KTM 250 EXC-F EU 2010 Owner'S Manual Download

Page: 105 / 136

TUNING THE ENGINE

103

17.1

Checking the play in the throttle cable

400192-11

–

Check the throttle grip for smooth operation.

–

Move the handlebar to the straight-ahead position. Move the throttle grip back and
forth slightly to ascertain 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. 103)

Danger

Danger of poisoning

Exhaust gases are toxic and inhaling them may result

in unconsciousness and/or death.

–

When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

–

Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the play in the throttle cable.

(

p. 103)

17.2

Adjusting the play in the throttle cable

Preparatory work

–

Remove the seat. (

p. 62)

–

Remove the fuel tank.

(

p. 68)

–

Check throttle cable routing. (

p. 75)

L02455-10

Main work

–

Move the handlebar to the straight-ahead position.

–

Push back sleeves



–

Loosen nut



. Turn adjusting screw



in as far as possible.

–

Loosen nut



. Turn adjusting screw



so that there is play in the throttle cable

at the throttle grip.
Guideline

Play in throttle cable

3… 5 mm (0.12… 0.2 in)

–

Tighten nut



–

Press and hold the throttle grip in the closed setting. Turn adjusting screw



out

until there is no play in throttle cable



–

Tighten nut



–

Push sleeves



on. Check the throttle grip for smooth operation.

Finishing work

–

Install the fuel tank.

(

p. 69)

–

Mount the seat. (

p. 62)

–

Check the play in the throttle cable. (

p. 103)

Summary of Contents for 250 EXC-F EU 2010

Page 1: ...OWNER S MANUAL 2016 250 EXC F EU 250 EXC F Six Days EU 250 EXC F AU 250 EXC F BR 250 XCF W US Art no 3213335en ...

Page 2: ......

Page 3: ... delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions misprints and other errors The models portrayed part...

Page 4: ... 7 Display mode SPEED speed 22 7 8 Display mode SPEED H service hours 22 7 9 Setup menu 23 7 10 Setting the unit of measurement 23 7 11 Display mode SPEED CLK time 24 7 12 Setting the clock 24 7 13 Display mode SPEED LAP lap time 24 7 14 Viewing the lap time 25 7 15 Display mode SPEED ODO odometer 25 7 16 Display mode SPEED TR1 trip master 1 25 7 17 Display mode SPEED TR2 trip master 2 26 7 18 Set...

Page 5: ...ip 76 12 45 Adjusting the basic position of the clutch lever 76 12 46 Checking correcting the fluid level of the hydraulic clutch 76 12 47 Changing the hydraulic clutch fluid 76 12 48 Removing the engine guard 77 12 49 Installing the engine guard 77 13 BRAKE SYSTEM 78 13 1 Checking free travel of hand brake lever 78 13 2 Adjusting free travel of hand brake lever All EXC F models 78 13 3 Adjusting ...

Page 6: ...ngine 117 23 2 Engine tightening torques 117 23 3 Capacities 119 23 3 1 Engine oil 119 23 3 2 Coolant 119 23 3 3 Fuel 119 23 4 Chassis 119 23 5 Electrical system 120 23 6 Tires 120 23 7 Fork 120 23 7 1 EXC F EU AU BR XCF W 120 23 7 2 EXC F Six Days 121 23 8 Shock absorber 121 23 9 Chassis tightening torques 122 24 SUBSTANCES 124 25 AUXILIARY SUBSTANCES 126 26 STANDARDS 128 27 LIST OF ABBREVIATIONS...

Page 7: ...e your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step 1 2 Formats used The typographical formats used in this document are explained below Specific name Identifies a proprietary...

Page 8: ...he vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Indica...

Page 9: ... clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety KTM recommends that you only operate the vehicle while wearin...

Page 10: ...hen will you find out how to cus tomize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle ...

Page 11: ...M PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis can lead to damage and breaka...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example M01021 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Filler cap 4 Side stand p 18 5 Shift lever p 18 6 Engine number p 12 ...

Page 13: ...4 1 Horn button p 15 1 Light switch p 15 1 Turn signal switch p 15 2 Emergency OFF switch p 15 2 Electric starter button p 16 3 Throttle grip p 14 4 Chassis number p 12 4 Type label p 12 5 Fork part number p 12 6 Kick starter p 18 7 Foot brake lever p 18 8 Shock absorber part number p 13 ...

Page 14: ...ed to the front of the steering head 5 3 Key number All EXC F models 402247 10 The key number for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number 401947 10 The fork part number is stamped on the inner side of the fork stub ...

Page 15: ...5 SERIAL NUMBERS 13 5 6 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 16: ...h 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 is pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Kill switch XCF W 102046 10 Kill switch is fitted on the left side of the handlebar Po...

Page 17: ... states Light off Light switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on 6 9 Turn signal switch All EXC F models 102044 12 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Turn signal switch is in the central po...

Page 18: ...n EFI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark Turn signal indicator light flashes green The turn signal is switched on 6 14 Overview of indicator lamps XCF W M00988 01 Possible states EFI warning lamp MIL lights up flashes orange The OBD has detected an...

Page 19: ...nt Do not allow fuel to get into the ground water the ground or the sewage system K00109 11 Press release button turn filler cap counterclockwise and lift it upwards and remove 6 16 Closing filler cap K00109 10 Replace the filler cap and turn clockwise until the release button locks in place Info Route the fuel tank breather hose without kinking 6 17 Idle speed adjusting screw L02462 10 Idle speed...

Page 20: ...tted on the right of the engine The engine can be started with either the kick starter or the electric starter The upper part of the kick starter can be swung out Info Before riding swing the top part of the kick starter inwards towards the engine 6 20 Foot brake lever 401956 10 The foot brake lever is attached in front of the right footrest The foot brake lever is used to activate the rear brake ...

Page 21: ...e may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Grease steering lock regularly Universal oil spray p 127 Insert the key in the steering lock p 19 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...

Page 22: ...ircumference of the 21 front wheel with stan dard tires The display then changes to the last selected mode 7 3 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Repeatedly press the button briefly until H appears ...

Page 23: ...he symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappears in the display and the next function appears 7 5 Setting the clock Condition The motorcycle is stationary 400330 01 Repeatedly press the button briefly until CLK appears at the bottom right of the display Press the button for 2 3 seconds The hour display flashes...

Page 24: ...y When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 7 8 Display mode SPEED H service hours 400316 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display In display mode H the service hours of the engine are displayed The service hour c...

Page 25: ...econds Changes to the next display without changes Wait 10 12 sec onds Setup menu starts stores the settings and changes to H or ODO 7 10 Setting the unit of measurement 400329 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds Repeatedly press the button briefly until Km h Mph flashes In...

Page 26: ... button Increases the value Press the button for 2 3 seconds Reduces the value Briefly press the button Reduces the value Wait 3 5 seconds Changes to the next value Wait 10 12 sec onds Closes the SETUP menu 7 13 Display mode SPEED LAP lap time 400320 01 Repeatedly press the button briefly until LAP appears at the bottom right of the display In the LAP display mode up to 10 lap times can be timed w...

Page 27: ...display mode ODO Press the button for 2 3 seconds No function Briefly press the button Next display mode Press the button for 2 3 seconds No function Briefly press the button No function 7 16 Display mode SPEED TR1 trip master 1 400323 01 Repeatedly press the button briefly until TR1 appears at the top right of the dis play TR1 trip master 1 runs constantly and counts up to 999 9 You can use it to...

Page 28: ...R2 value can also be corrected manually during the journey with the but ton and the button If 999 9 is exceeded the value of TR2 is automatically reset to 0 0 Press the button for 2 3 seconds Increases value of TR2 Briefly press the button Increases value of TR2 Press the button for 2 3 seconds Reduces value of TR2 Briefly press the button Reduces value of TR2 Wait 10 12 sec onds Saves and closes ...

Page 29: ... shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor The calculation of this value starts with the first impulse from the wheel speed sensor and ends 3 seconds after the last impulse Press the button for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the button for 2 3 seconds No...

Page 30: ...ETUP menu Display mode SPEED LAP lap time The stop watch and the lap time are reset Next display mode Stops the clock Starts the stop watch or stop the current lap time measure ment stores it and the stop watch starts the next lap Viewing the lap time The stop watch and the lap time are reset Select a lap from 1 10 No function View the next lap time Display mode SPEED ODO odometer No function Next...

Page 31: ...Setup menu Setting the unit of measurement Setting the clock Display mode SPEED LAP lap time Viewing the lap time Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Setting TR2 trip master 2 Display mode SPEED A1 average speed 1 Display mode SPEED A2 average speed 2 Display mode SPEED S1 stop watch 1 Display mode SPEED S2 stop watch 2 ...

Page 32: ...ke may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your ...

Page 33: ...During the first 3 operating hours 75 Avoid fully opening the throttle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reason it may be neces sary to inspect or replace...

Page 34: ...rts fitting instructions 600868 01 Clean the chain Chain cleaner p 126 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 8 5 Preparing for rides on wet sand M01001 01 Fit a rain cover on the air filter Waterproofing device for air filter 77206921100 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain clea...

Page 35: ... at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions 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 p 126 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 101 8 8 Preparing for rides at low temperature or in snow M...

Page 36: ...ated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting 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 N...

Page 37: ...ing increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch As a result the engine oil engine and cooling s...

Page 38: ...age Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift transmission to neutral All EXC F models Press and hold the kill switch while the engine is idling...

Page 39: ...wed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help Only refuel with clean fuel that meets the specified standards ...

Page 40: ... the fluid level of the hydraulic clutch p 76 Check the brake fluid level of the front brake p 79 Check the free travel of the hand brake lever p 78 Check the steering head bearing play p 59 Check the valve clearance Check the clutch Change the shaft seal rings of the water pump Change the engine oil and oil filter clean the oil screen p 107 Check all hoses e g fuel cooling bleeding drainage and s...

Page 41: ...m a fork service EXC F EU AU BR XCF W Service the shock absorber Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator ...

Page 42: ...speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between ...

Page 43: ...rresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nit...

Page 44: ...is the difference between measurements and Check the static sag Static sag 33 35 mm 1 3 1 38 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 43 11 8 Checking the riding sag of the shock absorber 400990 10 Measure distance of rear wheel unloaded p 42 With another person holding the motorcycle the rider wearing full protective cloth ing...

Page 45: ...ension Tighten the spring by turning adjusting ring to measurement Guideline Spring preload 8 mm 0 31 in 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 M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 62 Remove the motorcycle from the lift stand p 49 11 1...

Page 46: ...n damping determines the fork suspension behavior 402496 10 EXC F EU AU BR XCF W Remove protection caps Turn adjusting screws clockwise all the way Info Adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 22 clicks Standard 2...

Page 47: ...corresponding to the fork type Guideline Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping B01207 11 EXC F Six Days Turn the red adjusting screw all the way clockwise Info The adjusting screw is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB re...

Page 48: ...preload Preload Adjuster Comfort 0 turns Standard 0 turns Sport 1 turn 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 K00139 01 XCF W Turn the adjusting screws c...

Page 49: ... four different positions M00993 10 XCF W On the upper triple clamp there are two holes at a distance of to each other Hole distance 15 mm 0 59 in Hole distance 3 5 mm 0 138 in The handlebar supports can be mounted in four different positions 11 16 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue...

Page 50: ... screws and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap widths are even M00993 11 XCF W 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 Take off the handlebar supports Place the handlebar supports in the requi...

Page 51: ... fall over Always place the vehicle on a firm and even surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the motorcycle on it Info While riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory work Raise the motorcycle with the lift ...

Page 52: ...leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 127 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork pro...

Page 53: ...nto 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 K00086 11 Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft M00137 10 EXC F Six Days Position the fork legs Bleeder screws are positioned toward the front Info The re...

Page 54: ...iple clamp M8 20 Nm 14 8 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft K00088 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 binder Position the brake line wiring harness and clamp Mount and tighten screws Finishing work Install the front wheel p 87 Refit the headlight ...

Page 55: ...he handlebar cushion S00815 10 Main work EXC F EU AU BR Open the cable holder in front of the right radiator and detach the wiring har ness Remove screws and hang the voltage regulator to the side Remove screw Remove screw Take off the upper triple clamp with the handlebar and set it aside Info Cover the components to protect them against damage Do not kink the cables and lines S00816 10 Remove O ...

Page 56: ...ove screws and hang the voltage regulator to one side Release screw and remove screw Take off the upper triple clamp with the handlebar and set it aside Info Protect the components against damage by covering them Do not bend the cables and lines M00990 10 Remove O ring Remove protective ring Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 11 Install...

Page 57: ...front 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 K00090 10 Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft K00091 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft K00092 10 Mount and tighten screw Guideline Screw top steerin...

Page 58: ...front 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 M00139 10 Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S00637 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft S00638 10 Mount and tighten screw Guideline Screw top steerin...

Page 59: ...rectly Check the steering head bearing play p 59 Remove the motorcycle from the lift stand p 49 Check the headlight setting p 97 12 12 Installing the lower triple clamp XCF W B01605 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 126 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the u...

Page 60: ...e clamp M8 15 Nm 11 1 lbf ft K00142 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft K00142 11 Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft K00141 11 Tighten screws Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Secure the wiring harness with cable holder K00088 11 Position the brake caliper Mount and tighten screws Guideline Screw front br...

Page 61: ...738 11 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 All EXC F models Adjust the play of the steering head bearing p 59 XCF W Adjust the play of the steering head bearing p 60 Move the handlebar to and fro over the entire steering rang...

Page 62: ...ount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the steering head bearing play p 59 Remove the motorcycle from the lift stand p 49 12 15 Adjusting the play of the steering head bearing XCF W Preparatory work Raise the motorcycle with the lift stand p 49 K00144 10 Main work Loosen screws and Loosen and retighten screw Guideline Screw to...

Page 63: ...atory work Remove the headlight mask with the headlight p 95 K00072 10 Main work Remove screws K00073 10 Remove screws Remove the front fender 12 18 Installing the front fender K00072 10 Main work Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00073 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishi...

Page 64: ...d tighten screw 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 greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Finishing work Remove the motorcycle from the lift stand p 49 12 21 Removing the seat 1013...

Page 65: ...ilter as dust and dirt will enter the engine and lead to increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box cover p 63 K00077 10 Main work Detach air filter holding bracket at the bottom and swing it to on...

Page 66: ...r filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 63 Remove the air filter p 63 S00044 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 126 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oi...

Page 67: ...r K00079 10 Position the main silencer Mount screws but do not tighten yet Reconnect spring Spring hooks 50305017000 Tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 31 Cleaning spark arrestor XCF W 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 Info Soot particles accumul...

Page 68: ...ng on silencer cap Position silencer cap Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 65 12 32 Changing glass fiber yarn filling in 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 Info Over time the f...

Page 69: ...th insulating pad Clean the parts that need to be reinstalled and check for damage Mount the new insulating pad on the insert and fasten with adhesive tape Position the insert with the insulating pad in outer tube Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Mount O ring on the silencer cap Fit the new glass fiber yarn filling onto the perforated pipe Fit the c...

Page 70: ...an 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 Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the seat p 62 K00100 10 Main work Detach connector of the fuel pump Remove the tube from the fuel tank breather D00062 10 Thoroughly clean the pl...

Page 71: ...el is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with wat...

Page 72: ...r of the horn M01023 11 EXC F Six Days Position collar bushings between the spoiler and radiator shield Position the horn and fit and tighten screws with washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect the connector of the horn K00146 11 XCF W Position the collar bushings and mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft M01007 10 Plug in co...

Page 73: ...ds largely on its maintenance Preparatory work Raise the motorcycle with the lift stand p 49 400725 01 Main work Clean the chain regularly and then treat with chain spray Chain cleaner p 126 Off road chain spray p 126 Finishing work Remove the motorcycle from the lift stand p 49 12 37 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is to...

Page 74: ...is can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise the motorcycle with the lift stand p 49 Check the chain tension p 71 K00136 10 Main wor...

Page 75: ...n links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Change the power set Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on...

Page 76: ...ont of the chain guide If the light part of the chain guide is worn Change the chain guide K00149 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 49 12 40 Checking the frame 4013...

Page 77: ... fuel tank p 68 M00995 01 Main work Check throttle cable routing Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing If the throttle cable routing is not as specified Correct throttle cable routing Finishing work Install the fuel tank p 69 Mount the seat p 62 12 43 Checking the rubber grip 401197 01 Check the rubber grip...

Page 78: ...imited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 46 Checking correcting the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs M00208 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the flui...

Page 79: ...nings of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws 12 48 Removing the engine guard L02452 ...

Page 80: ... free travel of the hand brake lever p 78 Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by ha...

Page 81: ...re completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help K00106 10 Move the brake fluid reservoir mounted on the handleb...

Page 82: ...nt brake linings p 80 K00107 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to level Guideline Level brake fluid level below con tainer rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 124 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid ...

Page 83: ...riction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Hazardous substances ca...

Page 84: ... lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications 402026 10 Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder p...

Page 85: ...tem and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help L02464 10 Stand the vehicle upright Check the brake fluid level in level viewer If the brake fluid level h...

Page 86: ...brake fluid from a sealed container Preparatory work Check the rear brake linings p 84 101380 10 Main work Stand the vehicle upright Remove screw cap with membrane and the O ring Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 124 Mount the screw cap with the membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water 13 13 Checking the rear brake linings Warn...

Page 87: ...d for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid War...

Page 88: ...t the pin and mount the cotter pins Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point 101380 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 124 Mount screw cap with membrane and O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 89: ... out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged K00084 11 Remove spacers 14 2 Installing the front wheel 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 ...

Page 90: ... motorcycle with the lift stand p 49 K00113 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward ...

Page 91: ...ly on adjusting screws Check the chain tension p 71 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is ...

Page 92: ... years Change the tire 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure A...

Page 93: ...und frequencies in spokes with the same length and thickness this indicates different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 94: ...cable from the battery Pull back positive terminal cover and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the battery up and out 15 2 Installing the battery K00116 10 Main work Insert the battery into the battery compartment with the terminals facing forward Alternative 1 Battery YTX4L BS p 120 Reconnect rubber band Position the positive cable and mount and ...

Page 95: ...shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying th...

Page 96: ...ve screw K00098 10 Lift rear fairing slightly and pull starter relay out of the holder K00099 10 Remove protection caps Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109120 p 120 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so t...

Page 97: ...tor fan optional Fuses res 10 A spare fuse Fuses res 5 A spare fuse Info A defective fuse can be identified by the burned out fuse wire 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 Use spare fuses with the correct rating only Fuse 75011088010 p 120 Fuse 58011109105 p 120 Tip Replace ...

Page 98: ...k the headlight setting p 97 15 8 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 Preparatory work Remove the headlight mask with the headlight p 95 K00119 10 Main work Turn protection cap together with the underlying bulb socket coun...

Page 99: ...first mark Guideline Distance 5 cm 2 in Position the vehicle vertically a distance away from the wall Guideline Distance 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver If the light dark border does not meet specifications Adjust the headlight ra...

Page 100: ... it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal R10W socket BA15s p 120 Mount the orange cap Position the diffuser Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly Finishing work Check that the turn signal system is functioning properly 15 12 Changing the spee...

Page 101: ...utton on the speedometer The speedometer is activated Position the speedometer in the holder Mount and tighten the screws with washers Finishing work Refit the headlight mask with the headlight p 96 Check the headlight setting p 97 Set kilometers or miles p 20 Set the speedometer functions p 21 Set the clock p 21 ...

Page 102: ...ot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water ...

Page 103: ...ns 10 mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Coolant p 124 Mount the radiator cap 16 4 Draining the coolant 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 t...

Page 104: ... contaminated areas on the skin with soap and water If fuel is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children L02484 10 Main work Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 124 Refit...

Page 105: ...it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 103 17 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 62 Remove the fuel tank p 68 Check throttle cable routing p 75 L02455 10 Main work Move the handlebar to the straight ahead position Push back sl...

Page 106: ...be subject to an excessive load 400692 10 Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever Gap between the shift lever and the top of the boot 10 20 mm 0 39 0 79 in If the distance does not meet the specifications Adjust the basic position of the shift lever p 104 17 5 Adjusting the basic position of the shift lever 401950...

Page 107: ...17 TUNING THE ENGINE 105 Mount and tighten screw with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 108: ...em M01026 10 Clean the plug in connection of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plu...

Page 109: ...ark the motorcycle on a level surface L02450 10 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring Info Do not remove screws on both sides S00647 10 Remove plug with oil screen and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces S00648 10 Position oil screen with the O rings on a pin wrench Position ...

Page 110: ...0 Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 124 Alternative engine oil for harsh oper ating conditions and increased per formance Engine oil SAE 10W 60 00062010035 p 124 Info Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler pl...

Page 111: ...124 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engin...

Page 112: ... cleaner and then clean with a paintbrush Motorcycle cleaner p 126 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficienc...

Page 113: ...torcycle p 110 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted roads thoroughly wash the vehicle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax ba...

Page 114: ...e motorcycle out of service add fuel additive Fuel additive p 126 Refuel p 37 Clean the motorcycle p 110 Change the engine oil and oil filter clean the oil screen p 107 Check the antifreeze and coolant level p 100 Check the tire air pressure p 90 Remove the battery p 92 Charge the battery p 93 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dr...

Page 115: ...stem Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Ignition system defective Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator Engine has too little power Air filter heavily c...

Page 116: ...oute the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 106 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen p 107 Piston and cylinder worn Measure the piston cylinder mounting clear ance Battery discharged Battery is not being charged by alter nator Check the charging voltage Check the stator win...

Page 117: ... lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rollover sensor A D type input signal too high Blink code FI warning l...

Page 118: ...lamp MIL flashes 4x long 5x short Error level condition EXC F EU EXC F BR EXC F Six Days Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit EXC F EU EXC F BR EXC F Six Days Lambda sensor heater cylinder 1 sensor 1 input signal too high ...

Page 119: ... 6th gear 26 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9AI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter and kick starter 23 2 Engine tightening torques Nozzle crank chamber ventilation M4 2 Nm 1 5 lbf ft Loct...

Page 120: ... Screw plug crankshaft location M8 10 Nm 7 4 lbf ft Screw kick starter M8 25 Nm 18 4 lbf ft Loctite 243 Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Rotor screw M10x1 70 Nm 51 6 lbf ft Thread oiled with engine oil cone degreased Screw plug cam lever axis M10x1 10 Nm ...

Page 121: ...A 4CS Suspension travel EXC F EU AU BR XCF W Front 300 mm 11 81 in Suspension travel EXC F Six Days Front 300 mm 11 81 in Suspension travel Rear 335 mm 13 19 in Fork offset 20 mm 0 79 in Shock absorber WP Performance Systems 5018 PDS DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 ...

Page 122: ... plate lamp All EXC F models W5W socket W2 1x9 5d 12 V 5 W 23 6 Tires Validity Front tires Rear tires EXC F EU AU BR 80 100 21 M C 51M TT MAXXIS Maxx EnduPro 140 80 18 M C 70R TT MAXXIS Maxx EnduPro EXC F Six Days 90 90 21 M C 54M M S TT Metzeler MCE 6 Days Extreme 140 80 18 M C 70M M S TT Metzeler MCE 6 Days Extreme XCF W 90 90 21 54M TT Dunlop GEOMAX AT81F 110 100 18 64M TT Dunlop GEOMAX AT81 Ad...

Page 123: ...clicks Sport 10 clicks Spring length with preload spacer s 475 mm 18 7 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 4 4 N mm 25 1 lb in Weight of rider 85 95 kg 187 209 lb 4 6 N mm 26 3 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 Fork oil SAE 4 48601166S1 p 124 23 8 Shock...

Page 124: ...n on fuel pump M8 10 Nm 7 4 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp All EXC F models M8 15 Nm 11 1 lbf ft Screw bottom triple clamp XCF W M8 15 Nm 11 1 lbf ft Screw chain sliding ...

Page 125: ...ixing M12x1 20 Nm 14 8 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft ...

Page 126: ...0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 128 SAE p 128 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Engine oil SAE 10W 50 Standard classification JASO T903 MA p 128 SA...

Page 127: ...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 Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E1...

Page 128: ...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 Recommended supplier Motorex Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cl...

Page 129: ...25 AUXILIARY SUBSTANCES 127 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 130: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 131: ...27 LIST OF ABBREVIATIONS 129 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 132: ...s EFI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark 28 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator light lights up blue The high beam is switched on Turn signal indicator light flashes green The turn signal is s...

Page 133: ...justing 72 checking 71 Chassis number 12 Clutch fluid level checking correcting 76 fluid changing 76 Clutch lever 14 basic position adjusting 76 Compression damping fork adjusting 44 Compression damping high speed shock absorber adjusting 41 Compression damping low speed shock absorber adjusting 40 Coolant draining 101 refilling 102 Coolant level checking 100 101 Cooling system 100 Customer servic...

Page 134: ...rter 18 Kill switch 14 L Light switch 15 Lower triple clamp installing 54 57 removing 53 54 M Main fuse changing 94 Main silencer changing glass fiber yarn filling 66 installing 65 removing 65 spark arrestor cleaning 65 Motorcycle cleaning 110 raising with lift stand 49 removing from lift stand 49 O Oil filter changing 107 Oil screen cleaning 107 Operating substances 9 Overview of indicator lamps ...

Page 135: ...59 Storage 112 Swingarm checking 75 T Technical data capacities 119 chassis 119 chassis tightening torques 122 electrical system 120 engine 117 engine tightening torques 117 fork 120 shock absorber 121 tires 120 Throttle cable play adjusting 103 Throttle cable routing checking 75 Throttle grip 14 Tire air pressure checking 90 Tire condition checking 89 Transport 36 Troubleshooting 113 114 Turn sig...

Page 136: ... 3213335en 3213335en 04 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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