KTM 250 EXC Six Days TPI Owner'S Manual Download

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SERVICE WORK ON THE ENGINE 18

147

18.5

Checking the gear oil level

Info

The gear oil level must be checked when the engine is cold.

Preparatory work

–

Stand the motorcycle upright on a horizontal surface.

E00912-10

Main work

–

Detach the foot brake lever spring.

–

Remove gear oil level monitoring screw

–

Check the gear oil level.

A small quantity of gear oil must run out of the drilled hole.

» If no gear oil runs out:

–

Add the gear oil.

(

p. 148)

–

Mount and tighten the gear oil level monitoring screw.
Guideline

Screw, gear oil level
monitoring

10 Nm (7.4 lbf ft)

–

Attach the foot brake lever spring.

18.6

Changing the gear oil

Warning

Danger of scalding

Engine and gear oil get very hot when the motorcycle is ridden.

–

Wear suitable protective clothing and safety gloves.

–

In the event of scalding, rinse the area affected immediately with lukewarm water.

Note

Environmental hazard

Hazardous substances cause environmental damage.

–

Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info

Drain the gear oil while the engine is at operating temperature.

Preparatory work
(All special models)

–

Remove the engine guard. (

p. 97)

–

Park the motorcycle on a level surface.

–

Place an appropriate container under the engine.

Summary of Contents for 250 EXC Six Days TPI

Page 1: ...OWNER S MANUAL 2020 250 EXC TPI 250 EXC Six Days TPI 250 XC W TPI 300 EXC TPI 300 EXC Six Days TPI 300 XC W TPI 300 XC W Six Days TPI 300 EXC Erzberg Edition TPI Art no 3214007en ...

Page 2: ......

Page 3: ...ecifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without prior notice KTM accepts no liability for delivery options deviations from fig ures and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2019 KTM Sportmotorcycle GmbH Mattighofen Austria All...

Page 4: ... 18 6 13 Overview of indicator lamps All EXC models 19 6 14 Overview of indicator lamps All XC W models 19 6 15 Opening the fuel tank filler cap 19 6 16 Closing the fuel tank filler cap 20 6 17 Opening 2 stroke oil tank cap 20 6 18 Closing 2 stroke oil tank cap 21 6 19 Straps 300 EXC Erzberg Edition TPI EU 21 6 20 Cold start button 21 6 21 Idle speed adjusting screw 22 6 22 Shift lever 22 6 23 Foo...

Page 5: ...sag of the shock absorber 56 11 9 Adjusting the spring preload of the shock absorber 57 11 10 Adjusting the riding sag 58 11 11 Checking the basic setting of the fork 58 11 12 Adjusting the compression damping of the fork 59 11 13 Adjusting the rebound damping of the fork 60 11 14 Adjusting the spring preload of the fork All Six Days models 61 11 15 Handlebar position 62 11 16 Adjusting the handle...

Page 6: ...s of the rear brake 107 13 14 Changing the brake linings of the rear brake 107 14 WHEELS TIRES 110 14 1 Removing the front wheel 110 14 2 Installing the front wheel 111 14 3 Removing the rear wheel 112 14 4 Installing the rear wheel 113 14 5 Checking the tire condition 114 14 6 Checking tire pressure 115 14 7 Checking spoke tension 115 15 ELECTRICAL SYSTEM 117 15 1 Removing the 12 V battery 117 15...

Page 7: ...0 models 157 22 1 2 All 300 models 157 22 2 Engine tightening torques 158 22 3 Capacities 160 22 3 1 Gear oil 160 22 3 2 Coolant 160 22 3 3 Fuel 160 22 4 Chassis 160 22 5 Electrical system 161 22 6 Tires 161 22 7 Fork 162 22 7 1 All standard EXC XC W models 300 EXC Erzberg Edi tion TPI EU 162 22 7 2 All Six Days models 162 22 8 Shock absorber 163 22 9 Chassis tightening torques 163 23 SUBSTANCES 1...

Page 8: ...ined experts using the auxiliary 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 Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this documen...

Page 9: ...tions Info This vehicle is not approved for use on public roads This vehicle is designed for use in offroad endurance competition and not primarily for use in motocross 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also in...

Page 10: ...f noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencers baffles header pipes or any other components which conduct exh...

Page 11: ...les Special tools are necessary for certain tasks The tools are not a component of the vehicle but can be ordered using the number in parentheses Example bearing puller 15112017000 During assembly use new parts to replace parts which cannot be reused e g self locking screws and nuts seals sealing rings O rings pins and lock washers In the case of certain screws a screw adhesive e g Loctite is requ...

Page 12: ...use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold The Owner...

Page 13: ...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 An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can result in s...

Page 14: ...e lever p 16 2 Clutch lever p 16 3 Light switch p 17 All EXC models 3 Switch off button p 16 All EXC models 3 Turn signal switch p 18 All EXC models 3 Horn button p 17 All EXC models 4 Ignition curve plug in connector p 139 5 Air filter box cover 6 Side stand p 23 7 Shift lever p 22 ...

Page 15: ... OF VEHICLE 4 13 4 2 View of vehicle rear right example S03467 10 1 Fuel tank filler cap 2 Throttle grip p 16 3 Vehicle identification number p 14 4 Foot brake lever p 23 5 Level viewer for brake fluid rear ...

Page 16: ... of the steering head 5 2 Type label 401946 10 Type label 1 is fixed to the front of the steering head 5 3 Key number All EXC models 402247 10 The key number 1 for the steering lock is stamped onto the key connector 5 4 Engine number H01047 10 The engine number 1 is located on the left side of the engine over the engine sprocket ...

Page 17: ...01947 10 The fork part number 1 is stamped on the inside of the axle clamp 5 6 Shock absorber article number 401948 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 18: ...d brake lever 6 3 Throttle grip E00819 10 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Switch off button All EXC models E00820 10 Switch off button 1 is fitted on the left side of the handlebar Possible states The switch off button is in the basic position In this position the ignition circuit is closed and the engine can be started The switch off button is pressed In this posi...

Page 19: ...basic position The horn button is pressed The horn is operated in this position 6 7 Light switch All EXC models E00822 10 Light switch 1 is fitted on the left side of the handlebar Possible states Low beam on Light switch is in the central posi tion In this position the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and the ta...

Page 20: ...ing engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started 6 11 Start button E00824 10 Start button 1 is fitted on the right side of the handlebar Possible states The start button is in the basic position The start button is pressed In this position the starter motor is actuated 6 12 Map switch All special models E00859 10 The map switch 1 i...

Page 21: ... 01 Possible states High beam indicator lamp inoperative Malfunction indicator lamp lights up flashes yellow The OBD has detected an error in the vehicle elec tronics Come safely to a halt and contact an autho rized KTM workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark The oil level warning lamp lights up red Oil level has reached the MINmarking Ride...

Page 22: ...s correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system E00929 10 Press release button 1 turn the fuel tank filler cap counter clockwise and lift it off 6 16 Closing the fuel tank filler cap E00930 10 Mount the fuel tank filler cap ...

Page 23: ...ton 1 is fitted on the side of the throttle valve body If the engine is cold and the ambient temperature is low the electronic fuel injection system extends the injection time To help the engine burn the increased fuel quantity it must be supplied with additional oxygen by pulling the cold start button Info If the engine is warm the cold start button must be deacti vated Possible states The cold s...

Page 24: ...g the idle speed adjusting screw 1 Info If the idle speed is high the engine is slow to run the engine brake is low and the throttle response is aggressive the adjustment screw must be turned clockwise If the idle speed is low the engine is running fast the engine brake is high and the throttle response is not clean the adjusting screw must be turned counterclockwise 6 22 Shift lever 401950 10 Shi...

Page 25: ...tand 1 is located on the left of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber strap 2 6 25 Steering lock All EXC models E00862 10 Steering lock 1 is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and there fore riding is no longer possible...

Page 26: ...right Insert the key into 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 6 27 Unlocking the steering All EXC models 400731 01 Insert the key into the steering lock turn it to the left pull it out and turn it to the right Remove the key The handlebar can now be moved again Info Ne...

Page 27: ...WS wheel size After the display function check the wheel circumference WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with standard tires The display then changes to the last selected mode 7 3 Setting the 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 t...

Page 28: ...om right of the display Press the button 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 If no button is pressed for 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed Repeatedly press the button briefly unti...

Page 29: ...pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed 7 6 Viewing the lap time Info This function can only be opened if lap times have actually been timed Condition The motorcycle is stationary 400321 01 Repeatedly press the button briefly until LAP appears at the bottom right of the display Briefly press the ...

Page 30: ...ice hours of the motor are displayed The service hour counter stores the total traveling time Info The service hour counter is necessary for ensuring that service work is carried out at the right intervals If the combination instrument is in H display mode when starting off it automatically changes to the ODO display mode The H display mode is suppressed during the journey Press the but ton for 2 ...

Page 31: ... changes to H or ODO 7 10 Adjusting 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 measurement unit mode you can change the unit of measure ment Info If no button is pressed for 5 seconds the ...

Page 32: ...ly until CLK appears at the bottom right of the display Press the button for 2 3 seconds Press the but ton for 2 3 seconds Increases the value Briefly press the button Increases the value Press the but ton 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 seconds Closes the SETUP menu 7 13 Display mode SPEED LAP lap t...

Page 33: ...AP appears at the bottom right of the display Briefly press the button Press the but ton 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 but ton for 2 3 seconds No function Briefly press the button View the next lap time 7 15 Display mode SPEED ODO odometer 400317 01 Repeatedly press the button briefly until ODO appears at the bot...

Page 34: ...nction Briefly press the button No function 7 17 Display mode SPEED TR2 trip master 2 400324 01 Repeatedly press the button briefly until TR2 appears at the top right of the display TR2 trip master 2 runs constantly and counts up to 999 9 Press the but ton for 2 3 seconds Clears the values TR2 and A2 Briefly press the button Next display mode Press the but ton for 2 3 seconds Reduces value of TR2 ...

Page 35: ...ws the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the but ton for 2 3 seconds No function Briefly press the button N...

Page 36: ...l speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the but ton for 2 3 seconds No function Briefly press the button No function 7 22 Display mode SPEED S2 stop watch 2 400328 01 Repeatedly press the button briefly until S2 appears at the top right of the display S2 St...

Page 37: ...ion Activates Mph display Changes to the next dis play changes from selec tion to the Setup menu Stores and closes the Setup menu Display mode SPEED CLK time The display changes to the Setup menu of the clock Next display mode No function No function Setting the clock Increases the value Increases the value Reduces the value Reduces the value Changes to the next value Closes the SETUP menu Display...

Page 38: ... age speed 2 No function Next display mode No function No function Display mode SPEED S1 stop watch 1 Displays of TR1 A1 and S1 are reset to 0 0 Next display mode No function No function Display mode SPEED S2 stop watch 2 The displays of S2 and A2 are set to 0 0 Next display mode No function Starts or stops S2 7 24 Table of conditions and menu activation Display The motorcycle is stationary Menu c...

Page 39: ...ndling characteristic Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when yo...

Page 40: ... it 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 The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 14...

Page 41: ...rms up 8 4 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 compo nents For this reason it may be necessary to inspect or replace parts before the next scheduled service Seal the air filter box...

Page 42: ...In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 79006920000 Info Observe the KTM PowerParts fitting instructions M01105 01 Mount the air filter sand cover Air filter sand cover 79006922000 Info Observe the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain clean...

Page 43: ...ng temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the KTM PowerParts fitting instructions 600868 0...

Page 44: ...cap Value on the radiator cap 1 8 bar 26 psi If the indicated value does not correspond to the setpoint value Warning Danger of scalding During motorcycle oper ation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operat ing temperature Allow the cooling system and the engine t...

Page 45: ...ntly due to an excessively high sec ondary drive Clean the chain Chain cleaner p 168 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 131 8 9 Preparing the vehicle for low temperatures or snow M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the KTM PowerParts fitting instructions ...

Page 46: ...e condition p 114 Check tire pressure p 115 Check the spoke tension p 115 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 66 Bleed the fork legs p 65 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regula...

Page 47: ...efore riding the vehicle You will be seen earlier by other motorists When you are riding the side stand must be folded up and secured with the rubber strap Pull the clutch lever shift into first gear release the clutch lever slowly and at the same time open the throt tle carefully 9 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel blocks and the ...

Page 48: ...ear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if running at idle speed or stationary for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This causes the gear oil engine and cooling system to heat up Ride at a low engine speed instead of at a high engine speed with a slipping clutch 9 5 Braking Warning Danger of ac...

Page 49: ...of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it Apply the brakes on the motorcycle Shift the transmis...

Page 50: ...lothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly bec...

Page 51: ...il level warning light lights up the 2 stroke oil is sufficient for the remaining tank of fuel As soon as the oil level warning light lights up ride for no longer than until the remaining fuel in the tank is depleted At the next opportunity add 2 stroke oil before you refuel Time the oil pump if the 2 stroke oil hose has been removed or the 2 stroke oil tank has been fully depleted in error Open 2...

Page 52: ...nings of the rear brake p 107 Check the brake discs p 99 Check the brake lines for damage and leakage Check the rear brake fluid level p 105 Check the free travel of the foot brake lever p 104 Check the frame p 93 Check the link fork p 93 Check the fork bearing for play Check the heim joint for play Check the tire condition p 114 Check tire pressure p 115 Check the wheel bearing for play Check the...

Page 53: ...the headlight setting p 127 Check the idle speed Final check Check the vehicle for operating safety and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool Make a service entry in KTM Dealer net One time interval Periodic interval 10 3 Recommended work Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Eve...

Page 54: ...in the oil tank p 144 Clean the protection cap of the pressure sensor Perform minor engine service Check the exhaust control for functioning and smooth operation Check the clutch Perform major engine service including removing and installing the engine Change the connecting rod conrod bearing and crank pin Clean the hose connections of the pressure sensor Check the transmission and shift mecha nis...

Page 55: ... divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed compression adjuster has an effect for example when landing after a jump the rear wheel sus pension compresses quickly The low speed compression adjuster has an effect for example when riding over long ground swells the r...

Page 56: ...rts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info The effect of the high speed compression adjuster can be seen in fast compression of the shock absorber S03469 10 Using an open end wrench turn adjusting sc...

Page 57: ...wise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase the damping turn counter clockwise to reduce damping when the shock absorber rebounds 11 6 Measuring the dimension of the rear wheel unloaded Preparatory work Raise the motorcycle with a lift stand p 65 402415 10 Main w...

Page 58: ... preload of the shock absorber p 57 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 55 With another person holding the motorcycle the rider wear ing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person again measures t...

Page 59: ...moving the shock absorber clean it thoroughly 402405 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Hook wrench 90129051000 Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Measure the total spring length while the spring is not under tension Tension the spring by turning adjusting ring 2 ...

Page 60: ...inishing work Install the shock absorber p 78 Remove the motorcycle from the lift stand p 65 Check the static sag of the shock absorber p 56 Check the riding sag of the shock absorber p 56 Adjust the rebound damping of the shock absorber p 55 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 01 As with the shock absorber...

Page 61: ...o the fork type Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping during compression S03471 10 All Six Days models Turn white adjuster 1 clockwise as far as it will go Info Adjuster 1 is located at the upper end of the left fork leg The compression damping is located in left fork leg C...

Page 62: ...ideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase the damping turn coun terclockwise to reduce damping when the shock absorber rebounds S03473 10 All Six Days models Turn red adjuster 1 clockwise as far as it will go Info Adjuster 1 is located at the upper end of the right fork leg The rebound damping is located in right fork leg REB red a...

Page 63: ...ing wings clockwise Guideline Spring preload Preload Adjuster Comfort 0 Standard 0 Sport 3 The adjusting wings engage noticeably at the numerical values Info Adjust the spring preload to the numerical values only as the preload will not engage between the numerical values Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload Adjusting the spring preload h...

Page 64: ...7 10 All special models On the upper triple clamp there are 2 holes at a distance of A to each other Hole distance A 15 mm 0 59 in The holes on the handlebar support are placed at a distance of B from the center Hole distance B 3 5 mm 0 138 in The handlebar can be mounted in four different positions This allows the handlebar to be mounted in the most comfortable position for the rider 11 16 Adjust...

Page 65: ...he handlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position the handlebar clamps Mount screws 1 and tighten evenly Guideline Screw han...

Page 66: ...ndlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position the handlebar clamps Mount screws 1 and tighten evenly Guideline Screw handleba...

Page 67: ...e The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber strap 12 3 Bleeding the fork legs Preparatory ...

Page 68: ...ning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 169 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork prot...

Page 69: ...Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Raise the motorcycle with a lift stand p 65 Remove the front wheel p 110 Remove the headlight mask with the headlight p 125 E00375 10 Main work Remove screws 1 and take off the clamp Remove the cable tie Remove screws 2 and take off the brake caliper Hang the brake caliper and the brake line loosely to the side S03475 10 All standard EXC X...

Page 70: ...models Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S03476 11 All special models Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft E00375 11 Position the brake caliper and mount and tighten screws 4 Guidel...

Page 71: ...0 Remove screw 2 Loosen screw 3 Take off the upper triple clamp with the handlebar and hang them to the side Info Cover the components to protect them against damage Do not kink the cables and lines E00922 10 Remove O ring 4 Remove protective ring 5 Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Removing the lower triple clamp All special models...

Page 72: ...d lines E00925 10 Remove O ring 4 Remove protective ring 5 Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 11 Installing the lower triple clamp All standard EXC XC W models V00359 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 168 Insert the lower triple clamp with the steering stem Mount uppe...

Page 73: ...e fork legs Bleeder screws 6 are positioned toward the front Info The rebound damping is located in right fork leg REB red adjuster The compression damping is located in left fork leg COMP white adjuster 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 upper edge of the upper triple clamp S03525 11 Tighten screws 7 Guid...

Page 74: ...8 4 lbf ft Loctite 243 Mount the cable ties Position the brake line the wiring harness and the clamp Mount and tighten screws bl Finishing work Mount the handlebar cushion Install front fender p 77 Install the front wheel p 111 Install the headlight mask with the headlight p 125 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check ...

Page 75: ... clamp with the handlebar Mount screw 4 but do not tighten yet Position the clutch line and wiring harness S03515 11 Position the combination instrument holder and mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S03463 11 Position the fork legs Bleeder screws 6 are positioned toward the front Info The rebound damping is located in right fork leg REB red adjuster T...

Page 76: ... ft Loctite 243 S03524 10 Tighten screws 9 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft E00375 13 Position the brake caliper and mount and tighten screws bk Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable ties Position the brake line the wiring harness and the clamp Mount and tighten screws bl Finishing work Mount the handlebar cushion Install front fe...

Page 77: ...ing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 65 H01167 01 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bearing If there is detectable play Adjust the steering head bearing play p 75 Move the handlebar to and fro ...

Page 78: ...screw 2 Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft S03478 10 All special models Loosen screws 1 Remove screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Scr...

Page 79: ...s Remove the lower triple clamp p 69 Install the lower triple clamp p 73 12 16 Removing front fender Preparatory work Remove the headlight mask with the headlight p 125 V00340 10 Main work Remove screws 1 V00341 10 Remove screws 2 Take off front fender 12 17 Installing front fender V00341 11 Main work Position front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 ...

Page 80: ...on Remove screw 2 push splash protector 3 to the side and remove the shock absorber 12 19 Installing the shock absorber S03479 11 Main work Push splash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Mount and tighten screw 3 Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 I...

Page 81: ...ll the seat back and lift it off 12 21 Mounting the seat H02218 11 Mount the front of the seat on the two collar bushings of the fuel tank lower the seat at the rear and push the seat forward Make sure the seat is locked in correctly S03480 10 Mount and tighten screw 1 on the left side Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 82: ...ull off the air filter box cover in area A laterally and take it off at the front 12 23 Installing the air filter box cover S03526 12 Main work Insert the air filter box cover in area A and clip it into area B S03526 10 Condition The air filter box cover is secured Mount and tighten screw 1 Guideline Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft Finishing work Mount the seat p 79 ...

Page 83: ...e the seat p 79 Remove the air filter box cover p 80 S03482 10 Main work Detach retaining tab 1 Remove air filter with air filter sup port Remove air filter from air filter support 12 25 Installing the air filter H02459 01 Main work Mount the clean air filter on the air filter support Grease the air filter in area A Long life grease p 168 S03483 10 Insert air filter and position retaining pin 1 in...

Page 84: ...air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 168 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil Oil for foam air filter p 168 Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filter p 81 Install the air filte...

Page 85: ...11 Mount the main silencer with rubber sleeve 1 and the spring rings Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 30 Changing the glass fiber yarn filling of 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 before performing any work on the vehicle Info Over time the f...

Page 86: ... can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing co...

Page 87: ... into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100 E00881 10 Remove screws 4 with the collar bushings All EXC models Hang the horn and horn bracket to one side E00882 10 Remove screw 5 with the rubber bushing E00883 10 Pull both spoiler...

Page 88: ...d Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Check throttle cable routing p 93 E00883 11 Positi...

Page 89: ...ircumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 3 for the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system Attach fuel tank breather hose 4 Plug in connector 5 for the fuel pump Finishing work Mount the seat p 79 12 33 Checking the chain for dirt 400678 01 Ch...

Page 90: ...e motorcycle with a lift stand p 65 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 168 After drying apply chain spray Off road chain spray p 168 Finishing work Remove the motorcycle from the lift stand p 65 12 35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and resul...

Page 91: ...e chain tension p 89 Finishing work Remove the motorcycle from the lift stand p 65 12 36 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is t...

Page 92: ... 1 Guideline Nut rear wheel spin dle 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 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 65 12 37 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle...

Page 93: ...n 272 mm 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprock ets E00886 10 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain slidi...

Page 94: ...en screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide E00333 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining scr...

Page 95: ...e cracking or defor mation Change the link fork Info Always replace a damaged link fork Repairing the link fork is not authorized by KTM 12 40 Checking throttle cable routing Preparatory work Remove the seat p 79 Remove the fuel tank p 84 E01230 01 Main work Check throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars above the fuel tank bracket on th...

Page 96: ... Check that screw 1 is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 The diamond A must be positioned visibly as shown in the figure 12 42 Adjusting the basic position of the clutch lever E00842 10 Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw counterclockwise to decrease the distance between the...

Page 97: ...ose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid at...

Page 98: ...nvironmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid ...

Page 99: ...id level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water 12 45 Removing the engine guard All special models H01638 10 Remove screws 1 and engine guard 12 46 Installing the engine guard All special models H01638 10 Attach the engine guard on the...

Page 100: ...C W models Push the hand brake lever forward and check free travel A Free travel of hand brake lever 3 mm 0 12 in If the free travel does not match the specification Adjust the basic position of the hand brake lever p 99 13 2 Adjusting the free travel of the handbrake lever All EXC models E00844 12 Check the free travel of the hand brake lever p 98 Adjust the free travel of the handbrake lever wit...

Page 101: ...ng Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized KTM workshop will be glad to help 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings Brake discs wear limit All...

Page 102: ... of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid cau...

Page 103: ... 1 Take off cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 166 Position the cover with the membrane Mount and tighten the screws Info Immediately clean up any brake fluid that has over flowed or spilled with water 13 7 Checking the front brake linings Warning Danger of accidents Worn out brake linin...

Page 104: ... Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for KTM motorcycles The structure and friction coefficient...

Page 105: ...t pin 5 and remove the brake linings Clean the brake caliper and the brake caliper bracket 100397 01 Check that spring plate 6 in the brake caliper and sliding plate 7 in the brake caliper bracket are seated correctly E00345 10 Insert the new brake linings insert the pin and mount the cot ter pins Info Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake...

Page 106: ...foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 104 Reconnect spring 1 13 10 Adjusting the basic position of the foot brake lever Warning Danger of accidents Th...

Page 107: ...t Attach spring 1 13 11 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized...

Page 108: ...e eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filter...

Page 109: ... fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger ...

Page 110: ...ring Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir extract some if necessary Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston E00351 10 Remove cotter pin 3 pull out pin 4 and remove the brake linings Clean the brake caliper and the brake caliper bracket E0035...

Page 111: ...STEM 13 109 S03487 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 166 Mount screw cap 1 with membrane 2 and O ring Info Immediately clean up any brake fluid that has over flowed or spilled with water ...

Page 112: ...ons V00364 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 V00365 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do ...

Page 113: ...rings 1 and contact sur face A of the spacers Long life grease p 168 Insert the spacers Clean and grease the wheel spindle Long life grease p 168 Jack up the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned S01631 10 300 EXC Erzberg Edition TPI EU Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change ...

Page 114: ...raighten Tighten screws 3 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 14 3 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand p 65 V00366 10 Main work Manually press the brake caliper toward the brake disc to push back the brake piston Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston Remove nut 1 Take off c...

Page 115: ...ove spacers 4 14 4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H03001 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft sea...

Page 116: ...atedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 65 14 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and pressure of the tires all have a major impact on the handli...

Page 117: ...res optimal riding comfort and maximum tire service life 400695 01 Remove protection cap Check tire pressure when the tires are cold Street tire pressure All EXC models front 1 5 bar 22 psi rear 1 5 bar 22 psi Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct tire pressure Mount the protection cap 14 7 Checking spoke tension Wa...

Page 118: ...hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tensions You should hear a high note If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 Nm 3 7 lbf ft Spoke nipple rear wheel M4 5 5 Nm 3 7 lbf ft Torque wrench kit 58429094000 ...

Page 119: ...d the switch off button while the engine is idling until the engine stops Remove the seat p 79 S03489 10 Main work Warning Risk of injury 12 V batteries contain harmful sub stances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V bat teries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when cha...

Page 120: ... hang to the side S03491 10 Remove starter relay 5 and fuse box 6 from the battery compartment and hang to the side S03492 10 Detach wiring harness 7 disconnect relays 8 and plug 9 and hang to the side S03493 10 Remove screw bk and detach the battery compartment Lift out the 12 V battery ...

Page 121: ...ure with holding bracket 1 12 V battery HJTZ5S FP C p 161 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S03492 11 Place relays 3 and connector 4 on the battery compart ment and attach the wiring harness 5 S03491 11 Attach starter relay 6 and fuse box 7 to the battery com partment S03490 11 Secure EFI control unit 8 with the rubber lugs 9 ...

Page 122: ...es away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of 12 V batteries with less than the minimum voltag...

Page 123: ...n while the engine is idling until the engine stops All XC W models Press and hold the switch off button while the engine is idling until the engine stops Remove the seat p 79 Remove the 12 V battery p 117 S00863 10 Main work Check the battery voltage Battery voltage 9 V Do not charge the 12 V battery Replace the 12 V battery and dispose of the old 12 V battery properly If the specifications have ...

Page 124: ...rd Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle Preparatory work All EXC models Press and hold the switch off button while the engine is idling until the engine stops All XC W models Press and hold the switch off button while the engine is idling until the en...

Page 125: ...tection caps 4 Mount starter relay 3 onto the holder and route the cable S03495 10 Mount the EFI control unit 1 on the rubber lugs 2 Finishing work Mount the seat p 79 15 5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work All EXC models Press and hold the switch off button while the engi...

Page 126: ...bination instrument electronic fuel injection diagnostics con nector Fuse 2 10 A radiator fan optional Fuse 3 10 A low beam position light tail light Fuse 4 5 A fuel pump Fuses res 10 A spare fuse Info A faulty fuse has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical sys tem Only use fuses with the required ampere value Do not bypass or repair fuses Insert spar...

Page 127: ...d swing it forward E00900 10 All EXC models Detach plug in connectors 2 and take off the headlight mask with the headlight E00357 10 All XC W models Disconnect plug in connector 2 and take off the head light mask together with the headlight 15 7 Installing the headlight mask with the headlight E00900 11 Main work All EXC models Join plug in connectors 1 E00357 11 All XC W models Join plug in conne...

Page 128: ...ouch the bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 125 E00358 10 Main work Turn protection cap 1 together with the underlying bulb socket counterclockwise all the way and remove it Pull bulb socket 2 of the position light out of the reflector E00359 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 socket BX43t p 161 Insert th...

Page 129: ...ers and keep it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal R10W socket BA15s p 161 Mount the orange cap Position the turn signal glass Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk Tighten the screw lightly Finishing work Check that the turn signal system is functioni...

Page 130: ...rcycle with rider instructions on how to apply the mark Checking the headlight setting Info If you have a payload you may have to correct the headlight range Tighten screw 1 15 12 Changing the combination instrument battery Preparatory work Remove the headlight mask with the headlight p 125 E00901 10 Main work Remove screws 1 Pull the combination instrument upward out of the holder V00371 10 Using...

Page 131: ...tion the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install the headlight mask with the headlight p 125 Check the headlight setting p 127 Set the kilometers or miles p 25 Adjust combination instrument function p 26 Set the clock p 27 15 13 Diagnostics connector H00933 12 Diagnostics connector 1is located under the seat below the EFI control unit ...

Page 132: ...hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediate...

Page 133: ...ater in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level A above the radiator fins 10 mm 0 39 i...

Page 134: ...der the water pump cover S03527 10 Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling with coolant Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the ey...

Page 135: ...line Screw cylinder head temperature sensor M10x1 25 12 Nm 8 9 lbf ft Plug in connector 3 Position protection cap 2 400243 10 Pour coolant in up to measurement A above the radiator fins Guideline 10 mm 0 39 in Coolant p 166 E00906 10 Mount radiator cap 5 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficien...

Page 136: ...16 COOLING SYSTEM 134 Finishing work Check the coolant level p 131 ...

Page 137: ... speed Move the handle bar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the throttle cable play p 135 17 2 Adjusting the throttle cable play Info If the correct routing of the throttle cables has already been secured the fuel tank does not need to be removed Preparatory work Remove the seat p 79 Remove the fuel tank p 84 Check throttle c...

Page 138: ...teristic map is supplied E01228 10 Main work Push back sleeve 1 Remove screws 2 and half shells 3 Detach the throttle cables and take off the grip tube 102246 10 Remove guide plate 4 from handle tube 5 Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking A must be positioned at marking B Grey guide plate 79002014000 Alternative 1 Black guide plate ...

Page 139: ...may go out spontaneously if the idle speed is set too low Set the idle speed to the specified value Your authorized KTM workshop will be glad to help S03529 11 Run the engine until warm The cold start button is deactivated A further turn returns the cold start button back to the basic position p 21 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness ...

Page 140: ...ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Info If the vehicle is ridden with the engine running at various heights above sea level the ambient pressure is programmed on an ongoing basis If the vehicle is transported over great differences in height the ambient pressure must be reprogrammed H02349 01 Start the vehic...

Page 141: ...nector of the ignition timing map adjustment is joined to achieve higher performance 17 7 Changing the ignition timing map All standard EXC XC W models Info The ignition timing map connector has no function in the homologated restricted condition of the motor cycle Preparatory work Remove the seat p 79 Remove the fuel tank p 84 S03501 10 Switching the ignition timing map from Performance to Soft D...

Page 142: ...ween shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 140 17 9 Adjusting the basic position of the shift lever 401950 12 Remove screw 1 with the washers and take off shift lever 2 401951 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required...

Page 143: ... eyes Change your clothing in case of fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system E00911 10 Clean plug in connection 1 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 inje...

Page 144: ...nk Info For a full tank of fuel the 2 stroke oil tank must be filled up to at least the upper abutting edge A The 2 stroke oil tank must be completely filled if possible If the 2 stroke oil level is too low Add 2 stroke oil p 49 18 3 Priming oil pump Warning Engine failure The engine will not be lubricated unless there is 2 stroke oil in the oil tank If the oil level warning light lights up the 2 ...

Page 145: ...r 4 for priming the oil pump to the diagnostics connector 5 The combination instrument lighting is activated Info The connector is included as part of the motorcycle s separate enclosure Wait for at least five seconds Release the fixing means from the throttle grip The oil pump is timed Info The oil pump is actuated at various speeds The procedure is clearly audible Wait until you can no longer he...

Page 146: ...creen in the oil tank Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Raise the motorcycle with a lift stand p 65 Remove the main silencer p 83 Remove the seat p 79 Remove the fuel tank p 84 Remove the air filter box cover p 80 S...

Page 147: ...e valve body 7 towards the rear out of the intake flange and hang it to the side S03504 10 Open hose clamp 8 using a screwdriver Pull off the angle piece and collect the 2 stroke oil in a suit able container S03505 10 Remove oil screen 9 and clean it Check the oil screen for damage If the oil screen is damaged Change the oil screen S03506 10 Insert the oil screen and mount the angle piece with a n...

Page 148: ...ten screws 2 Guideline Screw sub frame bottom M8 30 Nm 22 1 lbf ft Loctite 2701 Remove screws 3 Mount and tighten screws 3 Guideline Screw sub frame top M8 35 Nm 25 8 lbf ft Loctite 2701 S03507 10 Position the frame protector Mount and tighten screw 1 with the washer Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft Mount the cable ties Finishing work Install the air filter box cover p 80 Inst...

Page 149: ... M6 10 Nm 7 4 lbf ft Attach the foot brake lever spring 18 6 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grea...

Page 150: ...ng Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check for tightness Finishing work Check the gear oil level p 147 All special models Install the engine...

Page 151: ...vel monitoring M6 10 Nm 7 4 lbf ft Mount and tighten filler plug 2 with the O ring Attach the foot brake lever spring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the...

Page 152: ...id direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray heavily soiled parts with a normal commercial motorcy cle cleaner and then brush off with a soft brush Motorcycle cleaner p 168 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcy...

Page 153: ...cau tions against aggressive road salt If the vehicle has been used on salted roads use cold water for cleaning after riding Warm water enhances the corrosive effects of salt 401060 01 Clean motorcycle p 150 Clean the brakes Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down and without removing them with cold water and dry them ...

Page 154: ...ar If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 Clean motorcycle p 150 Change the gear oil p 147 Check the antifreeze and coolant level p 130 When refueling for the last time before taking the motorcycle out of service add fuel addit...

Page 155: ...ecause the engine will not warm up sufficiently the water vapor produced during combustion will condense caus ing engine parts and the exhaust system to rust 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 65 Install the 12 V battery p 119 Perform checks and maintenance measures when preparing for use p 44 Make a test ride ...

Page 156: ...e spark plug or change it if necessary Plug gap of spark plug too wide Adjust plug gap Guideline Spark plug electrode gap 0 6 mm 0 024 in Faulty ignition Ignition coil check the primary wind ing Check the spark plug connector Check the stator winding of the alter nator Short circuit cable in wiring harness frayed switch off but ton or emergency OFF switch faulty Check wiring harness visual check C...

Page 157: ...ank breather Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change the glass fiber yarn filling of the main silencer p 83 Faulty ignition Ignition coil check the primary wind ing Check the spark plug connector Check the stator winding of the alter nator Diaphragm or reed valve hous ing damaged Check the diaphragm and reed valve...

Page 158: ...el p 147 Water in the gear oil Damaged shaft seal ring or water pump Check the shaft seal ring and water pump Malfunction indicator lamp lights up or flashes Defect in the fuel injection sys tem Check the cabling for damage and the electrical plug in connections for corro sion and damage Read out the fault memory using the KTM diagnostics tool 12 V battery discharged The 12 V battery is not being ...

Page 159: ...p 49 0 mm 1 929 in Primary transmission 26 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear transmission claw shifted Transmission ratio First gear 14 32 Second gear 16 26 Third gear 20 25 Fourth gear 22 23 Fifth gear 25 22 Sixth gear 26 20 Alternator 12 V 196 W Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Spark...

Page 160: ...electronic ignition with digital ignition adjustment Spark plug NGK BR 7 ES Spark plug electrode gap 0 6 mm 0 024 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter system 22 2 Engine tightening torques Screw inner membrane sheets EJOTDELTA PT 35x25 1 Nm 0 7 lbf ft Screw membrane support plate EJOTDELTA PT 30x12 1 Nm 0 7 lbf ft Screw outer membran...

Page 161: ...6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6 8 Nm 5 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbf ft Screw starter motor bearing bush M6 10 Nm 7 4 lbf ft Loctite 243 Screw starter motor protection cap M6 8 Nm 5 9 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw balancer...

Page 162: ...zberg Edition TPI EU WP XPLOR 5348 Fork All Six Days models WP XPLOR 5548 Suspension travel front 292 mm 11 5 in Suspension travel rear 310 mm 12 2 in Fork offset 22 mm 0 87 in Shock absorber WP XPLOR 5746 Brake system Disc brakes floating brake calipers Brake discs diameter front 260 mm 10 24 in rear 220 mm 8 66 in Brake discs wear limit All standard EXC XC W models front 2 5 mm 0 098 in rear 3 5...

Page 163: ...attery voltage 3 V Fuse 75011088005 5 A Fuse 75011088010 10 A Fuse 58011109120 20 A Headlight HS1 socket BX43t 12 V 35 35 W Position light W5W socket W2 1x9 5d 12 V 5 W Indicator lamps W2 3W socket W2x4 6d 12 V 2 3 W Turn signal All EXC models R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp All EXC mod els LED 22 6 Tires Validity Front tire Rear tire All standard EXC models 300...

Page 164: ...rk length 928 mm 36 54 in Fork oil per fork leg 625 10 ml 21 13 0 34 fl oz Fork oil SAE 4 48601166S1 p 167 22 7 2 All Six Days models Fork article number 14 18 8T 64 Fork WP XPLOR 5548 Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload Preload Adjuster Comfort 0 Standard 0 Sport 3 Spring lengt...

Page 165: ... 33 in Fitted length 415 mm 16 34 in Shock absorber fluid p 167 SAE 2 5 22 9 Chassis tightening torques Remaining screws chassis EJOT PT K60x25 Z 2 Nm 1 5 lbf ft Screw intake air temperature sen sor EJOTDELTA PT 45x12 Z 0 7 Nm 0 52 lbf ft Screw oil fill level sensor G 3 4 7 Nm 5 2 lbf ft Screw oil pump holder on oil tank EJOTDELTA PT 45x12 Z 0 7 Nm 0 52 lbf ft Screw pressure regulator EJOT PT K60x...

Page 166: ...Nm 7 4 lbf ft Nut foot brake lever M8 15 Nm 11 1 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut pull switch All XC W models M8 0 4 Nm 0 3 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 standard EXC XC W models M8 15 Nm...

Page 167: ...ining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Nut fuel pump M12 15 Nm 11 1 lbf ft Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw fron...

Page 168: ... stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility comp...

Page 169: ...ification SAE p 170 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up t...

Page 170: ...r High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX...

Page 171: ...Y SUBSTANCES 24 169 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 172: ...t motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classificati...

Page 173: ... transfer ducts Trans fer Port Injection Electronic fuel injection in which two injection valves in the transfer ducts of the cylinders are used OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics ...

Page 174: ...27 LIST OF ABBREVIATIONS 172 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 175: ...ror condition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols Malfunction indicator lamp lights up flashes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized KTM workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 28 3 Green and blue symb...

Page 176: ...f the rear brake changing 107 rear brake checking 107 C Capacity coolant 133 160 fuel 49 160 Gear oil 148 160 Chain checking 90 cleaning 88 Chain guide checking 90 Chain tension adjusting 89 checking 88 Characteristic map of the throttle response adjusting 136 Cleaning care 150 151 Clutch fluid level checking correcting 95 fluid changing 96 Clutch lever 16 basic position adjusting 94 Cold start bu...

Page 177: ...ning 19 Fuel oils etc 11 Fuse main fuse changing 122 of the individual power consumers changing 123 G Gear oil adding 148 changing 147 Gear oil level checking 147 H Hand brake lever 16 basic position adjusting 99 free travel adjusting 98 free travel checking 98 Handlebar position 62 adjusting 62 Headlight range adjusting 128 Headlight bulb changing 126 Headlight mask with headlight installing 125 ...

Page 178: ...n 8 Seat mounting 79 removing 79 Service 11 Service schedule 50 52 Shift lever 22 basic position adjusting 140 basic position checking 140 Shock absorber article number 15 compression damping general 53 installing 78 removing 78 riding sag checking 56 spring preload adjusting 57 static sag checking 56 Side stand 23 Spare parts 11 Spoke tension checking 115 Start button 18 Starting 44 Starting powe...

Page 179: ...ransporting 47 Troubleshooting 154 156 Turn signal bulb changing 127 Turn signal switch 18 Type label 14 U Use definition 7 V Vehicle identification number 14 View of vehicle front left 12 rear right 13 W Winter operation checks and maintenance steps 151 Work rules 9 ...

Page 180: ... 3214007en 3214007en 05 2019 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM ...

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KTM 250 EXC Six Days TPI, Owner'S Manual

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Summary of Contents for 250 EXC Six Days TPI

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