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12 service work on the chassis

1. 7 21 Display mode SPEED S1 stop watch 1 Repeatedly press the button briefly until S1 appears at the top right of the dis play S1 Stop watch 1 shows the riding time based on TR1 and continues running as soon S as an impulse arrives from the wheel speed sensor mnm wc The calculation of this value starts with the first impulse from the wheel speed sensor LILI te ae and ends 3 seconds after the last impulse Press the button Displays of TR1 A1 and S1 are reset to 0 0 for 2 3 seconds ican Briefly press the Next display mode button Press the button No function for 2 3 seconds Briefly press the No function button 7 22 Display mode SPEED S2 stop watch 2 Repeatedly press the button briefly until S2 appears at the top right of the dis play S2 Stop watch 2 is a manual stop watch g If S2 is running in the background the display S2 flashes on the speedometer nne a Press the button The displays of S2 and A2 are set to 0 0 A for 2 3 seconds Briefly press the Next display mode button 400328 0 Press the button No function for 2 3 seconds Briefly press the Starts or stops S2 button 7 23 Table of functions Display Press the but Briefly press the Press the but Briefly press the Wait 3 5 sec Wait 10 12 sec ton for 2 3 button ton for 2 3 button onds onds seconds seconds Display mo
2. Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc Remove the motorcycle from the lift stand p 50 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft Preparatory work Raise the motorcycle with the lift stand p 50 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut O Remove chain adjuster O Withdraw wheel spindle e only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket e Info I Protect the components against damage by covering them Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm e Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers Oo 14 WHEELS TIRES 88 T Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil
3. Loosen nut 2 and with push rod turn it back until you have maximum free travel To adjust the basic position of the foot brake lever to individual requirements loosen nut o and turn screw O accordingly e Info The range of adjustment is limited Turn push rod e accordingly until you have free travel O If necessary adjust the basic position of the foot brake lever M00595 10 Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw O and tighten nut O Guideline Nut foot brake lever stop M8 20 Nm 14 8 Ibf ft Hold push rod e and tighten nut e Guideline Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Reconnect spring O Warning Danger of accidents Brake system failure Ifthe brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Stand the vehicle upright Check the brake fluid level in the viewer Ifthe fluid has droppe
4. sssssssss Checking the routing of the throttle cable Checking the rubber grip sseeessses Additionally securing the rubber grip 12 40 12 41 12 42 12 43 12 44 12 45 Adjusting the basic position of the clutch LOVED scan ase 12 46 Checking correcting the fluid level of the hydra lic Clannad as Changing the hydraulic clutch fluid 4 12 47 12 48 Removing the engine guard Six Days EXC Factory Edition Js uti ire 12 49 Installing the engine guard Six Days EXC Factory Edition ccccccnncccccnnnononononinnnnnnns BRAKE SYSTEM 3 ips o iii 13 1 Checking the free travel of the hand brake aaa iaa 13 2 Adjusting free travel of hand brake lever All EXC models 2 5 ntes distet e eire minced eii 13 3 Adjusting the basic position of the hand brake lever All XC W models eeeeeeeee Checking the brake discs sssss Checking the front brake fluid level Adding front brake fluid ssssssuuus Checking the front brake linings Changing the front brake linings Checking the free travel of foot brake lever 13 4 13 5 13 6 13 7 13 8 13 9 13 10 Adjusting the basic position of the foot brake 13 11 13 12 13 13 13 14 Changing the brake linings of the rear brake 2s eec dene coner nes
5. 602720 11 12 SERVICE WORK ON THE CHASSIS 67 Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 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 The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Main work Check the routing of the throttle cable p 72 Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables are trapped or damaged Mount the fuel tank vent hose Mount and tighten screw with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft All EXC models Position the horn with the horn bracket Mount and tighten screws with the c
6. Using a coin turn protection cap 2 all the way counterclockwise and remove it Remove speedometer battery 6 Insert the new battery with the label facing upward Speedometer battery CR 2430 p 121 Check the O ring of the protection cap for correct seating Position protection cap e and turn all the way clockwise using a coin Press any button on the speedometer Y The speedometer is activated Position the speedometer in the holder Mount and tighten the screws with washers 602747 10 Finishing work Refit the headlight mask with the headlight p 94 Check the headlight setting p 96 Set kilometers or miles p 21 Set the speedometer functions p 22 Set the clock 7 p 22 16 COOLING SYSTEM 98 All 125 200 models Water pump o in the engine circulates the coolant The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap O This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect All 250 300 models Water pump amp b in the engine circulates the coolant The pressure resulting from the warming of the cooling system is regulated by a va
7. 22 1 2 All 200 models Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 193 cm 11 78 cu in Stroke 60 mm 2 36 in Bore 64 mm 2 52 in Crankshaft bearing 1 grooved ball bearing 1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 47 mm 1 85 in Primary transmission 23 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmission ratio lst gear 12 33 2nd gear 15 31 3rd gear 17 28 4th gear 19 26 22 TECHNICAL DATA 117 5th gear 17 19 6th gear 22 20 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Ignition point BTDC 1 6 mm 0 063 in Spark plug NGK BR 8 EG Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter and electric starter 22 1 3 All 250 models Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 249 cm 15 19 cu in Stroke 72 mm 2 83 in Bore 66 4 mm 2 614 in Exhaust valve Beginning of adjus
8. 7 5 Setting the clock 400330 0 7 6 Viewing the lap time menu is closed Repeatedly press the button briefly until the desired function flashes Y The selected function flashes Activating the function Press the button Y The symbol continues to appear in the display and the next function appears Deactivating a function Press the button Y The symbol disappears in the display and the next function appears Condition The motorcycle is stationary Repeatedly press the button briefly until CLK appears at the bottom right of the display Press the button for 2 3 seconds Y The hour display flashes Set the hour display with the button and or button Wait 3 5 seconds Y The next segment of the display flashes and can be set You can set the following segments in the same way as the hours by pressing the button and the button e Info I The seconds can only be set to zero If no button is actuated for 15 20 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the Setup menu is closed e Info This function can only be opened if lap times have actually been timed Condition The motorcycle is stationary 7 SPEEDOMETER 23 Repeatedly press the button briefly until LAP appears at the bottom right of the display Briefly press the button
9. Does not apply to sand surfaces 22 TECHNICAL DATA 22 10 11 300 EXC EU 300 EXC Six Days EU 300 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K N8RG N8RH Main jet 115 170 172 175 Idling jet 38X38 35 Starting jet 50 85 Idle air adjusting screw Open 1 75 turns Throttle slide 7 with cut out Slide stop Present 22 10 12 300 EXC AU Carburetor type KEIHIN PWK 36S AG Carburetor identification number 3600 Needle position 1 Position from top Jet needle N3CJ N8RG N8RH N2ZH N2ZJ N2ZW Main jet 160 170 172 175 Idling jet 35 38 40 Starting jet 85 Idle air adjusting screw Open 3 5 turns Throttle slide 7 with cut out Slide stop Present 22 10 13 300 XC W Six Days US 300 XC W US 300 EXC BR Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ7 Needle position 3rd position from top Jet needle N8RG N8RH Main jet 172 170 175 Idling jet 35 Starting jet 85 Idle air adjusting screw Open 2 0 turns Throttle slide 7 with cut out Slide stop 22 10 14 Carburetor tuning All 300 models Danger Al Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous
10. Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Setting TR2 trip master 2 Display mode SPEED A1 average speed 1 Display mode SPEED A2 average speed 2 Display mode SPEED S1 stop watch 1 Display mode SPEED S2 stop watch 2 8 PREPARING FOR USE 30 8 1 Advice on first use Danger Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired 0 Warning Risk of injury Missing or poor protective clothing presents an increased safety risk A A di nin A Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Critical riding behavior due to inappropriate riding Adapt your riding speed to the road conditions and your riding ability Danger of accidents Accident risk caused by presence of a passenger Your vehicle is not designed to carry passengers Do not ride with
11. Install the shock absorber 4 p 61 Remove the motorcycle from the lift stand p 50 Preparatory work Raise the motorcycle with the lift stand p 50 Remove the shock absorber 4 p 61 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guideline All 125 200 models Spring rate Weight of rider 65 75 kg 63 N mm 360 Ib in 143 165 Ib Weight of rider 75 85 kg 66 N mm 377 Ib in 165 187 Ib Weight of rider 85 95 kg 69 N mm 394 Ib in 187 209 Ib All 250 300 models Spring rate Weight of rider 65 75 kg 66 N mm 377 Ib in 143 165 Ib Weight of rider 75 85 kg 69 N mm 394 Ib in 165 187 Ib Weight of rider 85 95 kg 72 N mm 411 Ib in 187 209 Ib e Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber 4 p 61 Remove the motorcycle from the lift stand p 50 Check the static sag of the shock absorber p 43 Check the riding sag of the shock absorber p 44 Adjust the rebound damping of the shock absorber p 42 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the forks 11 TUNING THE CHASSIS 46 As with the shock absorber smaller differences in the rider s we
12. Only operate the vehicle when it is in perfect technical condition in accordance with its intended use and in a safe and environmen tally compatible manner The vehicle should only be used by trained persons An appropriate driver s license is needed to ride the vehicle on public roads Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop Adhere to the information and warning labels on the vehicle Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing Special tools are necessary for certain tasks The tools are not contained in the vehicle but can be ordered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite9 is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complet
13. Remove cover with membrane 6 12 SERVICE WORK ON THE CHASSIS 75 Fill bleeding syringe o with the appropriate hydraulic fluid Bleed syringe 50329050000 Hydraulic fluid 15 7 p 136 On the slave cylinder of the clutch remove bleeder screw O and mount bleed ing syringe O Inject the liquid into the system until it escapes from hole Q 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 Correct the fluid level of the hydraulic clutch Guideline Fluid level under top edge of con 4 mm 0 16 in tainer Position the cover with the membrane Mount and tighten the screws All 250 300 models Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws O Remove cover 2 with membrane Fill bleeding syringe o with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 135 On the slave cylinder of the clutch remove bleeder screw O and mount bleed ing syringe O Inject the liquid into the system until it escapes from hole QO of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and ti
14. p 109 Mount and tighten the screw in the opening used to check the gear oil level Guideline Screw gear oil level check M6 10 Nm 7 4 Ibf ft All 250 300 models Remove screw O from the opening used to check the gear oil level Check the gear oil level A small quantity of gear oil should flow out of the opening y AN 2 If gear oil does not flow out Qo Add gear oil A p 109 Mount and tighten the screw in the opening used to check the gear oil level Guideline Screw gear oil level check M6 10 Nm 7 4 Ibf ft Drain the gear oil 4 p 108 400721 01 Refill with gear oil 4 p 108 400722 01 18 SERVICE WORK ON THE ENGINE 108 183 Draining the gear oila 0 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 Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations e Info Only drain the gear oil while the engine is warm Preparatory work Park the motorcycle on a level surface Place a suitable container under the engine Main work All 125 200
15. Do not allow fuel to get into the ground water the ground or the sewage system Press release button O turn the filler cap counterclockwise and lift it free Um a Replace the filler cap and turn clockwise until the release button o locks in place e Info Run the fuel tank breather hose 12 without kinks The fuel tap is on the left side of the fuel tank Tap handle 1 on the fuel tap is used to open or close the supply of fuel to the carbu retor Possible states e Fuel supply closed OFF Fuel cannot flow from the fuel tank to the carburetor e Fuel supply open ON Fuel can flow from the fuel tank to the carburetor The fuel tank empties to the point of reserve capacity e Open the fuel reserve supply RES Fuel can flow from the fuel tank to the carbu retor The fuel tank empties fully 602702 10 6 CONTROLS 18 The choke lever O is fitted on the left side of the carburetor Activating the choke function frees an opening in the carburetor through which the engine can draw extra fuel This creates a richer fuel air mixture as is required for a cold start e Info If the engine is warm the choke function must be deactivated Possible states e Choke function activated The choke lever is pulled out all the way e Choke function deactivated The choke lever is pushed in all the way Shift lever is mounted on the left side of the engine 401950 10
16. Mount the shift lever on the shift shaft in the required position and engage the gearing e Info The range of adjustment is limited a 2 QD The shift lever must not come into contact with any other vehicle compo DSA nents during the shift procedure 401951 10 Mount and tighten the screw Guideline Screw shift lever M6 14 Nm Loctite 243 10 3 Ibf ft 17 8 Engine characteristic auxiliary spring All 250 300 models The auxiliary spring is located on the right side of the engine below the water pump cover Possible states e Auxiliary spring with yellow marking Auxiliary spring mounted at the factory with medium tuning standard for good rideability e Auxiliary spring with green marking Auxiliary spring for softer performance con amp SV tained in the separate enclosure JJ Auxiliary spring with red marking Auxiliary spring for more aggressive perfor mance contained in the separate enclosure 800056 10 The engine characteristic can be influenced by different spring strengths of the auxil iary spring 17 9 Engine characteristic setting the auxiliary spring 4 All 250 300 models Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Preparator
17. Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Switch off all power consumers and the engine Remove the seat p 62 Main work Disconnect negative cable o from the battery Pull back positive terminal cover 2 and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the battery out 15 2 Installing the battery 4 All 200 250 300 models Main work Insert the battery into the battery compartment with the terminals facing to the front All 200 250 300 EU AU US models Battery YTX4L BS p 121 300 EXC BR Battery YTX5L BS p 121 Attach rubber band Q Position the positive cable and mount and tighten the screw Guideline Screw battery terminal M5 2 5 Nm 1 84 Ibf ft e Info Contact disks O must be mounted between screws o and cable sock ets with the claws facing down Slide positive terminal cover QO ove
18. Indicator lamps W2 3W socket W1x4 6d 12V 2 3W Turn signal All EXC models R10W socket BA15s 12V 10W Brake tail light LED License plate lamp W5W socket W2 1x9 5d 12V 5 W 22 TECHNICAL DATA 122 22 6 Tires Validity Front tires Rear tires 125 EXC EU 80 100 21 M C 51M TT 120 90 18 M C 65R TT MAXXIS MAXX CROSS SI PRO MAXXIS MAXX ENDURO 125 EXC Six Days EU 125 EXC Fac 90 90 21 M C 54M TT 120 90 18 M C 65M TT tory Edition EU Metzeler 6 DAYS EXTREME Metzeler 6 DAYS EXTREME 200 250 300 EXC EU AU 80 100 21 M C 51M TT 140 80 18 M C 70R TT MAXXIS MAXX CROSS SI PRO MAXXIS MAXX ENDURO 250 300 Six Days EU 90 90 21 M C 54M TT 140 80 18 M C 70M TT 250 300 EXC Factory Edition Metzeler 6 DAYS EXTREME Metzeler 6 DAYS EXTREME 300 EXC BR All XC W models 90 90 21 54M TT 110 100 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 Additional information is available in the Service section under http www ktm com 22 7 Fork 22 7 1 125 EXC EU all 200 models 125 EXC Factory Edition EU Fork part number 14 18 7L 61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 t
19. The compression damping is located in the left fork leg COMP white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp Position bleeder screws 1 toward the front 12 SERVICE WORK ON THE CHASSIS 53 EXC Factory Edition Position the fork legs Info e I Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp Position bleeder screws 1 toward the front M00592 10 EXC XC W Tighten screws e Guideline Screw top triple clamp M8 20 Nm 14 8 Ibf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 Ibf ft Six Days EXC Factory Edition Tighten screws e Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 Ibf ft Position the brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm Loctite 243 18 4 Ibf ft Mount cable binder b Position the brake line and wiring harness Put the clamp on and mount and tighten screws _800798 11 Finishing work Install the front wheel 4 9 p 86 Re
20. The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears o 401950 11 Kick starter 1 is fitted on the right side of the engine The top part of the kick starter pivots e Info o Before riding swing the top part of the kick starter inward toward the engine 401954 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 401956 10 6 CONTROLS 19 626 Side stand 00 The side stand 1 is on the left side of the vehicle 401943 10 The side stand is used to park the motorcycle e Info When you are riding side stand 1 must be folded up and secured with rubber band e 401944 10 Steering lock is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible B02143 10 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 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 Y Steering is no longer possible e Info Never leave the key in the steering lock 400732 01 6 6 29 CONTROLS Unl
21. o oooooooooo 77 free travel adjusting o oo o oooooooooooo 77 free travel checking 0000 e eee eee 77 Handlebar position o o o o o oooooo oo 48 adjusting cx tese Aere oA eae alee ded 49 Headlight range adjusting s vonaeduee Qe BE Alpe ane T sme 96 Headlight bulb changing 4 cso dote do eye o rx 95 Headlight mask with headlight installing rata Rm OR AT eR mS 94 lemoVvIHg s ice acne E eee RENE da 94 Headlight setting checking m EP CP a etd eee aed ded ato 96 Horn button 14 Intended use Key number 0 00002 eee ee eee 11 141 Kick startet aii joel Ae tala ween e 18 Kill Switch 2e onem eel aan A eS 13 14 Light Switch ea ERR 14 15 Lower triple clamp ihstallillg hata eae sae NES RE a Routed 55 57 removing aiu a enr AA Bee ee e les 54 Main fuse CHANING zr mma a CE RE 93 Main silencer glass fiber yarn filling changing 65 installing aa es e bn 65 removilB Morro E EG NEUES Gau 65 Motorcycle leaning i ep e a pd Lae a eig 111 raising with lift stand llle 50 removing from lift stand o o oo o o oo ooooo o 50 Operating substances 0 0 00 cece nee 8 Overview of indicator lamps 16 Owner s Manual 00 000 cee eee eee 7 Preparing for use advice on Wrst se is ane a Ba dowd ae te a oe 4 30 afterstordge o4 v EA Euer vare du 113 checks and maintenance work when pre
22. Loosen screw O Pull off the upper triple clamp with the han dlebar and hang it to one side e Info Protect the components against damage by covering them Do not bend the cables and lines B02149 10 Remove O ring e Remove protective ring O Take off the lower triple clamp with the steering stem Remove the upper steering head bearing Preparatory work Raise the motorcycle with the lift stand p 50 Remove the front wheel 4 p 86 Remove the headlight mask with the headlight p 94 Remove the fork legs A p 52 Remove the front fender p 60 Remove the handlebar cushion 12 SERVICE WORK ON THE CHASSIS 55 Main work Remove screw O Remove screw O Pull off the upper triple clamp with the han dlebar and hang it to one side e Info Protect the components against damage by covering them Do not bend the cables and lines Remove O ring e Remove protective ring O Take off the lower triple clamp with the steering stem Remove the upper steering head bearing Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 137 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the top steering head seal o is correctly positioned gt Mount protective ring e 500151 10 Position the uppe
23. No function for 2 3 seconds Briefly press the No function button SPEED co LIL Km h TR2 36 4 400324 0 Repeatedly press the button briefly until TR2 appears at the top right of the dis play TR2 trip master 2 runs constantly and counts up to 999 9 Press the button Clears the values TR2 and A2 for 2 3 seconds Briefly press the button Press the button for 2 3 seconds Next display mode Reduces value of TR2 Briefly press the Reduces value of TR2 button SPEED ZJ LIL Km h TR2 36 4 400324 0 Condition e The motorcycle is stationary Repeatedly press the button briefly until TR2 appears at the top right of the dis play Press the button for 2 3 seconds until TR2 flashes The displayed value can be set manually with the button and the button This is a very practical function when riding using the road book 7 SPEEDOMETER 27 Info The TR2 value can also be corrected manually during the journey with the but ton and the button If 999 9 is exceeded the value of TR2 is automatically reset to 0 0 Press the button for 2 3 seconds Increases value of TR2 Briefly press the button Increases value of TR2 Press the button for 2 3 seconds Reduces value of TR2 Briefly press the
24. cally changes to the ODO display mode The H display mode is suppressed during the journey Press the button The display changes to the Setup menu of the speedometer for 2 3 seconds functions Briefly press the Next display mode button Press the button No function for 2 3 seconds Briefly press the No function button 7 9 Setup menu Condition e The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds TRI TR M A2 St 82 Kmh Mph 000 LAP CLK H The Setup menu displays the active functions e Info Repeatedly press the button briefly until the desired function is opened 400344 0 If no button is pressed for 20 seconds the settings are automatically stored 7 SPEEDOMETER 7 10 TRI TR M A2 St 82 24 Briefly press the button Activates the flashing display and changes to the next display Press the button for 2 3 seconds No function Briefly press the button Deactivates the flashing display and changes to the next dis play Press the button for 2 3 seconds No function Wait 3 5 seconds Changes to the next display without changes Wait 10 12 sec onds Setup menu starts stores the settings and changes to H or obo MZ M IKmh Mhz 0D0 LAP CLK H AAN
25. membrane core plate EJOT DELTA PT 30x12 1 Nm 0 7 Ibf ft Screw membrane holder EJOT DELTA PT 35x25 1 Nm 0 7 Ibf ft Screw angle lever exhaust control M5 6 Nm 4 4 Ibf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 Ibf ft Screw crankshaft position sensor M5 6 Nm 4 4 Ibf ft Loctite 243 Screw exhaust control cap M5 5 Nm 3 7 Ibf ft Screw exhaust control cover M5 6 Nm 4 4 Ibf ft Screw locking lever M5 6 Nm 4 4 Ibf ft Loctite 243 Screw retaining bracket of exhaust M5 7 Nm 5 2 Ibf ft Loctite 27017 control Screw water pump wheel M5 6 Nm 4 4 Ibf ft Loctite 243 Screw alternator cover M6 8 Nm 5 9 Ibf ft Screw bearing retainer M6 10 Nm 7 4 Ibf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 Ibf ft Screw control flap exhaust control M6 10 Nm 7 4 Ibf ft Loctite 243 Screw engine case M6 10 Nm 7 4 Ibf ft Screw exhaust flange M6 8 Nm 5 9 Ibf ft Screw gear oil level check M6 10 Nm 7 4 Ibf ft Screw intake flange reed valve housing M6 10 Nm 7 4 Ibf ft Screw intermediate wheel bolt M6 8 Nm 5 9 Ibf ft Loctite 648 Screw kick starter spring M6 10 Nm 7 4 Ibf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 Ibf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4 Ibf ft Loctite 243 22 TECHNICAL DATA 120 Screw shift lever M6 14 N
26. 165 187 Ib 4 2 N mm 24 Ib in Weight of rider 85 95 kg 187 209 Ib 4 4 N mm 25 1 Ib in Fork length 940 mm 37 01 in Air chamber length 110538 mm 4 33 058 in Fork oil per fork leg 625 ml 21 13 fl oz Fork oil SAE 4 4860116651 p 135 22 1 3 125 EXC Six Days EU Fork part number 24 18 7N 61 Fork WP Suspension Up Side Down 4860 4CS Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Spring length with preload spacer s 470 mm 18 5 in Spring rate Weight of rider 65 75 kg 143 165 Ib 3 6 N mm 20 6 Ib in Weight of rider 75 85 kg 165 187 Ib 3 8 N mm 21 7 Ib in Weight of rider 85 95 kg 187 209 Ib 4 0 N mm 22 8 Ib in Fork length 932 mm 36 69 in Air chamber length 100 mm 3 94 in Oil capacity per fork leg 635 ml 21 47 fl oz Fork oil SAE 4 4860116651 p 135 22 7 4 250 300 Six Days Fork part number 24 18 7N 63 Fork WP Suspension Up Side Down 4860 4CS Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Spring length with preload spacer s 470
27. 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase All 125 200 models 1 471 10 mm 57 91 0 39 in Wheelbase All 250 300 models 1 482 10 mm 58 35 0 39 in Seat height unloaded 960 mm 37 8 in Ground clearance unloaded 355 mm 13 98 in Homologated weight without fuel approx All 125 models 95 kg 209 Ib Homologated weight without fuel approx 200 EXC EU 200 EXC AU 101 5 kg 223 8 Ib Homologated weight without fuel approx All 250 300 EXC EU AU models 300 EXC BR 104 kg 229 Ib Weight without fuel approx 200 XC W US 99 5 kg 219 4 Ib Weight without fuel approx 250 XC W US 101 9 kg 224 6 Ib Weight without fuel approx 300 XC W Six Days US 300 XC W US 102 1 kg 225 1 Ib Maximum permissible front axle load 145 kg 320 Ib Maximum permissible rear axle load 190 kg 419 Ib Maximum permissible overall weight 335 kg 739 Ib 22 5 Electrical system Battery YTXAL BS All 200 250 300 EU AU US models Battery voltage 12 V Nominal capacity 3 Ah maintenance free Battery 300 EXC BR YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah maintenance free Speedometer battery CR 2430 Battery voltage 3 V Fuse All 200 250 300 models 58011109110 10A Headlight HS1 socket BX43t 12V 35 35 W Parking light W5W socket W2 1x9 5d 12V 5W
28. Adjust the basic position of the hand brake lever p 77 13 2 Adjusting free travel of hand brake lever All EXC models Check the free travel of the hand brake lever p 77 Adjust the free travel of the hand brake lever with the adjustment screw O e Info I Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 13 3 Adjusting the basic position of the hand brake lever All XC W models Check the free travel of the hand brake lever p 77 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing screw e Info I Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar 602744 12 The range of adjustment is limited E Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 13 BRAKE SYSTEM 78 13 4 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the wo
29. Loctite 27017 22 TECHNICAL DATA 126 Screw top steering stem EXC XC W M8 20 Nm 14 8 Ibf ft Screw top steering stem Six Days M8 17 Nm 12 5 Ibf ft Loctite 243 EXC Factory Edition Screw top triple clamp EXC XC W M8 20 Nm 14 8 Ibf ft Screw top triple clamp Six Days M8 17 Nm 12 5 Ibf ft EXC Factory Edition Engine bracket screw M10 60 Nm 44 3 Ibf ft Remaining nuts chassis M10 45 Nm 33 2 Ibf ft Remaining screws chassis M10 45 Nm 33 2 Ibf ft Screw handlebar support M10 40 Nm 29 5 Ibf ft Loctite 243 Screw bottom shock absorber M12 80 Nm 59 Ibf ft Loctite 27017 Screw top shock absorber M12 80 Nm 59 Ibf ft Loctite 2701 Nut seat fixing M12x1 20 Nm 14 8 Ibf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 Ibf ft Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft Screw top steering head M20x1 5 12 Nm 8 9 Ibf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 Ibf ft Loctite 243 Screw front wheel spindle M24x1 5 45 Nm 33 2 Ibf ft 22 TECHNICAL DATA 22 10 Carburetor 22 10 1 All 125 models 127 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position Ath position from top Jet needle N84I N1EF N1EG Main jet 100 172 175 Idling jet 38x38 42 45 Starting jet 50 85 Idle air adjusting screw
30. Open 2 75 turns Throttle slide 7 with cut out Slide stop 22 10 2 Carburetor tuning All 125 models 4 Danger Al Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous reduced version only Inthe derestricted version the motorcycle must be used only on closed off property remote from public road traffic 22 TECHNICAL DATA KEIHIN PWK 36S AG 128 i 20 C 7 C x2 F 20 F 3676 D G 19 F 41 F 6C 15 C 42 F 60 F 16 C 24 C OLF cc POOF 25 C 36 C LIT q 98 F 37 C 49 C 99 F LOF 3 000 m 10 000 ft 2 301m 7 501 ft 1 5 42 NIEG 3 175 2 300 m 7 500 ft 1 501m 5 001 ft 1 5 45 NIEG 3 175 1 500 m 5 000 ft A 751m 2 501 ft 1 5 45 3 750 m 2 500 ft 4 301m 1 001 ft 300 m 1 000 ft Om 2 42 NIEG 3 172 402138 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open lJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces 22 TECHNICAL DATA 22 10 3 200 EXC EU 129 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK027 Needle position 3rd position from top Jet needle
31. Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Al Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning A Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken 0 Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning xt Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise c
32. are cleared when the unit of measure is changed TRI TR M A2 St 2 MY W Km h Mhz 000 LAP CLK H AA 400329 0 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds Y The Setup menu is displayed and the active functions are shown Repeatedly press the button briefly until Km h Mph flashes Setting the Km h Press the button Setting the Mph Press the button Wait 3 5 seconds Y The settings are stored e Info I If no button is actuated for 10 12 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the Setup menu is closed 1 SPEEDOMETER 22 7 4 Setting the speedometer functions e Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds Mem M MSS Y The Setup menu is displayed and the active functions are shown ANS e Info de h in SEPT I If no button is pressed for 10 12 seconds the settings are automatically stored If no button is actuated for 20 seconds or there is no signal from the wheel 400318 0 speed sensor then the settings are automatically stored and the Setup
33. attacks paint Use only clean brake fluid from a sealed container Position the vehicle vertically Remove screw cap 1 with membrane 2 and the O ring Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove cotter pins O pull out pin O and remove the brake linings Clean the brake caliper and brake caliper support 13 BRAKE SYSTEM 100407 10 400233 10 85 Check that leaf spring 5 in the brake caliper and sliding plate QO in the brake caliper support are seated correctly Insert the new brake linings insert the pin and mount the cotter pins e Info Always change the brake linings in pairs Operate the foot brake lever several times until the brake linings are lying against the brake disc and there is a pressure point Correct the brake fluid level to marking Brake fluid DOT 4 DOT 5 1 p 135 Mount screw cap 1 with membrane 2 and the O ring e Info Wash off overflowed or spilled brake fluid immediately with water 14 WHEELS TIRES 86 14 1 Removing the front wheel 4 Preparatory work Raise the motorcycle with the lift stand p 50 Main work Press the brake caliper onto the brake disc by hand in
34. button Reduces value of TR2 Wait 10 12 sec onds Saves and closes the Setup menu Repeatedly press the button briefly until Al appears at the top right of the dis play A1 average speed 1 shows the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode button Press the button No function for 2 3 seconds Briefly press the No function 7 19 Display mode SPEED A1 average speed 1 ces 400325 0 7 20 Display mode SPEED A2 average speed 2 Repeatedly press the button briefly until A2 appears at the top right of the dis 400326 0 play A2 average speed 2 shows the average speed on the basis of the current speed if the stop watch S2 stop watch 2 is running e Iinfo The displayed value can differ from the actual average speed if 2 was not stopped after the ride button Briefly press the Next display mode button Press the button No function for 2 3 seconds Press the button No function for 2 3 seconds Briefly press the No function 7 SPEEDOMETER 28
35. cylinder head and cylinder head gas ket Gear oil exits at the vent hose Too much gear oil added Check the gear oil level p 107 Water in the gear oil Damaged shaft seal ring or water pump Check the shaft seal ring and water pump 22 TECHNICAL DATA 22 1 Engine 22 1 1 All 125 models 116 Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 124 8 cm 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 Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 43 7 mm 1 72 in Primary transmission 23 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmission ratio lst gear 12 33 2nd gear 15 31 3rd gear 17 28 4th gear 19 26 5th gear 21 25 6th gear 20 20 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan 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 Kick starter
36. fork leg red adjust WAI a ing screw v mmn Turn counterclockwise by the number of clicks corresponding to the fork type Guideline 125 EXC Six Days EU Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks 11 TUNING THE CHASSIS 47 250 300 Six Days Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping 11 13 Adjusting the rebound damping of the fork e Info The hydraulic rebound damping determines the fork suspension behavior EXC XC W EXC Factory Edition e info Turn adjusting screws 1 clockwise all the way Adjusting screws 1 are located at the top end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline 7 B02145 10 125 EXC EU all 200 models 125 EXC Factory Edition EU Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks 250 300 EXC EU AU XC W US 250 300 EXC Factory Edition 300 EXC BR Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping Six Days Info adjusting screw B01207 10 Guideline 125 EXC Six Day
37. models Remove the gear oil drain plug with magnet O Remove gear oil drain plug O Completely drain the gear oil Clean the gear oil drain plug thoroughly Clean the sealing area on the engine Mount the gear oil drain plug with magnet 1 and the seal ring and tighten EMI Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Mount gear oil drain plug e with the seal ring and tighten Guideline Gear oil drain plug M10x1 15 Nm 11 1 Ibf ft All 250 300 models Remove the gear oil drain plug with magnet O Completely drain the gear oil Clean the gear oil drain plug with the magnet thoroughly Clean the sealing area on the engine Mount the gear oil drain plug with magnet amp and the seal ring and tighten Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft e Info Too little gear oil or poor quality oil results in premature wear of the transmission Main work 9 Remove filler plug o and fill up with gear oil rs Gear oil 0 701 0 74 qt Engine oil 15W 50 p 135 f ARAS All 125 200 models Gear oil 0 80 0 85 qt Engine oil 15W 50 p 135 All 250 300 mod SA els 401955 10 18 SERVICE WORK ON THE ENGINE 109 Mount and tighten the oil filler plug Danger Danger of poisoning Exhaust gases are toxic and inh
38. of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover e with membrane O Manually press the brake caliper toward the brake disc to push back the brake pis tons Ensure that brake fluid does not flow out of the brake fluid reservoir extract ing it by suction if it does e info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove cotter pins O pull out pin O and remove the brake linings Clean the brake caliper and brake caliper support M00111 10 13 BRAKE SYSTEM 81 Check that leaf spring QO in the brake caliper and sliding plate in the brake caliper support are seated correctly Insert the new brake linings insert the pin and mount the cotter pins e Info Always change the full set of brake linings Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point M00112 01 Correct the brake fluid quantity to level O Gui
39. side of the handlebar Possible states e Kill switch amp in basic position In this position the ignition circuit is closed and the engine can be started e Kill switch amp pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start Neo1585 10 6 CONTROLS 14 65 Kill switch Six Days EW The kill switch is fitted on the left side of the handlebar Possible states e Kill switch amp in the basic position In this position the ignition circuit is closed and the engine can be started e Kill switch amp is pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 102044 10 The kill switch is fitted on the left side of the handlebar Possible states e Kill switch amp in basic position In this position the ignition circuit is closed and the engine can be started e Kill switch amp pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start The horn button o is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position Neo1sss 12 The horn button is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button press
40. substances 2 0 0 0 ccc eee oo 8 B Basic chassis setting checking with rider s weight llle 41 Battery installing sere are ds 91 recharglhg ac scende xg ater fef de ERU E 92 removing ia od Ba dui e rb Es 91 Brake discs CHECKING sus rd e eme en e dehet Dt ege ausos accedo 78 Brake fluid front brake adding cee ee ees 78 rear brake addilig asas tha ole a pepe 83 Brake fluid level front brake checking llle 78 rear brake checking llle 82 Brake linings front brake changing llle 80 front brake checking 0 0 00 eee eee eee 79 rear brake changing 0 00 eee 84 rear brake checking 0 0 0 eee ee eee 83 C Capacity COOlAN ES ost e mia hued eeu te ois IE 100 120 fuel aes e deeem aed uo ae oe e ad eet 38 120 gear oll 4 Ei o aere dos eR dr ertt e Bode ed 108 120 Carburetor float chamber emptying llle 104 na m 102 idle speed adjusting llle 103 Chain CHECKING iso agree he oe EE wae ae 70 cleaning ecc es Se at eae bd woes eee de 68 Chain guide GHECKING ciu Sor ar VT ESI RR 70 Chain tension ACJUSTING ns die cad eese Sd ede mot dled du ded 69 CHECKING 4o suh enr tnd ad ee ee te held 68 Chassis number 2 000 eee 11 Choke Wii Steen ee Ss Asa 18 Cleaning care 1 ee es 111 112 140 Clutch fluid level checking correcting ls 74 fluid
41. water vapor produced during combustion will con dense causing engine parts and the exhaust system to rust 20 2 Preparing for use after storage Remove the motorcycle from the lift stand p 50 All 200 250 300 models Install the battery 4 p 91 Perform checks and maintenance work when preparing the vehicle for use p 35 L Make a test ride OO 401059 01 21 TROUBLESHOOTING 114 Faults The engine cannot be cranked elec tric starter All 200 250 300 models Possible cause Operating error Action Carry out the start procedure p 35 Battery discharged Recharge the battery 4 p 92 Check the charging voltage 4 Check the closed current Check the alternator 4 Main fuse is blown Change the main fuse p 93 Starter relay faulty Check the starter relay Starter motor faulty Check the starter motor Engine turns but does not start Operating error Carry out the start procedure p 35 Motorcycle was out of use for a long time and there is old fuel in the float chamber Empty the carburetor float chamber p 104 Fuel feed interrupted Check the fuel tank breather Clean the fuel tap Check set the carburetor components Spark plug oily or wet Clean and dry the spark plug or change it if necessary Electrode distance plug gap of spark plug too wide Adjust th
42. 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 When conditions allow incline road situation etc you can shift into a higher gear To do so release the throttle while simulta neously pulling the clutch lever shift into the next gear release the clutch and open the throttle Ifthe choke function was activated deactivate it after the engine has warmed up When you reach maximum speed after fully opening the throttle turn back the throttle to about 34 of its range This barely reduces vehicle speed but lowers fuel consumption considerably Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 22min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch 9 5 Braking 0 Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road
43. 00062030051 p 137 401197 01 Preparatory work Check the rubber grip p 73 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps U6907854 Y The twisted wire ends face away from the hands and are bent toward the rub ber grip All 125 200 models Adjust the basic setting of the clutch lever to your hand size by turning adjust ing screw Q e Info When the adjusting screw is turned counterclockwise the clutch lever moves away from the handlebar When the adjusting screw is turned clockwise the clutch lever moves closer to the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding All 250 300 models Adjust the basic setting of the clutch lever to your hand size by turning adjust ing screw Q e Info When the adjusting screw is turned counterclockwise the clutch lever moves closer to the handlebar When the adjusting screw is turned clockwise the clutch lever moves away from the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 SERVICE WORK ON THE CHASSIS 74 e Info The fluid level rises with increasing wear of the clutch lining discs
44. 00243 10 Coolant p 135 Mount the radiator cap Warning ZUM Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water A Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Position the motorcycle upright Place a suitable container under the water pump cover All 125 200 models Remove screw O Take off radiator cap O Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Drain plug water pump cover M10x1 15 Nm 11 1 Ibf ft B02167 11 16 COOLING SYSTEM 100 All 250 300 models Remove screw O Take off radiator cap O Completely drain the coolant Mount and tighten screw with a new seal ring Guideline Drain plug water pump
45. 127 22 10 1 ATL model Sita ees 127 22 10 2 Carburetor tuning All 125 models 4 127 22 10 3 200 EXC EU coocoononncccccnnonnncnnnnonononnanannnnnnos 129 22 10 4 200 EXC AU dicas 129 22 10 5 200 XC W US iiie tertii bid n dedito 129 22 10 6 Carburetor tuning All 200 models 4 129 22 10 7 250 EXC EU 250 EXC Six Days EU 250 EXC Factory Edition EU 131 22 10 8 250 EXC AW escritas 131 22 10 9250 XC W US 131 22 10 10 Carburetor tuning All 250 models 131 22 10 11 300 EXC EU 300 EXC Six Days EU 300 EXC Factory Edition EU 133 22 10 12 300 EXC AU iicet rin reet oen tena 133 22 10 13 300 XC W Six Days US 300 XC W US 300 EXC BR iiinn adan 133 22 10 14 Carburetor tuning All 300 models 133 22 10 15 General carburetor tuning 134 23 SUBSTANCES esee ede io 135 24 AUXILIARY SUBSTANCES ooccccccnnnncnnnnnononanoninnnnnnnnnnnns 137 25 STANDARDS sinite eut rea esu aet kae caeci rax ERE eo RE Resp teens 139 INDEX qn 140 1 MEANS OF REPRESENTATION ol The meaning of specific symbols is described below Indicates an expected reaction e g of a work step or a function Indicates an unexpected reaction e g of a work step or a function All work marked with this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an autho
46. 35x25 1 Nm 0 7 Ibf ft models Screw outer clamping plate All 125 EJOT DELTA PT 30x6 1 Nm 0 7 Ibf ft models Screw membrane All 200 models M4 2 Nm 1 5 Ibf ft Loctite 243 Locking screw for bearing M5 6 Nm 4 4 Ibf ft Loctite 243 Screw alternator cover M5 5 Nm 3 7 Ibf ft Screw centrifugal timer M5 8 Nm 5 9 Ibf ft Loctite 243 Screw crankshaft position sensor M5 6 Nm 4 4 Ibf ft Loctite 243 Screw exhaust control cover M5 5 Nm 3 7 Ibf ft Screw exhaust flange M5 6 Nm 4 4 Ibf ft Screw ignition system stator All 125 M5 6 Nm 4 4 Ibf ft Loctite 2227 models Screw lock washer axle for control M5 6 Nm 4 4 Ibf ft Loctite 243 flap Screw locking lever M5 6 Nm 4 4 Ibf ft Loctite 243 Screw water pump wheel M5 6 Nm 4 4 Ibf ft Loctite 243 Adjustment cable exhaust control M6 10 Nm 7 4 Ibf ft Loctite 243 Bleeder screw cylinder head M6 10 Nm 7 4 Ibf ft Screw alternator cover M6 8 Nm 5 9 Ibf ft Screw clutch cover M6 10 Nm 7 4 Ibf ft Screw clutch slave cylinder M6 10 Nm 7 4 Ibf ft Loctite 243 Screw clutch spring M6 10 Nm 7 4 Ibf ft Screw engine case M6 10 Nm 7 4 Ibf ft Screw exhaust control M6 10 Nm 7 4 Ibf ft 22 TECHNICAL DATA 119 Screw gear oil level check M6 10 Nm 7 4 Ibf ft Screw ignition sys
47. 400329 0 7 11 Setting the unit of measurement Condition e The motorcycle is stationary display Repeatedly press the button briefly until H appears at the bottom right of the Press the button for 2 3 seconds Repeatedly press the button briefly until Km h Mph flashes In measurement unit mode you can change the unit of measurement e Info If no button is pressed for 5 seconds the settings are automatically stored Briefly press the button Starts selection activates Km h display Press the button for 2 3 seconds No function Briefly press the button Activates Mph display Press the button for 2 3 seconds No function Wait 3 5 seconds Changes to the next display changes from selection to the Setup menu Wait 10 12 sec onds Saves and closes the Setup menu Display mode SPEED CLK time Repeatedly press the button briefly until CLK appears at the bottom right of the display The time is shown in display mode CLK button RUNDE Press the button The display changes to the Setup menu of the clock Cua for 2 3 seconds CLK Briefly press the Next display mode button Press the button No function 400319 0 for 2 3 seconds Briefly press the No function 7 SPEEDOMETER 25 7 12 Setting the clock Condition e The motorcycle is stationary Repeatedl
48. 417 mm 16 42 in Shock absorber fluid 7 p 136 SAE 2 5 22 8 2 All 250 300 models Shock absorber part number 12 18 7N 63 Shock absorber WP Suspension PDS 5018 DCC Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Rebound damping 22 TECHNICAL DATA 125 Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload Comfort 7 mm 0 28 in Standard 7 mm 0 28 in Sport 7 mm 0 28 in Spring rate Weight of rider 65 75 kg 143 165 Ib Weight of rider 75 85 kg 165 187 Ib Weight of rider 85 95 kg 187 209 Ib 66 N mm 377 Ib in 69 N mm 394 Ib in 72 N mm 411 Ib in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 33 35 mm 1 3 1 38 in Riding sag 105 115 mm 4 13 4 53 in Fitted length 417 mm 16 42 in Shock absorber fluid p 136 SAE 2 5 22 9 Chassis tightening torques Spoke nipple front wheel M4 5 6 Nm 4 4 Ibf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 Ibf ft Remaining nuts chassis M5 5 Nm 3 7 Ibf ft Remaining screws chassis M5 5 Nm 3 7 Ibf ft Screw batt
49. 60 12 18 Removing the front fender sss 60 12 19 Installing the front fender 61 12 20 Removing the shock absorber A 61 12 21 Installing the shock absorber 61 12 22 Removing the seat i d s sdb 62 12 23 Mounting the SBat ooccccoccnccccnncccnnncninnneninonos 62 12 24 Removing the air filter box lid 63 12 25 Installing the air filter box lid 63 12 26 Removing the air filter aaiae rererere 63 12 27 Installing the air filter X 64 12 28 Cleaning the air filter and air filter box 64 12 29 Sealing the air filter box X 65 12 30 Removing the main silencer 65 12 31 Installing the main silencer 65 12 32 Changing the glass fiber yarn filling of the main silencer X eesesssssseeeee 65 12 33 Removing the fuel tank 4 66 12 34 Installing the fuel tank A cc ceeeeeeeeeeeeeeeees 67 12 35 Checking the chain for dirt sssse 68 12 36 Cleaning the chain ooccccoccncnccnnconnncnncnnnoninonon 68 12 37 Checking the chain tension 68 13 14 15 12 38 12 39 Checking the chain rear sprocket engine sprocket and chain guide Checking the frame esssessssssss Checking the Swingarm
50. All 125 200 models Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws Remove cover 2 with membrane Check the fluid level Fluid level under top edge of con 4 mm 0 16 in tainer Ifthe level of the fluid does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 136 Position the cover with the membrane Mount and tighten the screws All 250 300 models Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws O Remove cover 2 with membrane Check the fluid level Fluid level under top edge of con 4 mm 0 16 in tainer B01538 10 Ifthe level of the fluid does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 135 Position the cover with the membrane Mount and tighten the screws e Info Wash off overflowed or spilled brake fluid immediately with water oy Warning AS 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 125 200 models Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws O
51. Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover e with membrane O Add brake fluid to level Guideline Dimension Y brake fluid level below 5 mm 0 2 in top edge of container Brake fluid DOT 4 DOT 5 1 p 135 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water 602758 10 13 7 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Check the brake linings for minimum thickness O Minimum thickness gt 1 mm 2 0 04 in Ifthe minimum thickness is less than specified Change the front brake linings 4 p 80 Check the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings 4 p 80 13 BRAKE SYSTEM 80 13 8 Changing the front brake linings a Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cau
52. C EU EXC Six Days EXC Factory Edi 21 2 qt tion Fuel reserve approx EXC AU XC W XC W Six Days 2 5 1 2 6 qt 22 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork EXC XC W EXC Factory Edition WP Suspension Up Side Down 4860 MXMA PA Fork Six Days WP Suspension Up Side Down 4860 4CS Suspension travel Front 300 mm 11 81 in Suspension travel Rear 335 mm 13 19 in Fork offset All 125 200 models 22 mm 0 87 in Fork offset All 250 300 models 20 mm 0 79 in Shock absorber WP Suspension PDS 5018 DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit 22 TECHNICAL DATA 121 Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure road All EXC models Front 1 5 bar 22 psi Rear 1 5 bar 22 psi Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary ratio All 125 models 14 50 13 50 Secondary ratio 200 EXC EU 200 EXC AU 14 45 Secondary ratio 200 XC W US 14 48 Secondary ratio All 250 300 EXC EU AU models 14 50 13 50 Secondary ratio All 250 300 XC W models 13 50 Secondary ratio 300 EXC BR 13 52 Chain 5 8 x 1 4 Rear sprockets available
53. C W Six Days Engine oil 2 stroke p 135 Close the filler cap p 17 10 SERVICE SCHEDULE 10 1 Service schedule 39 Every 40 operating hours after every race Every 20 operating hours Check that the electrical equipment is functioning properly e o Check and charge the battery 4 All 200 250 300 models Check the front brake linings p 79 e Check the rear brake linings p 83 e e Check the brake discs p 78 e Check the brake lines for damage and leakage o Check the rear brake fluid level p 82 e e Check the free travel of the foot brake lever p 81 e Check the frame and swingarm o e Check the swingarm bearing 4 e Check the heim joints at the top and bottom of the shock absorber 4 e e Check the tire condition p 88 e Check the tire air pressure p 89 M e Check the wheel bearing for play e e Check the wheel hubs 4 e Check the rim run out e e Check the spoke tension p 89 e Check the chain rear sprocket engine sprocket and chain guide p 70 e Check the chain tension p 68 e Grease all moving parts e g side stand hand lever chain and check for smooth operation 4 e e Check correct the fluid level of the hydraulic clutch p 74 e Check the front brake fluid level p 78 e Check the f
54. Change the glass fiber yarn filling of the main silencer amp p 65 Fault in ignition system Check the ignition system Diaphragm or reed valve housing damaged Check the diaphragm and reed valve housing Engine stalls or is popping into the carburetor Lack of fuel Turn handle O of the fuel tap to the ON posi tion Figure 602702 10 p 17 Refuel p 38 21 TROUBLESHOOTING 115 Faults Engine stalls or is popping into the carburetor Possible cause Engine takes in bad air Action Check the intake flange and carburetor for tightness The connector or ignition coil is loose or oxidized Clean the connector and treat it with contact spray Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level p 99 Too little air stream Switch off engine when stationary Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant A p 99 Refill with coolant 4 p 100 Damaged cylinder head or cylinder head gasket Check the cylinder head and cylinder head gas ket Bent radiator hose Change the radiator hose Incorrect ignition point due to loose stator All 125 models Adjust the ignition 4 White smoke emission steam in exhaust gas Damaged cylinder head or cylinder head gasket Check the
55. Changing 22 s Dee Nee reped t wh Ace 4 74 Clutch lever i2 dus repe eR OR Re RUNS 13 basic position adjusting llle 73 Compression damping fork AG USTING aatra Lotes er BES e Lem RE 46 Compression damping high speed shock absorber adjusting llle 42 Compression damping low speed shock absorber adjusting lesen 41 Coolant A eee Sy See ek e OC Ab brie OA dew 99 r fillilg zara a ee ay eee 100 Coolant level Checking s a cate Xs Fe oa Pe RR dub POS 98 99 Cooling system llli 98 Customer service 0 00 eee 8 D Difficult operating conditions Ory Sand aida bh xL oso Sus 32 high temperatures llle 33 low temperatures llle 34 muddysurfaces lees 33 riding at low speeds o o oooooooooooo o 33 SHOW EA s ces eripe T wae A Ce OR ee a 34 WEE SANG narra a a inn an aed EDAM E ibt m rd 32 WetsurfaCeS nA ure Re a AO REESE ES 33 Difficult riding conditions 31 E Electric starter button o o o o o o 16 Emergency OFF switch o o o 15 Engine PUDE riadas 31 Engine characteristic auxiliary Spring llle 105 auxiliary spring setting o o ooooooo oo o 105 Engine guards installlgs a AS is 76 FemoyvIng s ders t t edet eO Ee Leute a ado TA iR 76 Engine number 0 0 0 cece eee eee 11 Engine sprocket CHECKING 2 A pet est or o
56. Cleaning the motorcycle 19 2 Checks and maintenance steps for winter OPEN ALON ERRORES 20 STORAGE ti ii 20 1 Storage uui e 20 2 Preparing for use after storage 21 TROUBEESHOOTING totes aane 22 TECHNICAL DATA eeeeeeeem m 22 1 Engine uoc inte Dre E E TC RR URA 22 1 1 All 125 models cion 22 1 2 All 200 models cceeeeeeeeeeeeeeeeeeeeeeeeees 22 1 3 AIL 250 tmodels ioco tea ette rer eere 22 1 4 All 300 MOU8IS oooccccccnnccccnnnoncccnncnnncnninnnnns 22 2 Engine tightening torques 22 2 1 All 125 200 models ssssssse 22 2 2 All 250 300 models ssssssse 22 3 CAPACITIES isset bd sese eoe eh no 22 3 1 Gear oil 22 3 2 22 3 9 aaa 22 4 CHASSIS vicodin 22 5 Electrical system e io tede sae 22 0 MS a ii LA MER Vo Mt E 22 7 1 125 EXC EU all 200 models 125 EXC Factory Edition EU 250 300 EXC EU AU XC W US 250 300 EXC Factory Edition BOO EXC BR use nidad 22 7 3 125 EXC Six Days EU sessesesess 22 7 4 250 300 Six DaYS ccccoooccccnnnnncccnncnnncninnnnnos 22 8 Shock absorber cete ene oic taria 22 8 1 All 125 200 models sssssse 22 8 2 All 250 300 models ssssssse 22 9 Chassis tightening torques 22 7 2 4 22 10 Carburetor uo nete eee ae ae caia
57. Make sure cables and wiring are positioned correctly Position the handlebar clamps Mount screws 1 and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 Ibf ft e Info Make sure the gap widths are even 12 SERVICE WORK ON THE CHASSIS 50 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Raise the motorcycle at the frame underneath the engine Lift stand 54829055000 Y Neither wheel is in contact with the ground 401942 01 Secure the motorcycle against falling over Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it e Info j When you are riding the side stand must be folded up and secured with the e rubber band 401943 10 Preparatory work Raise the motorcycle with the lift stand p 50 Main work EXC XC W EXC Factory Edition Release bleeder screws Y Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Six Days Release bleeder screws O Y Any excess pressure escapes from the interior of the fork Tighten the b
58. NPRH N1EH NIEI N1EJ Main jet 100 162 165 Idling jet 35x35 40 Starting jet 50 85 Idle air adjusting screw Open 1 5 turns Throttle slide 7 with cut out Slide stop Present 22 10 4 200 EXC AU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK012 Needle position 2nd position from top Jet needle R1475J N1EH NIEI NIEJ Main jet 162 165 Idling jet 35 40 Starting jet 85 Idle air adjusting screw Open 1 0 turn Throttle slide 7 with cut out Slide stop Present 22 10 5 200 XC W US Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ5 Needle position 2nd position from top Jet needle N1El N1EH N1EJ Main jet 165 162 Idling jet 40 Starting jet 85 Idle air adjusting screw Open 2 0 turns Throttle slide 7 with cut out Slide stop 22 10 6 Carburetor tuning All 200 models Danger Al Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous reduced version only Inthe derestricted version the motorcycle must be used only on closed off property remote from public road traffic 22 TECHNICAL DATA 130 KEIHIN PWK 36S AG 20 C 7 C 6 C 5 C 6 C 15 C 16 C 24 C 25 C 36 C 37 C 49 C 1 P
59. Nm 5 2 Ibf ft 401045 10 Finishing work Install the main silencer p 65 12 33 Removing the fuel tank a 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 The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the seat p 62 Main work Turn handle 1 of the fuel tap to the OFF position Figure 602702 10 p 17 Pull off the fuel hose e Info Remaining fuel may run out of the fuel hose Remove screws 1 with the collar sleeve All EXC models Hang the horn and horn bracket to one side Remove screw with the rubber bushing Remove the tube from the fuel tank vent line
60. ORK ON THE CHASSIS 72 1241 Checking the swingarm 000000 Check the swingarm for damage cracking and deformation Ifthe swingarm shows signs of damage cracking or deformation Change the swingarm 4 e Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by KTM 401341 01 Preparatory work Remove the seat p 62 Remove the fuel tank 4 p 66 Main work All 125 200 models Check the routing of the throttle cable The throttle cable must be routed behind the handlebar on the right of the upper frame tube and to the carburetor If the throttle cable is not routed as specified Correct the routing of the throttle cable All 250 300 models Check the routing of the throttle cable The throttle cable must be routed behind the handlebar on the right of the upper frame tube and to the carburetor Ifthe throttle cable is not routed as specified Correct the routing of the throttle cable M00587 01 Finishing work Install the fuel tank 4 p 67 Mount the seat p 62 12 SERVICE WORK ON THE CHASSIS 73 3243 Checking the rubber grip 0000 Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive
61. OWNER S MANUAL 2015 125 EXC EU 125 EXC Six Days EU 125 EXC Factory Edition EU 200 EXC EU 200 EXC AU 200 XC W US 250 EXC EU 250 EXC AU 250 EXC Six Days EU 250 EXC Factory Edition EU 250 XC W US a 300 EXC EU 300 EXC AU 300 EXC Six Days EU 300 EXC Factory Edition EU gt 300 XC W Six Days US x 300 XC W US 300 EXC BR Art no 3213233en Tiss DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle You are now the owner of a state of the art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly We wish you a lot of enjoyment in riding this vehicle Enter the serial numbers of your vehicle below Chassis number p 11 Dealer s stamp Engine number p 11 Key number All EXC models p 11 The Owner s Manual contained the latest information for this model series at the time of going to print Minor differences due to developments in design cannot be ruled out completely All specifications are non binding KTM Motorrad AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustr
62. P COS I99F 41 P 429F 00 P OI F 78F ZIP GSE GOP I20 F 3 000 m 2 5 2 5 2 5 235 10 000 ft 40 38 38 38 NIE I NIEI NIE J NIE J 2 2 2 1 2 301m 162 160 158 158 7 501 ft 2 300 m 2 5 2 5 2 5 2 5 7 500 ft 40 38 38 38 4 NIEI NIEI NIE J NIE J 2 2 2 1 1 501m 162 160 158 158 5 001 ft 1 500 m 2 5 2 5 2 5 5 000 ft 40 38 38 4 NIEI NIEI NIE J 2 2 2 751m 162 160 158 2 501 ft 750m 2 5 2 5 2 500 ft 40 38 4 N1E NIEI 2 2 301 m 162 160 1 001 ft 300 m 2 5 1 000 ft 40 4 NIEI 2 Om 162 402139 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces 22 TECHNICAL DATA 131 22 10 7 250 EXC EU 250 EXC Six Days EU 250 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K N2ZW N2ZH N2ZJ Main jet 110 172 175 Idling jet 38x38 38 40 Starting jet 50 85 Idle air adjusting screw Open 1 5 turns Throttle slide 7 with cut out Slide stop Present 22 10 8 250 EXC AU Carburetor type KEIHIN PWK 36S AG Carburetor identification number 3600 Needle position 1 Position from top Jet needle N3CJ N8RG N8RH N2ZH N2ZJ N2ZW Main jet 160 170 172 175 Idling jet 35 38 40 Starting jet 85 I
63. a passenger Warning Danger of accidents Failure of brake system Ifthe foot brake lever is not released the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads 0 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 Info When using your motorcycle remember that others may feel disturbed by excessive noise All All Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop Y You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 73 EXC models Adjust the free travel of the hand brake lever p 77 XC W models Adjust the basic position of the hand brake lever p 77 Adjust the basic position of the foot brake lever p 81 Adjust the basic position of the shift lever 4 p 105 Get used to handling the motorcycle on a suitable piece of land before making a longer trip e Info When offroad being accompanied by anoth
64. al system is functioning properly Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark a distance under the first mark Guideline Distance Q 5 cm 2 in Position the vehicle vertically a distance away from the wall Guideline 400726 10 Distance 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver Ifthe light dark border does not meet specifications Adjust the headlight range p 96 Preparatory work Check the headlight setting p 96 Main work Loosen screw Adjust the headlight range by swiveling the headlight Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver instructions on how to apply the mark Checking the headlight setting e info The headlight range may need to be corrected if luggage is carried on the vehicle Wi s02764 10 Tighten screw O 15 ELECTRICAL SYSTEM 97 Preparatory work Remove the headlight mask with the headlight p 94 Main work Remove screws O Pull the speedometer upward out of the holder
65. aling 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 Start the engine and check that it is oil tight Finishing work Check the gear oil level p 107 e Info Too little gear oil or poor quality gear oil results in premature wear of the transmission The gear oil level must be checked when the engine is cold Preparatory work Park the motorcycle on a level surface Main work All 125 200 models Remove screw a from the opening used to check the gear oil level All 250 300 models Remove screw O from the opening used to check the gear oil level Remove filler plug e Add gear oil until it emerges from the opening used to check the gear oil level Engine oil 15W 50 p 135 Mount and tighten the gear oil level check screw Guideline All 125 200 models Screw gear oil level check M6 10 Nm soc 7 4 Ibf ft All 250 300 models Screw gear oil level check M6 10 Nm 7 4 Ibf ft Mount and tighten filler plug O Danger Danger of poisoning Exhaust gases are toxic 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 engi
66. and grease and clean them with brake cleaner when necessary Main work Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease shaft seal rings O and bearing surface O of the spacers Long life grease p 137 Insert the spacers Lift the rear wheel into the swing arm position it and insert wheel spindle O Apply the chain Y The brake linings are correctly positioned PRA mo0125 10 Position chain adjuster Mount nut but do not tighten it yet Make sure that chain adjusters e are fitted correctly on adjusting screws O Check the chain tension p 68 Tighten nut O Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm 1 18 in enables different secondary ratios with the same chain length Chain adjusters e can be turned by 180 Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point K M00126 10 Finishing work Remove the motorcycle from the lift stand p 50 Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have an imp
67. ant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using infe rior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 25 45 C 13 anti corrosion antifreeze 49 F distilled water Recommended supplier Motorex COOLANT M3 0 Standard classification JASO T903 MA p 139 SAE p 139 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties Recommended supplier Motorex Top Speed 4T Standard classification JASO FD p 139 Guideline Only use high grade 2 stroke engine oil of a reputable brand Fully synthetic Recommended supplier Motorex Cross Power 2T Standard classification SAE p 139 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties 23 SUBSTANCES 136 Standard classification ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties Recommended supplier Motorex Hydraulic Fluid 75 Standard classification SAE p 139 SAE 2 5 Guideline Use only oils that comply with the specified standards
68. asure ment stores it and the stop watch starts the next lap Viewing the lap The stop watch Select a lap No function View the next time and the lap time from 1 10 lap time are reset Display mode No function Next display No function No function SPEED ODO mode odometer Display mode Displays of TR1 Next display No function No function SPEED TR1 trip A1 and S1 are mode master 1 reset to 0 0 Display mode Clears the val Next display Reduces value Reduces value SPEED TR2 trip ues TR2 and A2 mode of TR2 of TR2 master 2 Setting TR2 trip Increases value Increases value Reduces value Reduces value Saves and master 2 of TR2 of TR2 of TR2 of TR2 closes the Setup menu Display mode Displays of TR1 Next display No function No function SPEED A1 average A1 and S1 are mode speed 1 reset to 0 0 Display mode No function Next display No function No function SPEED A2 average mode speed 2 Display mode Displays of TR1 Next display No function No function SPEED S1 stop A1 and S1 are mode watch 1 reset to 0 0 Display mode The displays of Next display No function Starts or stops SPEED S2 stop S2 and A2 are mode S2 watch 2 set to 0 0 7 24 Table of conditions and menu activation Display The motorcycle is Menu can be acti stationary vated Setup menu Setting the unit of measurement Setting the clock Display mode SPEED LAP lap time Viewing the lap time
69. ations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2014 KTM Motorrad AG Mattighofen Austria All rights reserved Reproduction even in part as well as copying of all kinds is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 HA According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TUV Management Service 1S0 9001 REG NO 12 100 6061 KTM Motorrad AG 5230 Mattighofen Austria TABLE OF CONTENTS 1 MEANS OF REPRESENTATION eere 5 1 1 SVMBOIS USEC ue sedit eee a 5 1 2 Formats USCC iod C Ea lbn edt 5 24 SAFETY ADVICE x edere e patte et ert eec et 6 2 1 Use definition intended use sssss 6 2 2 Safety advice ies eli i a 6 2 3 Degrees of risk and symbols ussssse 6 2 4 Tampering warning eee 6 2 5 Sate operatlOn dti tete ce edet 7 2 6 Protective clothing coooocnccccnnccnccnconononononcnonns 7 2 7 Work r les io Dente Eee ote onerat 7 2 8 Environment esee teet ndi deer d 7 2 9 Owner s Manual esseeemm 7 3 IMPORTANT NOTES 5 tiefe fot tt ees reet des 8 3 1 Guarantee warranty ooccocncocccocnnncnnncnnnnnnncnoninnnos 8 3 2 Operating and auxiliary s
70. aud ete bcne sve dete WHEELS TIRES aura tirer ta eye tah Eee CURT osa UR Removing the front wheel s Installing the front wheel Removing the rear wheel ssss Installing the rear wheel ssssuss Checking the tire condition Checking the tire air pressure Checking the spoke tension ELECTRICAL SYSTEM sssseeeseeeeeeceeeeeeeessaeaaeeeseeeess 14 1 14 2 14 3 14 4 14 5 14 6 14 7 15 1 Removing the battery All 200 250 300 models 15 2 Installing the battery All 200 250 300 models 15 3 Recharging the battery 4 All 200 250 300 models 15 4 Changing the main fuse All 200 250 300 models 15 5 Removing the headlight mask with the HEA tse ducti ia 15 6 Refitting the headlight mask with the l ieadllight sua us eee tte t eere e ostendens Changing the headlight bulb 15 7 15 8 Changing the turn signal bulb All EXC 15 9 15 10 15 11 Adjusting the chain tension Checking the rear brake fluid level Adding brake fluid for the rear brake 4 Checking the rear brake linings Checking the headlight s
71. bed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer s Service amp Warranty Booklet and in the KTM Dealer net otherwise all warranty claims will be void No warranty claims can be consid ered for damage resulting from manipulations and or alterations to the vehicle Additional information on the guarantee or warranty and the procedures involved can be found in the Service amp Warranty Booklet Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s Manual For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are specified in parentheses in the descriptions Your authorized KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustm
72. bulb Changing est ee doe x p dob e SR dc E aequ 95 Turn signal switch llle 15 Type label ee kitted n nann Hae Pde dno et hb sss 11 142 U Usedefinition aae ree aae a a a ee 6 V View of vehicle front leftside 2 5 eL to ea eh oe ood daa 9 reartight Sad bate A aN ING HEUS ek 10 W Warranty oia A eure A a a 8 Winter operation checks and maintenance steps 112 Work rules 1 d o cm le to nak de ir od oe 7 WWW KTM COM 3213233en 10 2014 an KTM Motorrad AG GE 5230 Mattighofen Austria luus 4724 vc Photo Mitterbauer KTM http www ktm com rine B aii
73. ch as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reason it may be neces sary to inspect or replace parts before the next scheduled service Seal the air filter box 4 p 65 Clean the air filter and air filter box X p 64 e Info Check the air filter approx every 30 minutes Additionally secure the rubber grip p 73 Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficult riding conditions are Riding on dry sand p 32 Riding on wet sand p 32 Riding on wet and muddy surfaces p 33 Riding at high temperatures and low speeds p 33 Riding at low temperatures or in snow p 34 8 PREPARING FOR USE 32 8 4 Preparations for riding on dry sand Check the radiator cap Value on the radiator cap 1 8 bar 26 psi Ifthe displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling 600872 10 system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immedia
74. conditions Warning A Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently 9 RIDING INSTRUCTIONS 37 On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed 9 6 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 become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 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
75. counterclockwise to reduce Adjusting the spring preload has no influence on the absorption setting of the rebound damping Basically however you should set the rebound damping higher with a higher spring preload On the upper triple clamp there are two holes a distance of O apart Hole distance A 15 mm 0 59 in The holes on the handlebar support are placed at a distance of B from the center Hole distance B 3 5 mm 0 138 in The handlebar can be mounted in four different positions In this way the handlebar can be mounted in the position that is most comfortable for the rider 11 TUNING THE CHASSIS 49 11 16 Adjusting the handlebar position 4 Warning Danger of accidents Handlebar breakage Ifthe handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handle bar Remove screws O Remove the handlebar clamp Remove the handlebar and lay it to one side e Info I Protect the components against damage by covering them Do not bend the cables and lines Remove screws O Remove the handlebar support Place the handlebar support in the required position Mount and tighten 101488 10 Screws O Guideline Screw handlebar support M10 40 Nm Loctite 243 29 5 Ibf ft e Info Position the left and right handlebar supports evenly Position the handlebar e Info
76. cover M10x1 15 Nm 11 1 Ibf ft B02168 11 Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children All 125 200 models Make sure that screw is tightened Position the motorcycle upright Fill the radiator completely with coolant Coolant 1 21 1 3 qt Coolant p 135 B02169 10 Loosen screw O until coolant escapes without bubbles Mount and tighten screw Guideline Bleeder screw cylinder head M6 10 Nm 7 4 Ibf ft All 250 300 models Make sure that screw o is tightened Position the motorcycle upright Fill the radiator completely with coolant Coolant 1 21 1 3 qt Coolant p 135 B02171 10 M Position the vehicle as shown and secure it against rolling away A height differ ence of O must be reached Guideline Height difference 75 cm 29 5 in 1 e Info O O I To ensure that all of the air can escape from the cooling system the L front of the vehicle must be jack
77. d p 50 Remove screw O Lift up the seat at the rear pull it back and then remove from above 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 12 SERVICE WORK ON THE CHASSIS 63 Mount and tighten screw o of the seat fixation Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Pull off the air filter box lid in area sideways and remove it toward the front Insert the air filter box lid into the rear area O and clip it into the front area O Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear 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 Preparatory work Remove the air filter box lid p 63 Main work Detach air filter holder o 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 12 SERVICE WORK ON THE CHASSIS 64 Main work Mount the clean air filter on the air filter support Grease the air
78. d p 50 12 SERVICE WORK ON THE CHASSIS 70 12 39 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work X 400227 01 G GSL 9 O O O OX is 2 3 1 16 17 18 400987 10 B00823 01 Raise the motorcycle with the lift stand p 50 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear Ifthe rear sprocket and engine sprocket are worn Change the drivetrain kit amp e Info The engine sprocket rear sprocket and chain should always be changed together Pull on the upper part of the chain with the specified weight O Guideline Weight chain wear measurement 10 15 kg 22 33 Ib Measure the distance eo of 18 chain links in the lower chain section e Info Chain wear is not always even repeat this measurement at different chain positions Maximum distance at the longest 272 mm 10 71 in chain section Ifthe distance o is greater than the specified measurement Change the drivetrain kit 4 e Info When you replace the chain you should also change the rear sprocket and engine sprocket New chains wear out faster on old worn sprockets Check the chain sliding guard for wear Ifthe lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard amp Check the chain sliding guard
79. d 7 p 63 Main work Seal the air filter box in the marked area 401527 10 Finishing work Install the air filter box lid p 63 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 O Pull the main silencer off of the manifold at the rubber sleeve Mount the main silencer with rubber sleeve Mount and tighten screws e Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft RM 602718 11 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 e Info Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the main silencer p 65 12 SERVICE WORK ON THE CHASSIS 66 Main work Remove screws O Pull out inner tube Remove glass fiber yarn filling e from the inner tube Clean the parts that need to be reinstalled and check for damage Mount the new glass fiber yarn filling e on the inner tube Position outer tube o over the inner tube with the new glass fiber yarn filling Mount and tighten screws O Guideline Screws on the main silencer M5 7
80. d and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 83 Main work Stand the vehicle upright Remove screw cap 1 with membrane and the O ring Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 135 Mount the screw cap with the membrane and the O ring e info paa Clean up overflowed or spilt brake fluid immediately with water 13 13 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Check the brake linings for minimum thickness O Minimum thickness gt 1 mm 2 0 04 in Ifthe minimum thickness is less than specified Change the brake linings of the rear brake 4 p 84 Check the brake linings for damage and cracking If damage or cracking is visible Change the brake linings of the rear brake 4 p 84 13 BRAKE SYSTEM 84 13 14 Changing the brake linings of the rear brake 4 A A Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid c
81. d below marking o in the level viewer Add brake fluid for the rear brake 4 p 83 13 BRAKE SYSTEM 83 13 12 Adding brake fluid for the rear brake au A Warning Danger of accidents Brake system failure Ifthe brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 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 Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake flui
82. d salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt zs mc E Clean the motorcycle p 111 Pag un DE req Clean the brakes de E E ke i Info i After EVERY trip on salted roads thoroughly wash the brake calipers and Ca brake linings with cold water and dry carefully This should be done after oe the parts are cooled down and while they are installed ma L After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well 401060 01 Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor e Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 68 20 STORAGE 113 20 1 Storage 0 Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Info If you want to put the motorcycle into storag
83. de SPEED speed 7 8 Display mode SPEED H service hours 7 9 Setup menu cococccncnnncnncnnnnnnnnnnnnnnnannncnonnnnncnnnnos 7 10 Setting the unit of measurement 7 11 Display mode SPEED CLK time 7 12 Setting the clock i e e Ee 7 13 Display mode SPEED LAP lap time 7 14 Viewing the lap time eeeeeeeeeeees 7 15 Display mode SPEED ODO odometer 7 16 Display mode SPEED TR1 trip master 1 7 17 Display mode SPEED TR2 trip master 2 7 18 Setting TR2 trip master 2 sssssss 7 19 Display mode SPEED A1 average speed 1 7 20 Display mode SPEED A2 average speed 2 7 21 Display mode SPEED S1 stop watch 1 7 22 Display mode SPEED S2 stop watch 2 7 23 Table of functions eeesssseseeeseee 7 24 Table of conditions and menu activation PREPARING EOR USE uidit re Tode dA Ls 8 1 Advice on first use oococcccooocccnncnnnccnnnnnnnnccnnnnnnns 8 2 Running in the engine seeeeeeeeeees 8 3 Preparing the vehicle for difficult riding CONCITIONS e 8 4 Preparations for riding on dry sand 8 5 Preparations for riding on wet sand 8 6 Preparations for riding on wet and muddy SUMAS duis doter tue aber eds ture Dd 8 7 Preparations for riding at high temperatures and low Speeds
84. de The display Next display No function No function SPEED H service changes to the mode hours Setup menu of the speedome ter functions Setup menu No function Activates the No function Deactivates the Changes to the Setup menu flashing display flashing display next display starts stores and changes to and changes to without changes the settings the next display the next display and changes to H or ODO Setting the unit of No function Starts selection No function Activates Mph Changes to the Saves and measurement activates Km h display next display closes the Setup display changes from menu selection to the Setup menu Display mode The display Next display No function No function SPEED CLK time changes to the mode Setup menu of the clock Setting the clock Increases the Increases the Reduces the Reduces the Changes to the Closes the value value value value next value SETUP menu 7 SPEEDOMETER 29 Display mode SPEED H service hours Display Press the but Briefly press the Press the but Briefly press the Wait 3 5 sec Wait 10 12 sec ton for 2 3 button ton for 2 3 button onds onds seconds seconds Display mode The stop watch Next display Stops the clock Starts the stop SPEED LAP lap and the lap time mode watch or stop time are reset the current lap time me
85. deline Dimension Y brake fluid level below 5 mm 0 2 in top edge of container Brake fluid DOT 4 DOT 5 1 p 135 Position the cover with the membrane Mount and tighten the screws e Info Wash off overflowed or spilled brake fluid immediately with water 13 9 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel O Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in S je gt If the free travel does not meet specifications O et Adjust the basic position of the foot brake lever amp p 81 4 402026430 Reconnect spring O 13 10 Adjusting the basic position of the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications 13 BRAKE SYSTE 82 Disconnect spring A 10
86. dle air adjusting screw Open 3 5 turns Throttle slide 7 with cut out Slide stop Present 22 10 9 250 XC W US Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ6 Needle position 3rd position from top Jet needle N2ZW N2ZH N2ZJ Main jet 175 172 Idling jet 38 40 Starting jet 85 Idle air adjusting screw Open 2 0 turns Throttle slide 7 with cut out Slide stop 22 10 10 Carburetor tuning All 250 models 4 Danger Al Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous reduced version only Inthe derestricted version the motorcycle must be used only on closed off property remote from public road traffic 22 TECHNICAL DATA 132 KEIHIN PWK 36S AG 20 C ne TC 6 C 5 C 6 C 15 C 16 C 24 C 25 C 36 C 37 C 49 C 1 x2 F 20 F LIF 41 42 F 60 F 61 F 78 F 799F 98 F 99 F 120 F 3 000 m 10 000 ft 2 301m 7 501 ft 2 300 m 7 500 ft 1 501m 5 001 ft 1 500 m 5 000 ft A 751m 2 501 ft 750m 2 500 ft A 301 m 1 001 ft 300 m 2 1 000 ft 38 4 N2Z W 3 Om 175 402140 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open lJ Idling jet NDL Needle POS Needle position from above MJ Main jet
87. e for a longer period take the following actions Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season A Clean the motorcycle p 111 Change the gear oil 4 p 107 Check the antifreeze and coolant level p 98 When refueling for the last time before taking the motorcycle out of service add fuel additive 2 cler Fuel additive p 137 O O Refuel p 38 ao1058 01 Empty the carburetor float chamber X p 104 Check the tire air pressure p 89 All 200 250 300 models Remove the battery 4 p 91 Recharge the battery A p 92 Guideline Storage temperature of battery with 0 35 C 32 95 F out direct sunlight Store the vehicle in a dry location that is not subject to large fluctuations in tem perature e Info KTM recommends raising the motorcycle Raise the motorcycle with the lift stand p 50 Cover the vehicle with a tarp or cover that is permeable to air Info e Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Because the engine will not warm up sufficiently the
88. e plug gap Guideline All 125 200 models Spark plug electrode gap 0 60 mm 0 0236 in All 250 300 models Spark plug electrode gap 0 60 mm 0 0236 in Fault in ignition system Check the ignition system 4 Kill switch cable in wiring harness frayed kill switch defective Check the kill switch 4 The connector or ignition coil is loose or oxidized Clean the connector and treat it with contact spray Water in carburetor or jets blocked Check set the carburetor components Engine has no idle Idling jet blocked Check set the carburetor components Adjusting screws on carburetor dis torted Carburetor adjust the idle speed p 103 Spark plug defective Change the spark plug Ignition system defective Check the ignition coil amp Check the spark plug connector 4 Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor components Fault in ignition system Check the ignition system 4 Engine has too little power Fuel feed interrupted Check the fuel tank breather Clean the fuel tap Check set the carburetor components Air filter very dirty Clean the air filter and air filter box 4 p 64 Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage
89. e rain cover for the air filter Rain cover for air filter 59006021000 e Info Read the KTM PowerParts installation instructions Adjust the carburetor jetting and setting e Info oes Your authorized KTM workshop can recommend the right carburetor tuning Clean the chain Chain cleaner p 137 Mount the steel sprocket e Tip Do not grease the chain Clean the radiator fins 600868 01 Carefully align bent radiator fins If used in sand regularly replace the piston every 10 operating hours 8 6 Preparations for riding on wet and muddy surfaces Mount the rain cover for the air filter Rain cover for air filter 59006021000 e Info Follow the KTM PowerParts mounting instructions Adjust the carburetor jetting and setting e Info Your authorized KTM workshop can recommend the right carburetor tuning 600870 01 Mount the steel sprocket Clean the motorcycle p 111 Carefully align bent radiator fins 600868 01 8 7 Preparations for riding at high temperatures and low speeds Check the radiator cap Value on the radiator cap 1 8 bar 26 psi Ifthe displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap rad
90. e 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 This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free i e the acid level does not have to be checked Preparatory work Switch off all power consumers and the engine Remove the seat p 62 Disconnect the negative cable from the battery to avoid damage to the onboard electronics Main work Connect the battery charger with the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the battery and to test the alternator With this device you cannot overcharge the bat tery e Info 400240 10 Never remove the lid O Ja battery with at most 10 of the capacity specified on the bat tery Switch off the charger after charging Connect the negative cable with the battery Guideline The charge current charge voltage and charge time mu
91. e the repair or service work check the operating safety of the vehicle If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcy cle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are no legal regulations that pertain to the disposal of an end of life motorcycle Your authorized KTM dealer will be glad to advise you It is important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains useful information and many tips on how to operate handle and maintain your motorcycle Only then will you find out how to cus tomize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold 3 IMPORTANT NOTES oo The work prescri
92. e the steering head bearing 4 p 60 Check set the carburetor components 4 o e Perform a fork service EXC XC W EXC Factory Edition 4 O e e Perform a fork service Six Days 4 Oo e Service the shock absorber 4 e Check the starter drive X All 200 250 300 models Change the piston and check the cylinder 4 All 125 models e e Change the piston and check the cylinder 4 All 200 250 300 models Change the connecting rod conrod bearing and crank pin e Check the transmission and shift mechanism Change all engine bearings 4 o o One time interval Periodic interval 11 TUNING THE CHASSIS 41 11 1 Checking the basic chassis setting with the rider s weight e Info When adjusting the basic chassis setting first adjust the shock absorber and then the fork For optimal motorcycle riding characteristics and to avoid damage to forks shock C absorbers swingarm and frame the basic settings of the suspension components must match the rider s weight EN As delivered KTM offroad motorcycles are adjusted for a standard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 Ib If the rider s weight is above or below the standard range the basic setting of the suspension components must be adjusted accordingly Small weight differences can be compensated by adjusting the spring preload but in the case of large weight differ
93. e when the throttle slide is being opened This range is influenced by the idling jet and by the form of the throttle slide If the engine sputters and smokes heavily when it starts despite a good idle and part load setting and if it abruptly reaches full power at a high rpm the carburetor setting is too rich or the float level is too high or the float needle valve is leaky 500282 01 Part load range C Operation with the throttle slide partially open This range is influenced by the jet needle form and position The idle setting influences the engine tuning in the lower range and the main jet influences the engine tuning in the upper range If when accelerating with the throttle slide partially opened the engine only stutters while running the jet needle needs to be lowered by one level If the engine knocks especially when it reaches the full performance engine speed while accelerating the jet needle needs to be raised If the behavior described above occurs while idling or just above idling the idling system needs to be regulated to a leaner setting if the engine is stuttering and to a richer setting if knocking Full load range D Operation with the throttle slide open full throttle This range is influenced by the main jet and jet needle If the insulator of a new spark plug is very light or white after a brief ride at full throt tle or if the engine knocks a larger main jet needs to be used If the insulator is dark br
94. ead bearing p 58 Remove the motorcycle from the lift stand p 50 EXC XC W Remove the lower triple clamp p 54 Install the lower triple clamp 4 p 55 Six Days EXC Factory Edition Remove the lower triple clamp 4 p 54 Install the lower triple clamp 4 p 57 800010 10 Preparatory work Remove the headlight mask with the headlight p 94 Main work Remove screws li 3 lt 3 Remove screws O Remove the front fender 12 SERVICE WORK ON THE CHASSIS 61 Main work Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft WE J Mount and tighten screws e Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Y Finishing work Refit the headlight mask with the headlight p 94 Check the headlight setting p 96 Preparatory work Raise the motorcycle with the lift stand p 50 Main work All 125 200 models Remove screw e and lower the rear wheel with the swing arm as far as possi ble without blocking the rear wheel Fix the rear wheel in this position Remove screw O push splash protector O to the side and remove the shock absorber All 250 300 models Remove screw o and lower the rear wheel with the swing arm as far as possi ble without block
95. ebound damping of the fork 47 11 14 Adjusting the spring preload of the fork EXC XC W EXC Factory Edition 48 11 15 Handlebar position eeeseeeeeeeeee 48 11 16 Adjusting the handlebar position X 49 SERVICE WORK ON THE CHASSIS sese 50 12 1 Raising the motorcycle with the lift stand 50 12 2 Removing the motorcycle from the lift stand 50 12 3 Bleeding the fork legs eesesssssse 50 12 4 Cleaning the dust boots of the fork legs 51 12 5 Loosening the fork protection 51 12 6 Positioning the fork protection 51 12 7 Removing the fork legs sseeessessssse 52 12 8 Installing the fork legs sssseeseessssse 52 12 9 Removing the fork protector 53 12 10 Installing the fork protector A 54 12 11 Removing the lower triple clamp amp EXC XCW ainda 54 12 12 Removing the lower triple clamp a Six Days EXC Factory Edition essen 54 12 13 Installing the lower triple clamp 4 EXC on C 55 12 14 Installing the lower triple clamp Six Days EXC Factory Edition ccoccoccocooooconanocnccnnnnnnnnnos 57 12 15 Checking the play of the steering head ble ER 58 12 16 Adjusting the play of the steering head DET e ic ii 59 12 17 Greasing the steering head bearing
96. ect chain tension Ifthe chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise the motorcycle with the lift stand p 50 12 SERVICE WORK ON THE CHASSIS 69 Main work Pull o chain at the end of the chain sliding piece upward to measure chain ten sion e Info l The bottom chain section 1 must be taut When the chain guard is mounted it must be possible to pull up the chain at least to the point where it makes contact with chain guard O Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in Ifthe chain tension does not meet specifications Adjust the chain tension p 69 M00102 10 Finishing work Remove the motorcycle from the lift stand p 50 12 38 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension Ifthe chain is too taut the components
97. ed The horn is operated in this position 102044 11 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 e is switched off zD Low beam on Light switch is in the central position In this position z the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and the tail light are switched on Neoises 12 6 CONTROLS 15 C es The light switch is fitted on the left side of the handlebar Possible states z Low beam on Light switch is in the central position In this position z the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the zD high beam and the tail light are switched on The light switch o is on the right of the speedometer Possible states Light off Light switch is pressed in up to the stop In this position the light is switched off e Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on Turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off The turn signal switch is in the central position a Left turn signal on The turn signal switch is turned to the left Right turn si
98. ed up A poorly bled cooling system is Io enan less effective at cooling and may result in overheating of the engine 16 COOLING SYSTEM 101 Place the vehicle back on a level surface Fill the radiator completely with coolant Mount radiator cap 6 Run the engine until it is warm q Y Qoo Finishing work Check the coolant level p 99 17 TUNING THE ENGINE 102 17 1 Checking the play in the throttle Cable Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Move the throttle grip back wards and forwards to ascertain the play in the throttle cable Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable X p 102 Danger 400192 10 Al Danger of poisoning Exhaust gases are toxic 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 Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable amp p 102 Main work Move the handlebar to
99. el in the radiator 400243 10 Coolant level above the radiator 10 mm 0 39 in fins If the coolant level does not match the specified value Correct the coolant level Coolant p 135 Mount the radiator cap 16 COOLING SYSTEM 99 163 Checking the coolant level 0 A Warning A Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning 4E Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator 10 mm 0 39 in fins If the coolant level does not match the specified value Correct the coolant level 4
100. ences the springs must be replaced 401030 01 11 2 Compression damping of shock absorber The compression damping of the shock absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example affects the compression when landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example affects the compression when riding over long ground swells the rear wheel suspension com presses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the low speed range and vice versa 11 3 X Adjusting the low speed compression damping of the shock absorber Caution 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 e Info The low speed setting can be seen during the slow to normal compression of the shock absorber Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click e Info Do not loosen nut e Turn counterclockwise by the number of clicks corresponding to the shock absorber
101. ent and tuning of the engine and chassis can lead to damage and breakage of components Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much longer service life for your motorcycle The figures contained in the manual may depict special equipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to dis assemble the component to perform the activity in question Please follow the instructions in the text Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com 4 VIEW OF VEHICLE 9 Hand brake lever p 13 Kill switch p 13 Kill switch p 14 Clutch lever p 13 Chain guide Air filter box lid Side stand p 19 Shift lever p 18 Fuel tap p 17 CO N D om BI PM NMI 4 VIEW OF VEHICLE 10 Filler cap Throttle grip p 13 Chassi
102. ent 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 Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality JASO FD is a classification for a 2 stroke engine oil that was specifically developed for the extreme demands of racing Thanks to first rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions INDEX A Accessories sucesivas oe mU uo RC 8 Air filter cleaning a uses d uk bua RS Pee 64 installing usas tum erede b tro o del 64 removing cives bet dus Eig VeL Ls bei teda 63 Air filter box cleaning a a eR ACH e PME Rt 64 sealing 5 osa e RS er Tg RC s 65 Air filter box lid installing ludunt Y ees 63 FEMOVING 22 b anda ood dente Ie Gt Mee ere ced 63 Antifreeze CHECKING ao usb ettet T ESTE eS 98 Auxiliary
103. er person on another vehicle so that you can help each other is recommended Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle Do not make any offroad trips that over stress your ability and experience 8 PREPARING FOR USE 31 Hold the handlebar firmly with both hands and keep your feet on the footrests when riding 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 e Info Motorcycles react sensitively to any changes of weight distribution Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 Ib Maximum permissible front axle load 145 kg 320 Ib Maximum permissible rear axle load 190 kg 419 Ib Check the spoke tension p 89 e Info The spoke tension must be checked after half an hour of operation Run in the engine p 31 8 2 Running in the engine During the running in phase do not exceed the specified engine performance Guideline Maximum engine performance During the first 3 operating hours lt 70 During the first 5 operating hours lt 100 Avoid fully opening the throttle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions su
104. ery terminal M5 2 5 Nm 1 84 Ibf ft All 200 250 300 models Screw shock absorber adjusting ring M5 5 Nm 3 7 Ibf ft Screws on the main silencer M5 7 Nm 5 2 Ibf ft Nut cable on starter motor M6 4 Nm 3 Ibf ft All 200 250 300 models Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Remaining screws chassis M6 10 Nm 7 4 Ibf ft Screw ball joint of push rod on foot M6 10 Nm 7 4 Ibf ft Loctite 2437 brake cylinder Screw chain sliding guard M6 6 Nm 4 4 Ibf ft Loctite 2437 Screw front brake disc M6 14 Nm 10 3 Ibf ft Loctite 243 Screw rear brake disc M6 14 Nm 10 3 Ibf ft Loctite 243 Screw throttle grip M6 5 Nm 3 7 Ibf ft Nut foot brake lever stop M8 20 Nm 14 8 Ibf ft Nut rear sprocket screw M8 35 Nm 25 8 Ibf ft Loctite 27017 Nut rim lock M8 12 Nm 8 9 Ibf ft Remaining nuts chassis M8 25 Nm 18 4 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw bottom triple clamp EXC M8 15 Nm 11 1 Ibf ft XC W Screw bottom triple clamp Six Days M8 15 Nm 11 1 Ibf ft EXC Factory Edition Screw chain sliding piece M8 15 Nm 11 1 Ibf ft Screw engine brace M8 33 Nm 24 3 Ibf ft Loctite 2701 Screw fork stub M8 15 Nm 11 1 Ibf ft Screw front brake caliper M8 25 Nm 18 4 Ibf ft Loctite 2437 Screw handlebar clamp M8 20 Nm 14 8 Ibf ft Screw side stand attachment M8 45 Nm 33 2 Ibf ft Loctite 27017 Screw subframe M8 35 Nm 25 8 Ibf ft
105. es can move freely and are routed correctly Check the play of the steering head bearing p 58 Remove the motorcycle from the lift stand p 50 Check the headlight setting p 96 12 SERVICE WORK ON THE CHASSIS 57 clamp a Six Days EXC Factory Edition Main work Clean the bearing and sealing elements check for damage and grease 12 14 Installing the lower tri High viscosity grease p 137 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the upper steering head seal 1 is correctly positioned Mount protective ring 2 and O ring O Position the upper triple clamp with the handlebar Mount screw o but do not tighten yet Position the clutch line and wiring harness 602736 10 Six Days Position the fork legs e Info The rebound damping is located in the right fork leg REB red adjusting screw The compression damping is located in the left fork leg COMP white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp Position bleeder screws 5 toward the front EXC Factory Edition Position the fork legs e Info I Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with t
106. etting Adjusting the headlight range Changing the speedometer battery TABLE OF CONTENTS 16 COOLING SYSTEM ee eren in tu in Hana nav nena a 16 1 Cooling System ib la 16 2 Checking the antifreeze and coolant level 16 3 Checking the coolant level 16 4 Draining the coolant esssessssessssse 16 5 Refilling with coolant ssssessssss 17 TUNING THE ENGINE t riz nennen 17 1 Checking the play in the throttle cable 17 2 Adjusting the play in the throttle cable 4 17 3 Carburetor dl ooccoooonnccnccnnnccnnnnnnnnnnnnnnonanos 17 4 Carburetor adjusting the idle speed amp 17 5 Emptying the carburetor float chamber 17 6 Checking the basic position of the shift lever 17 7 Adjusting the basic position of the shift CA A AE E 17 8 Engine characteristic auxiliary spring All 250 300 models nee 17 9 Engine characteristic setting the auxiliary spring A All 250 300 models 18 SERVICE WORK ON THE ENGINE eene 18 1 Checking the gear oil level 18 2 Changing the gear oil X eesssseuuesss 18 3 Draining the gear oil a e rrer 18 4 Refilling with gear oil X 18 5 Adding gear oil X 19 CLEANING CARE eeeeeeeeee rennen 19 1
107. filter in area Long life grease p 137 301262 10 Insert both parts together position them and fasten them using air filter holder O X The arrow of marking UP faces up e Info If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Finishing work Install the air filter box lid p 63 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 e Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box lid p 63 Remove the air filter 4 p 63 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 137 e Info Only squeeze the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil S00044 10 Oil for foam air filter 7 p 137 Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filter A p 64 Install the air filter box lid p 63 12 SERVICE WORK ON THE CHASSIS 65 1229 Sealing the air filter boxa 0 Preparatory work Remove the air filter box li
108. fit the headlight mask with the headlight p 94 Check the headlight setting p 96 Preparatory work Raise the motorcycle with the lift stand p 50 Remove the front wheel amp p 86 Remove the headlight mask with the headlight 7 p 94 Remove the fork legs amp p 52 Main work Remove screws 1 on the left fork leg Lift off the fork protector Remove the screws on the right fork leg Lift off the fork protector 101327 10 12 SERVICE WORK ON THE CHASSIS 54 320 Installing the fork protector 00 Main work Position the fork protection on the left fork leg Mount and tighten screws O Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft 101327 10 Finishing work Install the fork legs amp p 52 Install the front wheel amp p 86 Refit the headlight mask with the headlight 7 p 94 Check the headlight setting p 96 Preparatory work Raise the motorcycle with the lift stand p 50 Remove the front wheel 4 p 86 Remove the headlight mask with the headlight p 94 Remove the fork legs A p 52 Remove the front fender p 60 Remove the handlebar cushion Main work Remove screw O
109. for tightness Ifthe chain sliding guard is loose Tighten the screws on the chain sliding guard Guideline Screw chain sliding M6 6 Nm Loctite 243 guard 4 4 Ibf ft 12 SERVICE WORK ON THE CHASSIS 7 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece 4 Check the chain sliding piece for tightness Ifthe chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 Ibf ft B00824 01 Check the chain guide for wear e Info Wear can be seen on the front of the chain guide Ifthe light part of the chain guide is worn Change the chain guide 4 400985 01 NU Y DI gt Check the chain guide for tightness Ifthe chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Finishing work Remove the motorcycle from the lift stand p 50 Check the frame for cracking and deformation Ifthe frame exhibits cracking or deformation due to a mechanical impact Change the frame e info A frame that has been damaged due to a mechanical impact must be replaced Repair of the frame is not authorized by KTM 401347 01 12 SERVICE W
110. g Warning 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 with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Preparatory work Raise the motorcycle with the lift stand p 50 12 SERVICE WORK ON THE CHASSIS 59 Main work 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 Adjust the play of the steering head bearing 4 p 59 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range There should be no perceptible detent positions 400738 11 If detent positions are noticeable Adjust the play of the steering head bearing 4 p 59 Check the steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 50 12 16 Adjusting the play of the steering head bearing a Preparatory work Raise the motorcycle with the lift stand p 50 Main work EXC XC W Loosen screws 1 and O Loosen and retighten sc
111. ghten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level under top edge of con 4 mm 0 16 in tainer B01540 10 Position the cover with the membrane Mount and tighten the screws 12 SERVICE WORK ON THE CHASSIS 76 1248 Removing the engine guard Six Days EXC Factory Edition Turn quick release 1 counterclockwise until it disengages Remove the engine guard Attach the engine guard at the back of the frame and swing it up at front Turn quick release 1 all the way clockwise B01205 10 13 BRAKE SYSTEM 7 13 1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure If there is no free travel on the hand brake lever pressure builds up on the front brake circuit The front brake can fail due to overheating Adjust the free travel on hand brake lever according to specifications All EXC models Press the hand brake lever toward the handlebar and check free travel O Free travel of hand brake lever gt 3 mm 20 12 in Ifthe free travel does not equal the specification Adjust the free travel of the hand brake lever p 77 All XC W models Press the hand brake lever forward and check free travel O Free travel of hand brake lever gt 3 mm 20 12 in Ifthe free travel does not equal the specification
112. gnal on The turn signal switch is turned to the right 101633 10 Turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off The turn signal switch is in the central position Left turn signal on The turn signal switch is turned to the left E Right turn signal on The turn signal switch is turned to the right 102044 12 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started 602728 10 6 CONTROLS 16 6 15 Electric starter button All 200 250 300 EU US models 300EXCBR 0 The electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated 602699 10 The electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated 602728 11 _ Ak Possible states The hig
113. gs p 79 Check the rear brake linings p 83 Check that the brake system is functioning properly Check the coolant level p 99 Check the chain for dirt p 68 Check the chain rear sprocket engine sprocket and chain guide p 70 Check the chain tension p 68 Check the tire condition p 88 Check the tire air pressure p 89 Check the spoke tension p 89 Clean the dust boots of the fork legs p 51 Bleed the fork legs p 50 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting Danger Al Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Info If the motorcycle does not start easily there may be old fuel in the float chamber The easily ignitable components of the fuel evaporate during lengthy periods of disuse When the float chamber is filled with fresh ign
114. h beam indicator lamp lights up blue The high beam is D switched on EFI warning lamp MIL inoperative EFI R Low fuel warning lamp inoperative P on m Possible states O The high beam indicator lamp lights up blue inoperative EFI warning lamp MIL inoperative EFI Turn signal indicator light flashes green The turn signal is switched E R Low fuel warning lamp inoperative 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 The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling 6 CONTROLS 17 Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment
115. he distance between the rear axle and the fixed point again o e Info The static sag is the difference between measurements Y and Note down the value as dimension Check the static sag All 125 200 models Static sag 29 32 mm 1 14 1 26 in All 250 300 models Static sag 33 35 mm 1 3 1 38 in Ifthe static sag is less or more than the specified value i Adjust the spring preload of the shock absorber p 44 400989 10 11 TUNING THE CHASSIS 11 8 Checking the riding sag of the shock absorber o O 400990 10 Measure distance of the unloaded rear wheel p 43 With another person holding the motorcycle the rider wearing full protective cloth ing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now measures the distance between the rear axle and a fixed point Note down the value as dimension Q e Info The riding sag is the difference between measurements y and Check the riding sag Guideline All 125 200 models Riding sag 100 110 mm 3 94 4 33 in All 250 300 models Riding sag 105 115 mm 4 13 4 53 in Ifthe riding sag differs from the specified measurement Adjust the riding sag p 45 11 9 Adjusting the spring preload of the shock absorber 4 Cautio
116. he top edge of the upper triple clamp Position bleeder screws 5 toward the front l M00594 10 v z Tighten screws 407 Guideline Screw bottom triple clamp M8 15 Nm 11 1 Ibf ft 160273810 12 SERVICE WORK ON THE CHASSIS 58 Tighten screw O r Guideline f Screw top steering head M20x1 5 12 Nm 8 9 Ibf ft come Ee 4 z S AE 602739 10 Mount and tighten screw Guideline Screw top steering stem M8 17 Nm Loctite 243 12 5 Ibf ft Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft Position the brake caliper Mount and tighten screws O Guideline Screw front brake caliper M8 25 Nm Loctite 243 18 4 Ibf ft Mount cable binder Position the brake line and wiring harness Put on the clamp and mount and tighten screws 11 Install the front fender p 61 Mount the handlebar cushion Refit the headlight mask with the headlight p 94 Install the front wheel 4 p 86 Finishing work Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 58 Remove the motorcycle from the lift stand p 50 B00798 13 12 15 Checking the play of the steering head bearin
117. iator hoses or other cooling 600872 10 system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water 8 PREPARING FOR USE 34 Change the radiator cap Adjust the secondary ratio to the terrain e Iinfo The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive Clean the chain Chain cleaner p 137 Clean the radiator fins 600868 01 8 8 Carefully align bent radiator fins Check the coolant level p 99 Preparing for riding at low temperatures or in snow Mount the rain cover for the air filter Rain cover for air filter 59006021000 e Info I Follow the KTM PowerParts mounting instructions Adjust the carburetor jetting and setting e Info Your authorized KTM workshop can recommend the right carburetor tuning 600870 01 9 RIDING INSTRUCTIONS 35 9 1 Checks and maintenance work when preparing for use e Info Before riding the vehicle always check its condition and operating safety The vehicle must be in perfect technical condition when used Check the gear oil level p 107 Check the electrical system Check the front brake fluid level p 78 Check the rear brake fluid level p 82 Check the front brake linin
118. ight can be com pensated by the spring preload However if the fork is often overloaded hard end stop on compression harder springs must be fit to avoid damage to the fork and frame 401000 01 11 12 Adjusting the compression damping of the fork e Info The hydraulic compression damping determines the fork suspension behavior EXC XC W EXC Factory Edition Remove protection caps O Turn adjusting screws 2 clockwise all the way e Info Adjusting screws 2 are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline 125 EXC EU all 200 models 125 EXC Factory Edition EU Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks 250 300 EXC EU AU XC W US 250 300 EXC Factory Edition 300 EXC BR Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping Mount protection caps O Six Days Turn the white adjusting screw e all the way clockwise 7 7 i Info Adjusting screw e is located at the upper end of the left fork leg The compression damping is located in the left fork leg white adjusting NE ci screw The rebound damping is located in the right
119. ing the headlight mask with the headlight 00 Switch off all power consumers and switch off the engine Remove screw o and take off the clamp Release rubber straps e Slide the headlight mask up and swing it forward 602762 10 All EXC models Detach plug in connectors e and take off the headlight mask with the head light All XC W models Detach plug in connector e and take off the headlight mask with the head light Main work All EXC models Connect plug in connectors O All XC W models Connect plug in connector O 15 ELECTRICAL SYSTEM 95 Position the headlight mask and fix it with rubber straps X The holding lugs engage Position the brake line and wiring harness Put the clamp on and mount and tighten screw Finishing work Check the headlight setting p 96 Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Remove the headlight mask with the headlight p 94 Main work Turn protection cap amp together with the underlying bulb socket counterclockwise all the way and remove it Pull lamp socket e of the parking light out of the reflector Pull out headlight bulb 6 Insert the new headlight bulb Headlight HS1 soc
120. ing the rear wheel Fix the rear wheel in this position Remove screw O push splash protector to the side and remove the shock absorber Main work All 125 200 models Push splash protector 1 to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock M12 80 Nm Loctite 2701 absorber 59 Ibf ft Mount and tighten screw 12 SERVICE WORK ON THE CHASSIS 62 Guideline Screw bottom shock M12 80 Nm Loctite 2701 absorber 59 Ibf ft Info e l The heim joint for the shock absorber at the swing arm is Teflon coated It must not be lubricated with grease or with other lubricants Lubricants dissolve the Teflon coating thereby drastically reducing the service life All 250 300 models Push splash protector 1 to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock M12 80 Nm Loctite 2701 absorber 59 Ibf ft Mount and tighten screw Guideline 02158 11 ee Screw bottom shock M12 80 Nm Loctite 2701 absorber 59 Ibf ft Info e I The heim joint for the shock absorber at the swing arm is Teflon coated It must not be lubricated with grease or with other lubricants Lubricants dissolve the Teflon coating thereby drastically reducing the service life Finishing work Remove the motorcycle from the lift stan
121. itable fuel the engine will start immediately Condition The motorcycle was stationary for more than 1 week Empty the carburetor float chamber 4 p 104 Turn handle 1 of the fuel tap to the ON position Figure 602702 10 p 17 Y Fuel can flow from the fuel tank to the carburetor Take the motorcycle off of the stand Shift gear to neutral EXC AU Turn the emergency OFF switch to the position Condition The engine is cold 9 RIDING INSTRUCTIONS 36 Pull out the choke lever all the way All 200 250 300 models Press the electric starter button or press the kick starter robustly through its full range e Info Do not turn the throttle All 125 models Press the kick starter robustly through its full range e Info Do not turn the throttle 9 3 Start off e Info Before riding switch on the lights if your vehicle is equipped with a lighting system This will make it easier for other road users to see you When you are riding the side stand must be folded up and secured with the rubber band Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 9 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can lock up e Info If
122. ket BX43t p 121 Insert the protection cap with the bulb socket into the reflector and turn it clock wise all the way e Info Ensure that the O ring o is seated properly B01563 10 Insert the lamp socket of the parking light into the reflector Finishing work Refit the headlight mask with the headlight p 94 Check the headlight setting p 96 Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 15 ELECTRICAL SYSTEM 96 Main work Remove the screw on the rear of the turn signal housing Carefully remove turn signal glass O Lightly squeeze orange cap 2 in the area of the holding lugs and take it off Press the turn signal bulb carefully into the socket turn it counterclockwise by about 30 and take it out of the socket e Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal R1OW socket BA15s p 121 Mount the orange cap Position the turn signal glass Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly 101722 10 Finishing work Check that the turn sign
123. leeder screws Finishing work Remove the motorcycle from the lift stand p 50 12 SERVICE WORK ON THE CHASSIS 51 124 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with the lift stand p 50 Loosen the fork protection p 51 Main work Push dust boots o of both fork legs downwards e Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray 7 p 138 Press the dust boots back into their normal position Remove excess oil Finishing work Position the fork protection p 51 Remove the motorcycle from the lift stand p 50 Remove screws 1 and take off the clamp Remove screws e on the left fork leg Push the fork protection downwards Remove the screws on the right fork leg Push the fork protection downwards M00094 10 Position the fork protection on the left fork leg Mount and tighten screws O Guideline Remaining scre
124. let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral EXC EU AU EXC Factory Edition 300 EXC BR Press and hold the kill switch amp 3 while the engine is idling until the engine stops All XC W models Press and hold the kill switch amp while the engine is idling until the engine stops Turn handle 1 of the fuel tap to the OFF position Figure 602702 10 p 17 Park the motorcycle on firm ground 9 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 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 Switch off the engine Use tension belts or other suitable devices to secure the motorcycle against acci dents or falling over 401475 01 9 RIDING INSTRUCTIONS 38 9 8 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near ope
125. luid has dropped below marking O Add front brake fluid amp p 78 602745 10 13 6 Adding front brake fluid a Warning Danger of accidents Brake system failure Ifthe brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately 13 BRAKE SYSTEM 79 Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 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 e Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts
126. lve in radiator cap O This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream Y The lower the speed the less the cooling effect Dirty cooling fins also reduce the b N B02168 10 cooling effect Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant antifreeze 25 45 C 13 49 F If the antifreeze in the coolant does not match the specified value Correct the coolant antifreeze Check the coolant lev
127. m 10 3 Ibf ft Loctite 243 Screw slave cylinder of the clutch M6 10 Nm 7 4 Ibf ft Screw starter motor M6 8 Nm 5 9 Ibf ft Screw stator M6 8 Nm 5 9 Ibf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 Ibf ft Screw cylinder head M8 27 Nm 19 9 Ibf ft Screw kick starter M8 25 Nm 18 4 Ibf ft Loctite 27017 Nut cylinder base M10 35 Nm 25 8 Ibf ft Drain plug water pump cover M10x1 15 Nm 11 1 Ibf ft Nut rotor M12x1 60 Nm 44 3 Ibf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Spark plug M14x1 25 25 Nm 18 4 Ibf ft Nut inner clutch hub M18x1 5 120 Nm 88 5 Ibf ft Loctite 648 Nut primary gear M18LHx1 5 150 Nm 110 6 Ibf ft Loctite 648 22 3 Capacities 22 3 1 Gear oil Gear oil All 125 200 models 0 70 I 0 74 qt Engine oil 15W 50 p 135 Gear oil All 250 300 models 0 80 0 85 qt Engine oil 15W 50 p 135 22 3 2 Coolant Coolant 1 2 I 1 3 qt Coolant p 135 22 3 3 Fuel Total fuel tank capacity approx EXC EU EXC Six Days EXC Factory Edition 300 EXC BR 9 5 2 51 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 136 Total fuel tank capacity approx EXC AU XC W XC W Six Days 10 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 136 Fuel reserve approx EX
128. mm 18 5 in 22 TECHNICAL DATA 124 Spring rate Weight of rider 65 75 kg 143 165 Ib 3 8 N mm 21 7 Ib in Weight of rider 75 85 kg 165 187 Ib 4 0 N mm 22 8 Ib in Weight of rider 85 95 kg 187 209 Ib 4 2 N mm 24 Ib in Fork length 932 mm 36 69 in Air chamber length 100 mm 3 94 in Oil capacity per fork leg 635 ml 21 47 fl oz Fork oil SAE 4 4860116681 p 135 22 8 Shock absorber 22 8 1 All 125 200 models Shock absorber part number 12 18 70 61 Shock absorber WP Suspension PDS 5018 DCC Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload Comfort 10 mm 0 39 in Standard 10 mm 0 39 in Sport 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 Ib 63 N mm 360 Ib in Weight of rider 75 85 kg 165 187 Ib 66 N mm 377 Ib in Weight of rider 85 95 kg 187 209 Ib 69 N mm 394 Ib in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 29 32 mm 1 14 1 26 in Riding sag 100 110 mm 3 94 4 33 in Fitted length
129. n 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 e Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work 401026 10 Raise the motorcycle with the lift stand p 50 Remove the shock absorber p 61 After removing the shock absorber clean it thoroughly Main work Loosen screw O Turn adjusting ring 2 until the spring is no longer under tension Hook wrench T106S Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring e to measurement O Guideline All 125 200 models Spring preload Comfort 10 mm 0 39 in Standard 10 mm 0 39 in Sport 10 mm 0 39 in All 250 300 models Spring preload Comfort 7 mm 0 28 in Standard 7 mm 0 28 in Sport 7 mm 0 28 in 11 TUNING THE CHASSIS 45 11 10 Adjusting the riding sag a B00292 10 11 11 e Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw O Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 Ibf ft Finishing work
130. n 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 The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Switch off the engine Open the filler cap p 16 MT Fill the fuel tank with fuel up to measurement f Guideline Sy 35 mm 1 38 in Measurement of o Total fuel tank 9 5 Super unleaded 95 octane mixed capacity approx 2 51 US gal with 2 stroke engine oil 1 60 EXC EU p 136 EXC Six Days M EXC Fac L 477 400382 10 tory Edition 300 EXC BR Total fuel tank 10 I 2 6 US gal Super unleaded 95 octane mixed capacity approx with 2 stroke engine oil 1 60 EXC AU XC W p 136 X
131. ne in an enclosed space without an effective exhaust extraction system 18 SERVICE WORK ON THE ENGINE Start the engine and check that it is oil tight Finishing work Check the gear oil level p 107 110 19 CLEANING CARE 19 1 Cleaning the motorcycle 111 Note Material damage Damage and destruction of components by high pressure cleaning equipment When cleaning the vehicle with a pressure cleaner do not point the water jet directly onto electrical components connectors cables bearings etc Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component Excessive pressure can cause malfunctions or destroy these parts 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 e Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunlight on the motorcycle during cleaning 401061 01 Close off the exhaust system to prevent water from entering Remove coarse dirt particles by spraying gently with water Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft brush Motorcycle cleaner p 137 Info e I Use warm water containing normal motorcycle cleaner and a soft sponge Never appl
132. ocking the steering All EXC models Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key Y You can now steer the bike again 20 e Info Never leave the key in the steering lock 400731 01 7 SPEEDOMETER 7 1 Speedometer overview g 401761 01 7 2 Activation and test LAP aa Oo 2 TR 898 Aig Bi Dp B5 aB5 im WS Km h Mph Mies ODO LAP CLK H 400313 0 JIN Leu 400314 0 7 3 Setting kilometers or miles Info 21 Press the button to control different functions Press the button to control different functions e info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor Display test To enable you to check that the display is functioning properly all display segments light up briefly WS wheel size After the display function check the wheel size WS is displayed briefly e Info The number 2205 equals the circumference of the 21 front wheel with stan dard tires The display then changes to the last selected mode If you change the unit the value ODO is retained and converted accordingly The values TR1 TR2 A1 A2 and S1
133. of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise the motorcycle with the lift stand p 50 Check the chain tension p 68 Main work Loosen nut Q Loosen nuts e Adjust the chain tension by turning adjusting screws e left and right Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws e on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks O The rear wheel is then correctly aligned Tighten nuts e Make sure that chain adjusters o are fitted correctly on adjusting screws O Tighten nut O Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft Info e I The wide adjustment range of the chain adjusters 32 mm 1 18 in enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Finishing work Remove the motorcycle from the lift stan
134. ollar sleeve Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Connect the fuel hose E 602742211 Finishing work Mount the seat p 62 12 SERVICE WORK ON THE CHASSIS 68 12 35 Checking the chain for dirt Check the chain for heavy soiling Ifthe chain is very dirty Clean the chain p 68 400678 01 12 36 Cleaning the chain 0 Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 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 Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the lift stand p 50 Main work Clean the chain regularly and then treat with chain spray Chain cleaner p 137 Off road chain spray p 137 400725 01 Finishing work Remove the motorcycle from the lift stand p 50 12 37 Checking the chain tension Warning Danger of accidents Danger caused by incorr
135. on dee e asta YR ENS 22 speedometer overview llle 21 Spoke tension CHECKING ctr ett tS xax ee uti mem ESO ET 89 St rtilip oes te et uae Ez cA tao iE Eos 35 Steering lOCKInp seco A oa fed cute anita Sea HO E 19 UNIOCKING anio eher Ress abv ale e ev tebe te 20 Steering head bearing greasing ceder dale ER MD S CRURA E AS 60 Steering head bearing play ACIUSEING Asi sadaa a Gd hd adam exi dled ules ee alee 59 checking Lia e dL beet Re Ep usd itg 58 O 4 od se eh eds to ee et a 113 Swingarm CHECKING ics er areis oe doe dete eat era cite ae anaes aed 72 T Technical data Capacitan td DIES 120 Carburetors taaie kasd e a 127 Chassis lia ges ee ep d A ace ee 120 chassis tightening torques llle 125 electrical system ww ee 121 ERBIN arriti rr MP at oes 116 engine tightening torques llle 118 TOEKS trono circu Sah reg URL on Se eO A ee ache a RY 122 Shock absorber ligean eased ole ota daha ds whos 124 LINES d S peso citar aed ee stet etos o eese ede quond 122 Throttle cable play AC USTING scc e Tue eae ee eet eee WEB 102 CHECKING d a tee Sas ces ol E ee ds 102 Throttle cable routing checking svi Boe ob aa aa ae a Pe eS 72 Throttleorip 4 ci peia REG ee ee 13 Tire air pressure CHECKING e Sad A awe rd ota as bla dod Bele ee 89 Tire condition Checking cu c et nu ba Sac bath Si d Rei 88 Transport A a ee ee ie 37 Troubleshooting oooo 114 115 Turn signal
136. ontact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to use of non approved 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 The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid 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 Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid
137. ontrol prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases Removal or puncturing of parts of the intake system Lack of proper maintenance B WN Hn Replacing moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manu facturer 2 SAFETY ADVICE N Danger Al Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired Danger Al Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them
138. order to push back the brake pistons e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes M00116 10 Loosen screw 1 by several rotations Loosen screws e Press on screw o to push the wheel spindle ouf of the axle clamp Remove screw O M00117 10 Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e 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 Remove spacers e 14 2 Installing the front wheel a Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease shaft seal rings o and bearing surface O of the spacers Long life grease p 137 Insert the spacers 14 WHEELS TIRES M00117 11 87 Lift the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 Ibf ft
139. ortant impact on the handling characteristics of the motorcycle Worn tires have a negative effect on handling characteristics especially on wet surfaces 14 WHEELS TIRES 89 Check the front and rear tires for cuts run in objects and other damage If the tire exhibits cuts run in objects or other damage Change the tire Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth Minimum tread depth 22mm 2 0 08 in AON 400602 10 Ifthe tread depth is less than the minimum permissible depth Change the tire Check the tire age Info e The tire s date of manufacture is usually part of the tire markings and is indicated by the last four digits of the 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 Ifthe tire is older than five years Change the tire 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure road All EXC models Front 1 5 bar 22 psi Rear 1 5 ba
140. own or sooty a smaller main jet needs to be used 17 4 Carburetor adjusting the idle speed 4 Open 2 75 turns Idle air adjusting screw All XC W models 300 EXC BR Open 2 0 turns A Idle air adjusting screw 200 EXC EU Open 1 5 turns Idle air adjusting screw 200 EXC AU Open 1 0 turn Idle air adjusting screw 250 300 EXC AU Open 3 5 turns Screw idle air adjusting screw 1 all the way in Turn the idle air adjusting screw to the specified basic setting Guideline Idle air adjusting screw All 125 models Idle air adjusting screw 250 EXC EU 250 EXC Six Days EU 250 EXC Fac tory Edition EU Open 1 5 turns Idle air adjusting screw 300 EXC EU 300 EXC Six Days EU 300 EXC Fac tory Edition EU Open 1 75 turns Run the engine until warm Guideline Warm up time 25min Danger Danger of poisoning Exhaust gases are toxic 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 17 TUNING THE ENGINE 104 Adjust the idle speed with adjusting screw O Guideline Choke function deactivated The choke lever is pushed in all the way p 18 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 1 slowly in a clockwi
141. paring for use 35 Protective clothing llle 7 Rear sprocket CHECKING cru A a haute ce 70 Rear wheel installing 2 a a edd ee nee id ER 88 FEMOVING sudden w aah EEA A RAI EE s 87 Rebound damping fork adJUsting eros peo hx E Pu de os 47 shock absorber adjusting o o o oooooooo o 42 Riding sag adjusting a ences i w ve a i 45 Rubber grip CHECKING e aee cui ur ba e Aa aC Lx dca tee a EA 73 SECUNDE iue READER RR LR HUE RA 73 Safe operation 0 00 cee eee 7 Seat MOUNTING iens c aye a tee ana fa hag Bede use dE wae dey A 62 VEMOVING 24 024 vA NER E AAT E av ees 62 SemICes uei haw wild We EN Ee ids 8 Service schedule o o o ooooooo o 39 40 Shift levels Co tica o br a lo rra whe eed SS 18 basic position adjusting o oooooooo o 105 basic position checking o o ooooooooooo 105 Shock absorber compression damping general information 41 INDEX installing icerum m ers ea ds 61 FEMOVING coi nd sees eed sx en p eee SS 61 riding sag checking llle 44 spring preload adjusting o o oo oooooooo o 44 static sag checking eee eee eee 43 Shock absorber part number 12 Side stand 35s A 19 Spare parts acarrea 8 Speedometer battery changing llle 97 clock setting i eiu ses ii Be tw Pg eR 22 kilometers or miles setting o ooooooo 21 Seting ue a A d
142. r 22 psi Tire air pressure off road Front 1 0 bar 15 psi 40969901 Rear 1 0 bar 15 psi Ifthe tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 14 7 Checking the spoke tension 0 Warning 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 If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 14 WHEELS TIRES Info eter Briefly strike each spoke with the tip of a screwdriver 90 e I The tone frequency depends on the length of the spoke and the spoke diam If you hear different tone frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note 400694 01 If the spoke tension varies Correct the spoke tension 4 Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 Ibf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 Ibf ft Torque wrench with various accessories in set 58429094000 15 ELECTRICAL SYSTEM 91 15 1 Removing the battery 4 All 200 250 300 models
143. r the positive terminal B02136 10 ESE Position the negative cable e and mount and tighten the screw Guideline Screw battery terminal M5 2 5 Nm 1 84 Ibf ft Finishing work Mount the seat p 62 15 15 3 ELECTRICAL SYSTEM 92 Recharging the battery a All 200 250 300 models A Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environment Do not dispose of batteries with the household waste Dispose of a defective battery in an environmentally friendly manner Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries 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 Info Even when there is no load on the battery it still loses power steadily The charg
144. r triple clamp with the steering Position the clutch line and wiring harness Mount screw e but do not tighten yet B02151 10 Position the fork legs e Info I Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp Position bleeder screws o toward the front B02152 10 12 SERVICE WORK ON THE CHASSIS 56 X Ee pe Ae A A a ADD D e Aan Y B00798 12 Tighten screws O Guideline Screw bottom triple clamp M8 15 Nm 11 1 Ibf ft Tighten screw O Guideline Screw top steering head M20x1 5 12 Nm 8 9 Ibf ft Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 Ibf ft Tighten screws Guideline Screw top triple clamp M8 20 Nm 14 8 Ibf ft Position the brake caliper Mount and tighten screws O Guideline Screw front brake caliper M8 25 Nm Loctite 243 18 4 Ibf ft Mount cable binder O Position the brake line and wiring harness Put on the clamp and mount and tighten screws QD Finishing work Mount the handlebar cushion Install the front fender p 61 Install the front wheel 4 p 86 Refit the headlight mask with the headlight p 94 Check that the wiring harness throttle cables and brake and clutch lin
145. reduced version only Inthe derestricted version the motorcycle must be used only on closed off property remote from public road traffic 22 TECHNICAL DATA 134 KEIHIN PWK 36S AG 20 C a TC 6 C 5 C 6 C 15 C 16 C 24 C 25 C 36 C 37 C 49 C 1 x2 F 20 F LIF 41 F 42 F 60 F 619F 78 F ZIF sc 98 99 F LOF 3 000 m 10 000 ft 2 301m 7 501 ft 2 300 m 7 500 ft 4 1 501 m 5 001 ft 1 500 m 5 000 ft 4 751m 2 501 ft 750m 2 500 ft A 301 m 1 001 ft 300 m 2 1 000 ft 35 4 N8R H 3 Om 172 402141 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open lJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces 22 10 15 General carburetor tuning A 1 5 Needle position from above The five needle positions are shown here 2 The carburetor tuning depends on the defined ambient and operating conditions B00075 10 23 SUBSTANCES 135 Standard classification DOT Guideline Use only brake fluid that complies with the specified standard see specifications on the container and that exhibits the corre sponding properties Recommended supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Guideline Only use high quality cool
146. ree travel of the hand brake lever p 77 e Check the play of the steering head bearing p 58 Change the spark plug and spark plug connector 4 o e Check the intake diaphragm 4 e e Check the exhaust control for functioning and smooth operation e Check the clutch 4 Change the gear oil 4 p 107 e e Check all hoses e g fuel cooling bleeding drainage and sleeves for cracking leaks and incorrect routing o e Check the antifreeze and coolant level 7 p 98 Check the cables for damage and routing without sharp bends o e Check that the throttle cables are undamaged routed without sharp bends and set correctly o Clean the air filter and air filter box A p 64 e e Change the glass fiber yarn filling of the main silencer 4 p 65 oo e Check the screws and nuts for tightness 4 e e Check the headlight setting 7 p 96 e Check the idle e e Final check Check the vehicle for safe operation and take a test ride e e Make the service entry in the KTM Dealer net and in the Service and Warranty Booklet 4 e Periodic interval 10 SERVICE SCHEDULE 40 10 2 Service work as additional order Annually Every 80 operating hours every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours Change the front brake fluid o Change the rear brake fluid A e Change the hydraulic clutch fluid A p 74 Greas
147. rew e Guideline Screw top steering head M20x1 5 12 Nm 8 9 Ibf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains B02154 10 A Tighten screws O Guideline Screw top triple clamp M8 20 Nm 14 8 Ibf ft Tighten screw e Guideline Screw top steering stem M8 20 Nm 14 8 Ibf ft Six Days Loosen screws O Remove screw O Loosen and retighten screw e Guideline Screw top steering head M20x1 5 12 Nm 8 9 Ibf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft Mount and tighten screw e Guideline Screw top steering stem M8 17 Nm Loctite 2437 12 5 Ibf ft 12 SERVICE WORK ON THE CHASSIS 60 EXC Factory Edition Loosen screws O Remove screw O Loosen and retighten screw 6 Guideline Screw top steering head M20x1 5 12 Nm 8 9 Ibf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains EN Renee ae Tighten screws O Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft Mount and tighten screw e Guideline Screw top steering stem M8 17 Nm Loctite 243 12 5 Ibf ft Finishing work Check the play of the steering h
148. rized KTM workshop There your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required EXS Indicates a page reference more information is provided on the specified page The typographical formats used in this document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market 2 SAFETY ADVICE 6 2 1 Use definition intended use All EXC models KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations e Info The motorcycle is authorized for public road traffic in the homologated reduced version only In the derestricted version the motorcycle must be used only on closed off properties remote from public road traffic This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross All XC W models KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations e Info I This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross 2 2
149. rn 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 O e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 2 5 mm 0 098 in 400257 10 Rear 3 5 mm 0 138 in Ifthe brake disc thickness is less than the specified value Change the brake disc Check the front and rear brake discs for damage cracking and deformation Ifthe brake disc exhibits damage cracking or deformation Change the brake disc 13 5 Checking the front brake fluid level Warning Danger of accidents Brake system failure Ifthe brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake 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 Check the brake fluid level in the viewer O gt Ifthe brake f
150. s 70 Environment coin E Euch ose RR 7 F EQU aia ARA a 8 Filler cap CLOSING rare a ad 17 Opening ouium enl aa ieee Pe ad 16 Filling up fuel cS DT WEN ER on piu 38 Foot brake lever 00 00 cee eee eee 18 basic position adjusting llle 81 free travel checking llle 81 INDEX Fork basic setting checking llle 45 Fork legs bleeding ias ade mer pp ow ae de la els 50 dust boots cleaning 0 00 ce eee eee 51 installing neiaa Ee Ruts wigs PAA Hess 52 fEMOVING saciar Aww ae ald b p age es 52 spring preload setting o o oooooooo oooo 48 Fork part number 00000 eee eee eee 11 Fork protector installing es 2c ctae Rn e E ced od ure 54 remoVvilg iu de eR DM wR Ee 53 Frame CHECKING 2a a 4 ado oO rta tee TA a FA EE a 71 Front fender installing tt medo rS Ae 61 remoVvIHnBg s Me patricia ds a 60 Front wheel installing sei prne be tret RR E eco s 86 removing Sat She a ra ex RR E da 86 Fuel tank installing iae seb tem Em ue doe Ec 67 removing Skok Sb ea ERE ERR PER E de 66 Eueltap 54 5e meo debe et ete 17 Fuse main fuse changing llle 93 Gear oil adding usce ped ut OR a acs slm 109 charging use Rm mh exe des 107 draining ilg ees er ai eR De Y es 108 AA UR ee 108 Gear oil level checking o n bd d doped e eet et rta 107 Hand brake lever 00020002 eee eae 13 basic position adjusting
151. s EU Turn the red adjusting screw 2 all the way clockwise e Adjusting screw e is located at the upper end of the right fork leg The rebound damping is located in the right fork leg red adjusting screw The compression damping is located in the left fork leg white Turn counterclockwise by the number of clicks corresponding to the fork type Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks 11 TUNING THE CHASSIS 11 14 Adjusting the spring preload of the fork EXC XC W EXC Factory Edition 11 15 Handlebar position 48 250 300 Six Days Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping e Info Turn the adjusting screws counterclockwise all the way Make the same adjustment on both fork legs Guideline Turn clockwise by the number of turns corresponding to the fork type 125 EXC EU all 200 models 125 EXC Factory Edition EU Spring preload Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns 250 300 EXC EU AU XC W US 250 300 EXC Factory Edition 300 EXC BR Spring preload Preload Adjuster spring preload Comfort 1 turn Standard 2 turns Sport 2 turns Info Turn clockwise to increase spring preload turn
152. s number p 11 Kick starter p 18 Foot brake lever p 18 Level viewer for brake fluid rear oa AI WIN e 5 SERIAL NUMBERS 11 A IS 401946 10 The chassis number 1 is stamped on the right side of the steering head The type label O is fixed to the front of the steering head Ns 401946 10 1 AAN The key number 1 for the steering lock is stamped onto the key connector 402247 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 401949 10 The fork part number is stamped on the inner side of the fork stub F 401947 10 5 SERIAL NUMBERS 401948 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side 6 CONTROLS 13 All 125 200 models The clutch lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting All 250 300 models The clutch lever o is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting Hand brake lever is located on the right side of the handlebar The hand brake lever is used to activate the front brake 602697 10 Throttle grip o is fitted on the right side of the handlebar The kill switch is fitted on the left
153. s on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Info Carry out this work with a cold engine Water in the float chamber results in malfunctioning Preparatory work Turn handle o of the fuel tap to the OFF position Figure 602702 10 p 17 Y Fuel no longer flows from the fuel tank to the carburetor Main work Place a cloth beneath the carburetor to soak up emerging fuel Remove plug O Completely drain the fuel Mount and tighten the plug 17 TUNING THE ENGINE 105 Checking the basic position of the shift lever Sit on the vehicle in the riding position and determine the distance o between the upper edge of your boot and the shift lever Distance between shift lever and upper 10 20 mm 0 39 0 79 in edge of boot Ifthe distance does not meet specifications Adjust the basic position of the shift lever A p 105 400692 10 17 7 Adjusting the basic position of the shift lever 4 Remove screw 1 and take off shift lever O 401950 12 Clean gear teeth of the shift lever and shift shaft
154. se direction until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed falls again Adjust to the point between these two positions with the highest idle speed e 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 If you can turn the idle air adjusting screw to the end without any change of engine speed you need to install a smaller idling jet After changing the idling jet repeat the adjusting steps from the beginning Following extreme air temperature or altitude changes adjust the idle speed again 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 The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated area
155. se skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake 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 Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved 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 The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed
156. see specifications on the container and that exhibit the corresponding properties Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use e Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Standard classification DIN EN 228 JASO FD p 139 1 60 Mixture ratio 1 60 Engine oil 2 stroke p 135 Super unleaded ROZ 95 RON 95 PON 91 p 136 Recommended supplier Motorex Cross Power 2T 24 AUXILIARY SUBSTANCES 13 Recommended supplier Motorex Racing Bio Dirt Remover Recommended supplier Motorex Chain Clean Recommended supplier Motorex Fuel Stabilizer Recommended supplier SKF LGHB 2 Recommended supplier Motorex Bike Grease 2000 Recommended supplier Motorex Moto Clean Recommended supplier Motorex Chainlube Offroad Recommended supplier Motorex Racing Bio Liquid Power Recommended supplier Motorex Moto Protect Recommended supplier KTM Motorrad AG GRIP GLUE Recommended supplier Motorex Quick Cleaner 24 AUXILIARY SUBSTANCES 138 Universal oil spray 500 Recommended supplier Motorex Joker 440 Synthetic 25 STANDARDS 139 Different technical developm
157. st not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Finishing work Mount the seat p 62 15 ELECTRICAL SYSTEM 93 Q Warning A Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Info The main fuse protects all power consumers of the vehicle It is located in the starter relay housing under the air filter box cover Preparatory work Switch off all power consumers and the engine Remove the air filter box lid p 63 Main work Remove screw O Lift rear fairing e slightly and pull starter relay e out of the holder Remove the protection caps Remove the faulty main fuse O e Info A defective fuse is indicated by a burned out fuse wire A reserve fuse 5 is located in the starter relay Fita new main fuse Fuse 58011109110 p 121 Check the functioning of the electrical equipment e Tip I Insert the spare fuse so that it is available if needed Fit the protection caps Mount the starter relay onto the holder and lay the cable Position the rear fairing Mount and tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Finishing work Install the air filter box lid p 63 15 ELECTRICAL SYSTEM 94 15 5 Remov
158. st valve end of adjustment with red auxiliary spring 7 200 rpm Exhaust valve end of adjustment with yellow auxiliary spring 7 900 rpm Exhaust valve end of adjustment with green auxiliary spring 8 400 rpm 22 TECHNICAL DATA 118 Crankshaft bearing 1 grooved ball bearing 1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 48 5 mm 1 909 in Primary transmission 26 72 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmission ratio 1st gear 14 32 2nd gear 16 26 3rd gear 20 25 4th gear 22 23 5th gear 25 22 6th gear 26 20 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Ignition point BTDC 1 9 mm 0 075 in Spark plug NGK BR7 ES Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter and electric starter 22 2 Engine tightening torques 22 2 1 All 125 200 models Screw membrane core plate All 125 EJOT DELTA PT 30x12 1 Nm 0 7 Ibf ft models Screw membrane holder All 125 EJOT DELTA PT
159. t of the display LAP ONO 0 Briefly press the button uuu 32 LAP Press the button The stop watch and the lap time are reset for 2 3 seconds Briefly press the Select a lap from 1 10 400321 0 button Press the button No function for 2 3 seconds Briefly press the View the next lap time button 7 SPEEDOMETER Repeatedly press the button briefly until ODO appears at the bottom right of the display The total traveled distance is shown in display mode ODO CI nn Press the button No function MP uu Li i LILI 53 Bg for 2 3 seconds SPEED kmh 000 Briefly press the Next display mode button Press the button No function 400317 0 for 2 3 seconds Briefly press the No function button SPEED cc Oo Km h TRI 109 3 400323 0 Repeatedly press the button briefly until TR1 appears at the top right of the dis play TR1 trip master 1 runs constantly and counts up to 999 9 You can use it to measure trips or the distance between refueling stops TR1 is coupled with A1 average speed 1 and S1 stop watch 1 e Info If 999 9 is exceeded the values of TR1 A1 and S1 are automatically reset to 0 0 Press the button for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the button
160. tch EXC EU AU EXC Factory Edition 300 EXC BR 15 6 13 Turn signal switch Six Days EU 15 6 14 Emergency OFF switch EXC AU 15 6 15 Electric starter button 6 16 6 17 6 18 6 19 6 20 6 21 6 22 6 23 6 24 All 200 250 300 EU US models 300 EXC BR aiite teet roe bt d 16 Electric starter button EXC AU 16 Overview of indicator lamps All EXC models 16 Overview of indicator lamps All XC W Mies Eyes ME 16 Opening the filler Cap occococccconcnccocnnconcnnno 16 Closing the filler cap cccoocccccocnnccccncconnnnoninnno 17 IA ce estote rere ce hour Dan adve e 17 GHOKE ia adel 18 Shift Ie Ver uis iaa 18 KICK Starter ird er ro potrete td eva 18 10 11 6 25 Foot brake lever ooooconccconcccconcocononoconnnconinncnno 6 26 Side stands seco tet esses dos te Rad 6 27 Steering lock All EXC models 6 28 Locking the steering All EXC models 6 29 Unlocking the steering All EXC models SPEEDOMETER ie che eo tei ert a e ion 7 1 Speedometer overview cccecceeceeeeseeeeeeeeeees 7 2 Activation and testcni iiaiai 7 3 Setting kilometers or miles 7 4 Setting the speedometer functions 7 5 Setting the Clock ieee iiec ds 7 6 Viewing the lap tiM occooccccccccnccncncnoncncnacnnnns 7 7 Display mo
161. tely with lukewarm water Change the radiator cap Mount the dust cover for the air filter Dust cover for air filter 59006019000 e Info Read the KTM PowerParts installation instructions 600869 01 Mount the dust cover for the air filter for sand Sand cover for air filter 59006022000 e info Read the KTM PowerParts installation instructions Adjust the carburetor jetting and setting e info 60087101 Your authorized KTM workshop can recommend the right carburetor tuning Clean the chain Chain cleaner p 137 Mount the steel sprocket e Tip I Do not grease the chain Clean the radiator fins Carefully align bent radiator fins 600868 01 If used in sand regularly replace the piston every 10 operating hours 8 5 Preparations for riding on wet sand Check the radiator cap Value on the radiator cap 1 8 bar 26 psi Ifthe displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling 600872 10 system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water 8 PREPARING FOR USE 33 Change the radiator cap Mount th
162. tem stator M6 8 Nm 5 9 Ibf ft Loctite 243 All 200 models Screw intake flange reed valve housing M6 10 Nm 7 4 Ibf ft Screw kick starter stop plate M6 10 Nm 7 4 Ibf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 Ibf ft Loctite 243 Screw shifting gate M6 10 Nm 7 4 Ibf ft Loctite 243 Screw starter motor All 200 models M6 8 Nm 5 9 Ibf ft Screw water pump cover M6 10 Nm 7 4 Ibf ft Loctite 243 Screw cylinder head M7 18 Nm 13 3 Ibf ft Axle for control flap exhaust control M8 Step 1 3 Nm 2 2 Ibf ft Step 2 loosen counter clockwise 1 4 turn Nut cylinder base M8 30 Nm 22 1 Ibf ft Screw kick starter M8 25 Nm 18 4 Ibf ft Loctite 243 Screw shift drum locating M8 25 Nm 18 4 Ibf ft Loctite 243 Stud cylinder base M8 35 Nm 25 8 Ibf ft Drain plug water pump cover M10x1 15 Nm 11 1 Ibf ft Gear oil drain plug M10x1 15 Nm 11 1 Ibf ft Nut rotor M12x1 60 Nm 44 3 Ibf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Spark plug M14x1 25 25 Nm 18 4 Ibf ft Nut primary gear M16LHx1 5 130 Nm 95 9 Ibf ft Loctite 243 Nut inner clutch hub M18x1 5 130 Nm 95 9 Ibf ft Loctite 243 Cap nut exhaust control M26x1 35 Nm 25 8 Ibf ft 22 2 2 All 250 300 models Screw clamping plate EJOT DELTA PT 30x6 1 Nm 0 7 Ibf ft Screw
163. the rebound damping of the shock absorber Caution 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 11 TUNING THE CHASSIS 43 Turn adjusting screw o clockwise up to the last perceptible click e Info Do not loosen nut O Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline All 125 200 models Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks All 250 300 models Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 6 Measuring the sag of the unloaded rear wheel Preparatory work Raise the motorcycle with the lift stand p 50 Main work Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the rear fairing O Note down the value as dimension T 400988 10 Finishing work Remove the motorcycle from the lift stand p 50 11 7 Checking the static sag of the shock absorber Measure distance of the unloaded rear wheel p 43 Hold the motorcycle upright with the aid of an assistant Measure t
164. the straight ahead position Push back sleeve O Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster O Loosen nut O Turn adjusting screw e in such a way there is throttle cable play O in the throt tle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut Slide on sleeve 602752 10 Finishing work Check the throttle grip for smooth operation The idle setting of the carburetor has a big influence on the starting behavior stable idling and the response to throttle opening That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly e Info The carburetor and its components are subject to greater wear due to engine vibrations Wear can lead to malfunctions The factory setting for the carburetor is set for the following values B00048 11 Altitude above sea level 500 m 1 640 ft Ambient temperature 20 C 68 F Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 136 17 TUNING THE ENGINE 103 The idle speed is adjusted with adjusting screw O The idle mixture is adjusted with the idle air adjusting screw e WW Idle air range A Operation with the throttle slide closed This range is influenced by adjusting screw o and the idle air adjusting screw e Transition range B Behavior of the engin
165. tment 5 700 rpm Exhaust valve end of adjustment with red auxiliary spring 7 300 rpm Exhaust valve end of adjustment with yellow auxiliary spring 8 000 rpm Exhaust valve end of adjustment with green auxiliary spring 8 500 rpm Crankshaft bearing 1 grooved ball bearing 1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 48 mm 1 89 in Primary transmission 26 72 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmission ratio lst gear 14 32 2nd gear 16 26 3rd gear 20 25 4th gear 22 23 bth gear 25 22 6th gear 26 20 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan 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 Kick starter and electric starter 22 1 4 All 300 models Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 293 cm 17 88 cu in Stroke 72 mm 2 83 in Bore 72 mm 2 83 in Exhaust valve Beginning of adjustment 5 600 rpm Exhau
166. type Guideline All 125 200 models B02144 10 Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks 11 TUNING THE CHASSIS All 250 300 models 42 Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks e Info I Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 4 Adjusting the high speed compression damping of the shock absorber Caution 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 e Info The high speed setting can be seen during the fast compression of the shock absorber Turn adjusting screw o all the way clockwise with a socket wrench Info Do not loosen nut e Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline All 125 200 models B02144 11 Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns All 250 300 models Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns e Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 5 Adjusting
167. ubstances 8 3 3 Spare parts accessories ooocccconcnccncnnconononononnnn 8 3 4 NIU 8 3 5 i e PS 8 3 6 Customer SCrViC cccccceeeeeceeeeeeeeeeecaeeeeeeeeaeeees 8 4 VIEW OF VEHICLE a mnn 9 4 1 View of vehicle front left example 9 4 2 View of vehicle rear right example 10 5 SERIAL NUMBERS iuit te secca strate Fortes tio aded 11 5 1 Chassis number ccccceeeeeeeeeeeeeeeeeeaeeeeeeeseaes 11 5 2 Type label a oia 11 5 3 Key number All EXC models 11 5 4 Engirie niumber iiti eese orte lots 11 5 5 Fork part nufmber uaa etre P Eon eds 11 5 6 Shock absorber part number 12 67 CONTROLS ecards Pert T eee afe us 13 6 1 Clutch levar cascada ias 13 6 2 Hand brake lever sess 13 6 3 Thirottle grip siu du edo Hoe Na Mae eerte 13 6 4 Kill switch EXC EU AU EXC Factory Edition 300 EXC BR iouis ene tne ca ene eh tells 13 6 5 Kill switch Six Days EU eese 14 6 6 Kill switch All XC W models 14 6 7 Horn button EXC EU AU EXC Factory Edition SOO EXC BR deeper oh gendi perge heme E e 14 6 8 Horn button Six Days EU 14 6 9 Light switch EXC EU AU EXC Factory Edition 300 EXC Bat ires sexes ERR E Ead 14 6 10 Light switch Six Days EU cooooconnncnnncnnnnnnnnnos 15 6 11 Light switch All XC W models 15 6 12 Turn signal swi
168. ueicet ries ede sene 8 8 Preparing for riding at low temperatures or in RIDING INSTRUCTIONS 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 10 1 10 2 11 1 11 2 11 3 Checks and maintenance work when preparing TO a SA E IA NICE Shifting riding ences Braking vs aee e ERES Stopping ParkiNB ccccoocccconnncnccnncnnonononnnnoninos TRANS DOME a ixi fonce d ere ees even teer ues Refueling inne terio Ec Ie IOS SERVICE SCHEDULE Service sched le i ecce eius Service work as additional order TUNING THE CHASSIS Checking the basic chassis setting with the rider sWelglits ecc ce ater te di ed cipue Compression damping of shock absorber Adjusting the low speed compression damping of the shock absorber occoccoccocconconiorincnoncnnon TABLE OF CONTENTS 12 11 4 Adjusting the high speed compression damping of the shock absorber 42 11 5 Adjusting the rebound damping of the shock Cleri sas 42 11 6 Measuring the sag of the unloaded rear wheel 43 11 7 Checking the static sag of the shock absorber 43 11 8 Checking the riding sag of the shock absorber 44 11 9 Adjusting the spring preload of the shock absorber Weca ori pi enc E beu dugd 44 11 10 Adjusting the riding sag sssssse 45 11 11 Checking the basic setting of the fork 45 11 12 Adjusting the compression damping of the jg EE 46 11 13 Adjusting the r
169. up i NM Y LAP 1 appears on the left side of the display i GGG 39 The laps 1 10 can be viewed with the button LAP Press and hold the button for 3 5 seconds to clear the lap times Briefly press the button Y Next display mode 400321 0 e Info When a signal from the wheel speed sensor arrives the left side of the dis play changes back to the SPEED mode 7 1 Display mode SPEED speed Repeatedly press the button briefly until SPEED appears on the left side of the display The current speed is displayed in the SPEED display mode The current speed can be displayed in Km h or Mph JS Lu LI d LILI 0 3 Ci e Info SEED kmh 000 I Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 400317 02 7 8 Display mode SPEED H service hours Condition e The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display nu ES j In display mode H the service hours of the engine are displayed LILI LILI L The service hour counter stores the total traveling time e Info I The service hour counter is necessary for ensuring that service work is carried 400316 0 out at the right intervals If the speedometer is in H display mode at the start of the journey it automati
170. urns Spring length with preload spacer s Weight of rider 65 75 kg 143 165 Ib 513 mm 20 2 in Weight of rider 75 85 kg 165 187 Ib 513 mm 20 2 in Weight of rider 85 95 kg 187 209 Ib 513 mm 20 2 in Spring rate Weight of rider 65 75 kg 143 165 Ib 3 8 N mm 21 7 Ib in Weight of rider 75 85 kg 165 187 Ib 4 0 N mm 22 8 Ib in Weight of rider 85 95 kg 187 209 Ib 4 2 N mm 24 Ib in Fork length 940 mm 37 01 in Air chamber length 11038 mm 4 33 838 in Fork oil per fork leg 620 ml 20 96 fl oz Fork oil SAE 4 4860116681 p 135 22 1 2 250 300 EXC EU AU XC W US 250 300 EXC Factory Edition 300 EXC BR Fork part number 14 18 7L 63 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping 22 TECHNICAL DATA 123 Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Spring length with preload spacer s Weight of rider 65 75 kg 143 165 Ib 513 mm 20 2 in Weight of rider 75 85 kg 165 187 Ib 513 mm 20 2 in Weight of rider 85 95 kg 187 209 Ib 513 mm 20 2 in Spring rate Weight of rider 65 75 kg 143 165 Ib 4 0 N mm 22 8 Ib in Weight of rider 75 85 kg
171. ws chassis M6 10 Nm 7 4 Ibf ft Position the brake line and wiring harness Put on the clamp and mount and tighten screws Y Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft M00094 11 12 SERVICE WORK ON THE CHASSIS 52 12 7 Removing the e Preparatory work Raise the motorcycle with the lift stand p 50 Remove the front wheel 4 p 86 Remove the headlight mask with the headlight p 94 Main work Remove screws 1 and take off the clamp Remove cable binder Remove screws e and take off the brake caliper Hangthe brake caliper and the brake line loosely to the side EXC XC W Loosen screws Oo Remove the fork leg on the left Loosen screws O Remove the fork leg on the right Six Days EXC Factory Edition Loosen screws Oo Remove the fork leg on the left Loosen screws O Remove the fork leg on the right Main work EXC XC W Position the fork legs e Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp Position bleeder screws 1 toward the front Six Days Position the fork legs e Info I The rebound damping is located in the right fork leg REB red adjusting screw
172. y motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber 4 p 104 Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently After cleaning take a short ride until the engine reaches operating temperature e info The heat produced causes water at inaccessible locations in the engine and brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 68 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Preserving materials for paints metal and rubber p 137 Treat all plastic parts and powder coated parts with a mild cleaning and care prod uct Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 137 All EXC models Oil the steering lock Universal oil spray p 138 19 CLEANING CARE 112 19 2 Checks and maintenance steps for winter operation e Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corro sion If the vehicle was operated in roa
173. y press the button briefly until CLK appears at the bottom right of the display pu UD IES Press the button for 2 3 seconds LL CLK Press the button Increases the value for 2 3 seconds Briefly press the Increases the value 400319 0 button Press the button Reduces the value for 2 3 seconds Briefly press the Reduces the value button Wait 3 5 seconds Changes to the next value Wait 10 12 sec Closes the SETUP menu onds 7 13 Display mode SPEED LAP lap time Repeatedly press the button briefly until LAP appears at the bottom right of the display In the LAP display mode up to 10 lap times can be timed with the stop watch nnng 30 E no LILI LILI d l If the lap time continues running after the button is pressed 9 memory loca LAP tions are occupied Lap 10 must be timed using the button 400320 0 Press the button The stop watch and the lap time are reset for 2 3 seconds Briefly press the Next display mode button Press the button Stops the clock for 2 3 seconds Briefly press the Starts the stop watch or stop the current lap time measure button ment stores it and the stop watch starts the next lap 7 14 Viewing the lap time Condition e The motorcycle is stationary Repeatedly press the button briefly until LAP appears at the bottom righ
174. y work Tilt the motorcycle approx 45 to the left and secure it to prevent it from falling 17 TUNING THE ENGINE 106 Main work Remove screws O Take cap O adjusting spring e auxiliary spring O and spring insert 5 out of 29 the clutch cover Pull both springs off of the spring insert e y B00056 11 Mount the required auxiliary spring o and adjusting spring e and slide them into the clutch cover together Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 v The recess in spring insert 5 engages in the angle lever e Info Screw must not be turned as this would worsen the engine characteris tic Check the O ring in the cap Position the cap Mount and tighten the screws Guideline Screw exhaust control cover M5 6 Nm 4 4 Ibf ft 18 SERVICE WORK ON THE ENGINE 107 18 1 Checking the gear oil level e Info The gear oil level must be checked while the engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface Main work All 125 200 models Remove screw o from the opening used to check the gear oil level Check the gear oil level A small quantity of gear oil should flow out of the opening If gear oil does not flow out Add gear oil A

12 service work on the chassis

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