is assembled! – By changing the position of the spring ring in the groove you will change the spring preload more or less with 1.5 mm! –...
Page 793 4-28 – Turn the membrane holder up side down and remove the spring. – The check valve pin. NOTE: It is not possible to disassemble the check-valve pin out of the membrane holder! Check valve SX 2007: – Press against the check valve with a suitable screwdriver and lift out.
Page 794 4-29 – Place the tube in the clamping block T14.015 at the level of the screw sleeve. Heat the membrane holder at the level of the spring ring groove. NOTE: the membrane holder and tube come as a unit for SX models starting in 2007 and do not need to be disassembled.
Page 795 4-30 Disassembling the screw sleeve – Turn the screw sleeve out of the tube – Screw sleeve complete. – Remove the O-ring – Remove the spring ring – Remove the check-valve ring...
Page 796 4-31 – Screw the threaded bush T14.023 on the screw sleeve till about 0.5 mm just above the edge of the thread of the screw sleeve – Place the screw sleeve with clamping block T14.015 in the vice. – Heat the threaded bush to a temperature of approx. 50°C. –...
Page 797 4-32 – This side of the oil seal is visible when the oil seal is assembled in the screw sleeve. NOTE: Always replace the oil seal! CAUTION 2006 O NOT MOUNT THE OIL GASKET YET FOR FORKS STARTING WITH THE MODEL T WILL BE MOUNTED DURING ASSEMBLY –...
Page 798 4-33 Disassembling the rebound adjustment adaptor – The rebound adjustment adaptor complete. – Remove the O-ring – Remove the copper washer NOTE: Always replace the copper washer. – Turn the adjustment screw clockwise and remove the needle. – Remove the O-ring with a hobby knife out of the groove inside the rebound adjustment adaptor.
Page 799 4-34 Disassembling the tap rebound – The tap rebound complete. – Pull the rebound adjustment needle out of the tap rebound. – Needle with spring – Take the O-ring of the needle. – Place the tap rebound in the vice according to the picture.
Page 800 4-35 – Pay attention to the position of the rebound triangular shims – Unscrew the lock nut. – Remove the lock nut – Remove the bush (does not apply to SX 2007). – Place a screwdriver on top of the tap rebound.
Page 801 4-36 – Slide the complete rebound setting over the shaft of the screwdriver. – Remove the check-valve spring – Remove the O-ring (does not apply to SX 2007). – The tap rebound with components.
Page 802 4-37 – Rebound piston, setting side shown! – Rebound piston, Check-valve setting side shown! Inspection of the rebound setting – Polish both sides of the rebound piston with sandpaper 600 on a flat plate. – Check the first shim of the rebound setting that is assembled on the rebound piston if it is not bended.
Page 803 4-38 Disassembling the screw-cap / membrane CC – Place the screw cap / membrane CC in the vice according to the picture. – Loosen the Allen bolt , (Size 3) NOTE: from model 2006 on a Phillips flat-head screw M4 is used. –...
Page 804 4-39 Disassembling model 2005 – Place the screw-cap in the vice according to the picture. – Loosen the tap compression , (Size 17). – Screw the tap compression out of the rod. – Remove the the tap compression complete. – Remove the adjustment tube...
Page 805 4-40 – Take the membrane out of the groove of the screw-cap. – The screw-cap with the membrane CC with the components. – Place the rod of the screw-cap in clamping-block T14.016. – Push the rubber plug out of the screw-cap. –...
Page 806 4-41 – Heat the screw-cap to a temperature of approx. 50°C near the rod. – Untighten the screw-cap with T14.018. – Unscrew the screw-cap of the rod. – Turn the adjustment screw fully clockwise and remove the adjustment needle. – Screw-cap –...
Page 807 4-42 Dissembling (from 2006 model on): – Hold the screw cap with T103 or clamp in a vise with T103 (see photo). NOTE: tighten vise gently. – Loosen the compression damping fixture (A/F 13). – Unscrew the compression damping fixture. –...
Page 808 4-43 – Loosen the nut on the piston rod and screw a few turns away from the screw cap. – Clamp the piston rod with T14.016S, heat the screw cap to approx. 50°C and unscrew with T103. NOTE: the piston rod and screw cap come as a unit for SX models starting in 2007 and do not need to be disassembled.
Page 809 4-44 Assembling the screw-cap/membrane CC – Always assemble a new rubber plug when the rubber plug removed out of the screwcap. – Push the rubber plug as far as posibble into the screw-cap. – Assemble the needle. – Turn the adjustment screw anti-clockwise fully open. –...
Page 810 4-45 – Turn the rod in the screw-cap – Clamp the rod in the clamping-block T14.016 and tighten the screw-cap with T14.018 – Assemble the Allen bolt with the seal. – Place the O-ring – Place the screw-cap in the vice according to the picture.
Page 811 4-46 – Place the membrane – Assemble the membrane in the groove of the screw-cap. – Assemble the membrane over the rod – The complete tap compression. NOTE: the adjusting screw stays in the piston rod starting with the 2006 model. The following steps will not be necessary. Continue at the bottom of page 4-48.
Page 812 4-47 – Apply the thread with T131. – Remove the spring from the needle. – Grease the O-ring of the needle with T158. – Replace the adjustment needle with the assembled spring into the tap compression. – Place the adjustment tube on the end of the needle.
Page 813 4-48 – Place the screw-cap with membrane CC over the adjustment tube – Screw the membrane on the tap compression. – Place the screw-cap in the vice according to the picture. – Tighten the compression tap...
Page 814 4-49 Disassembling the tap compression – Unscrew the lock nut , (Size 10). up to the 2005 model: – Remove the lock nut – Take off the shuttle valve – Take off the check-valve spring starting with the 2006 model: –...
Page 815 4-50 – Slide the complete compression setting over the shaft of the screwdriver. – Disassemble the O-ring of the compression piston – Compression setting with the components. – Compression piston, check-valve setting side shown. – Compression piston, setting side shown.
Page 816 4-51 Inspection of the compression setting – Polish both sides of the compression piston with sandpaper 600 on a flat plate. – Check the first shim of the compression setting that is assembled on the compression piston if it is not bended. –...
Page 817 4-52 up to the 2005 model: – Place the compression check-valve setting – Place the check-valve spring – Place the shuttle valve NOTE: Assure that the check-valve shim(s) is fitting over the shuttle valve! – Screw a new lock nut on the compression tap.
Page 818 4-53 Assembling the holder membrane – Blow with high air pressure through the valve – Blow with high air pressure through the other side of the valve. – Place the valve spring – Turn the adjustment screw at the level of the edge of the hole. –...
Page 819 4-54 – Assemble the O-ring in the groove inside the membrane holder. – Place the O-ring NOTE: the filling screw is in this position starting with the 2007 model. Do not mount yet. – Screw the plug in the holder and tighten the plug. –...
Page 820 4-55 – Assemble the O-ring – Apply the O-ring with T158. – Apply the inside O-ring with T158. – Membrane holder complete.
Page 821 4-56 Assembling the tap rebound – Place a new O-ring – Place the tap rebound in the vice. – Place the check-valve spring – Place the check-valve setting NOTE: the disks must be pressed down against the spring force; they are centered by the collar.
Page 822 4-57 – Place the shim setting – Place the bush NOTE: a nut with a collar is used instead of a bushing starting in 2007. Mount with the collar facing the disks and lock the thread with T131. – Screw a new lock nut on the tap (up to the 2006 model).
Page 823 4-58 – Place the O-ring – Place the spring – Grease the O-ring with T158. – Assemble the adjustment needle in the tap rebound.
Page 824 4-59 Assembling the rebound adjustment adaptor – Place a new O-ring in the adaptor. – Assemble the O-ring in the groove inside the adaptor. – Assemble the needle – Turn the adjustment screw anti-clockwise fully open. – Place a new copper washer...
Page 825 4-60 – Assemble the O-ring in the groove. – Rebound adjustment adaptor complete. Assembling the screw sleeve – Screw T14.023 on the screw sleeve and then press in the new guide bush with T14.022 – Apply the calibrate mandrel T14.021 with front fork oil.
Page 826 4-61 – Place the screw-sleeve in the clamping block and heat the screw sleeve to a temperature of approx. 50°C. – Apply the outside of the new oil seal with front fork oil. CAUTION 2006 O NOT MOUNT THE OIL GASKET YET FOR FORKS STARTING WITH THE MODEL T WILL BE MOUNTED DURING ASSEMBLY NOTE: Pay attention to the assembling direction!
Page 827 4-62 Assembling the closed cartridge (Model 2005) – Assemble the guiding ring in the groove of the tube. – Tube complete. – Screw the screw sleeve in the tube completely. – Wet the thread of the tube with T132. – Clamp the tube in the clamping-block T14.015.
Page 828 4-63 – Screw the membrane holder on the tube – Tighten the membrane holder with T14.017 – Unscrew the screw sleeve out of the tube. – Piston rod – Rebound spring – Washer – Contra nut – Screw the contra nut to the end of the thread of the piston rod.
Page 829 4-64 – Place the piston rod in the clamping block T14.016 – Slide carefully the screw sleeve over the piston rod. – Place the washer – Assemble the rebound spring – Wet the thread of the tap rebound with T131 –...
Page 830 4-65 – Piston ring , always place a new piston ring! – Roll the piston ring over the shaft of a screwdriver! – Place the piston ring in the groove of the rebound piston. – Assemble carefully and slowly the piston into the tube of the cartridge.
Page 831 4-66 Assembling the closed cartridge (starting with the 2006 model) – Assemble the guiding ring in the groove of the tube (SXS) or the guiding ring adapters (SX). – Clamp the piston rod with T14.016S (inner thread facing up). – Slide on the rebound spring with spring guiding.
Page 832 4-67 – Oil the piston ring. – Slide the piston rod into the pipe, use a T-type wrench (10 mm) to center if necessary. – Slide on the washer – Slide the special tool T 14.029 over the thread in the piston rod. –...
Page 833 4-68 – Screw the locknut on the piston rod. – Apply T 131 to the screw bushing. – Screw on the screw bushing. – Clamp the cartridge as shown in the photo and tighten the screw bushing to 40 Nm.
Page 834 4-69 Bleeding the closed cartridge (model 2005) – Place the membrane holder in the vice according to the picture. – Drain slowly front fork oil in the closed cartridge. The oil level must be about 70 mm from the top of the membrane holder. The piston rod must be fully extended! 70 mm –...
Page 835 4-70 – Place slowly the membrane into the membrane holder – Screw the screw-cap in the membrane holder NOTE: Oil has to overflow from bleedhole to assure 100% bleeding. – Place T14.018 on the screw-cap. – Tighten the screw-cap to a torque of 30 Nm.
Page 836 4-71 Bleeding the closed cartridge (starting with the 2006 model) – Clamp the membrane holder in the vise as illustrated. – Slowly pour fork oil into the closed cartridge. The oil level should be approx. 185 mm under the upper edge of the membrane holder. The piston rod should be fully extended.
Page 837 4-72 – Screw on the adapter T 14.030 and tighten by hand. – Screw the filling adapter "A" in the adapter T 14.030. – Connect the filling adapter "A" to the vacuum/filling device T 1240S. CAUTION – T HE VACUUM FILLING DEVICE SHOULD ONLY BE OPERATED BY PERSONS WHO HAVE READ AND UNDERSTOOD THE PERATING...
Page 838 4-73 – As soon as the pressure gauge (bar) reaches approx. 3 bar, turn the "Damper" control lever back to "Vacuum". NOTE: the pressure gauge (bar) will drop to 0 bar. – Switch off the vacuum/filling device. – Lay the cartridge down as shown in the photo, remove the filling adapter "A"...
Page 839 4-74 On pressure with nitrogen – Nitrogen filling gauge T14.019 – Remove the protecting cap of the needle – Place the needle in the center of the filling hole of the screw-cap and push the needle completely through the rubber plug! –...
Page 840 4-75 – Screw the Allen bolt into the screw-cap. – Tighten the Allen bolt. Starting with the 2007 model: – Mount the compression adjusting screw and apply T131 to the thread on the screw . Hold the compression adjusting screw and tighten the screw.
Page 841 4-76 Assembling the inner-tube / outer-tube – Place the hydraulic sleeve in the axle-clamp – Place a new O-ring in the groove inside the axle-clamp. – Place the spacer – Grease the thread of bolts with T159. – Wet the thread of the inner-tube with T132.
Page 842 4-77 – Screw the inner-tube in the axle-clamp. – Place the inner-tube with axle clamp in the vice according to the picture. – Tighten the inner-tube with T 1404S – Apply the surface of the inner-tube with front fork oil! –...
Page 843 4-78 – Grease the inside of the dust stripper with T 511. – Slide the dust stripper over the tool and inner-tube. – Place the lock ring – Grease the innerside of the oil seal with T 511. – Slide the oil seal over the tool and innertube. –...
Page 844 4-79 – Polish with sandpaper the edges of the DU-bush inner-tube, (Sandpaper 400 / 600). – Clean the DU-bush after polishing! – Assemble the DU-bush inner-tube. – Apply the outerside of the dust stripper and oil seal with front fork oil. –...
Page 845 4-80 – T 1402S, assembling side for the DU-bush outer-tube. – Press the DU-bush and the support ring into the outer-tube with T 1402S – T 1402S, assembling side for the oil seal. – Press the oil seal into the outer-tube.
Page 846 4-81 – Assemble the lock ring in the groove of the outer-tube. NOTE: be sure that the lock washer is correctly assembled into the groove!!! – Assemble the dust stripper – Outer-tube / inner-tube complete!
Page 847 4-82 Assembling the cartridge in the front fork leg – Place the front fork leg in the vice according to the picture. – Assemble the spring with spacer(s) NOTE: do not forget the bush (Modell 2006). – Assemble the closed cartridge into the front fork leg..
Page 848 4-83 – Place the needle of the rebound adjustment adaptor into the adjustment tube and screw the rebound adjustment adaptor fully on the thread of the piston rod. – Tighten the rebound adjustment adaptor against the contra nut a torque of 30 Nm. –...
Page 849 4-84 Filling oil in the front fork leg – Fill the measuring jug with the correct amount of front fork oil, siehe see-list! Max. amount of oil = 425 ml Min. amount of oil = 360 ml – Fill the amount of oil into the front fork leg. –...
Page 850 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling 12_234 Frontfork 4357 / 4860 MX Multi Adjuster Introduction Exploded view Disassembly forkleg Disassembly screw-cap Assembling screw-cap Disassembly cartridge Disassembly compression holder Assembling compression holder Disassembly tap rebound Assembling tap rebound Assembling cartridge Assembling forkleg...
Page 851 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Introduction General notice: Pay attention to the following notes, when you are working with WP Suspension products as described in this workshop manual. Always use clean and professional tools. Regular you need next to the general equipment, the special tools of WP Suspension.
Page 852 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & assembling Exploded view...
Page 853 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly forkleg Note the rebound position by turning the knob to the right. 12_062 After removing the rubber cap. Note the compression position by turning the screw to the right. 12_063 Clamp the outer-tube in (4357) T501S / (4860) T1403S and unscrew the...
Page 854 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards... 12_067 ...and place open-end spanner (size 22) on the hydraulic stop. 12_068 Unscrew the screw-cap.
Page 855 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove the screw-cap from the piston- rod. 12_070 Remove the preload spacers. 12_074 Pull the spring downwards and remove the spanner. 12_075...
Page 856 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove the spring. 12_076 Remove the adjustment tube with the O-ring. 12_089...
Page 857 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Drain the oil out the forkleg. 12_094 Clamp the axle-clamp in the vice so that the forkleg is at an angle of ±45 degrees. 12_095 Unscrew the compression holder out of the axle-clamp.
Page 858 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove holder compression. Caution: oil iscoming out the cartridge. 12_097 Disassemble the cartridge out the forkleg. 12_098 Disassemble the dust-wiper. 12_099...
Page 859 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the circlip. 12_100 Heat the outer-tube near the oilseal. (not too hot) 12_101 Pull with both hands the outer-tube from the inner-tube. 12_102...
Page 860 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove DU-bush inner-tube. 12_103 Remove DU-bush outer-tube. 12_104 Remove support ring. 12_105...
Page 861 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the oilseal. Pay attention to the assembling direction!!! 12_106 Remove the circlip. 12_107 Remove the dust wiper. 12_108...
Page 862 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling - Dust wiper - circlip - oilseal - support ring - DU-bush outer-tube - DU-bush inner-tube 12_109/ Heat the axle-clamp. 12_111 Use (4357) T503S / (4860) T1404S... 12_112...
Page 863 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling ...and unscrew the inner-tube from the axle-clamp. 12_113 Remove the inner-tube. 1 2 - 1 1 4 Remove the O-ring out the groove of the axle-clamp. 12_115...
Page 864: Disassembly Screw-Cap
Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly screw-cap Disassemble the adjustment knob. Pay attention to the steel balls and spring!!! For PA version: Manual PA Front Fork 12_227 2000 Unscrew plastic holder adjustment tube out of the screw-cap.
Page 865 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling - Rebound adjusting knob with steel balls and spring - holder adjustment tube - airrelease screw with O-ring 12_229 - screw-cap with O-ring...
Page 866: Assembling Screw-Cap
Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assembling screw-cap Assemble the air release screw 12_231 Screw the holder adjustment tube in the screw-cap. 12_232 Grease the O-ring, steel balls and spring with T158. Assemble the knob with steel balls and spring.
Page 867 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly cartridge 1. Clamp the tube with plug in the clamping-block (Tool T508S + T509). 12_116 12_117 12_118...
Page 868 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Unscrew the screw sleeve (size 22). 12_119 Turn the screw sleeve out of the tube. 12_120 Disassemble the piston-rod “complete”. Pay attention to the piston ring!!! 12_121...
Page 869 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the piston rod in T508S “not too tight” and unscrew the hydraulic stop from the piston-rod. 12_164 Remove the hydraulic stop. 12_165...
Page 870 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove the screw sleeve with spring retainer. 12_167 Disassemble the DU-bush with T507 and press it out the screw sleeve with support of the vice. 12_168 - Spring retainer - screw sleeve - DU-bush 12_169...
Page 871 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly holder compression Clamp the compression holder in the vice and unscrew the check-valve nut. (size 17) Version with a locking: remove the locking with a file. 12_124 Remove the check-valve nut.
Page 872 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove the check-valve shim. 12_127 Disassemble the compression piston with O-ring. Pay attention to the assembling direction!!! 12_128 Place a screwdriver on top of the holder and remove the entire shim packet. 12_129...
Page 873 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassemble the O-ring. 12_130 Remove the copper washer. 12_131 - Holder compression - copper washer - O-ring - shims compression - piston compression with O- 12_132 ring - shim check-valve - spring check-valve - nut check-valve...
Page 874 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assembling holder compression Replace copper washer. 12_133 Assemble the O-ring. 12_134 Replace the entire shim packet. 12_135...
Page 875 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Replace piston. Pay attention to the assembling direction!!! 12_136 Replace shim check-valve. 12_137 Replace spring check-valve. Pay attention to the assembling direction!!! 12_138...
Page 876 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Wetting the thread of the nut with T132 and tighten it... 12_140 ...to a torque of 5Nm. 12_141 Check if the spring is correctly placed in the chamber of the nut. 12_142...
Page 877 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Disassembly tap rebound Clamp the piston-rod (at the level where the hydraulic stop is mounted) in T508S and unscrew the rebound tap. (Size 17) 12_143 Remove the rebound tap “complete”. 12_144/ 145/146 - posterize...
Page 878 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Pull the rebound needle with spring out of the tap rebound. 12_148 Check the O-ring. 12_149 Pay attention to the position of the triangular shims on the piston!!! Clamp the tap in the vice and unscrew the nut.
Page 879 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove the nut. Pay attention to the assembling direction!!! 12_151 Place a screwdriver on top of the tap and remove the entire shim packet. 12_152 Remove piston rebound. Pay attention to the assembling direction!!! 12_153...
Page 880 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Remove check-valve shims. 12_154 Remove spring check-valve. 12_155 - Rebound adjustment needle with O-ring - spring - tap rebound - spring check-valve 12_156 - shims check-valve - piston rebound - shims - nut M6x0.5...
Page 881 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assembling tap rebound Assemble the spring and shims check- valve. 12_157 Assemble the piston rebound. Pay attention to the assembling direction!!! 12_158 Replace the shims. Pay attention to the position of the triangular shims on the piston!!! 12_159...
Page 882 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Wetting the thread of the nut with T132. Screw the nut on the tap... 12_160 ...tighten the nut to a torque of 5 Nm. 12_161 Grease the O-ring of the adjustment needle with T158.
Page 883 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Mount the needle with spring into the tap rebound. 12_163...
Page 884 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assembling cartridge Press with T507 the DU-bush into the screw sleeve. 12_171 Clamp the piston-rod in T508S. At the level where the hydraulic stop is mounted. 12_172 Wetting the thread with T131. And screw the tap in the piston-rod.
Page 885 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Tighten the tap rebound. 12_174 Clamp the piston-rod “not too tight” in at the other side and replace the screw sleeve with spring retainer. 12_175 Screw the hydraulic stop “hand tight” to the end of the thread of the piston-rod.
Page 886 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Clamp the tube with plug in the clamping block (T508S and T509) and assemble the piston-rod “cpl.” into the tube. Guide the piston ring!!! 12_177 Before assembling wet the thread of the screw sleeve with T131.
Page 887 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assembling forkleg Replace a new O-ring in the groove of the axle-clamp. 12_180 Wetting the thread of the axle-clamp with T132. 12_181 Wetting the thread of the inner-tube with T132.
Page 888 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the inner-tube in the axle- clamp. 12_183 Screw very tight the inner-tube with T503S / T1404S. 12_184 Apply the dust wiper with T511. 1 4 _ 0 0 0 7...
Page 889 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Place (4357) T512 / (4860) T1401 over the inner-tube and assemble the dust wiper. 14_0008 Replace the circlip. 14_0011 Apply the innerside of the oilseal with T511 and the outerside with frontfork oil. 14_0010...
Page 890 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the oilseal. Pay attention to the assembling direction!!! 14_0012 Remove the tool and replace the support ring. 12_190 Assemble both DU-bushes. 12_191 14_0013...
Page 891 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Slide carefully the outer-tube over the inner-tube. 12_193 Assemble with (4357) T502S / (4860) T1402S the DU-bush -with the flat side- and... 12_194 ...tap or push it into the outer-tube. 12_195...
Page 892 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Use the other side of T502S / T1402S... 12_196 ...and tap the oilseal into the outer-tube. 12_197 Assemble the circlip into the groove of the outer-tube. Important: Check this very carefully!!! 12_198...
Page 893 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the dust wiper with T502S / T1402S. 12_199 Place the cartridge into the forkleg. Apply the O-ring of the compression piston with frontfork oil. 12_202...
Page 894 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Assemble the cartridge in the center of the axle-clamp and tighten the holder compression to a torque of 25Nm. 12_203 Assemble the adjustment tube with the O-ring into the piston-rod. 12_204...
Page 895 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Keep the outer-tube down and the piston- rod a little bit extended (like picture), fill the forkleg with oil till the edge of the outer-tube, wait a few moments, you will see air bubbles rising 12_206 The oil must stay above the 4 holes of...
Page 896 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Pull the piston-rod out and assemble the spring. 12_211 Pull the spring downwards and place open-end spanner 22 on the hydraulic stop. 12_212 Replace first the steel washer on the spring, then the preload spacer(s).
Page 897 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Turn the adjusting knob completely to the left. 12_220 12_214 Screw handtight the screw-cap on the piston-rod. 12_221 12_215 Screw down the screw-cap, till the hydr. stop is against the screw-cap and tighten it to a torque of 20Nm.
Page 898 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Pull the spring downwards and remove the spanner. 12_223 12_217 Tighten the screw-cap to a torque of 25Nm. Use T103 with the PA version. 12_224 12_218 Position rebound! 12_225 12_219...
Page 899 Workshop manual 4357 / 4860 MXMA Product Exploded View Disassembly & Assembling Position compression! And replace the rubber cap. 12_226...

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KTM 125 SX 2010 Owner's Manual

Owner's Manual 2010

Technical Data - Engine Tightening Torques

Adjusting the Spring Preload of the Shock Absorber Adjusting the Riding Sag X

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