KTM 250 EXC AUS Manuals

Manuals and User Guides for KTM 250 EXC AUS. We have 3 KTM 250 EXC AUS manuals available for free PDF download: Repair Manual, Owner's Manual

KTM 250 EXC AUS Repair Manual

KTM 250 EXC AUS Repair Manual (289 pages)

Brand: KTM | Category: Motorcycle | Size: 12.59 MB

Table of Contents

Table of Contents
4
Table of Contents 2
4
1 Means of Representation

8
- Symbols Used
  8
- Formats Used
  8
2 Safety Advice

9
- Repair Manual
  9
- Degrees of Risk and Symbols
  9
- Work Rules
  9
3 Important Information

10
- Guarantee, Warranty
  10
- Operating and Auxiliary Substances
  10
- Spare Parts, Accessories
  10
- Figures
  10
4 Serial Numbers

11
- Chassis Number
  11
- Type Label
  11
- Engine Number
  11
- Fork Part Number
  11
- Shock Absorber Part Number
  11
5 Motorcycle

12
6 Fork, Triple Clamp

14
7 Handlebar, Controls

56
8 Frame

59
- Removing the Engine Guard (250/300 SIX DAYS)
  59
- Installing the Engine Guard (250/300 SIX DAYS)
  59
9 Shock Absorber, Swingarm

60
10 Exhaust

83
11 Air Filter

85
12 Fuel Tank, Seat, Trim

87
- Opening the Filler Cap
  87
- Closing the Filler Cap
  87
- Removing the Seat
  87
- Mounting the Seat
  88
- Removing the Fuel Tank
  88
- Installing the Fuel Tank
  89
- Fuel Tap
  90
13 Mask, Fender

91
14 Wheels

93
15 Wiring Harness, Battery

103
- Plug-In Connection, Ignition Timing Map
  103
- Removing the Main Fuse
  103
- Installing the Main Fuse
  103
- Recharging the Battery
  103
- Disconnecting the Negative Cable of the Battery
  104
- Connecting the Negative Cable of the Battery
  105
- Removing the Battery
  105
- Installing the Battery
  106
- Checking the Charging Voltage
  106
- Checking the Closed Current
  106
- Checking the Starter Relay
  107
16 Brake System

108
17 Lighting System, Instruments

119
- Checking the Headlight Setting
  119
- Adjusting the Headlight Range
  119
- Exc Eu/Aus, XC-W
  119
- Speedometer Overview
  119
- Activation and Test
  120
- Setting Kilometers or Miles
  120
- Adjusting the Speedometer Functions
  120
- Setting the Clock
  121
- Activating the Additional Functions
  121
- Setting the Wheel Circumference
  122
- Querying Lap Time
  122
- 250/300 Six Days
  123
- Speedometer Overview
  123
- Activation and Test
  123
- Setting Kilometers or Miles
  123
- Setting the Speedometer Functions
  124
- Setting the Clock
  124
- Setting the Wheel Circumference
  125
- Viewing the Lap Time
  125
18 Engine

126
- Removing the Engine
  126
- Installing the Engine
  130
- Engine Disassembly
  135
- Clamping the Engine into the Engine Work Stand
  135
- Draining the Gear Oil
  135
- Removing the Clutch Push Rod
  135
- Removing the Shift Lever
  135
- Removing the Engine Sprocket
  135
- Removing the Spacer
  136
- Removing the Starter Motor
  136
- Removing the Kick Starter
  137
- Removing the Cylinder Head
  138
- Removing the Cylinder
  138
- Removing the Piston
  139
- Removing the Water Pump Cover
  140
- Removing the Clutch Cover
  140
- Removing the Clutch Discs
  140
- Removing the Clutch Basket
  141
- Removing the Kick Starter Shaft
  142
- Removing the Intermediate Kick Starter Gear
  142
- Removing the Shift Shaft
  143
- Removing the Shift Drum Locating Unit
  143
- Removing the Locking Lever
  143
- Removing the Rotor
  143
- Removing the Reed Valve Housing
  144
- Removing the Left Engine Case Section
  144
- Removing the Shift Rails
  144
- Removing the Shift Drum
  145
- Removing the Shift Forks
  145
- Removing the Transmission Shafts
  145
- Removing the Crankshaft
  145
- Work on Individual Parts
  146
- Work on the Right Section of the Engine Case
  146
- Work on the Left Section of the Engine Case
  147
- Removing the Crankshaft Bearing Inner Race
  147
- Installing the Crankshaft Bearing Inner Race
  148
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin
  148
- Checking the Crankshaft Run-Out at the Bearing Pin
  149
- Checking/Measuring the Cylinder
  149
- Removing the Exhaust Control
  150
- Checking the Exhaust Control
  152
- Installing the Exhaust Control
  152
- Cylinder - Nikasil ® Coating
  154
- Checking/Measuring the Piston
  155
- Checking the Piston Ring End Gap
  156
- Piston/Cylinder - Measuring the Mounting Clearance
  156
- Checking the Reed Valve Housing, Reed Valve, and Intake Flange
  157
- Work on the Clutch Cover
  157
- Checking the Clutch
  161
- Preassembling the Shift Shaft
  162
- Checking the Shift Mechanism
  163
- Disassembling the Main Shaft
  164
- Disassembling the Countershaft
  165
- Checking the Transmission
  165
- Assembling the Main Shaft
  166
- Assembling the Countershaft
  167
- Checking the Kick Starter
  169
- Preassembling the Kick Starter Shaft
  169
- Checking the Electric Starter Drive
  171
- Engine Assembly
  172
- Installing the Crankshaft
  172
- Installing the Transmission Shafts
  172
- Installing the Shift Forks
  173
- Installing the Shift Drum
  173
- Installing the Shift Rails
  173
- Installing the Left Engine Case Section
  173
  - Installing the Reed Valve Housing
    174
  - Installing the Rotor
    174
  - Installing the Locking Lever
    175
  - Installing the Shift Drum Locating Unit
    175
  - Installing the Shift Shaft
    175
  - Installing the Intermediate Kick Starter Gear
    175
  - Installing the Kick Starter Shaft
    175
  - Installing the Clutch Basket
    176
  - Installing the Clutch Discs
    177
  - Installing the Clutch Cover
    178
  - Installing the Water Pump Cover
    179
  - Installing the Piston
    179
  - Installing the Cylinder
    180
  - Checking the X-Distance
    181
  - Adjusting the X-Distance
    182
  - Adjusting the Z-Distance
    182
  - Installing the Cylinder Head
    184
  - Installing the Kick Starter
    184
  - Installing the Starter Motor
    184
  - Installing the Spacer
    186
  - Installing the Engine Sprocket
    186
  - Installing the Shift Lever
    186
  - Installing the Clutch Push Rod
    187
  - Installing the Gear Oil Drain Plug
    187
  - Removing the Engine from the Work Stand
    187
19 Carburetor

188
- Choke
  188
- Carburetor - Adjusting the Idle Speed
  188
- Emptying the Carburetor Float Chamber
  189
- Removing the Carburetor
  189
- Installing the Carburetor
  190
- Checking/Adjusting the Carburetor Components
  191
- Disassembling the Carburetor
  192
- Checking the Choke Slide
  193
- Checking the Jet Needle
  193
- Checking the Throttle Slide
  193
- Checking the Float Needle Valve
  194
- Assembling the Carburetor
  194
- Checking/Adjusting the Float Level
  195
20 Clutch

196
- Checking/Correcting the Fluid Level of the Hydraulic Clutch
  196
- Changing the Hydraulic Clutch Fluid
  196
21 Water Pump, Cooling System

197
- Cooling System
  197
- Checking the Antifreeze and Coolant Level
  197
- Checking the Coolant Level
  197
- Draining the Coolant
  198
- Refilling with Coolant
  198
22 Exhaust Control

200
- Engine Characteristic - Setting the Auxiliary Spring
  200
23 Lubrication System

201
- Changing the Gear Oil
  201
- Draining the Gear Oil
  201
- Refilling with Gear Oil
  202
- Checking the Gear Oil Level
  202
- Adding Gear Oil
  202
24 Ignition System

204
25 Electric Starter

209
- Checking the Starter Motor
  209
26 Technical Data

210
- Engine
  210
- All 250 Models
  210
- All 300 Models
  210
- Engine Tolerance, Wear Limits
  211
- Engine Tightening Torques
  212
- Capacities
  212
- Gear Oil
  212
- Coolant
  212
- Fuel
  213
- Chassis
  213
- Electrical System
  214
- Tires
  214
- Fork
  214
- Exc Eu/Aus, XC-W
  214
- 250/300 Six Days
  215
- Shock Absorber
  215
- Chassis Tightening Torques
  216
- Carburetor
  217
- Exc Eu, 250 Exc Six Days Eu
  217
- Exc aus
  217
- XC-W Usa
  217
- Exc Eu, 300 Exc Six Days Eu
  217
- Exc aus
  218
- XC-W Usa, 300 XC-W Six Days Usa
  218
- Carburetor Tuning
  219
- Carburetor Tuning (All 250 Models)
  219
- Carburetor Tuning (All 300 Models)
  220
- General Carburetor Tuning
  221
27 Cleaning, Care

222
- Cleaning the Motorcycle
  222
- Checks and Maintenance Steps for Winter Operation
  223
28 Storage

224
- Preparing for Use after Storage
  224
29 Service Schedule

225
- Service Work (as Additional Order)
  226
30 Wiring Diagram

228
- 250 Exc Eu, 300 Exc Eu)
  228
- 250 Exc Eu, 300 Exc Eu)
  230
- 250 Exc Eu, 300 Exc Eu)
  232
- 250 Exc Eu, 300 Exc Eu)
  234
- 250 Exc Eu, 300 Exc Eu)
  236
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)
  238
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)
  240
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)
  242
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)
  244
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)
  246
- 250/300 Exc Aus)
  248
- 250/300 Exc Aus)
  250
- 250/300 Exc Aus)
  252
- 250/300 Exc Aus)
  254
- 250/300 Exc Aus)
  256
- 250 XC-W Usa, 300 XC-W Usa)
  258
- 250 XC-W Usa, 300 XC-W Usa)
  260
- 250 XC-W Usa, 300 XC-W Usa)
  262
- 300 XC-W Six Days Usa)
  264
- Page 1 of 3 (300 XC‑W SIX DAYS USA)
  264
- 300 XC-W Six Days Usa)
  266
- Page 2 of 3 (300 XC‑W SIX DAYS USA)
  266
- 300 XC-W Six Days Usa)
  268
- Page 3 of 3 (300 XC‑W SIX DAYS USA)
  268

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KTM 250 EXC AUS Owner's Manual

KTM 250 EXC AUS Owner's Manual (139 pages)

201 year

Brand: KTM | Category: Motorcycle | Size: 4.41 MB

Table of Contents

Table of Contents
4
1 Means of Representation

7
- Symbols Used
  7
- Formats Used
  7
2 Safety Advice

8
- Use Definition - Intended Use
  8
- Degrees of Risk and Symbols
  8
- Tampering Warning
  8
- Safe Operation
  9
- Protective Clothing
  9
- Work Rules
  9
- Environment
  9
- Owner's Manual
  9
3 Important Notes

10
- Guarantee, Warranty
  10
- Operating and Auxiliary Substances
  10
- Spare Parts, Accessories
  10
- Service
  10
- Figures
  10
- Customer Service
  10
4 View of Vehicle

11
- View of Vehicle, Front Left (Example)
  11
- View of Vehicle, Rear Right (Example)
  12
5 Serial Numbers

13
- Chassis Number
  13
- Type Label
  13
- Key Number (All EXC Models)
  13
- Engine Number
  13
- Fork Part Number
  13
- Shock Absorber Part Number
  14
6 Controls

15
- Clutch Lever
  15
- Hand Brake Lever
  15
- Throttle Grip
  15
- Kill Switch (All EXC Models)
  15
- Kill Switch (XC-W)
  16
- Horn Button (All EXC Models)
  16
- Light Switch (All EXC Models)
  16
- Light Switch (XC-W)
  16
- Turn Signal Switch (All EXC Models)
  16
- Emergency off Switch (EXC AUS)
  17
- Electric Starter Button (200/250/300 EXC EU, 250/300 EXC SIX DAYS EU, XC-W)
  17
- Electric Starter Button (EXC AUS)
  17
- Overview of Indicator Lamps (All EXC Models)
  17
- Speedometer
  17
- Overview
  17
- Activation and Test
  18
- Tripmaster Switch
  18
- Setting Kilometers or Miles
  18
- Adjusting the Speedometer Functions
  18
- Setting the Clock
  19
- Querying Lap Time
  19
- Display Mode SPEED (Speed)
  20
- Display Mode SPEED/H (Operating Hours)
  20
- Display Mode SPEED/CLK (Clock)
  20
- Display Mode SPEED/LAP (Lap Time)
  21
- Display Mode SPEED/ODO (Odometer)
  21
- Display Mode SPEED/TR1 (Trip Master 1)
  21
- Display Mode SPEED/TR2 (Trip Master 2)
  21
- Display Mode SPEED/A1 (Average Speed 1)
  22
- Display Mode SPEED/A2 (Average Speed 2)
  22
- Display Mode SPEED/S1 (Stop Watch 1)
  22
- Display Mode SPEED/S2 (Stop Watch 2)
  23
- 6.14.19 Table of Functions
  23
- 6.14.20 Table of Conditions and Menu Activation
  23
- Opening the Filler Cap
  24
- Closing the Filler Cap
  24
- Fuel Tap
  25
- Choke
  25
- Shift Lever
  25
- Kick Starter
  26
- Foot Brake Lever
  26
- Side Stand
  26
- Steering Lock (All EXC Models)
  26
- Locking the Steering (All EXC Models)
  27
- Unlocking the Steering (All EXC Models)
  27
7 Preparing for Use

28
8 Riding Instructions

33
- Checks and Maintenance Work When Preparing for Use
  33
- Starting
  33
- Start off
  34
- Shifting, Riding
  34
- Braking
  34
- Stopping, Parking
  35
- Transport
  35
- Refueling
  36
9 Service Schedule

37
- Service Work (as Additional Order)
  38
10 Tuning the Chassis

39
11 Service Work on the Chassis

48
12 Brake System

75
13 Wheels, Tires

84
- Removing the Front Wheel
  84
- Installing the Front Wheel
  84
- Removing the Rear Wheel
  85
- Installing the Rear Wheel
  85
- Checking the Tire Condition
  86
- Checking the Tire Air Pressure
  87
- Checking the Spoke Tension
  87
14 Electrical System

89
15 Cooling System

96
16 Tuning the Engine

100
17 Service Work on the Engine

105
- Checking the Gear Oil Level
  105
- Changing the Gear Oil
  105
- Draining the Gear Oil
  106
- Refilling with Gear Oil
  106
- Adding Gear Oil
  107
18 Cleaning, Care

109
- Cleaning the Motorcycle
  109
- Checks and Maintenance Steps for Winter Operation
  110
19 Storage

111
- Preparing for Use after Storage
  111
20 Troubleshooting

112
21 Technical Data

114
- Engine
  114
- Exc Eu, 125 Exc Six Days Eu
  114
- All 200 Models
  114
- All 250 Models
  115
- All 300 Models
  115
- Engine Tightening Torques
  116
- All 125/200 Models
  116
- All 250/300 Models
  117
- Capacities
  118
- Gear Oil
  118
- Coolant
  118
- Fuel
  118
- Chassis
  118
- Electrical System
  119
- Tires
  119
- Fork
  120
- EXC EU, All 200 Models
  120
- 250/300 Exc Eu, 250/300 Exc Aus, 250/300 XC-W
  120
- Exc Six Days Eu
  121
- Shock Absorber
  122
- All 125/200 Models
  122
- All 250/300 Models
  122
- Chassis Tightening Torques
  123
- Carburetor
  124
- 21.10.1 125 Exc Eu, 125 Exc Six Days Eu
  124
- 21.10.2 200 Exc Eu
  124
- 21.10.3 200 Exc aus
  124
- 21.10.4 200 XC-W Usa
  124
- 21.10.5 250 Exc Eu, 250 Exc Six Days Eu
  125
- 21.10.6 250/300 Exc aus
  125
- 21.10.7 250 XC-W Usa
  125
- 21.10.8 300 Exc Eu, 300 Exc Six Days Eu
  126
- 21.10.9 300 XC-W Usa
  126
- Carburetor Tuning (125 EXC EU, 125 EXC SIX DAYS EU)
  126
- Carburetor Tuning (All 200 Models)
  127
- Carburetor Tuning (All 250 Models)
  128
- Carburetor Tuning (All 300 Models)
  129
- General Carburetor Tuning 16.7 Adjusting the Basic Position of the Shift 22
  131

KTM 250 EXC AUS Owner's Manual

KTM 250 EXC AUS Owner's Manual (136 pages)

2012 Motorcycle

Brand: KTM | Category: Motorcycle | Size: 4.26 MB

Table of Contents

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