OWNER'S MANUAL 2016 125 EXC EU 125 EXC Six Days EU 200 EXC EU 200 EXC AU 200 XC‑W US 250 EXC EU 250 EXC AU 250 EXC Six Days EU 250 XC‑W US 300 EXC EU 300 EXC AU 300 EXC Six Days EU 300 EXC BR 300 XC‑W US 300 XC‑W Six Days US 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 accordingly. DEAR KTM CUSTOMER We hope you enjoy your new vehicle! Enter the serial numbers of your vehicle below. Chassis number ( p. 11) Engine number ( p. 11) Key number (All EXC models) ( Dealer's stamp p.
TABLE OF CONTENTS TABLE OF CONTENTS 1 2 3 4 5 6 7 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 11.10 Adjusting the riding sag ............................... 11.11 Checking the basic setting of the fork ............... 11.12 Adjusting the compression damping of the fork ............................................................... 11.13 Adjusting the rebound damping of the fork ........ 11.14 Adjusting the spring preload of the fork (EXC, XC‑W) ............................................................ 11.15 Handlebar position.......................................... 11.
TABLE OF CONTENTS 17.3 17.4 17.5 17.6 17.7 18 19 20 21 22 Carburetor - idle............................................ Carburetor - adjusting the idle speed ........... Emptying the carburetor float chamber ........ Checking the basic position of the shift lever ... Adjusting the basic position of the shift lever ......................................................... 17.8 Engine characteristic - auxiliary spring (All 250/300 models).................................... 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 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 2.5 Safe operation 7 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. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
3 IMPORTANT NOTES 3.1 Guarantee, warranty 8 The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
4 VIEW OF VEHICLE 4.1 View of vehicle, front left (example) 9 102249-10 1 Hand brake lever ( 2 Light switch ( 2 Kill switch ( 2 Turn signal switch ( 2 Horn button ( 2 Kill switch ( 3 Clutch lever ( 4 Chain guide 5 Air filter box lid 6 Side stand ( p. 18) 7 Shift lever ( p. 17) 8 Fuel tap ( p. 13) p. 14) p. 13) p. 14) p. 14) p. 14) p. 13) p.
4 VIEW OF VEHICLE 4.2 View of vehicle, rear right (example) 10 102250-10 1 Filler cap 2 Throttle grip ( 3 Chassis number ( 4 Kick starter ( 5 Foot brake lever ( 6 Level viewer for brake fluid, rear p. 13) p. 11) p. 18) p.
5 SERIAL NUMBERS 5.1 Chassis number 11 The chassis number is stamped on the right side of the steering head. 401946-10 5.2 Type label The type label is fixed to the front of the steering head. 401946-10 5.3 Key number (All EXC models) The key number for the steering lock is stamped onto the key connector. 402247-10 5.4 Engine number The engine number sprocket. is stamped on the left side of the engine under the engine 401949-10 5.
5 SERIAL NUMBERS 5.6 Shock absorber part number 12 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.
6 CONTROLS 6.1 Clutch lever 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. 102251-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 102265-10 6.2 Hand brake lever 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 6.
6 CONTROLS 6.5 Kill switch (All XC-W models) 14 The kill switch is fitted on the left side of the handlebar. Possible states • Kill switch in basic position – In this position, the ignition circuit is closed and the engine can be started. • Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. B01144-10 6.6 Horn button (All EXC models) The horn button is fitted on the left side of the handlebar.
6 CONTROLS 6.10 Emergency OFF switch (EXC AU) 15 The emergency OFF switch is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running 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.
6 CONTROLS 6.15 Opening the filler cap 16 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.
6 CONTROLS 6.17 Fuel tap 17 The fuel tap is on the left side of the fuel tank. Tap handle on the fuel tap is used to open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. • Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties to the point of reserve capacity. • Open the fuel reserve supply RES – Fuel can flow from the fuel tank to the carburetor.
6 CONTROLS 6.20 Kick starter 18 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 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.22 Side stand The side stand is on the left side of the vehicle.
6 CONTROLS 6.24 Locking the steering (All EXC models) 19 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. Steering is no longer possible. Info Never leave the key in the steering lock. 400732-01 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 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. 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.
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 distribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads.
8 PREPARING FOR USE 8.4 Preparations for riding on dry sand – 32 Check the radiator cap. Value on the radiator cap » 1.8 bar (26 psi) If the displayed value does not equal the setpoint value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – 600872-10 – – 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.
8 PREPARING FOR USE 33 – – Change the radiator cap. Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info 600870-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( – p. 144) Mount the steel sprocket. Tip Do not grease the chain. 600868-01 8.6 – Clean the radiator fins.
8 PREPARING FOR USE 34 – – Change the radiator cap. Adjust the secondary ratio to the terrain. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive. – Clean the chain. Chain cleaner ( 600868-01 8.8 p. 144) – Clean the radiator fins. – Carefully align bent radiator fins. – Check the coolant level. ( p. 103) Preparing for riding at low temperatures or in snow – Mount the rain cover for the air filter.
9 RIDING INSTRUCTIONS 9.1 Checks and maintenance work when preparing for use 35 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. ( – 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. ( – Check that the brake system is functioning properly.
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. Info Do not turn the throttle. (All 125 models) – 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. This will make it easier for other road users to see you.
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.
9 RIDING INSTRUCTIONS 9.8 Refueling 38 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.
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. ● ● Check and charge the battery. ● ● ● ● ● ● (All 200/250/300 models) Check the front brake linings. ( p. 83) Check the rear brake linings. ( p. 87) ● ● Check the brake lines for damage and leakage. ● ● Check the rear brake fluid level. ( ● ● ● ● ● ● Check the brake discs. ( p. 82) p.
10 SERVICE SCHEDULE 10.2 Service work (as additional order) 40 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. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. ( p. 78) ● Grease the steering head bearing. ( p. 64) ● ● Check/set the carburetor components. Perform a fork service. (EXC, XC‑W) ○ ● ● Perform a fork service.
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 (All 250/300 models) Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 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.
11 TUNING THE CHASSIS – 43 Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut – ! Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) B00792-10 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 Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
11 TUNING THE CHASSIS 11.8 Checking the riding sag of the shock absorber 44 – Measure distance – With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times. of the unloaded rear wheel. ( p. 43) 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 .
11 TUNING THE CHASSIS 45 Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw . Guideline Screw, shock absorber adjusting ring Finishing work – Install the shock absorber. – 11.10 ( M5 5 Nm (3.7 lbf ft) p. 65) Remove the motorcycle from the lift stand. ( p. 52) Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) – Remove the shock absorber.
11 TUNING THE CHASSIS 46 – As with the shock absorber, smaller differences in the rider's weight can be compensated 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 Info The hydraulic compression damping determines the fork suspension behavior. (EXC, XC‑W) – Remove protection caps – Turn adjusting screws .
11 TUNING THE CHASSIS 47 (250/300 Six Days) Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 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. (EXC EU/AU) – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs.
11 TUNING THE CHASSIS 48 (250/300 Six Days) Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – Turn adjusting screws clockwise all the way. Info Adjusting screws 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.
11 TUNING THE CHASSIS 49 Info Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. 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. (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs.
11 TUNING THE CHASSIS 50 (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) On the upper triple clamp, there are two 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. In this way, the handlebar can be mounted in the position that is most comfortable for the rider. M00993-10 11.
11 TUNING THE CHASSIS 51 (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – 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 support in the required position. Mount and tighten screws . . Remove the handlebar support. Guideline Screw, handlebar support M10 40 Nm (29.
12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand 52 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) Neither wheel is in contact with the ground. 401942-01 12.2 – Secure the motorcycle against falling over.
12 SERVICE WORK ON THE CHASSIS 53 (Six Days) – Release bleeder screws . Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. 602754-10 Finishing work – Remove the motorcycle from the lift stand. ( 12.4 p. 52) Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( – Remove the fork protector. ( Main work – Push dust boots p. 52) p. 53) of both fork legs downwards.
12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – 54 Position the fork protection on the left fork leg. Mount and tighten screws . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line, wiring harness, and clamp. Mount and tighten screws – Position the fork protector on the right fork leg. Mount and tighten screws . . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 102264-11 12.
12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs 55 Main work (EXC EU/AU) – Position the fork legs. 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 toward the front. 102263-10 (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs.
12 SERVICE WORK ON THE CHASSIS (Six Days) – Tighten screws 56 . Guideline Screw, top triple clamp – Tighten screws M8 17 Nm (12.5 lbf ft) M8 15 Nm (11.1 lbf ft) . Guideline Screw, bottom triple clamp B02147-11 – Position the brake caliper and mount and tighten screws . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™ – Mount cable binder – Position the brake line and wiring harness. Put the clamp on and mount and tighten screws . .
12 SERVICE WORK ON THE CHASSIS 12.10 Removing the lower triple clamp 57 (EXC EU, EXC Six Days, EXC EU/AU, Six Days) Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) – Remove the front wheel. – Remove the headlight mask with the headlight. ( – Remove the fork legs. – Remove the front fender. ( – Remove the handlebar cushion. ( ( p. 90) p. 98) p. 54) p. 64) Main work – Remove screw . Remove screw dlebar and hang it to one side. .
12 SERVICE WORK ON THE CHASSIS – 58 Position the fork legs. 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 toward the front. 102269-10 – Tighten screws . Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) M20x1.5 12 Nm (8.9 lbf ft) M8 20 Nm (14.8 lbf ft) M8 20 Nm (14.8 lbf ft) 102270-10 – Tighten screw .
12 SERVICE WORK ON THE CHASSIS 59 Finishing work – Mount the handlebar cushion. 12.12 – Install the front fender. ( – Install the front wheel. – Refit the headlight mask with the headlight. ( – 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. ( – Remove the motorcycle from the lift stand. ( – Check the headlight setting. ( Installing the lower triple clamp p. 65) ( p. 90) p.
12 SERVICE WORK ON THE CHASSIS – Tighten screws 60 . Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) M20x1.5 12 Nm (8.9 lbf ft) 102275-10 – Tighten screw . Guideline Screw, top steering head 102276-10 – Mount and tighten screw . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243™ 102277-10 – Tighten screws . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) 102278-10 – Position the brake caliper. Mount and tighten screws .
12 SERVICE WORK ON THE CHASSIS 61 (Six Days) – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 144) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether the upper steering head seal – Mount protective ring – Position the upper triple clamp with the handlebar. – Mount screw – Position the clutch line and wiring harness. – Position the fork legs. is correctly positioned.
12 SERVICE WORK ON THE CHASSIS – 62 Mount and tighten screw . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243™ 602740-10 – Tighten screws . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) 602741-10 – Position the brake caliper. Mount and tighten screws . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™ – Mount cable tie(s) – Position the brake line and wiring harness. Put on the clamp and mount and tighten screws . .
12 SERVICE WORK ON THE CHASSIS 63 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. p. 63) The handlebar must be able to move easily over the entire steering range. There should be no perceptible detent positions.
12 SERVICE WORK ON THE CHASSIS 64 (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – Loosen screws and . – Loosen and retighten screw . Guideline Screw, top steering head 102279-10 M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Tighten screws . Guideline Screw, top triple clamp – Tighten screw M8 20 Nm (14.8 lbf ft) M8 20 Nm (14.8 lbf ft) .
12 SERVICE WORK ON THE CHASSIS 12.17 Installing the front fender 65 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) B02156-10 – . Mount and tighten screws Guideline Remaining screws, chassis B02155-11 Finishing work – Refit the headlight mask with the headlight. ( – 12.18 Check the headlight setting. ( p. 98) p.
12 SERVICE WORK ON THE CHASSIS 66 Guideline Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite® 2701™ Info 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 and tighten screw . to the side and position the shock absorber.
12 SERVICE WORK ON THE CHASSIS – 67 Mount and tighten screw of the seat fixation. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) B00817-10 12.22 Removing the air filter box lid – Pull off the air filter box lid in area – Insert the air filter box lid into the rear area sideways and remove it toward the front. 102283-10 12.23 Installing the air filter box lid and clip it into the front area . 102283-11 12.
12 SERVICE WORK ON THE CHASSIS 12.25 Installing the air filter 68 Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( . p. 144) 301262-10 – Insert both parts together, position them and fasten them using air filter holder . The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage. B02160-11 Finishing work – Install the air filter box lid. ( 12.
12 SERVICE WORK ON THE CHASSIS 12.27 Sealing the air filter box 69 Preparatory work – Remove the air filter box lid. ( p. 67) Main work – Seal the air filter box in the marked area . 401527-10 Finishing work – Install the air filter box lid. ( 12.28 p. 67) Removing the main silencer 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.
12 SERVICE WORK ON THE CHASSIS 70 Main work – Remove screws – . Pull out inner tube . – Remove glass fiber yarn filling – Clean the parts that need to be reinstalled and check for damage. – Mount the new glass fiber yarn filling – Position outer tube – from the inner tube. on 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 – 71 Pull both spoilers off of the sides of the radiator bracket tank. and lift off the fuel 602721-10 12.32 Installing 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.
12 SERVICE WORK ON THE CHASSIS 12.33 Checking the chain for dirt – 72 Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 72) 400678-01 12.34 Cleaning the chain 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.
12 SERVICE WORK ON THE CHASSIS 73 Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension . Info The bottom chain section 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 . Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension » 55… 58 mm (2.17… 2.
12 SERVICE WORK ON THE CHASSIS 12.37 Checking the chain, rear sprocket, engine sprocket and chain guide 74 Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the drivetrain kit. Info The engine sprocket, rear sprocket, and chain should always be changed together.
12 SERVICE WORK ON THE CHASSIS – 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: – – 75 Change the chain sliding piece. Check the chain sliding piece for tightness. » If the chain sliding piece is loose: – Tighten the screw on the chain sliding piece. Guideline Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) B00824-01 – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide.
12 SERVICE WORK ON THE CHASSIS 12.39 Checking the swingarm – 76 Check the swingarm for damage, cracking, and deformation. » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 401341-01 12.40 Checking the routing of the throttle cable Preparatory work – Remove the seat. ( – p. 66) Remove the fuel tank. ( p.
12 SERVICE WORK ON THE CHASSIS 12.41 Checking the rubber grip – 77 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. Grip adhesive (00062030051) ( p. 144) 401197-01 12.42 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 77) Main work – Secure the rubber grip at two points using the securing wire.
12 SERVICE WORK ON THE CHASSIS 12.44 Checking/correcting the fluid level of the hydraulic clutch 78 Info The fluid level rises with increasing wear of the clutch lining discs. (All 125/200 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – – . Remove cover with membrane . – Check the fluid level.
12 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe 79 with the appropriate hydraulic fluid. Bleed syringe (50329050000) Hydraulic fluid (15) ( – p. 142) On the slave cylinder of the clutch, remove bleeder screw ing syringe . and mount bleed- B02164-10 – Inject the liquid into the system until it escapes from hole cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe.
12 SERVICE WORK ON THE CHASSIS 12.46 Removing the engine guard – Turn quick release guard. – Attach the engine guard at the back of the frame and swing it up at front. – Turn quick release counterclockwise until it disengages. Remove the engine B01204-10 12.47 Installing the engine guard B01205-10 all the way clockwise.
13 BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever 81 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 Free travel of hand brake lever » . ≥ 3 mm (≥ 0.
13 BRAKE SYSTEM 13.4 Checking the brake discs 82 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement . Info Wear reduces the thickness of the brake disc around the area used by the brake linings. Brake discs - wear limit 400257-10 » Front 2.
13 BRAKE SYSTEM 83 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.
13 BRAKE SYSTEM 13.8 Changing the front brake linings 84 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 contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles.
13 BRAKE SYSTEM 85 – Check that leaf spring in the brake caliper and sliding plate caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cotter pins. in the brake 100397-01 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. – Correct the brake fluid quantity to level 102289-01 .
13 BRAKE SYSTEM 86 – Disconnect spring – Loosen nut travel. – To adjust the basic position of the foot brake lever to individual requirements, loosen nut and turn screw accordingly. . 402026-10 and, with push rod , turn it back until you have maximum free Info The range of adjustment is limited. – M00595-10 Turn push rod accordingly until you have free travel the basic position of the foot brake lever. .
13 BRAKE SYSTEM 13.12 Adding brake fluid for the rear brake 87 Warning Danger of accidents Brake system failure. – If the 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.
13 BRAKE SYSTEM 13.14 Changing the brake linings of the rear brake 88 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 contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles.
13 BRAKE SYSTEM 89 – Check that leaf spring in the brake caliper and sliding plate caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cotter pins. in the brake 100407-10 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 M00115-01 Brake fluid DOT 4 / DOT 5.
14 WHEELS, TIRES 14.1 Removing the front wheel 90 Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. 102290-10 – – – – by several rotations. Loosen screws . Press on screw to push the wheel spindle ouf of the axle clamp. Remove screw .
14 WHEELS, TIRES 91 (Six Days) – Align the brake disc guard so that gaps and are the same size. M01022-10 – Mount and tighten screw . Guideline Screw, front wheel spindle 102291-11 M20x1.5 35 Nm (25.8 lbf ft) – 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. ( – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Tighten screws p.
14 WHEELS, TIRES 14.4 Installing the rear wheel 92 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. Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Change the wheel bearing. Clean and grease shaft seal rings Long-life grease ( and bearing surface of the spacers. p.
14 WHEELS, TIRES 93 – 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. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth 400602-10 » If the tread depth is less than the minimum permissible depth: – – ≥ 2 mm (≥ 0.08 in) Change the tire. Check the tire age.
14 WHEELS, TIRES 94 – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diameter. 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. Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 6 Nm (4.
15 ELECTRICAL SYSTEM 15.1 Removing the battery 95 (All 200/250/300 models) 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. – In the event of skin contact, rinse with large amounts of water.
15 ELECTRICAL SYSTEM 15.3 Recharging the battery 96 (All 200/250/300 models) 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. – In the event of skin contact, rinse with large amounts of water.
15 ELECTRICAL SYSTEM 15.4 Changing the main fuse (All 200/250/300 models) 97 Warning 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.
15 ELECTRICAL SYSTEM 15.5 Removing the headlight mask with the headlight 98 – Switch off all power consumers and switch off the engine. – Remove screw – and take off the clamp. Release rubber straps . Slide the headlight mask up and swing it forward. 602762-10 (All EXC models) – Detach plug-in connectors light. and take off the headlight mask with the head- M00589-10 (All XC-W models) – Detach plug-in connector light. and take off the headlight mask with the head- M00590-10 15.
15 ELECTRICAL SYSTEM 99 – Position the headlight mask and fix it with rubber straps – Position the brake line and wiring harness. Put the clamp on and mount and tighten screw . . The holding lugs engage. 602762-11 Finishing work – Check the headlight setting. ( 15.7 p. 100) Changing the headlight bulb 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 100 Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze orange cap – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket. . in the area of the holding lugs and take it off. Info Do not touch the reflector with your fingers, and keep it free from grease.
15 ELECTRICAL SYSTEM 15.11 Changing the speedometer battery 101 Preparatory work – Remove the headlight mask with the headlight. ( Main work – Remove screws p. 98) . – Pull the speedometer upward out of the holder. – Using a coin, turn protection cap – Remove speedometer battery – Insert the new battery with the label facing upward. 602746-10 all the way counterclockwise and remove it. . Speedometer battery (CR 2430) ( p.
16 COOLING SYSTEM 16.1 Cooling system 102 (All 125/200 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 16.3 Checking the coolant level 103 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.
16 COOLING SYSTEM 104 (All 250/300 models) – Remove screw . Take off radiator cap . – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) B02168-11 16.5 Refilling with coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing.
16 COOLING SYSTEM 105 – Place the vehicle back on a level surface. – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. . M00597-10 Finishing work – Check the coolant level. ( p.
17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable 106 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. 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 specifications: – Adjust the play in the throttle cable. ( p.
17 TUNING THE ENGINE 107 The idle speed is adjusted with adjusting screw . The idle mixture is adjusted with the idle air adjusting screw . Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw and the idle air adjusting screw . Transition range B Behavior of the engine when the throttle slide is being opened. This range is influenced by the idling jet and by the form of the throttle slide.
17 TUNING THE ENGINE – 108 Adjust the idle speed with adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in all the way. ( Idle speed p. 17) 1,400… 1,500 rpm – Turn idle air adjusting screw 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.
17 TUNING THE ENGINE 17.6 Checking the basic position of the shift lever – 109 Sit on the vehicle in the riding position and determine the distance the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot » between 10… 20 mm (0.39… 0.79 in) If the distance does not meet specifications: – Adjust the basic position of the shift lever. ( p. 109) 400692-10 17.
17 TUNING THE ENGINE 110 Main work – Remove screws . 102296-10 – Take cap , adjusting spring the clutch cover. – Pull both springs off of the spring insert. – Mount the required auxiliary spring into the clutch cover together.
18 SERVICE WORK ON THE ENGINE 18.1 Checking the gear oil level 111 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 – 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: – – B02173-10 Add gear oil. ( p.
18 SERVICE WORK ON THE ENGINE 18.3 Draining the gear oil 112 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.
18 SERVICE WORK ON THE ENGINE Main work – Remove filler plug 1 0 and fill up with gear oil. Gear oil (All 125/200 models) 401955-10 – 113 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 141) Gear oil 0.80 l (0.85 qt.) (All 250/300 models) Engine oil (15W/50) ( p. 141) Mount and tighten the oil filler plug. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – 18.
18 SERVICE WORK ON THE ENGINE 114 (All 250/300 models) Screw, gear oil level check – Mount and tighten filler plug M6 10 Nm (7.4 lbf ft) . 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 ventilation, 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.
19 CLEANING, CARE 19.1 Cleaning the motorcycle 115 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.
19 CLEANING, CARE 19.2 Checks and maintenance steps for winter operation 116 Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corrosion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance 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. – 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 has been contaminated with fuel.
21 TROUBLESHOOTING 118 Faults Possible cause Action The engine cannot be cranked (electric starter) (All 200/250/300 models) 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. 96) – Check the alternator. Main fuse is blown – Change the main fuse. ( Starter relay faulty – Check the starter relay.
21 TROUBLESHOOTING 119 Faults Possible cause Action Engine stalls or is popping into the carburetor 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 – Check the coolant level. ( Too little air stream – Switch off engine when stationary.
22 TECHNICAL DATA 22.1 Engine 22.1.1 All 125 models 120 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing 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.
22 TECHNICAL DATA 6th gear 121 22:20 Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan 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 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Bore 66.4 mm (2.
22 TECHNICAL DATA Gearbox 122 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 ignition adjustment, type Kokusan Spark plug NGK BR 7 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.
22 TECHNICAL DATA 123 Axle for control flap, exhaust control M8 Step 1 3 Nm (2.2 lbf ft) Step 2 (loosen, counterclockwise) 1/4 turn – Nut, cylinder base M8 30 Nm (22.1 lbf ft) – Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, shift drum locating M8 25 Nm (18.4 lbf ft) Loctite® 243™ Stud, cylinder base M8 35 Nm (25.8 lbf ft) – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Gear oil drain plug M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.
22 TECHNICAL DATA 124 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 M18x1.5 120 Nm (88.5 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 (All 125/200 models) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 141) Gear oil (All 250/300 models) 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 141) 1.2 l (1.3 qt.
22 TECHNICAL DATA 125 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 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.
22 TECHNICAL DATA 22.
22 TECHNICAL DATA 127 Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload - Preload Adjuster Comfort 0 turns Standard 0 turns Sport 1 turn Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 510 mm (20.08 in) Weight of rider: 75… 85 kg (165… 187 lb.) 510 mm (20.08 in) Weight of rider: 85… 95 kg (187… 209 lb.) 510 mm (20.08 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.
22 TECHNICAL DATA 128 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 100 mm (3.94 in) Oil capacity per fork leg 630 ml (21.3 fl. oz.) 22.8 Shock absorber 22.8.1 All 125/200 models Fork oil (SAE 4) (48601166S1) ( p. 141) Shock absorber part number 12.18.7O.
22 TECHNICAL DATA 129 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 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/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.
22 TECHNICAL DATA 130 Screw, top steering stem (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) M8 20 Nm (14.8 lbf ft) – Screw, top steering stem (EXC EU, EXC Six Days, EXC EU/AU, Six Days) M8 17 Nm (12.5 lbf ft) Loctite® 243™ Screw, top triple clamp (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) M8 20 Nm (14.8 lbf ft) – Screw, top triple clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days) M8 17 Nm (12.5 lbf ft) – Engine bracket screw M10 60 Nm (44.
22 TECHNICAL DATA 22.10 Carburetor 131 22.10.1 All 125 models Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th 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 Open 2.75 turns Throttle slide 7 with cut-out Slide stop - 22.10.
22 TECHNICAL DATA 132 Throttle slide 7 with cut-out Slide stop - 22.10.5 250 EXC EU, 250 EXC Six Days 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.
22 TECHNICAL DATA Open 133 1.75 turns Throttle slide 7 with cut-out Slide stop Present 22.10.9 300 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.
23 CARBURETOR TUNING 23.1 Carburetor tuning (All 125 models) 134 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 23.2 Carburetor tuning (All 200 models) 135 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 23.3 Carburetor tuning (All 200 models) 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 (All 250 models) 137 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 23.5 Carburetor tuning (All 300 EXC EU/AU/Six Days, 300 XC-W US/Six Days) 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 EXC BR) 139 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. KEIHIN PWK 36S AG M/FT ASL 3.000 m 10,000 ft 2.301 m 7,501 ft 2.300 m 7,500 ft 1.501 m 5,001 ft 1.
23 CARBURETOR TUNING 23.7 General carburetor tuning 1... 5 0 1 30 5 0 140 Needle position from above The five needle positions are shown here. The carburetor tuning depends on the defined ambient and operating conditions.
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 Hydraulic fluid (15) 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 corresponding properties. Recommended supplier Motorex® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 146) (SAE 2.
24 SUBSTANCES Info Do not use fuel made of methanol (e. g. M15, M85, M100). Do not use fuel with less than 20 % ethanol (e. g. E10). Do not use fuel with more than 25 % ethanol (e. g. E30, E85, E100).
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 Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE 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 R
25 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex® – Joker 440 Synthetic 145
26 STANDARDS 146 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 LISY OF SYMBOLS 28.1 Yellow and orange symbols 148 Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. EFI warning lamp (MIL) – inoperative Low fuel 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 149 Cleaning, care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-116 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Air filter box cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 150 Fork basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 45 Fork legs bleeding . . . . . . . . . dust boots, cleaning . installing . . . . . . . . . removing . . . . . . . . . spring preload, setting Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX installing . . . . . . . . . . . removing . . . . . . . . . . . riding sag, checking . . . spring preload, adjusting static sag, checking . . . 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 65 44 44 43 Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . 12 Side stand . . . . . .
*3213334en* 3213334en 05/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria http://www.ktm.
