OWNER'S MANUAL 2017 125 XC‑W 150 XC‑W 250 EXC 250 XC‑W 300 EXC 300 XC‑W Art. no.
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 properly. DEAR KTM CUSTOMER We hope you enjoy your new vehicle! Enter the serial numbers of your vehicle below. Chassis number ( p. 12) Engine number ( p. 12) Dealer's stamp Key number (All EXC/EXC Six Days models, 125 XC‑W EU) ( p.
TABLE OF CONTENTS TABLE OF CONTENTS 1 2 3 4 5 6 MEANS OF REPRESENTATION ..................................... 5 1.1 Symbols used ................................................... 5 1.2 Formats used.................................................... 5 SAFETY ADVICE........................................................... 6 2.1 Use definition – intended use............................. 6 2.2 Safety advice.................................................... 6 2.3 Degrees of risk and symbols .......
TABLE OF CONTENTS Adjusting the high-speed compression damping of the shock absorber......................... 11.5 Adjusting the rebound damping of the shock absorber......................................................... 11.6 Measuring the rear wheel dimension unloaded........................................................ 11.7 Checking the static sag of the shock absorber .... 11.8 Checking the riding sag of the shock absorber.... 11.9 Adjusting the spring preload of the shock absorber ................
TABLE OF CONTENTS 17 18 19 20 21 22 16.2 Checking the antifreeze and coolant level .......... 99 16.3 Checking the coolant level ............................. 100 16.4 Draining the coolant .................................. 100 16.5 Refilling with coolant ................................. 101 TUNING THE ENGINE.............................................. 103 17.1 Checking the play in the throttle cable ............ 103 17.2 Adjusting the play in the throttle cable ........ 103 17.
1 MEANS OF REPRESENTATION 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). 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 authorized KTM workshop.
2 SAFETY ADVICE 2.1 Use definition – intended use 6 (All EXC/EXC Six Days 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. Info The motorcycle is authorized for public road traffic in the homologated (reduced) version only.
2 SAFETY ADVICE 1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 2.5 7 Safe operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
2 SAFETY ADVICE 2.9 Owner's Manual 8 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 customize 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.
3 IMPORTANT NOTES 3.1 Manufacturer and implied warranty 9 The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
4 VIEW OF VEHICLE 4.1 View of vehicle, front left (example) 10 E00320-10 1 Hand brake lever ( p. 14) 2 Light switch ( 2 Kill switch ( 2 Turn signal switch ( 2 Horn button ( p. 15) 3 Clutch lever ( p. 14) 4 Chain guide 5 Air filter box cover 6 Side stand ( 7 Shift lever ( 8 Fuel tap ( p. 15) p. 14) p. 18) p. 18) p. 17) p.
4 VIEW OF VEHICLE 4.2 View of vehicle, rear right (example) 11 E00319-10 1 Filler cap 2 Throttle grip ( 3 Chassis number ( 4 Kick starter ( 5 Foot brake lever ( 6 Level viewer for brake fluid, rear p. 14) p. 12) p. 18) p.
5 SERIAL NUMBERS 5.1 Chassis number 12 The chassis number is stamped on the right side of the steering head. 401945-10 5.2 Type label Type label is fixed to the front of the steering head. 401945-10 5.3 Key number (All EXC/EXC Six Days models, 125 XC‑W EU) The key number for the steering lock is stamped onto the key connector. 402247-10 5.4 Engine number (All 125/150 models) The engine number sprocket.
5 SERIAL NUMBERS 5.5 Fork part number 13 The fork part number is stamped on the inside of the axle clamp. 401947-10 5.6 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side.
6 CONTROLS 6.1 Clutch lever 14 Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. V00322-10 6.2 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. E00311-10 6.3 Throttle grip Throttle grip is fitted on the right side of the handlebar. E00312-10 6.
6 CONTROLS 6.6 Horn button (All EXC/EXC Six Days models, 125 XC‑W EU) 15 (125 XC‑W EU) The horn button is fitted on the left side of the handlebar. Info The horn button has no function when the vehicle is delivered. (All EXC/EXC Six Days models) The horn button is fitted on the left side of the handlebar. E00318-11 6.7 Possible states • Horn button in neutral position • Horn button pressed – The horn is operated in this position.
6 CONTROLS 6.11 Electric starter button (All 250/300 models, XC‑W US, XC‑W Six Days US) 16 The electric starter button Possible states • Electric starter button • Electric starter button is fitted on the right side of the handlebar. in basic position pressed – In this position, the electric starter is actuated. E00313-10 6.12 Indicator lamps overview (All EXC/EXC Six Days models) Possible states The high beam indicator lamp lights up blue – The high beam is switched on.
6 CONTROLS 17 Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Press release button – Replace the filler cap and turn clockwise until the release button place. , turn the filler cap counterclockwise and lift it free. V00325-10 6.15 Closing the filler cap locks in Info Run the fuel tank breather hose without kinks. V00325-11 6.
6 CONTROLS 6.18 Shift lever 18 Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.19 Kick starter Kick starter is fitted on the right side of the engine. The top part of the kick starter pivots. Info 1 0 Before riding, swing the top part of the kick starter inward toward the engine. 401954-10 6.
6 CONTROLS 19 The side stand is used to park the motorcycle. Info When you are riding, side stand band . must be folded up and secured with rubber 401944-10 6.22 Steering lock (All EXC/EXC Six Days models, 125 XC‑W EU) 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. V00328-10 6.
7 SPEEDOMETER 7.1 Speedometer overview 20 – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 7.2 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.
7 SPEEDOMETER 7.4 Setting the speedometer functions 21 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 display. – Press the button briefly until H appears at the bottom right of the for 2–3 seconds. The Setup menu is displayed and the active functions are shown. Info If no button is pressed for 10–12 seconds, the settings are automatically saved.
7 SPEEDOMETER 22 – Repeatedly press the button display. – Briefly press the button – The laps 1–10 can be viewed with the button – Press and hold the button briefly until LAP appears at the bottom right of the . LAP 1 appears on the left side of the display. . for 3-5 seconds. The lap times are deleted. – 400321-01 Briefly press the button . Next display mode Info When an impulse is received from the wheel speed sensor, the left side of the display changes back to the SPEED mode. 7.
7 SPEEDOMETER 7.9 Setup menu 23 Condition • The motorcycle is stationary. – Repeatedly press the button display. – Press the button briefly until H appears at the bottom right of the for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. 400344-01 7.10 Briefly press the button .
7 SPEEDOMETER 7.11 Display mode SPEED/CLK (time) 24 – Repeatedly press the button display. briefly until CLK appears at the bottom right of the The time is shown in display mode CLK. 400319-01 7.12 Press the button for 2–3 seconds. The display changes to the Setup menu of the clock. Briefly press the button . Next display mode Press the button for 2–3 seconds. No function Briefly press the button . No function Setting the clock Condition • The motorcycle is stationary.
7 SPEEDOMETER 7.14 Viewing the lap time 25 Condition • The motorcycle is stationary. – Repeatedly press the button display. – Briefly press the button 400321-01 7.15 briefly until LAP appears at the bottom right of the . Press the button for 2–3 seconds. The stop watch and the lap time are reset. Briefly press the button . Select a lap from 1–10 Press the button for 2–3 seconds. No function Briefly press the button . View the next lap time.
7 SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) 26 – Repeatedly press the button play. briefly until TR2 appears at the top right of the dis- TR2 (trip master 2) runs constantly and counts up to 999.9. 400324-01 7.18 Press the button for 2–3 seconds. Clears the values TR2 and A2. Briefly press the button . Next display mode Press the button for 2–3 seconds. Reduces value of TR2. Briefly press the button . Reduces value of TR2.
7 SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) 27 – Repeatedly press the button play. briefly until A2 appears at the top right of the dis- 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. Info The displayed value can differ from the actual average speed if S2 was not stopped after the ride. 400326-01 7.21 Briefly press the button . Next display mode Press the button for 2–3 seconds.
7 SPEEDOMETER 7.23 Table of functions 28 Display Press the button for 2–3 seconds. Briefly press the button . Press the button for 2–3 seconds. Briefly press the button . Wait 3–5 seconds Wait 10–12 seconds Display mode SPEED/H (service hours) The display changes to the Setup menu of the speedometer functions.
7 SPEEDOMETER 7.24 Table of conditions and menu activation Display 29 The motorcycle is stationary.
8 PREPARING FOR USE 8.1 Advice on first use 30 Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. – Do not operate the vehicle if you are physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk.
8 PREPARING FOR USE 31 – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.
8 PREPARING FOR USE 8.4 Preparing for rides on dry sand – 32 Check the radiator cap. Value on the radiator cap » 1.8 bar (26 psi) If the indicated value does not correspond to the required value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
8 PREPARING FOR USE 8.5 Preparing for rides on wet sand – 33 Check the radiator cap. Value on the radiator cap » 1.8 bar (26 psi) If the indicated value does not correspond to the required value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
8 PREPARING FOR USE 34 – Mount the steel sprocket. – Clean the motorcycle. ( – Carefully align bent radiator fins. p. 115) 600868-01 8.7 Preparing for rides at high temperature and slow speed – Check the radiator cap. Value on the radiator cap » 1.8 bar (26 psi) If the displayed value does not correspond to the setpoint value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
9 RIDING INSTRUCTIONS 9.1 Checks and maintenance measures when preparing for use 35 Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. – Check the gear oil level. ( – Check the electrical system. – Check the front brake fluid level. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( – Check the rear brake linings.
9 RIDING INSTRUCTIONS – 36 Pull the choke lever out as far as possible. (All 250/300 models, XC‑W US, XC‑W Six Days US) – Press the electric starter button or press the kick starter robustly through its full range. Info Do not turn the throttle. (125 XC‑W EU) – Press the kick starter robustly through its full range. Info Do not turn the throttle. 9.3 Start off Info Before riding, switch on the lights if your vehicle is equipped with a lighting system.
9 RIDING INSTRUCTIONS 37 Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – 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.
9 RIDING INSTRUCTIONS 38 – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 401475-01 9.8 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
10 SERVICE SCHEDULE 10.1 Additional information 39 Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately. 10.2 Required work Every 40 operating hours/after every race Every 20 operating hours Once after 5 operating hours Once after 1 operating hour ○ Check that the electrical system is functioning properly. Check and charge the battery.
10 SERVICE SCHEDULE 10.3 Recommended work 40 Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours/every 10 operating hours when used for motorsports Once after 10 operating hours Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. Lubricate the steering head bearing. ( ● p. 74) ( ● p. 59) ● Check/adjust the carburetor components. ○ Service the fork. Service the shock absorber.
11 TUNING THE CHASSIS 11.1 Checking the basic chassis setting with the rider's weight 41 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 absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).
11 TUNING THE CHASSIS 42 Guideline Compression damping, low-speed (All 125/150 models) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, low-speed (All 250/300 models) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.
11 TUNING THE CHASSIS 43 – Turn adjusting screw – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. clockwise up to the last perceptible click. Guideline Rebound damping (All 125/150 models) Comfort V00331-10 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping (All 250/300 models) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.
11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber 44 – Measure dimension – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and marking SAG on the rear fender using the sag gauge. – Note down the value as dimension of rear wheel unloaded. ( p. 43) . Info The static sag is the difference between measurements – and . Check the static sag. » Static sag (All 125/150 models) 35 mm (1.
11 TUNING THE CHASSIS – 45 After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – . Turn adjusting ring until the spring is no longer under tension. Hook wrench (90129051000) – Measure the overall spring length while the spring is not under tension. – Tighten the spring by turning adjusting ring to measurement . Guideline Spring preload (All 125/150 models) Comfort 6 mm (0.24 in) Standard 6 mm (0.24 in) Sport 6 mm (0.
11 TUNING THE CHASSIS 11.11 46 – Check the static sag of the shock absorber. ( p. 44) – 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 fork. – As with the shock absorber, smaller differences in the rider's weight can be compensated by the spring preload.
11 TUNING THE CHASSIS 47 Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All standard EXC/XC-W models) – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the right fork leg.
11 TUNING THE CHASSIS 11.14 Adjusting the spring preload of the fork (All Six Days models) 48 Preparatory work – Raise the motorcycle with a lift stand. ( Main work – Turn the adjusting wings p. 51) counterclockwise all the way. The marking +0 aligns with the right wing on both fork legs. Info Make the adjustment by hand only. Do not use a tool. Make the same adjustment on both fork legs. – E00327-10 Turn the adjusting wings clockwise.
11 TUNING THE CHASSIS 49 (All Six Days models) On the upper triple clamp, there are 2 holes at a distance of Hole distance A to each other. 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of Hole distance B from the center. 3.5 mm (0.138 in) The handlebar can be mounted in four different positions. This allows the handlebar to be mounted in the most comfortable position for the rider. M00987-10 11.
11 TUNING THE CHASSIS 50 (All Six Days models) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws – Place the handlebar supports in the required position. Mount and tighten screws . . Take off the handlebar supports. Guideline Screw, handlebar support M10 40 Nm (29.
12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand 51 Note Danger of damage The parked vehicle can roll away or fall over. – – Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground. 401942-01 12.2 – Secure the motorcycle against falling over. Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over.
12 SERVICE WORK ON THE CHASSIS 52 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Clean and oil the dust boots and inner fork tubes of both fork legs. Universal oil spray ( p. 143) – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( 12.5 p.
12 SERVICE WORK ON THE CHASSIS 53 (All standard EXC/XC-W models) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. E00376-10 (All Six Days models) – Loosen screws – . Take out the left fork leg. Loosen screws . Take out the right fork leg. E00377-10 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw).
12 SERVICE WORK ON THE CHASSIS – 54 Position the brake caliper, and mount and tighten screws . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™ – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws . E00375-11 Finishing work – Install the front wheel. 12.9 ( p. 85) – Install the headlight mask with the headlight. ( – Check the headlight setting. ( Removing the lower triple clamp p. 95) p.
12 SERVICE WORK ON THE CHASSIS 55 Main work – Remove screw . Remove screw dlebar and hang it to one side. . Pull off the upper triple clamp with the han- Info Protect the components against damage by covering them. Do not bend the cables and lines. V00357-10 – Remove O-ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. . Remove protective ring . V00358-10 12.
12 SERVICE WORK ON THE CHASSIS – Tighten screws 56 . Guideline Screw, top triple clamp – Tighten screws M8 20 Nm (14.8 lbf ft) M8 15 Nm (11.1 lbf ft) M20x1.5 12 Nm (8.9 lbf ft) M8 20 Nm (14.8 lbf ft) . Guideline Screw, bottom triple clamp V00338-10 – Tighten screw . Guideline Screw, top steering head V00337-10 – Tighten screw . Guideline Screw, top steering stem V00337-11 – Position the brake caliper, and mount and tighten screws .
12 SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp 57 (All Six Days models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 143) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether upper steering head seal – is correctly positioned. Mount protective ring and O-ring . – Position the upper triple clamp with the handlebar.
12 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 58 . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243™ V00361-10 – Position the brake caliper, and mount and tighten screws . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™ – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws . E00375-12 Finishing work – Install the front fender. ( 12.13 p.
12 SERVICE WORK ON THE CHASSIS 12.14 Adjusting the steering head bearing play 59 Preparatory work – Raise the motorcycle with a lift stand. ( Main work (All standard EXC/XC-W models) – Loosen screws and – p. 51) . Loosen and retighten screw . Guideline Screw, top steering head V00339-10 M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screws . Guideline Screw, top triple clamp – Tighten screw M8 20 Nm (14.
12 SERVICE WORK ON THE CHASSIS 12.16 Removing the front fender 60 Preparatory work – Remove the headlight mask with the headlight. ( Main work – Remove screws . – . Remove the front fender. p. 94) V00340-10 Remove screws V00341-10 12.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) M6 10 Nm (7.4 lbf ft) V00341-11 – Mount and tighten screws .
12 SERVICE WORK ON THE CHASSIS 61 Main work – Remove screw and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Secure the rear wheel in this position. – Remove screw absorber. , push splash protector to the side, and remove the shock V00344-10 12.19 Installing the shock absorber Main work – Push splash protector tighten screw . to the side and position the shock absorber.
12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws 62 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) V00342-10 12.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw . V00346-10 – Pull off the air filter box cover in area sideways and remove it toward the front. V00346-11 12.23 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area .
12 SERVICE WORK ON THE CHASSIS 12.24 Removing the air filter 63 Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
12 SERVICE WORK ON THE CHASSIS 64 Preparatory work – Remove the air filter box cover. ( – Remove the air filter. ( p. 62) p. 63) Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 143) Info Only squeeze the air filter to dry it; never wring it out. – Oil the dry air filter with a high quality filter oil. Oil for foam air filter ( 102191-01 – Clean the air filter box.
12 SERVICE WORK ON THE CHASSIS 12.29 Removing the main silencer 65 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. – Remove screws – Pull the main silencer off of the manifold at the rubber sleeve – Mount the main silencer with rubber sleeve – Mount and tighten screws . . V00348-10 12.30 Installing the main silencer . .
12 SERVICE WORK ON THE CHASSIS 66 Main work – Remove screws – . Pull out inner tube . – Remove the glass fiber yarn filling – Clean the parts that need to be reinstalled and check for damage. – Fit the new glass fiber yarn filling – Position outer tube – from the inner tube. into the inner tube. over the inner tube with the new glass fiber yarn filling. Mount and tighten screws . Guideline Screws on the main silencer M5 7 Nm (5.
12 SERVICE WORK ON THE CHASSIS 67 – Remove screw – Remove the tube from the fuel tank breather. – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. with the rubber bushing. V00351-10 V00352-10 12.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws 68 with the collar bushings. Guideline Remaining screws, chassis – M6 10 Nm (7.4 lbf ft) Connect the fuel hose. V00350-11 Finishing work – Mount the seat. ( 12.34 p. 61) Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 68) 400678-01 12.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip.
12 SERVICE WORK ON THE CHASSIS 12.36 Checking the chain tension 69 Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
12 SERVICE WORK ON THE CHASSIS 70 Main work – Loosen nut – . Loosen nuts . – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks . The rear wheel is then correctly aligned. – Tighten nuts – Make sure that chain adjusters – Tighten nut .
12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pin is at the level of or below the chain sliding guard: – – 71 Change the chain sliding guard. Check that the chain sliding guard is firmly seated. » If the chain sliding guard is loose: – Tighten the screws on the chain sliding guard. Guideline Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™ E00331-10 – Check the chain sliding piece for wear.
12 SERVICE WORK ON THE CHASSIS 12.39 Checking the frame – 72 Check the frame for cracks and deformation. » If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. S01316-10 12.40 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.
12 SERVICE WORK ON THE CHASSIS 12.42 Checking the rubber grip – 73 Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. The rubber grip can only be replaced with the sleeve or the throttle tube. » If a rubber grip is damaged or worn: – 401197-01 – Change the rubber grip. Check that screw is firmly seated.
12 SERVICE WORK ON THE CHASSIS 74 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – . Remove cover with membrane . – Check the fluid level. Fluid level below container rim » 4 mm (0.16 in) If the level of the fluid does not meet specifications: – E00337-10 Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( – p. 141) Position the cover with the membrane. Mount and tighten the screws.
12 SERVICE WORK ON THE CHASSIS 75 – Now inject the fluid into the system until it emerges from drill hole ter cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. – Correct the fluid level of the hydraulic clutch. of the mas- Guideline Fluid level below container rim E00339-10 – 4 mm (0.16 in) Position the cover with the membrane. Mount and tighten the screws.
13 BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever 76 Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. – Set the free travel on the hand brake lever in accordance with the specification. (All EXC/EXC Six Days models, 125 XC‑W EU) – Press the hand brake lever toward the handlebar and check free travel Free travel of hand brake lever » . ≥ 3 mm (≥ 0.
13 BRAKE SYSTEM 13.4 Checking the brake discs 77 Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness . Info Wear reduces the thickness of the brake disc around the area used by the brake linings.
13 BRAKE SYSTEM 13.6 Adding front brake fluid 78 Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
13 BRAKE SYSTEM 13.7 Checking the front brake linings 79 Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness Minimum thickness » ≥ 1 mm (≥ 0.04 in) If the minimum thickness is less than specified: – – . Change the front brake linings. ( p. 79) Check the brake linings for damage and cracking.
13 BRAKE SYSTEM 80 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. Only use clean brake fluid from a sealed container. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – – . Remove cover with membrane .
13 BRAKE SYSTEM 13.9 Checking the free travel of foot brake lever 81 Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake. – Set the free travel on the foot brake lever in accordance with the specification. – Disconnect spring – 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 .
13 BRAKE SYSTEM 13.11 Checking the rear brake fluid level 82 Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.
13 BRAKE SYSTEM 83 Preparatory work – Check the rear brake linings. ( p. 83) Main work – Stand the vehicle upright. – – with membrane and the O-ring. Add brake fluid to level . Remove screw cap Brake fluid DOT 4 / DOT 5.1 ( – Mount the screw cap with the membrane and the O-ring. Info E00348-10 13.13 p. 141) Clean up overflowed or spilled brake fluid immediately with water. Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect.
13 BRAKE SYSTEM 84 Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info 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.
14 WHEELS, TIRES 14.1 Removing the front wheel 85 Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. V00363-10 – – – – by several rotations. Loosen screws . Press on screw to push the wheel spindle out of the axle clamp. Remove screw .
14 WHEELS, TIRES 86 – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw The brake linings are correctly positioned. . Guideline Screw, front wheel spindle V00364-11 M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc. – Remove the motorcycle from the lift stand. ( – Operate the front brake and compress the fork a few times firmly.
14 WHEELS, TIRES 14.4 Installing the rear wheel 87 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Change the rear wheel bearing. Clean and grease shaft seal rings Long-life grease ( and contact surface of the spacers. p.
14 WHEELS, TIRES 14.5 Checking the tire condition 88 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 a major impact on the handling of the motorcycle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces. – Check the front and rear tires for cuts, run-in objects, and other damage.
14 WHEELS, TIRES 14.7 Checking spoke tension 89 Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle.
15 ELECTRICAL SYSTEM 15.1 Removing the battery 90 (All 250/300 models, XC‑W US, XC‑W Six Days US) Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.
15 ELECTRICAL SYSTEM 15.2 Installing the battery 91 (All 250/300 models, XC‑W US, XC‑W Six Days US) Main work – Insert the battery into the battery compartment with the terminals facing forward and secure with holding bracket . (XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models) Battery (HJTZ5S-FP) ( p. 127) (300 EXC BR) Battery (YTX5L-BS) ( – Mount and tighten screw p. 127) . Guideline Remaining screws, chassis – Connect positive cable M6 10 Nm (7.4 lbf ft) M5 2.5 Nm (1.
15 ELECTRICAL SYSTEM 92 Main work (XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models) Warning Risk of injury Batteries contain harmful substances. S00863-10 – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries.
15 ELECTRICAL SYSTEM 93 (300 EXC BR) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. 400240-10 – – 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. – In the event of skin contact, rinse with large amounts of water.
15 ELECTRICAL SYSTEM 94 Main work – Pull starter relay from the holder. E00361-10 – – . Remove faulty main fuse . Take off protection caps Info You can recognize a defective fuse by a burned-out fuse wire A spare fuse is located in the starter relay. . – Install a new main fuse. Fuse (58011109110) ( – p. 127) Check that the electrical equipment is functioning properly. Tip Insert a spare fuse so that it is available if needed. – Mount the protection caps.
15 ELECTRICAL SYSTEM 95 (All XC‑W/XC‑W Six Days models) – Detach plug-in connector light. and take off the headlight mask with the head- E00357-10 15.6 Installing the headlight mask with the headlight Main work (All EXC/EXC Six Days models) – Connect plug-in connectors . E00356-11 (All XC‑W/XC‑W Six Days models) – Connect plug-in connector . E00357-11 – Position the headlight mask and fix it with rubber bands – Position the brake line and wiring harness in the brake line guide. .
15 ELECTRICAL SYSTEM 96 Main work – Turn protection cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull bulb socket – Pull out headlight bulb – Insert the new headlight bulb. of the parking light out of the reflector. E00358-10 . Headlight (HS1/socket BX43t) ( – p. 127) Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way. Info Ensure that O-ring is seated properly.
15 ELECTRICAL SYSTEM 15.9 Checking the headlight setting 97 – 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 at a distance under the first mark. Guideline Distance – 5 cm (2 in) Position the vehicle vertically a distance away from the wall. Guideline Distance 400726-10 5 m (16 ft) – The rider now sits down on the motorcycle. – Switch on the low beam.
15 ELECTRICAL SYSTEM 98 – Position protection cap – Press any button on the speedometer. and turn all the way clockwise using a coin. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work – Install the headlight mask with the headlight. ( – Check the headlight setting. ( – Set kilometers or miles. ( – Set the speedometer functions. ( – Set the clock. ( p. 21) p. 97) p. 20) p. 21) p.
16 COOLING SYSTEM 16.1 Cooling system 99 (All 125/150 models) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified 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.
16 COOLING SYSTEM 100 – 16.3 Mount the radiator cap. Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. – Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
16 COOLING SYSTEM 101 – Place a suitable container under the water pump cover. (All 125/150 models) – Remove screw . Take off radiator cap . – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline V00373-11 Drain plug, water pump cover (125 XC‑W EU) M6 8 Nm (5.9 lbf ft) Drain plug, water pump cover (150 XC‑W US) M6 8 Nm (5.9 lbf ft) (All 250/300 models) – Remove screw . Take off radiator cap . – Completely drain the coolant.
16 COOLING SYSTEM 102 (All 250/300 models) – Make sure that screw is tightened. – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant ( p. 141) V00376-10 – – and wait until coolant escapes without bubbles. Mount and tighten screw . Loosen screw Guideline Bleeder screw, cylinder head M6 10 Nm (7.4 lbf ft) V00380-10 – Completely fill the radiator with coolant. Coolant ( – p. 141) Mount radiator cap .
17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable 103 – Check the throttle grip for smooth operation. – Turn the handlebar as far as possible to the right. Move the throttle grip backwards 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 the specified value: – Adjust the play in the throttle cable. ( p.
17 TUNING THE ENGINE 17.3 Carburetor setting 104 Effects of the carburetor setting H01400-01 The different carburetor components must be tuned both to one another and for the use intended. Main jet MJ The main jet MJ has the greatest influence with the throttle slide open (full throttle). If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger main jet needs to be used.
17 TUNING THE ENGINE 105 1 1 /4 3 1 /2 1 /2 1 /4 /8 1 /4 /8 3 1 1 0 /4 0 K00496-01 When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindrical part of the needle is less. When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling jet is only minimal.
17 TUNING THE ENGINE 17.4 Carburetor - idle 106 The idle setting of the carburetor has a big influence on the starting behavior, stable idling, and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle speed is set wrongly. Info The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning. The factory setting for the carburetor is set for the following values.
17 TUNING THE ENGINE 107 Info If there is a big 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, mount a smaller idling jet. After changing the jet, start from the beginning with the adjusting steps.
17 TUNING THE ENGINE 108 – Clean gear teeth – Mount the shift lever on the shift shaft in the required position and engage the gearing. of the shift lever and shift shaft. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure. 401951-10 – Mount and tighten screw with the washers. Guideline 17.10 Screw, shift lever (125 XC‑W EU) M6 14 Nm (10.
17 TUNING THE ENGINE 109 – Remove cap , adjusting spring insert from the clutch cover. – Pull both springs off of the spring insert. – Mount the required auxiliary spring ( p. 108) and position them together in the clutch cover.
17 TUNING THE ENGINE 110 – Mount the required auxiliary spring ( p. 108) and position them together in the clutch cover. and adjusting spring Auxiliary spring with yellow marking (54637072300) Auxiliary spring with green marking (54837072100) Auxiliary spring with red marking (54837072000) The recess in spring insert engages in the angle lever. Info E00365-10 must not be turned as this would worsen the engine charac- Screw teristic. – Check the O-ring in the cap. – Position the cap.
18 SERVICE WORK ON THE ENGINE 18.1 Emptying the carburetor float chamber 111 Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. – If any fuel is spilled, wipe it off immediately. – Observe the specifications for refueling.
18 SERVICE WORK ON THE ENGINE 112 Main work (All 125/150 models) – Remove gear oil monitoring screw – . Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. » If no gear oil runs out: – – E00367-10 Add gear oil. ( p. 114) Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level check (125 XC‑W EU) M6 8 Nm (5.9 lbf ft) Screw, gear oil level check (150 XC‑W US) M6 8 Nm (5.
18 SERVICE WORK ON THE ENGINE 113 Main work (All 125/150 models) – Remove gear oil drain plug – with magnet. Remove gear oil drain plug . – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug. – Clean the sealing surface on the engine. – Mount and tighten gear oil drain plug with the magnet and a new seal ring. Guideline – Gear oil drain plug with magnet (125 XC‑W EU) M12x1.5 20 Nm (14.8 lbf ft) Gear oil drain plug with magnet (150 XC‑W US) M12x1.5 20 Nm (14.
18 SERVICE WORK ON THE ENGINE 114 (All Six Days models, EXC AU) – Install the engine guard. ( 18.4 p. 75) Adding gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold. Preparatory work – Park the motorcycle on a level surface. Main work (All 125/150 models) – Remove gear oil monitoring screw . (All 250/300 models) – Remove gear oil monitoring screw .
19 CLEANING, CARE 19.1 Cleaning the motorcycle 115 Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. – Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
19 CLEANING, CARE 19.2 Checks and maintenance steps for winter operation 116 Info If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precautions against aggressive road salt. If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water enhances the corrosive effects of salt. – Clean the motorcycle. ( – Clean the brakes. p.
20 STORAGE 20.1 Storage 117 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them.
20 STORAGE 20.2 Preparing for use after storage 118 – Remove the motorcycle from the lift stand. ( p. 51) (All 250/300 models, XC‑W US, XC‑W Six Days US) – Install the battery. ( p. 91) 401059-01 – Perform checks and maintenance measures when preparing for use. ( – Make a test ride. p.
21 TROUBLESHOOTING 119 Faults Possible cause Action The engine cannot be cranked (electric starter) (All 250/300 models, XC‑W US, XC‑W Six Days US) Operating error – Carry out the start procedure. ( Battery discharged – Recharge the battery. – Check the charging voltage. – Check the closed current. Engine turns but does not start ( p. 35) p. 91) – Check the alternator. Main fuse is blown – Change the main fuse. ( Starter relay faulty – Check the starter relay.
21 TROUBLESHOOTING 120 Faults Possible cause Action Engine stalls or is popping into the carburetor Lack of fuel – Turn handle of the fuel tap to the ON position. (Figure V00326-10 p. 17) – Refuel. ( Engine takes in bad air – 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. Too little coolant in cooling system – Check the cooling system for leakage. Engine overheats p.
22 TECHNICAL DATA 22.1 Engine 22.1.1 125 XC‑W EU 121 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.
22 TECHNICAL DATA 122 Second gear 15:31 Third gear 17:28 Fourth gear 19:26 Fifth gear 21:25 Sixth gear 20:20 Alternator 12 V, 75 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter and kick starter 22.1.
22 TECHNICAL DATA 123 Exhaust valve, beginning of adjustment Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings X distance (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z distance (height of control flap) 49.5 mm (1.
22 TECHNICAL DATA 124 Screw, intermediate clutch cover M6x30 10 Nm (7.4 lbf ft) – Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, outer clutch cover M6x20 8 Nm (5.9 lbf ft) – Screw, outer clutch cover M6x50 8 Nm (5.9 lbf ft) – Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™ Screw, stator M6 8 Nm (5.9 lbf ft) Loctite® 243™ Screw, stop plate of exhaust control M6 10 Nm (7.
22 TECHNICAL DATA 125 Screw, stator M6 8 Nm (5.9 lbf ft) Loctite® 243™ Screw, stop plate of exhaust control M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Screw, cylinder head M7 18 Nm (13.3 lbf ft) – Nut, cylinder base M8 23 Nm (17 lbf ft) – Screw, cylinder base M8 20 Nm (14.8 lbf ft) – Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite® 243™ Gear oil drain plug M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 50 Nm (36.
22 TECHNICAL DATA 126 Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Spark plug M14x1.25 25 Nm (18.4 lbf ft) – Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite® 648™ Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite® 648™ 22.3 Capacities 22.3.1 Gear oil Gear oil 22.3.2 Engine oil (15W/50) ( p. 141) 1.2 l (1.3 qt.) Coolant ( 9.5 l (2.
22 TECHNICAL DATA 127 Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase (All 125/150 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 370 mm (14.57 in) Weight without fuel, approx. (125 XC‑W EU) 91 kg (201 lb.) Weight without fuel, approx. (150 XC‑W US) 91.5 kg (201.7 lb.) Weight without fuel, approx.
22 TECHNICAL DATA 22.7 Fork 22.7.1 All 125/150 models 128 Fork part number 14.18.8Q.61 Fork WP Performance Systems MXMA 4860 upside down Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 3.8 N/mm (21.7 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.0 N/mm (22.
22 TECHNICAL DATA 129 Standard 15 clicks Sport 12 clicks Spring preload - Preload Adjuster Comfort +0 Standard +0 Sport +3 Spring length with preload spacer(s) 477 mm (18.78 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.4 N/mm (25.1 lb/in) Fork length 932 mm (36.69 in) Air chamber length +0.39 110+10 −20 mm (4.33−0.
22 TECHNICAL DATA 130 Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload Comfort 8 mm (0.31 in) Standard 8 mm (0.31 in) Sport 8 mm (0.31 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 60 N/mm (343 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 63 N/mm (360 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.
22 TECHNICAL DATA 131 Screw, bottom triple clamp (All standard EXC/XC-W models) M8 15 Nm (11.1 lbf ft) – Screw, bottom triple clamp (All Six Days models) M8 15 Nm (11.1 lbf ft) – Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) – Screw, engine brace M8 25 Nm (18.4 lbf ft) Loctite® 2701™ Screw, fork stub M8 15 Nm (11.1 lbf ft) – Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, handlebar clamp M8 20 Nm (14.
22 TECHNICAL DATA 22.10 Carburetor 132 22.10.1 125 XC‑W EU Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 77 Needle position 3rd position from top Jet needle 6BFY44‑73 (6BFY43‑73) Main jet 480 (470, 490, 500, 520) Idling jet 45 (42.5) Starting jet 80 Needle jet R‑8 Idle air adjusting screw Open Throttle slide 2 turns 4 22.10.
22 TECHNICAL DATA 133 Idle air adjusting screw Open Throttle slide 1.5 turns 4 22.10.5 300 EXC EU, 300 EXC AU, 300 EXC Six Days EU Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 78 Needle position 1st position from top Jet needle 6BFY43‑74 (6BFY44‑73, 6BFY43‑73) Main jet 100 (420, 430, 440, 450, 460) Idling jet 17.5 (35/37.5/40) Starting jet 50 (80) Needle jet R‑8 Idle air adjusting screw Open 2 turns Throttle slide 4 Slide stop Present 22.10.
23 CARBURETOR TUNING 23.1 Carburetor tuning (125 XC‑W EU) 134 402698-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain.
23 CARBURETOR TUNING 23.2 Carburetor tuning (150 XC‑W US) 135 402699-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain.
23 CARBURETOR TUNING 23.3 Carburetor tuning (250 EXC EU, 250 EXC AU, 250 EXC Six Days EU) 136 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
23 CARBURETOR TUNING 23.4 Carburetor tuning (250 XC‑W US) 137 402701-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain.
23 CARBURETOR TUNING 23.5 Carburetor tuning (300 EXC EU, 300 EXC AU, 300 EXC Six Days EU) 138 Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
23 CARBURETOR TUNING 23.6 Carburetor tuning (300 XC‑W US, 300 XC‑W Six Days US) 139 402703-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain.
23 CARBURETOR TUNING 23.7 Carburetor tuning (300 EXC BR) 140 402729-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Does not apply on sandy terrain.
24 SUBSTANCES 141 Brake fluid DOT 4 / DOT 5.1 Standard/classification – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Guideline – Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures).
24 SUBSTANCES 142 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 144) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) 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.
25 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex® – Chain Clean Fuel additive Recommended supplier Motorex® – Fuel Stabilizer High viscosity grease Recommended supplier SKF® – LGHB 2 Long-life grease Recommended supplier Motorex® – Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex® – Moto Clean Off-road chain spray Recommended supplier Motorex® – Chainlube Offroad Oil for foam air filter Reco
26 STANDARDS 144 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
27 LIST OF ABBREVIATIONS Art. no. Article number ca. circa cf. compare e.g. for example etc. et cetera i.a. inter alia no. number poss.
28 LIST OF SYMBOLS 28.1 Yellow and orange symbols 146 Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp – inoperative Fuel level warning lamp – inoperative 28.2 Green and blue symbols Green and blue symbols reflect information. The high beam indicator lamp lights up blue – The high beam is switched on.
INDEX 147 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Air filter box cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 148 Fork article number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 46 Indicator lamps overview . . . . . . . . . . . . . . . . . . . . . . . . . 16 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fork legs bleeding . . . . . . . . . . . dust boots, cleaning . . . installing . . . . . . . . . . . removing . . . . . . . . . . . spring preload, adjusting Key number . . . . . . .
INDEX 149 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-40 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-120 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . 107 basic position, checking . . . . . . . . . . . . . . . . . . . . . 107 Turn signal bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*3213477en* 3213477en 07/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria http://www.ktm.
