KTM 300 EXC Repair Manual Download Page 7

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TABLE OF CONTENTS

24.2

Ignition coil - checking the primary winding..... 202

24.3

Ignition coil - checking the secondary
winding........................................................ 203

24.4

Checking the spark plug connector ................. 203

24.5

Alternator - checking the charging coil of the
ignition ........................................................ 204

24.6

Alternator - checking the battery winding ........ 204

24.7

Alternator - checking the light winding ............ 205

24.8

Checking the ignition pulse generator ............. 205

24.9

Removing the stator and crankshaft position
sensor.......................................................... 206

24.10 Installing the stator and crankshaft position

sensor.......................................................... 206

25 ELECTRIC STARTER ................................................ 207

25.1

Checking the starter motor............................. 207

26 TECHNICAL DATA.................................................... 208

26.1

Engine ......................................................... 208

26.1.1

All 250 models......................................... 208

26.1.2

All 300 models......................................... 208

26.2

Engine tolerance, wear limits ......................... 209

26.3

Engine tightening torques .............................. 210

26.4

Capacities .................................................... 210

26.4.1

Gear oil.................................................... 210

26.4.2

Coolant .................................................... 210

26.4.3

Fuel ........................................................ 211

26.5

Chassis ........................................................ 211

26.6

Electrical system........................................... 212

26.7

Tires ............................................................ 212

26.8

Fork............................................................. 212

26.8.1

EXC EU/AUS, XC

‑

W................................... 212

26.8.2

250/300 SIX DAYS................................... 213

26.9

Shock absorber ............................................. 213

26.10 Chassis tightening torques ............................. 214
26.11 Carburetor .................................................... 215
26.11.1 250 EXC EU, 250 EXC SIX DAYS EU ......... 215
26.11.2 250 EXC AUS .......................................... 215
26.11.3 250 XC

‑

W USA......................................... 215

26.11.4 300 EXC EU, 300 EXC SIX DAYS EU ......... 215
26.11.5 300 EXC AUS .......................................... 216
26.11.6 300 XC

W SIX DAYS USA.......................... 216

26.12 Carburetor tuning.......................................... 217
26.12.1 Carburetor tuning (All 250 models) ............ 217
26.12.2 Carburetor tuning (All 300 models) ............ 218
26.12.3 General carburetor tuning .......................... 219

27 CLEANING, CARE .................................................... 220

27.1

Cleaning the motorcycle ................................ 220

27.2

Checks and maintenance steps for winter
operation...................................................... 221

28 STORAGE................................................................ 222

28.1

Storage ........................................................ 222

28.2

Preparing for use after storage........................ 222

29 SERVICE SCHEDULE ............................................... 223

29.1

Service schedule........................................... 223

29.2

Service work (as additional order) ................... 224

30 WIRING DIAGRAM ................................................... 226

30.1

Page 1 of 5 (250 EXC EU, 300 EXC EU)......... 226

30.2

Page 2 of 5 (250 EXC EU, 300 EXC EU)......... 228

30.3

Page 3 of 5 (250 EXC EU, 300 EXC EU)......... 230

30.4

Page 4 of 5 (250 EXC EU, 300 EXC EU)......... 232

30.5

Page 5 of 5 (250 EXC EU, 300 EXC EU)......... 234

30.6

Page 1 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 236

30.7

Page 2 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 238

30.8

Page 3 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 240

30.9

Page 4 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 242

30.10 Page 5 of 5 (250 EXC SIX DAYS EU,

300 EXC SIX DAYS EU)................................. 244

30.11 Page 1 of 5 (250/300 EXC AUS).................... 246
30.12 Page 2 of 5 (250/300 EXC AUS).................... 248
30.13 Page 3 of 5 (250/300 EXC AUS).................... 250
30.14 Page 4 of 5 (250/300 EXC AUS).................... 252
30.15 Page 5 of 5 (250/300 EXC AUS).................... 254
30.16 Page 1 of 3 (250 XC

W USA)............................................ 256

30.17 Page 2 of 3 (250 XC

W USA)............................................ 258

30.18 Page 3 of 3 (250 XC

W USA)............................................ 260

30.19 Page 1 of 3 (300 XC

‑

W SIX DAYS USA) .......... 262

30.20 Page 2 of 3 (300 XC

‑

W SIX DAYS USA) .......... 264

30.21 Page 3 of 3 (300 XC

‑

W SIX DAYS USA) .......... 266

31 SUBSTANCES ......................................................... 268
32 AUXILIARY SUBSTANCES ........................................ 270
33 SPECIAL TOOLS ...................................................... 272
34 STANDARDS ........................................................... 282
INDEX ............................................................................ 283

Summary of Contents for 300 EXC

Page 1: ...REPAIR MANUAL 2014 250 EXC EU 250 EXC SIX DAYS EU 250 EXC AUS 250 XC W USA 300 EXC EU 300 EXC SIX DAYS EU 300 EXC AUS 300 XC W USA 300 XC W SIX DAYS USA Art no 3206179en...

Page 2: ......

Page 3: ...modify or 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 a...

Page 4: ...protection 34 6 2 7 Removing the fork legs 34 6 2 8 Installing the fork legs 35 6 2 9 Removing the fork protector 35 6 2 10 Installing the fork protector 36 6 2 11 Performing a fork service 36 6 2 12...

Page 5: ...ging the battery 101 15 5 Disconnecting the negative cable of the battery 102 15 6 Connecting the negative cable of the battery 103 15 7 Removing the battery 103 15 8 Installing the battery 104 15 9 C...

Page 6: ...ts 170 18 5 3 Installing the shift forks 171 18 5 4 Installing the shift drum 171 18 5 5 Installing the shift rails 171 18 5 6 Installing the left engine case section 171 18 5 7 Installing the reed va...

Page 7: ...models 217 26 12 2 Carburetor tuning All 300 models 218 26 12 3 General carburetor tuning 219 27 CLEANING CARE 220 27 1 Cleaning the motorcycle 220 27 2 Checks and maintenance steps for winter operati...

Page 8: ...age reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current...

Page 9: ...are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the...

Page 10: ...anger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s M...

Page 11: ...teering head 4 3 Engine number B01139 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number B01494 10 The fork part number 1 is stamped on the...

Page 12: ...r death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine fail...

Page 13: ...fficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Shift gear to neutral 250 300 EXC AUS Turn the emergency OFF switch to the p...

Page 14: ...uce damp ing Mount protection caps 1 6 1 2 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 602708 10 Turn adjusting screws 1 clockw...

Page 15: ...tand p 10 6 1 5 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with the lift stand p 10 Loosen the fork protection p 14 B00797 10 Main work Push dust boots 1 of both fo...

Page 16: ...Remaining screws chassis M6 10 Nm 7 4 lbf ft 6 1 8 Removing the fork legs Preparatory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 93 Remove the headlight mask with the...

Page 17: ...aratory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 93 Remove the headlight mask with the headlight p 89 Remove the fork legs p 14 101327 10 Main work Remove screws 1 o...

Page 18: ...mble the fork legs p 24 6 1 13 Disassembling the fork legs Info The steps are identical for both fork legs Condition The fork legs are disassembled 200736 10 Remove protective cover A Note down the pr...

Page 19: ...sh the outer tube downward Pull the spring downward Place the special tool on the hexagonal part Open end wrench T14032 p 279 Info The preload spacers 4 should be above the special tool 200739 10 Clam...

Page 20: ...201350 10 Remove the cartridge 200741 10 Remove dust boot 7 Remove fork protector ring B Info The fork protector ring does not necessarily need to be disassembled for the further repair 200742 10 Remo...

Page 21: ...ring bm Take off lock ring 8 Take off dust boot 7 Take out the fork leg 6 1 14 Cartridge disassembly Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs p 16 20...

Page 22: ...is unnecessary for the further disassembly 200697 10 Degrease the piston rod Clamp the piston rod with the special tool Clamping stand T14016S p 279 200698 10 Remove nut 6 Remove shim stack 7 complet...

Page 23: ...Remove shim stack 4 200704 10 Remove O ring 5 and seal ring 6 from the compression damping fitting Extract the compression damping fitting 6 1 16 Checking the fork legs Condition The fork legs must b...

Page 24: ...Guideline Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 513 mm 20 2 in Weight of rider 75 85 kg 165 187 lb 513 mm 20 2 in Weight of rider 85 95 kg 187 209 lb 513 mm 20 2 in...

Page 25: ...y locking Extract the compression damping fitting 6 1 18 Assembling the cartridge Info The steps are identical for both fork legs 200715 10 Clamp in the piston rod Clamping stand T14016S p 279 Mount v...

Page 26: ...the nut by locking 200749 11 Degrease the cartridge and clamp using the special tool Clamping stand T14015S p 278 Mount and tighten screwsleeve 9 Guideline Screwsleeve M29x1 46 Nm 33 9 lbf ft Loctite...

Page 27: ...ring 2 Grease and slide on seal ring 3 Lubricant T511 p 270 Info The sealing lip should face downward and the open side upward Slide on support ring 4 Remove the special tool 200670 10 Roughen clean a...

Page 28: ...spring force The adjustment tube extends more than 7 mm 0 276 in out from the car tridge and cannot be pressed inward against the spring force Screw on water excluder C to the stop Info The water exc...

Page 29: ...tool on the hexagonal part Open end wrench T14032 p 279 Remove the special tool Gripping tool T14026S1 p 279 200743 10 Clamp the special tool in the bench vise Grease the thread of the piston rod Lubr...

Page 30: ...pression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Turn the adjusting screw of spring preload bl counterclockwise all the way Turn back clockwise the number of turns corresponding t...

Page 31: ...ht mask with the headlight p 89 Remove the fork legs p 34 Remove the front fender p 89 Remove the handlebar cushion 602725 10 Main work Remove screw 1 Loosen screw 2 Take off the upper triple clamp wi...

Page 32: ...g 2 602725 11 Position the upper triple clamp with the steering Position the clutch line and wiring harness Mount screw 3 but do not tighten yet B00809 10 Position the fork legs Info Grooves are mille...

Page 33: ...eel p 93 Refit the headlight mask with the headlight p 90 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steeri...

Page 34: ...1 and 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 strains Tighten screws 1 Guideline...

Page 35: ...clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 6 2 3 Bleeding the fork legs Preparatory work Raise the motorcycle with the...

Page 36: ...wards Remove the screws on the right fork leg Push the fork protection downwards 6 2 6 Positioning the fork protection B01515 11 Position the fork protection on the left fork leg Mount and tighten scr...

Page 37: ...toward the front 602732 11 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 B00798 11 Position the brak...

Page 38: ...tall the fork legs p 35 Install the front wheel p 93 Refit the headlight mask with the headlight p 90 Check the headlight setting p 117 6 2 11 Performing a fork service Condition The fork legs have be...

Page 39: ...03S p 279 Remove the screw Remove adjuster 3 201701 10 Release screw cap 4 Special socket T14047 p 280 Info The cartridge cannot be taken off yet 201702 10 Unclamp the fork leg Push the outer tube dow...

Page 40: ...bushing Guideline 50 C 122 F Pull the outer tube forcefully off of the inner tube Info The lower sliding bushing 8 must be pulled out of its bearing seat 201708 10 Remove the upper sliding bushing 9...

Page 41: ...n Remove the open end wrench Remove the screw cap Remove the spring with the preload spacer s 6 2 14 Disassembling the cartridge Info The steps are identical for both fork legs Preparatory work Disass...

Page 42: ...bling the piston rod Info The steps are identical for both fork legs except for the hydrostop needle and valve Preparatory work Disassemble the fork legs p 36 Remove the spring p 38 Disassemble the ca...

Page 43: ...washer Remove spring 8 201789 10 Remove valve needle 9 from the piston rod Info The adjusting tube can be used for this 6 2 16 Disassembling the hydrostop unit Info The steps are identical for both fo...

Page 44: ...isassembling the seal ring retainer Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs p 36 Remove the spring p 38 Disassemble the cartridge p 39 201799 10 Main...

Page 45: ...20 mm 1 937 in If the measured value is larger than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the outer tube 200665 10 Check the surface of t...

Page 46: ...hers 5 Info It is possible that only one or no washer is present Mount and tighten adapter 6 Guideline Hydrostop unit adapter M6x0 5 7 Nm 5 2 lbf ft 201785 10 Mount shim stack 7 with the smaller washe...

Page 47: ...ownward 201792 10 Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper Clean the piston Lubricate the piston ring Fork oil SAE 4 48601166S1 p 268 Mount the piston with chamfer...

Page 48: ...spacer 46 mm 1 81 in If the length is out of tolerance Correct the preload spacers Position the spring with the preload spacers in the reservoir Position sleeve 4 in the reservoir 201796 10 Clamp the...

Page 49: ...damping side screw cap with mark REB no brake caliper holder red adjuster Preparatory work Assemble the hydrostop unit p 44 201714 10 Main work Clamp the inner tube with the axle clamp Guideline Use s...

Page 50: ...ction of the special tool Mounting tool T14040S p 280 Push the sliding bushing all the way into the outer tube 201718 10 Position the support ring Hold the seal ring with the shorter section of the sp...

Page 51: ...lightly Air bubbles emerge and the cartridge is bled Keep bleeding until no more air bubbles emerge The piston rod moves out automatically to the middle of the total stroke distance Info When fully bl...

Page 52: ...clicks Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Turn counterclockwise by the number of clicks corresponding to the fork type Alternative 2 Warning Danger of accidents...

Page 53: ...them Do not bend the cables and lines 602735 10 Remove O ring 3 Remove protective ring 4 Take out the lower triple clamp with the steering stem Take out the upper steering head bearing 6 2 26 Install...

Page 54: ...9 lbf ft 602740 10 Mount and tighten screw 7 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 602741 10 Tighten screws 8 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft B00798...

Page 55: ...le play present Adjust the play of the steering head bearing p 53 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range...

Page 56: ...not bend the cables and lines Remove screws 2 Remove the handlebar support Place the handlebar support in the required position Mount and tighten screws 2 Guideline Screw handlebar support M10 40 Nm 2...

Page 57: ...the handlebar to the straight ahead position Move the throttle grip back wards and forwards to ascertain the play in the throttle cable Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable...

Page 58: ...back sleeve 1 Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster 2 Loosen nut 3 Turn adjusting screw 2 in such a way there is throttle cable play A in the throttle grip...

Page 59: ...4 10 Turn quick release 1 counterclockwise until it disengages Remove the engine guard 8 2 Installing the engine guard 250 300 SIX DAYS B01205 10 Attach the engine guard at the back of the frame and s...

Page 60: ...1 5 turns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 9 2 Adjusting the low speed compression damping of the shock absorber Caution Danger of acc...

Page 61: ...g of the unloaded rear wheel Preparatory work Raise the motorcycle with the lift stand p 10 400988 10 Main work Measure the distance as vertically as possible between the rear axle and a fixed point s...

Page 62: ...parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by m...

Page 63: ...59 9 9 Removing the shock absorber Preparatory work Raise the motorcycle with the lift stand p 10 602714 10 Main work Remove screw 1 and lower the rear wheel with the swing arm as far as possible with...

Page 64: ...semble the rebound adjuster p 67 Remove the heim joint p 68 Install the heim joint p 69 Assemble the rebound adjuster p 70 Assemble the seal ring retainer p 70 Assemble the piston rod p 71 Assemble th...

Page 65: ...tment elements of the rebound damping and compres sion damping Remove rubber cap 3 of the reservoir 201616 10 Slowly unscrew screw 4 The pressurized nitrogen is bled off 201617 10 Remove locking cap 5...

Page 66: ...ing p 62 Disassemble the damper p 63 200761 10 Main work Clamp the piston rod with the fork in a bench vise Guideline Use soft jaws Remove nut 1 Info If mount 2 is loosened apply counteractive force R...

Page 67: ...ng shim stack 8 Info Guide the compression damping shim stack onto a screwdriver and put them aside together 200765 10 Remove rebound damping washer 9 Remove seal ring retainer bk 200766 10 Remove loc...

Page 68: ...pilot bushing 1 onto the special tool Press drift T1504 p 280 Position the pilot bushing in the seal ring retainer using the special tool Press drift T1504 p 280 Support seal ring retainer 2 with the...

Page 69: ...rod Diameter 17 95 mm 0 7067 in If the measured value is smaller than the specified value Replace the piston rod Measure the run out of the piston rod Piston rod Run out 0 02 mm 0 0008 in If the measu...

Page 70: ...he heim joint Condition The shock absorber has been demounted 200799 10 Clamp the shock absorber in a vise using soft jaws Remove the collar bushing of the heim joint Pin T120 p 276 Turn the shock abs...

Page 71: ...g the heim joint 200803 10 Position new heim joint 1 and special tool Pressing tool T1206 p 277 Press in the heim joint all the way 200801 10 Press the heim joint against the lock ring using the speci...

Page 72: ...rew sleeve 7 Guideline Screw sleeve M14x1 18 Nm 13 3 lbf ft Screw out the rebound damping adjusting screw 6 to the stop 200810 10 Grease the O ring of the rebound damping seat Lubricant T159 p 270 Mou...

Page 73: ...the fork in a bench vise Guideline Use soft jaws Mount bump rubber 1 and locking cap 2 Position the special tool on the piston rod Mounting sleeve T1215 p 278 Grease the dust boot and slide seal ring...

Page 74: ...sandpaper Clean the piston Mount the piston Guideline View A Top view of piston View B Bottom view of piston 200772 10 Mount rebound damping shim stack bl with the smaller shims facing upward Grease...

Page 75: ...as been assem bled 201619 11 Mount screw 3 but do not tighten yet 201620 10 Grease the O ring of the seal ring retainer Lubricant T158 p 270 Fill the damper cartridge approximately half way Shock abso...

Page 76: ...high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Turn adjusting screw bl clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to th...

Page 77: ...rod moves in and out during filling do not immobilize it by hold ing it with your hand 200271 10 Position the control lever as shown in the photo Control lever External tank 3 is set to Closed Damper...

Page 78: ...cuum gauge drops to the required value 8 mbar 200267 10 When the vacuum gauge reaches the required value turn control lever Oil reser voir 5 to Equalize Pressure Guideline 8 mbar The pressure gauge dr...

Page 79: ...ine Filling port screw M10x1 14 Nm 10 3 lbf ft 9 26 Filling the damper with nitrogen 201616 11 Screw in the screw 1 approx two turns but do not tighten Info The piston rod is completely extended 20162...

Page 80: ...her 2 and spring retainer 3 Mount ring 4 Alternative 1 Tighten the spring by turning adjusting ring to measurement Guideline Spring preload Comfort 7 mm 0 28 in Standard 7 mm 0 28 in Sport 7 mm 0 28 i...

Page 81: ...nd lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Info Raise the wheel slightly to make it easier to remove the screw Mo...

Page 82: ...ck 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 303609 1...

Page 83: ...the main silencer with rubber sleeve 1 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 3 Changing the glass fiber yarn filling of the main silencer Warning Danger...

Page 84: ...yarn filling 3 from the inner tube Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling 3 on the inner tube Slide outer tube 4 over the inner tube with the new glass fibe...

Page 85: ...ce dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc shou...

Page 86: ...regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box lid p 83 Remove the air filter p 83 S00044 10 Mai...

Page 87: ...er immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated wi...

Page 88: ...ions 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 w...

Page 89: ...the in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed co...

Page 90: ...ly of fuel to the carbure tor Possible states Fuel supply closed OFF Fuel cannot flow from the fuel tank to the carburetor Fuel supply open ON Fuel can flow from the fuel tank to the carburetor The fu...

Page 91: ...der Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 602712 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Refit t...

Page 92: ...ght mask with the headlight 602763 10 Main work Connect the electric plug connector 1 602762 11 Position the headlight mask and fix it with the rubber band 2 Info Ensure that the holding lugs engage i...

Page 93: ...andling characteristics of the motorcycle The front and rear wheels must be mounted with tires with similar profiles Worn tires have a negative effect on handling characteristics especially on wet sur...

Page 94: ...poke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Info A loose spoke causes wheel imbalance and rapidly leads to more l...

Page 95: ...front wheel withdraw the wheel spindle Take the front wheel 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...

Page 96: ...eline Screw fork stub M8 15 Nm 11 1 lbf ft 14 5 3 Removing the brake disc of the front brake Preparatory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 93 303561 10 Main w...

Page 97: ...rear wheel out of the swingarm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 101390 10 Remove spacers 4...

Page 98: ...against the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 10 14 6 3 Removing the brake disc of the rear brake Preparatory work Raise the motorcycl...

Page 99: ...t the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear...

Page 100: ...b Measure the distance B of 18 chain links in the lower chain section Info Chain wear is not always even repeat this measurement at different chain positions Maximum distance B at the longest chain se...

Page 101: ...Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 10 14 6 9 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect cha...

Page 102: ...n the same position relative to the reference marks A The rear wheel is then correctly aligned Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1...

Page 103: ...sert the main fuse Fuse 58011109110 p 212 Info A reserve fuse 1 is located in the starter relay Replace a burned out fuse 2 only by an equivalent fuse Replace the protection cover Install the air filt...

Page 104: ...ery is maintenance free i e the acid level does not have to be checked Preparatory work Switch off all power consumers and the engine Remove the seat p 85 Disconnect the minus negative cable of the ba...

Page 105: ...h of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In...

Page 106: ...ishing work Mount the seat p 86 15 9 Checking the charging voltage Condition The battery must be fully functional and completely charged 600897 10 Carry out the start procedure p 10 Measure the voltag...

Page 107: ...ing harness and perform the measurement again 15 11 Checking the starter relay Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 85 Remove the air filter box...

Page 108: ...ke according to the service schedule 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 wi...

Page 109: ...the brake caliper and brake caliper support 100397 01 Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly 100398 10 Insert the new brak...

Page 110: ...744 12 Check the free travel of the hand brake lever p 108 Adjust the free travel of the hand brake lever with the adjustment screw 1 Info Turn the adjustment screw clockwise to reduce free travel The...

Page 111: ...e in the brake system or worn out brake linings Check the brake system and do not continue riding Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and e...

Page 112: ...into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fue...

Page 113: ...fluid reservoir Tighten the bleeder screw Remove the hose of the bleeder bottle Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover 309386 10 Add brake fluid to level C...

Page 114: ...al 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 de...

Page 115: ...s 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...

Page 116: ...continue riding 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 602760 10 Stand the...

Page 117: ...ar brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and gog...

Page 118: ...Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve 3 Open the bleeder screw again until brake fluid stops emerging Info T...

Page 119: ...et specifications Adjust the headlight range p 117 17 2 Adjusting the headlight range Preparatory work Check the headlight setting p 117 602764 10 Main work Loosen screw 1 Adjust the headlight range b...

Page 120: ...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 Press the button briefly and repeatedly until H appears at...

Page 121: ...s The hour display flashes Set the hour display with the button and or button Press the button briefly The next segment of the display flashes and can be set You can set the following segments in the...

Page 122: ...ottom right of the display Press the button for 3 5 seconds The setup menu is displayed and the active functions shown Press the button until the WS indicator blinks 400314 01 Press the button The whe...

Page 123: ...hen the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated 17 4 2 Activation and test 400313 01 Activating the speedometer The speedometer is activated when one of the but...

Page 124: ...tup menu is displayed and the active functions are shown Info If no button is pressed for 10 12 seconds the settings are automatically stored If no button is actuated for 20 seconds or there is no sig...

Page 125: ...illimeters Enlarging the wheel circumference Press the button Reducing the wheel circumference Press the button Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed...

Page 126: ...inus cable of the battery p 102 Drain the coolant p 196 Remove the main silencer p 81 308540 10 Main work Remove springs 1 Spring hooks 50305017000 p 272 308541 10 Loosen screw 2 Remove screw 3 308542...

Page 127: ...he positive cable to the side 308546 10 Release hose clip bk 308547 10 Remove screw bl Loosen screw bm Repeat these steps on the opposite side Swing up the subframe and secure it 308548 10 Remove scre...

Page 128: ...ver while the clutch slave cylinder is removed 308551 10 Remove the connecting link of the chain Take off the chain 308552 10 Remove screw bq Take off the shift lever 308553 10 Pull off the spark plug...

Page 129: ...r hose 308558 10 Loosen hose clip cn Pull off the radiator hose 308559 10 Loosen hose clip co Pull the carburetor rearward out of the intake flange and hang it to one side 308560 10 Remove fittings cp...

Page 130: ...lling the engine 308563 10 Main work Position the engine in the frame 308562 11 Mount screws 1 but do not tighten yet Guideline Engine bracket screw M10 60 Nm 44 3 lbf ft 308561 11 Position the swinga...

Page 131: ...308559 11 Slide the carburetor into the intake flange Position and tighten hose clip 4 308558 11 Mount the radiator hose Position and tighten hose clip 5 308557 11 Mount the radiator hose Position and...

Page 132: ...rew bm Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 308564 10 Mount the chain Connect the chain with connecting link bn 308550 11 Position the clutch slave cylinder with the O ring Mou...

Page 133: ...ite 2701 Remove screw bs Mount and tighten screw bs Guideline Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Repeat these steps on the opposite side 308546 11 Position and tighten hose clip bt 30854...

Page 134: ...rews chassis M6 10 Nm 7 4 lbf ft Tighten screw cs Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the main silencer p 81 Connect the negative cable of the battery p 103 308565 10 Remove...

Page 135: ...unt the engine on special tool 1 18 3 2 Draining the gear oil 308113 01 Remove gear oil drain plug 1 with the magnet and seal ring Completely drain the gear oil 18 3 3 Removing the clutch push rod 308...

Page 136: ...spacer 308118 10 Remove spacer 1 308119 10 Remove O ring 2 18 3 7 Removing the starter motor 308120 10 Remove screws 1 Take off cover 2 308121 10 Remove screws 3 Remove starter motor 308122 10 Remove...

Page 137: ...8124 10 Remove starter idler gear 7 308125 10 Remove screws 8 Remove the alternator cover 308126 10 Remove gasket and dowels 9 308127 10 Take off Bendix bk 18 3 8 Removing the kick starter 308128 10 R...

Page 138: ...move the cylinder head 308130 10 All 250 models Remove O rings 2 and 3 302963 10 All 300 models Remove O rings 2 and 3 18 3 10 Removing the cylinder 308131 10 Remove screws 1 and 2 Take off both cover...

Page 139: ...ff 308134 10 All 250 models Take off gasket 6 302967 10 All 300 models Take off gasket 6 18 3 11 Removing the piston 308143 10 All 250 models Uncover the crankcase Remove the piston pin retainer 1 Rem...

Page 140: ...e water pump cover Remove the form ring 18 3 13 Removing the clutch cover 308146 10 Remove screws 1 Take off the clutch cover Info Ensure that the kick starter shaft remains in the engine case 308147...

Page 141: ...Remove clutch pressure piece 7 18 3 15 Removing the clutch basket 308155 10 Hold the primary gear using special tool 1 Gear segment 56012004000 p 274 Remove nut 2 with the washer Info Left handed thre...

Page 142: ...nd collar bushing 8 308159 10 Take off primary gear 9 Remove the distance sleeve 18 3 16 Removing the kick starter shaft 308162 10 Remove screw 1 Remove kick starter shaft 2 with the washer Info Turn...

Page 143: ...ating unit 3 and remove the shift drum locating unit Relieve tension from the locking lever 18 3 20 Removing the locking lever 308166 10 Remove screw 1 Take off locking lever 2 with the sleeve and spr...

Page 144: ...e screws 1 Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm Loosen the left section of the engine case by striking it lightly with a plastic ha...

Page 145: ...shift forks 308178 10 Remove shift forks 1 Info Do not misplace the shift rollers 18 3 27 Removing the transmission shafts 308179 10 Pull both transmission shafts 1 out of the bearing seats together...

Page 146: ...arings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing the bearing in ensure th...

Page 147: ...e bearings in via the outer ring otherwise the bearings will be damaged when they are pressed in After the engine case section has cooled check that the bearings are firmly seated Info If the bearings...

Page 148: ...r inner bearing race 58429037040 p 275 Ensure that the new crankshaft bearing inner race is flush 18 4 5 Changing the connecting rod conrod bearing and crank pin 303485 10 Main work Position crankshaf...

Page 149: ...ge 59029041100 p 275 Connecting rod axial play of lower conrod bearing 0 60 0 70 mm 0 0236 0 0276 in If the specification is not reached Correct it so the dimension is equal to the specified value Fin...

Page 150: ...e 1 is labeled on the right side of the cylinder 303016 10 Using a straightedge and the special tool check the sealing area of the cylinder head for distortion Feeler gauge 59029041100 p 275 Cylinder...

Page 151: ...10 Remove screw 5 Remove screw 6 with the washer Take off the stop plate 303071 10 Take off gear segment 7 303072 10 Remove screws 8 Take off the retaining bracket 303073 10 Remove control shaft 9 30...

Page 152: ...e and wear If there is damage or wear Change the gear segments Check bearing sleeves 3 for damage and wear If there is damage or wear Change the bearing sleeves Check control flap 4 for damage and wea...

Page 153: ...03620 10 Mount and grease O rings 3 Long life grease p 270 303621 10 Mount and grease bearing sleeves 4 Long life grease p 270 303622 10 Position the control flap Mount O rings 5 303623 10 Degrease th...

Page 154: ...9 303627 10 Position the stop plate Mount screw bk but do not tighten yet Mount screw bl with the washer but to not tighten yet Info The screws are tightened when the Z distance is adjusted 18 4 11 Cy...

Page 155: ...ston pin seating has excessive play Change the connecting rod and piston pin 303015 10 All 300 models Check the piston sliding surface for damage If the piston sliding surface is damaged Replace the p...

Page 156: ...ified tolerance Change the piston ring Mount the piston ring with the marking facing toward the piston head 18 4 14 Piston cylinder measuring the mounting clearance 303083 10 All 250 models Check meas...

Page 157: ...for damage and wear If there is damage or wear Change the intake flange Check membrane 2 for damage and wear If there is damage or wear Change the membrane Check reed valve housing for damage and wea...

Page 158: ...5 10 Take off angle lever 4 Remove linkage 5 303036 10 Remove adjusting lever 6 with the washers 303037 10 Remove screw 7 Take off water pump impeller 8 Remove the centrifugal timer 303041 10 Press ou...

Page 159: ...ng lever for damage and wear If there is damage or wear Change the adjusting lever Check ball heads bo of the linkage for damage and wear If there is damage or wear Change the linkage Check centrifuga...

Page 160: ...haft seal ring 303041 10 Press in both needle bearings 9 303037 10 Mount the centrifugal timer Position water pump impeller 8 Mount and tighten screw 7 Guideline Screw water pump wheel M5 6 Nm 4 4 lbf...

Page 161: ...pring insert 303032 10 Position the locking cap Mount and tighten screws 1 Guideline Screw exhaust control cover M5 6 Nm 4 4 lbf ft 18 4 17 Checking the clutch 304690 10 Check pressure piece 1 for dam...

Page 162: ...and the outer clutch hub Check needle bearing bl and collar sleeve bm for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check the intermediate discs bn for dam...

Page 163: ...d wear If there is damage or wear Change the shift rollers Check the springs of shift rails 4 for damage and wear If the spring is damaged or worn Change the spring of the shift rail Check the shift r...

Page 164: ...specifications Change the sliding plate 18 4 20 Disassembling the main shaft 303334 10 Secure the main shaft with the toothed end facing downward in the vise Guideline Use soft jaws Remove stop disk 1...

Page 165: ...stop disk 4 Remove 6th gear sliding gear 5 Remove lock ring 6 Remove stop disk 7 Remove 3rd gear idler gear 8 and needle bearing 9 Remove 4th gear idler gear bk Remove needle bearing bl Remove stop di...

Page 166: ...age or wear Change the gear wheel pair Check the tooth faces of idler gears 4 sliding gears 5 and fixed gear 6 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth...

Page 167: ...ar 2 Mount stop disk 3 and lock ring 4 Mount 3rd 4th gear sliding gear 5 with the small gear wheel facing downward Mount lock ring 6 and stop disk 7 Mount needle bearing 8 Mount 5th gear idler gear 9...

Page 168: ...and lock ring 4 Mount 5th gear sliding gear 5 with the shift groove facing up Mount lock ring 6 and stop disk 7 Mount needle bearing 8 and 4th gear idler gear 9 Mount needle bearing bk Mount 3rd gear...

Page 169: ...e or wear Change the intermediate kick starter gear Check the gear mesh and contact surface of kick starter ratchet wheel 3 for damage and wear If there is damage or wear Change the kick starter ratch...

Page 170: ...d with the hole in the kick starter shaft 303050 10 Mount kick starter spring 7 The end of the kick starter spring engages in the hole 303051 10 Mount kick starter ratchet wheel 8 with the spring Mark...

Page 171: ...mage or wear Change the starter motor Change O ring 4 of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the po...

Page 172: ...Lubricant T625 p 270 18 5 Engine assembly 18 5 1 Installing the crankshaft 308181 11 Mount O ring 1 308180 11 Position the right section of the engine case in the engine work stand Engine assembly sta...

Page 173: ...bearing seat Put shift forks 2 in the shift drum Info Do not misplace the shift rollers 18 5 5 Installing the shift rails 308176 11 Install shift rail 1 together with upper spring 2 and the lower spr...

Page 174: ...crew engine case M6x60 10 Nm 7 4 lbf ft Fix the engine in the engine work stand Remove the excess lengths of the engine case gasket in the area of the cylinder support and the reed valve housing 18 5...

Page 175: ...ount and tighten screw 2 Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 18 5 11 Installing the shift shaft 308164 11 Slide shift shaft 1 with the washer into the bearing seat Push...

Page 176: ...alling the clutch basket 308159 11 Mount the distance sleeve Info Do not damage the shaft seal ring Position primary gear 1 308158 11 Mount collar bushing 2 Oil and mount needle bearing 3 Engine oil 1...

Page 177: ...at it can move easily 18 5 15 Installing the clutch discs 308152 11 Thoroughly oil the clutch facing discs Beginning with an intermediate clutch disc alternately insert all other clutch fac ing discs...

Page 178: ...gauge 59029041100 p 275 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value was not attained Remove screws 6 and mount the spring retainer with marking Z Using a straightedge and th...

Page 179: ...d position it in the connecting rod Position the piston Piston marking 1 must face the exhaust side 308143 11 Slide piston pin 2 into the connecting rod by hand 302973 10 Cover the engine case opening...

Page 180: ...r base gasket 1 Info If neither the piston cylinder crankshaft or engine case need to be changed the same gasket thickness can be used as before Oil the cylinder and piston 308140 10 Position the pist...

Page 181: ...es and the engine loses power If the X distance is too small the engine knocks and overheats 308141 10 All 250 models Apply special tool 1 to the cylinder Adjustment gauge 54829001100 p 273 Position t...

Page 182: ...302967 12 Replace cylinder base gasket 2 with a cylinder base gasket of the required X distance Info Multiple cylinder base gaskets can be combined Finishing work Install the cylinder p 178 18 5 22 Ad...

Page 183: ...ght of control flap All 250 mod els 48 mm 1 89 in Z height of control flap All 300 mod els 48 5 mm 1 909 in 308137 10 Mount gasket 6 Press the control flap all the way down Mount ball socket 7 Info Th...

Page 184: ...in place Mount screws 3 with the washers and tighten them in a crisscross pattern Guideline Screw cylinder head M8 27 Nm 19 9 lbf ft Info Use new washers 18 5 24 Installing the kick starter 308128 10...

Page 185: ...308124 11 Grease and mount starter idler gear 4 Lubricant T625 p 270 308123 11 Mount dowels 5 Position the gasket 308122 11 Position the cover Mount and tighten screws 6 Guideline Screw alternator co...

Page 186: ...Long life grease p 270 Push spacer 1 with the O ring onto the countershaft with a twisting motion The cut out with the O ring must face inward The shaft seal ring rests against the spacer along the e...

Page 187: ...ug 1 with the magnet and the new seal ring Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Activate the kick starter several times to check whether the engine turns over freely 18...

Page 188: ...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 wit...

Page 189: ...aratory work Turn handle 1 of the fuel tap to the OFF position Fuel no longer flows from the fuel tank to the carburetor B01158 10 Main work Place a cloth beneath the carburetor to soak up emerging fu...

Page 190: ...of the carburetor Drain the remaining fuel 308537 10 Pull back the throttle slide spring and plastic lock 4 Detach throttle cable 5 Remove the throttle slide 19 5 Installing the carburetor 308538 10...

Page 191: ...en hose clip 5 Finishing work Install the fuel tank p 87 Mount the seat p 86 Check the play in the throttle cable p 55 Carburetor adjust the idle speed p 186 19 6 Checking adjusting the carburetor com...

Page 192: ...ve the float chamber Pull the hoses off of the carburetor 303352 10 Remove main jet 2 Remove idling jet 3 Remove cold start jet 4 303353 10 Remove fulcrum pin 5 Remove float 6 and the float needle val...

Page 193: ...maged or brittle or if the lock is not functioning Change the choke slide 19 9 Checking the jet needle Condition The jet needle has been removed 303355 10 Check the jet needle for bending and wear of...

Page 194: ...unt and tighten choke slide 1 Guideline Choke slide M10 5 Nm 3 7 lbf ft 303359 11 Alternative 1 Mount idle air adjusting screw 2 with the spring and O ring Set the idle air adjusting screw to the spec...

Page 195: ...lbf ft 19 13 Checking adjusting the float level Condition The carburetor and float chamber have been removed 303357 10 Tilt the carburetor sideways preventing the fulcrum pin from falling out Tilt th...

Page 196: ...ause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations B01538 10 Move the clutch fluid reservoir mounted on the handle...

Page 197: ...y Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiato...

Page 198: ...eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed con...

Page 199: ...y A height differ ence of A must be reached Guideline Height difference A 75 cm 29 5 in Info To ensure that all of the air can escape from the cooling system the front of the vehicle must be jacked up...

Page 200: ...1 B00056 11 Take cap 2 adjusting spring 3 auxiliary spring 4 and spring insert 5 out of the clutch cover Pull both springs off of the spring insert B00058 10 Mount the required auxiliary spring 4 and...

Page 201: ...vironmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Only drain the gear oil while the engine is warm Preparatory work...

Page 202: ...ear oil level p 200 23 4 Checking the gear oil level Info The gear oil level must be checked while the engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface B00050 10 Ma...

Page 203: ...level Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft Mount and tighten screw cap 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or d...

Page 204: ...e CDI controller and ignition coil Check the cable from the CDI controller to the ignition coil Info The CDI controller cannot be tested using simple methods but only using an ignition test bench Igni...

Page 205: ...oltage Measure the voltage between the specified points Ignition coil pin 1 Ignition coil pin 2 Info Connect the black measuring lead to pin 1 and the red measuring lead to pin 2 of the ignition coil...

Page 206: ...l ignition pulse generator connector AN pin 2 Alternator Resistance of ignition charging coil at 20 C 68 F 12 16 5 The specifications have not been met Replace the stator 601213 10 601223 10 Measure t...

Page 207: ...cified points Alternator charging coil ignition pulse generator connector AN pin 3 Alternator charging coil ignition pulse generator connector AN pin 4 Crankshaft position sensor Resistance at 20 C 68...

Page 208: ...r Condition The alternator cover has been removed 303441 10 Remove screw 1 Remove cable support sleeve 2 from the alternator cover 303442 10 Remove screw 3 Remove the stator and crankshaft position se...

Page 209: ...removed 303410 10 Clamp the negative cable of a 12 Volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly to the connection of the starter motor...

Page 210: ...ission ratio 1st gear 14 32 2nd gear 16 26 3rd gear 20 25 4th gear 22 23 5th gear 25 22 6th gear 26 20 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type...

Page 211: ...drill hole diameter All 250 models Size I 66 400 66 412 mm 2 61417 2 61464 in Size II 66 412 66 425 mm 2 61464 2 61515 in Cylinder drill hole diameter All 300 models Size I 72 000 72 012 mm 2 83464 2...

Page 212: ...f ft Screw exhaust flange M6 8 Nm 5 9 lbf ft Screw gear oil level check M6 10 Nm 7 4 lbf ft Screw intake flange reed valve housing M6 10 Nm 7 4 lbf ft Screw kick starter spring M6 10 Nm 7 4 lbf ft Loc...

Page 213: ...13 19 in Fork offset 20 mm 0 79 in Shock absorber WP Suspension PDS 5018 DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 i...

Page 214: ...MAX MX 51 Additional information is available in the Service section under http www ktm com 26 8 Fork 26 8 1 EXC EU AUS XC W Fork part number 14 18 7L 63 Fork WP Suspension Up Side Down 4860 MXMA PA C...

Page 215: ...er fork leg 635 ml 21 47 fl oz Fork oil SAE 4 48601166S1 p 268 26 9 Shock absorber Shock absorber part number 12 18 7L 63 Shock absorber WP Suspension PDS 5018 DCC Compression damping low speed Comfor...

Page 216: ...f ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handle...

Page 217: ...N4DW N4DJ N4DK Main jet 160 165 168 Idling jet 35 38 40 42 Starting jet 85 Idle air adjusting screw Open 3 5 turns Throttle slide 7 with cut out Slide stop Present 26 11 3 250 XC W USA Carburetor type...

Page 218: ...jet 160 165 168 Idling jet 35 38 40 42 Starting jet 85 Idle air adjusting screw Open 3 5 turns Throttle slide 7 with cut out Slide stop Present 26 11 6 300 XC W USA 300 XC W SIX DAYS USA Carburetor ty...

Page 219: ...thorized for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 401770 01 M...

Page 220: ...public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 401767 01 M FT ASL Sea l...

Page 221: ...3 General carburetor tuning 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 1 5 Needle position from above The five needle positions are shown here The carburetor tuning depends on the defined ambie...

Page 222: ...rm 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 water spray a...

Page 223: ...he brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while the...

Page 224: ...he antifreeze and coolant level p 195 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 270 Refuel Empty the carburetor float chamber p 187...

Page 225: ...r chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 194 Check the front brake fluid level p 109 Check the free travel of the hand brake lever p 108 Check the...

Page 226: ...115 Change the hydraulic clutch fluid p 194 Grease the steering head bearing p 50 Check set the carburetor components Perform a fork service 250 300 SIX DAYS p 36 Perform a fork service EXC EU AUS XC...

Page 227: ...225...

Page 228: ...18 X1 7 6 1 c CA 4 X30 3 CA 4 X30 4 2 1 CU 4 X8 2 EE 1 X9 1 EE 1 X21 1 5 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 10A 3 1 2 4 0 1 G 0 1 M AF 4 X38 2 3 AF 4 X38 4 BR 4 X39 4 BR 4 X39 3 1 2 BU 18 X1 5 BF...

Page 229: ...30 WIRING DIAGRAM 227 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button T20 Voltage regulator...

Page 230: ...X23 2 d BP 4 X24 1 2 BP 4 X24 3 4 DG 4 X25 1 2 DG 4 X25 3 4 AC 6 X26 2 AC 6 X26 1 3 CR 1 X32 1 4 FO 2 X23 1 AC 6 X26 5 c 6 CR 1 X36 1 b S22 BC 6 BC 6 3 1 4 6 2 1 5 BF 1 BC 6 BA 1 X22 1 FF 1 X27 1 FF 1...

Page 231: ...30 WIRING DIAGRAM 229 Components E13 Low beam high beam P15 Horn P23 High beam indicator lamp P35 Parking light S22 Light switch horn button kill switch...

Page 232: ...2 AK 2 1 2 AH 2 X33 2 AH 2 X34 2 4 AH 2 X33 1 AH 2 X34 1 E60 2 1 DI 2 X35 1 DI 2 X35 2 P36 CV 4 CV 4 4 1 2 3 2 b BY 4 X31 1 BY 4 X31 3 e CV 4 X19 1 2 CV 4 X19 3 4 2 BY 4 X20 3 BY 4 X20 4 d b 3 2 1 2 1...

Page 233: ...Components B70 Wheel speed sensor front B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P13 Speedometer P36 Brake tail light S36 Tripmaster switch X285 Connector for r...

Page 234: ...B8 3 B8 R L K20 2 1 P21 1 2 P42 1 CW 2 2 CW 2 P41 1 CW 2 2 CW 2 P46 1 CW 2 2 CW 2 P45 1 CW 2 2 CW 2 AJ 3 X10 1 AH 2 X11 2 2 1 CX 2 X13 1 CX 2 X16 1 AJ 3 X10 3 CX 2 X17 1 CX 2 X18 1 AH 2 X11 1 CX 2 X1...

Page 235: ...DIAGRAM 233 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signa...

Page 236: ...A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 5 250 300 EXC EU 2014 1 A7 A15 R51 1 X300 BU 18 X1 1 CR 1 X4 1 BU 18 X1 2 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1 1 1 S50 EI 1 E...

Page 237: ...ion sensor R51 Ignition coil cylinder 1 S50 Map switch for ride mode optional X280 Connector ignition timing map X281 Connector ignition timing map Cable colors bl Black br Brown bu Blue gn Green gr G...

Page 238: ...c a X301 T20 CE 4 CE 4 2 4 1 3 BU 18 X1 7 6 1 b CA 4 X30 3 CA 4 X30 4 2 1 CU 4 X8 2 EE 1 X9 1 EE 1 X21 1 5 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 10A 3 1 2 4 0 1 G 0 1 M AF 4 X38 2 3 AF 4 X38 4 BR 4 X...

Page 239: ...30 WIRING DIAGRAM 237 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button T20 Voltage regulator...

Page 240: ...4 X24 3 4 DG 4 X25 1 2 DG 4 X25 3 4 AC 6 X26 2 AC 6 X26 1 3 CR 1 X32 1 4 AC 6 X26 5 b 6 CR 1 X36 1 a S22 BC 6 BC 6 3 1 4 6 2 1 5 BF 1 BC 6 BA 1 X22 1 FF 1 X27 1 FF 1 X6 1 FP 1 X5 1 DI 2 X3 1 DI 2 X3...

Page 241: ...30 WIRING DIAGRAM 239 Components A15 CDI controller E13 Low beam high beam P15 Horn P23 High beam indicator lamp P35 Parking light S22 Light switch horn button kill switch...

Page 242: ...AK 2 AK 2 1 2 B77 AK 2 AK 2 1 2 AH 2 X33 2 AH 2 X34 2 4 AH 2 X33 1 AH 2 X34 1 E60 2 1 DI 2 X35 1 DI 2 X35 2 P36 CV 4 CV 4 4 1 2 3 2 b BY 4 X31 1 BY 4 X31 3 e CV 4 X19 1 2 CV 4 X19 3 4 2 BY 4 X20 3 BY...

Page 243: ...30 WIRING DIAGRAM 241 Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P13 Speedometer P36 Brake tail light X285 Connector for radiator fan optional...

Page 244: ...4 3 2 1 4 5 G 3 B8 3 B8 R L K20 2 1 P21 1 2 P42 1 CW 2 2 CW 2 P45 1 CW 2 2 CW 2 P46 1 CW 2 2 CW 2 P41 1 CW 2 2 CW 2 AJ 3 X10 1 AH 2 X11 2 2 1 CX 2 X13 1 CX 2 X16 1 AJ 3 X10 3 CX 2 X17 1 CX 2 X18 1 AH...

Page 245: ...DIAGRAM 243 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signa...

Page 246: ...B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 5 250 300 EXC Six Days EU 2014 1 A7 A15 R51 1 X300 BU 18 X1 1 CR 1 X4 1 BU 18 X1 2 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1...

Page 247: ...ion sensor R51 Ignition coil cylinder 1 S50 Map switch for ride mode optional X280 Connector ignition timing map X281 Connector ignition timing map Cable colors bl Black br Brown bu Blue gn Green gr G...

Page 248: ...6 1 b CA 4 X30 3 CA 4 X30 4 2 1 CU 4 X8 2 EE 1 X9 1 EE 1 X21 1 5 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 10A 3 1 2 4 0 1 G 0 1 M AF 4 X38 2 3 AF 4 X38 4 BR 4 X39 4 BR 4 X39 3 1 2 X302 2 C2 S23 BK 4 BK...

Page 249: ...30 WIRING DIAGRAM 247 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button T20 Voltage regulator...

Page 250: ...5 3 4 AC 6 X26 2 AC 6 X26 1 3 CR 1 X32 1 4 FO 2 X23 1 AC 6 X26 5 b 6 CR 1 X36 1 a FF 1 X27 1 FF 1 X6 1 FP 1 X5 1 DI 2 X3 1 DI 2 X3 2 CW 2 X14 1 CW 2 X14 2 CX 2 X15 1 CX 2 X15 2 c b a d BC 6 BC 6 BC 6...

Page 251: ...DIAGRAM 249 Components A15 CDI controller E13 Low beam high beam P15 Horn P23 High beam indicator lamp P35 Parking light S22 Light switch horn button kill switch S23 Emergency OFF switch electric star...

Page 252: ...AK 2 1 2 AH 2 X33 2 AH 2 X34 2 4 AH 2 X33 1 AH 2 X34 1 E60 2 1 DI 2 X35 1 DI 2 X35 2 P36 CV 4 CV 4 4 1 2 3 2 a BY 4 X31 1 BY 4 X31 3 d CV 4 X19 1 2 CV 4 X19 3 4 2 BY 4 X20 3 BY 4 X20 4 c a 3 2 1 2 1 4...

Page 253: ...M 251 Components B70 Wheel speed sensor front B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P13 Speedometer P36 Brake tail light S36 Tripmaster switch X285 Connector...

Page 254: ...B8 3 B8 R L K20 2 1 P21 1 2 P42 1 CW 2 2 CW 2 P45 1 CW 2 2 CW 2 P46 1 CW 2 2 CW 2 P41 1 CW 2 2 CW 2 AJ 3 X10 1 AH 2 X11 2 2 1 CX 2 X13 1 CX 2 X16 1 AJ 3 X10 3 CX 2 X17 1 CX 2 X18 1 AH 2 X11 1 CX 2 X13...

Page 255: ...DIAGRAM 253 Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signa...

Page 256: ...C B F A E D C B F A 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 5 2 A1 A15 R51 1 X300 BU 18 X1 1 CR 1 X4 1 BU 18 X1 2 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1 1 1 S50 EI 1 EH...

Page 257: ...osition sensor R51 Ignition coil cylinder 1 S50 Map switch for ride mode X280 Connector ignition timing map X281 Connector ignition timing map Cable colors bl Black br Brown bu Blue gn Green gr Gray l...

Page 258: ...F1 U 2 F1 G M c a X301 T20 CE 4 CE 4 2 4 1 3 BU 18 X1 7 6 1 b CA 4 X13 3 CA 4 X13 4 2 1 CU 4 X8 2 EE 1 X9 1 EE 1 X17 1 3 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 10A 3 1 2 4 0 1 G 0 1 M AF 4 X11 2 3 AF 4...

Page 259: ...30 WIRING DIAGRAM 257 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button T20 Voltage regulator...

Page 260: ...1 F8 E11 1 1 1 P35 2 1 c 2 BP 4 X16 3 4 DG 4 X15 1 2 DG 4 X15 3 4 b FF 1 X14 1 FF 1 X6 1 FP 1 X5 1 DI 2 X3 1 DI 2 X3 2 S30 2 1 FF 1 X18 1 FF 1 X19 1 4 P37 CV 4 CV 4 3 1 2 4 BY 4 X12 3 3 2 1 2 1 4 3 2...

Page 261: ...ING DIAGRAM 259 Components B70 Wheel speed sensor front E11 Low beam S30 Light switch S36 Tripmaster switch optional P13 Speedometer P35 Parking light P37 Tail light X285 Connector for radiator fan op...

Page 262: ...5 4 3 2 1 3 3 250 300 XC W USA 2014 1 A1 A15 R51 1 X300 BU 18 X1 1 CR 1 X4 1 BU 18 X1 2 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1 1 1 S50 EI 1 EH 1 X281 1 1 2 4 14 11...

Page 263: ...or R51 Ignition coil cylinder 1 S20 Kill switch S50 Map switch for ride mode optional X280 Connector ignition timing map X281 Connector ignition timing map Cable colors bl Black br Brown bu Blue gn Gr...

Page 264: ...F1 U 2 F1 G M c a X301 T20 CE 4 CE 4 2 4 1 3 BU 18 X1 7 6 1 b CA 4 X13 3 CA 4 X13 4 2 1 CU 4 X8 2 EE 1 X9 1 EE 1 X17 1 3 D4 G20 1 1 2 1 CR 1 CR 1 AN 4 6 7 K10 10A 3 1 2 4 0 1 G 0 1 M AF 4 X11 2 3 AF 4...

Page 265: ...30 WIRING DIAGRAM 263 Components A15 CDI controller G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button T20 Voltage regulator...

Page 266: ...8 1 F8 1 F8 E11 1 1 1 P35 2 1 c 2 BP 4 X16 3 4 DG 4 X15 1 2 DG 4 X15 3 4 b FF 1 X14 1 FF 1 X6 1 FP 1 X5 1 DI 2 X3 1 DI 2 X3 2 S30 2 1 FF 1 X18 1 FF 1 X19 1 4 P37 CV 4 CV 4 3 1 2 4 BY 4 X12 3 2 CY 3 X2...

Page 267: ...30 WIRING DIAGRAM 265 Components B70 Wheel speed sensor front E11 Low beam S30 Light switch P13 Speedometer P35 Parking light P37 Tail light X285 Connector for radiator fan optional...

Page 268: ...2 1 3 3 300 XC W Six Days USA 2014 1 A1 A15 R51 1 X300 BU 18 X1 1 CR 1 X4 1 BU 18 X1 2 BU 18 X1 4 BU 18 X1 11 10 3 CU 4 X8 4 14 1 D1 B37 3 4 AN 4 EI 1 X280 1 EH 1 1 1 S50 EI 1 EH 1 X281 1 1 2 4 14 11...

Page 269: ...or R51 Ignition coil cylinder 1 S20 Kill switch S50 Map switch for ride mode optional X280 Connector ignition timing map X281 Connector ignition timing map Cable colors bl Black br Brown bu Blue gn Gr...

Page 270: ...res Using inferior antifreeze can result in corrosion and foaming Use only coolant based on ethylene glycol Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 dis...

Page 271: ...5 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 containi...

Page 272: ...additive Recommended supplier Motorex Fuel Stabilizer High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Lubricant T158 Recommended s...

Page 273: ...mmended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motorex Chainlube Offroad Oil for foam air filter Recommended supplier Motorex Twin Air Liquid Bio Power Universal oil spr...

Page 274: ...eder cover 201597 10 Art no 00029013005 Bleeder cover 201598 10 Art no 00029013006 Bleeding device 201491 10 Art no 00029013100 Spring hooks 400363 01 Art no 50305017000 Mounting tool heim joint 20142...

Page 275: ...3 Bleed syringe 400058 01 Art no 50329050000 Clutch holder 400289 01 Art no 51129003000 Adjustment gauge 303079 10 Art no 54829001100 Separator plate 303483 10 Art no 54829009000 Lift stand 500071 01...

Page 276: ...crankshaft pressing tool 303484 10 Art no 54829108000 Holding spanner rotor 302997 10 Art no 55129001000 Gear segment 302982 10 Art no 56012004000 Engine fixing arm 302945 10 Art no 56029002030 Extrac...

Page 277: ...rt no 58429037040 Peak voltage adapter 400083 01 Art no 58429042000 Torque wrench with various accessories in set 200910 10 Art no 58429094000 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 590...

Page 278: ...OOLS 276 Pressing device for crankshaft complete 400185 01 Art no 75029047000 Pin wrench 200734 10 Art no T103 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Pin 201235 10...

Page 279: ...IAL TOOLS 277 Mounting sleeve 200788 10 Art no T1204 Calibration pin 200790 10 Art no T1205 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Centering sleeve 200777 10 Art no...

Page 280: ...AL TOOLS 278 Mounting sleeve 300568 10 Art no T1215 Disassembly tool 200816 10 Art no T1216 Vacuum pump 200273 10 Art no T1240S Protecting sleeve 200635 10 Art no T1401 Clamping stand 200733 10 Art no...

Page 281: ...L TOOLS 279 Clamping stand 200688 10 Art no T14016S Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art no T1402S Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art n...

Page 282: ...CIAL TOOLS 280 Mounting tool 200634 10 Art no T14040S Special socket 201710 01 Art no T14047 Clamping stand 202338 10 Art no T14049S Press out tool 201779 10 Art no T14051 Press drift 200789 10 Art no...

Page 283: ...33 SPECIAL TOOLS 281 Assembly tool 200791 10 Art no T150S Nitrogen filling tool 300574 10 Art no T170S1...

Page 284: ...rom the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performan...

Page 285: ...ng 190 float chamber emptying 187 idle speed adjusting 186 installing 188 removing 187 technical data carburetor 215 216 Carburetor work on individual parts choke slide checking 191 float level checki...

Page 286: ...arter installing 182 left engine case section installing 171 locking lever installing 173 piston installing 177 reed valve housing installing 172 rotor installing 172 shift drum locating unit installi...

Page 287: ...ng 108 Handlebar position 54 adjusting 54 Headlight range adjusting 117 Headlight mask with headlight installing 90 removing 89 Headlight setting checking 117 Heim joint changing 79 Hydrostop unit for...

Page 288: ...119 122 kilometers or miles setting 118 121 setting 122 speedometer overview 117 121 wheel circumference setting 120 123 Spoke tension checking 92 Spring fork legs removing 38 Starter motor checking...

Page 289: ...3206179en 3206179en 09 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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Summary of Contents for 300 EXC

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KTM 300 EXC, Repair Manual

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Summary of Contents for 300 EXC

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