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12 SERVICE WORK ON THE CHASSIS

E00375-12

–

Position the brake caliper, and mount and tighten screws

Guideline

Screw, front
brake caliper

25 Nm (18.4 lbf ft)

Loctite

243™

–

Mount the cable tie(s).

–

Position the brake line, wiring harness, and clamp. Mount and
tighten screws

Finishing work

–

Install front fender. (

p. 74)

–

Mount the handlebar cushion.

–

Install the headlight mask with the headlight. (

p. 120)

–

Check the headlight setting. (

p. 122)

–

Install the front wheel.

(

p. 108)

–

Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.

–

Check the play of the steering head bearing. (

p. 72)

–

Remove the motorcycle from the lift stand. (

p. 63)

12.13

Checking the play of the steering head bearing

Warning

Danger of accidents

Incorrect steering head bearing play impairs the handling characteristic and dam-

ages components.

–

Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad
to help.)

Info

If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.

Preparatory work

–

Raise the motorcycle with a lift stand. (

p. 63)

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 bear-
ing.

» If there is detectable play:

–

Adjust the steering head bearing play.

(

p. 73)

–

Move the handlebar to and fro over the entire steering range.

It must be possible to move the handlebar easily over
the entire steering range. There should be no detectable
detent positions.

» If detent positions are detected:

–

Adjust the steering head bearing play.

(

p. 73)

Содержание F7360R6

Страница 1: ...OWNER S MANUAL 2018 250 EXC 250 XC W 300 EXC 300 XC W 300 XC W Six Days Art no 3213644en...

Страница 2: ......

Страница 3: ...rior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options dev...

Страница 4: ...button 19 6 12 Map switch All Six Days models 19 6 13 Indicator lamps overview All EXC models 20 6 14 Indicator lamps overview All XC W models 20 6 15 Opening the filler cap 20 6 16 Closing the fille...

Страница 5: ...etting of the fork 56 11 12 Adjusting the compression damping of the fork 57 11 13 Adjusting the rebound damping of the fork 58 11 14 Adjusting the spring pretension of the fork All Six Days models 59...

Страница 6: ...the front wheel 107 14 2 Installing the front wheel 108 14 3 Removing the rear wheel 108 14 4 Installing the rear wheel 109 14 5 Checking the tire condition 111 14 6 Checking the tire air pressure 11...

Страница 7: ...154 22 3 4 Carburetor tuning All XC W models 155 22 3 5 EXC BR 156 22 3 6 Carburetor tuning EXC BR 157 22 4 Capacities 158 22 4 1 Gear oil 158 22 4 2 Coolant 158 22 4 3 Fuel 158 22 5 Chassis 158 22 6...

Страница 8: ...red for there by specially trained experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or t...

Страница 9: ...the top international motorsport organiza 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 i...

Страница 10: ...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...

Страница 11: ...cle while wearing protective clothing 2 8 Work rules 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 Examp...

Страница 12: ...then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it a...

Страница 13: ...products are specified in parentheses in the descriptions Your authorized KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM website Internation...

Страница 14: ...ustomer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM A list of authorized KTM dealers can be found on the KTM website International KTM...

Страница 15: ...nd brake lever p 17 2 Light switch p 18 All EXC models 2 Kill switch p 17 All EXC models 2 Turn signal switch p 19 All EXC models 2 Horn button p 18 All EXC models 3 Clutch lever p 17 4 Chain guide 5...

Страница 16: ...IEW OF VEHICLE 14 4 2 View of vehicle rear right example E00816 10 1 Filler cap 2 Throttle grip p 17 3 Chassis number p 15 4 Kick starter p 22 5 Foot brake lever p 23 6 Level viewer for brake fluid re...

Страница 17: ...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...

Страница 18: ...10 The fork part number 1 is stamped on the inside of the axle clamp 5 6 Shock absorber article number 0 0 1 1 401948 10 Shock absorber article number 1 is stamped on the top of the shock absorber ab...

Страница 19: ...using the hand brake lever 6 3 Throttle grip E00819 10 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch All EXC models E00820 10 The kill switch 1 is fitted on the left si...

Страница 20: ...button 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...

Страница 21: ...rted 6 11 Electric starter button E00824 10 The electric starter button 1 is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button...

Страница 22: ...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 Obser...

Страница 23: ...Fuel tap E00826 10 The fuel tap is on the left side of the fuel tank Open or close the supply of fuel to the carburetor using tap han dle 1 on the fuel tap Possible states Fuel supply closed OFF Fuel...

Страница 24: ...hoke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed in to the stop 6 19 Shift lever 401950 10 Shift lever 1 is mounted on the left si...

Страница 25: ...1 is located on the left side 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 band 2 6 23 Ste...

Страница 26: ...the right Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 25...

Страница 27: ...ly 400314 01 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...

Страница 28: ...ppears at the bottom 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 ar...

Страница 29: ...ressed 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 op...

Страница 30: ...H the service hours of the engine 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...

Страница 31: ...changes to H or ODO 7 10 Setting the unit of measurement 400329 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press...

Страница 32: ...y 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...

Страница 33: ...P 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...

Страница 34: ...ction 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 r...

Страница 35: ...average speed 1 shows 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 sec...

Страница 36: ...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...

Страница 37: ...function Starts selec tion acti vates Km h display No function Activates Mph display Changes to the next dis play changes from selec tion to the Setup menu Stores and closes the Setup menu Display mod...

Страница 38: ...splay mode No function No function Display mode SPEED A2 aver 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 t...

Страница 39: ...eristic 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 o...

Страница 40: ...and keep your feet on the footrests when riding If you carry luggage make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the fr...

Страница 41: ...armed up internally to increase its starting power current output The starting power increases as the battery warms up 8 4 Preparing the vehicle for difficult riding conditions Info Use of the vehicle...

Страница 42: ...perature 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...

Страница 43: ...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...

Страница 44: ...over for the air filter Waterproofing device for air filter 79006921000 Info Follow the KTM PowerParts mounting instructions Adjust the carburetor jetting and setting Info Your authorized KTM workshop...

Страница 45: ...lukewarm water Change the radiator cap 600868 01 Adjust the secondary drive to the road conditions Info The transmission oil heats up quickly when the clutch is operated frequently due to an excessiv...

Страница 46: ...tire condition p 111 Check the tire air pressure p 111 Check the spoke tension p 112 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Cl...

Страница 47: ...ts if your vehicle is equipped with a lighting system This will make it eas ier for other road users to see you When you are riding the side stand must be folded up and secured with the rubber band Pu...

Страница 48: ...Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM...

Страница 49: ...l EXC models Press and hold the kill switch while the engine is idling until the engine stops All XC W models Press and hold the kill switch while the engine is idling until the engine stops Turn hand...

Страница 50: ...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 spill...

Страница 51: ...k the frame p 89 Check the swingarm p 89 Check the swingarm bearing for play Check the heim joint for play Check the tire condition p 111 Check the tire air pressure p 111 Check the wheel bearing for...

Страница 52: ...interval 10 3 Recommended work Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once af...

Страница 53: ...of the shock absorber is 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 sp...

Страница 54: ...ury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your...

Страница 55: ...urn counterclockwise 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 dam...

Страница 56: ...retension of the shock absorber p 55 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 53 With another person holding the motorcycle the rider w...

Страница 57: ...emove the shock absorber p 75 After removing 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 90...

Страница 58: ...rk Install the shock absorber p 75 Remove the motorcycle from the lift stand p 63 Check the static sag of the shock absorber p 54 Check the riding sag of the shock absorber p 54 Adjust the rebound dam...

Страница 59: ...lockwise by the number of clicks correspond ing to the fork type Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping Comfort 18 clicks Standard 15 cl...

Страница 60: ...screw 1 clockwise as far as it will go Info Adjusting screw 1 is located at the upper end of the right fork leg The rebound damping is located in right fork leg REB red adjusting screw The compression...

Страница 61: ...icks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 11 14 Adjusting the spring pretension of the fork All Six Days models Preparato...

Страница 62: ...uld set the rebound damp ing higher with a higher spring pretension Finishing work Remove the motorcycle from the lift stand p 63 11 15 Handlebar position M00993 10 All standard EXC XC W models On the...

Страница 63: ...d handlebar poses a safety risk If the handlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent M009...

Страница 64: ...e components to protect them against dam age Do not kink the cables and lines Remove screws 2 Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten sc...

Страница 65: ...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...

Страница 66: ...ing 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 an...

Страница 67: ...screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Raise the motorcycle with a lift stand p 63 Remove the front wheel p 107 Remove the headlig...

Страница 68: ...is located in left fork leg COM white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the up...

Страница 69: ...riple clamp All standard EXC XC W models Preparatory work Raise the motorcycle with a lift stand p 63 Remove the front wheel p 107 Remove the headlight mask with the headlight p 119 Remove the fork le...

Страница 70: ...o one side Info Protect the components against damage by covering them Do not bend the cables and lines V00358 10 Remove O ring 3 Remove protective ring 4 Take off the lower triple clamp with the stee...

Страница 71: ...on damping is located in left fork leg COMP white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top ed...

Страница 72: ...120 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 72 Remove the motorcycle from the li...

Страница 73: ...is located in left fork leg COMP white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the u...

Страница 74: ...rect steering head bearing play impairs the handling characteristic and dam ages components Correct incorrect steering head bearing play immediately Your authorized KTM workshop will be glad to help I...

Страница 75: ...le clamp to avoid stresses Tighten screws 1 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screw 2 Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft E00833 10 All Six Days models L...

Страница 76: ...s Remove the lower triple clamp p 68 Install the lower triple clamp p 70 12 16 Removing front fender Preparatory work Remove the headlight mask with the headlight p 119 V00340 10 Main work Remove scre...

Страница 77: ...ition Remove screw 2 push splash protector 3 to the side and remove the shock absorber 12 19 Installing the shock absorber E00834 10 Main work Push splash protector 1 to the side and position the shoc...

Страница 78: ...V00343 10 Hook in the front of the seat on the collar bushing of the fuel tank lower it at the rear and push it forward Make sure that the seat is correctly locked in V00342 10 Mount and tighten screw...

Страница 79: ...filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft 12 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will ente...

Страница 80: ...ning tab 2 Retaining pin 3 is secured by retaining tab 2 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter b...

Страница 81: ...lange and check it for damage and tightness Finishing work Install the air filter p 78 Install the air filter box cover p 77 12 27 Securing the air filter box cover Preparatory work Remove the air fil...

Страница 82: ...37 11 Mount the main silencer with the rubber sleeve 1 and spring ring Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 31 Changing the glass fiber yarn filling in...

Страница 83: ...pe 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 v...

Страница 84: ...he tube from the fuel tank breather V00352 10 Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank 12 33 Installing the fuel tank Danger Fire hazard Fuel is highly flamm...

Страница 85: ...se of fuel spills on them V00352 11 Main work Check throttle cable routing p 89 Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables or throttl...

Страница 86: ...l and grease Clean the brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents br...

Страница 87: ...ted it must be possible to pull up the chain at least to the point where it makes contact with chain guard B Chain wear is not always even so you should repeat this measurement at different chain posi...

Страница 88: ...hten nut 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 18 in enables different secondary ratios with the same chain length C...

Страница 89: ...n If distance B is greater than the specified measurement Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out fas...

Страница 90: ...the 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 lig...

Страница 91: ...e cracking and deformation If the swingarm shows signs of damage cracking or defor mation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by KTM 12 4...

Страница 92: ...tank p 82 Mount the seat p 76 12 42 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the l...

Страница 93: ...safety glasses Do not allow brake 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 wa...

Страница 94: ...nd safety glasses Do not allow brake 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...

Страница 95: ...inject the fluid into the system until it emerges from drill hole 6 of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the...

Страница 96: ...94 12 47 Installing the engine guard All Six Days models EXC AU H01638 10 Attach the engine guard on the frame at the rear and swing up at the front Mount and tighten screws 1 Guideline Remaining scre...

Страница 97: ...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 h...

Страница 98: ...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 f...

Страница 99: ...cidents 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...

Страница 100: ...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 164 Position the cover with the membrane Mount and t...

Страница 101: ...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 Dang...

Страница 102: ...ut pin 5 and remove the brake linings Clean 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 sea...

Страница 103: ...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 doe...

Страница 104: ...Reconnect 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...

Страница 105: ...the 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...

Страница 106: ...ontact 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 t...

Страница 107: ...ing Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir if necessary extract excess Info Make sure when pushing back the brak...

Страница 108: ...BRAKE SYSTEM 106 E00348 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 164 Mount screw cap 1 with membrane 2 and O ring Info Clean up overflowed or spilled brake fluid immediately with wat...

Страница 109: ...back the brake pistons 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 accide...

Страница 110: ...rs Clean and grease the wheel spindle Long life grease p 167 Lift the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned V00364 11 Mount and...

Страница 111: ...ar sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake di...

Страница 112: ...nings are correctly positioned V00368 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain ten...

Страница 113: ...egally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufac...

Страница 114: ...in the spokes is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your author...

Страница 115: ...ne is idling until the engine stops Remove the seat p 76 F00138 10 Main work All AU US models Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Ke...

Страница 116: ...attery gases get into the eyes Disconnect negative cable 1 from the battery Pull back positive terminal cover 2 and disconnect the positive cable from the battery Remove screw 3 Pull holding bracket 4...

Страница 117: ...pose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Even when there is no load on the battery it discharges steadily The c...

Страница 118: ...e is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the mini mum voltage correctly Check the battery voltage Battery voltage 9...

Страница 119: ...ries Switch off the battery charger after charging and discon nect from the battery 400240 10 EXC BR Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries o...

Страница 120: ...m of 10 of the capacity specified on battery housing 2 Switch off the battery charger after charging and discon nect from the battery Guideline The charging current charging voltage and charging time...

Страница 121: ...nsert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing work Mount the seat p 76 15 5 Removing the headligh...

Страница 122: ...e off the headlight mask with the headlight 15 6 Installing the headlight mask with the headlight E00356 11 Main work All EXC models Connect plug in connectors 1 E00357 11 All XC W models Connect plug...

Страница 123: ...socket 2 of the parking light out of the reflector E00359 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 socket BX43t p 159 Insert the protection cap with the bulb socket in...

Страница 124: ...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 functioning properly 15 9 Checking the headlight se...

Страница 125: ...setting Info If you have a payload you may have to correct the headlight range Tighten screw 1 15 11 Changing the combination instrument Preparatory work Remove the headlight mask with the headlight p...

Страница 126: ...instrument The combination instrument is activated Position the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install the headlight mask with the headl...

Страница 127: ...her 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...

Страница 128: ...ter 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...

Страница 129: ...11 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...

Страница 130: ...th coolant Coolant p 164 Mount radiator cap 3 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventila...

Страница 131: ...them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in...

Страница 132: ...the way into barrel adjuster 2 Loosen nut 3 Turn barrel adjuster 2 so that there is play A in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 3...

Страница 133: ...nce in the mid throttle slide range If the engine stutters when accelerating with a partially open throttle slide the jet needle must be lowered If the engine knocks when accelerating at the full powe...

Страница 134: ...open the idling jet and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle h...

Страница 135: ...t The optimal carburetor tuning is shown under the respective model 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 Clip position 1 5 Clip position from above The five possible clip positions are sh...

Страница 136: ...99 11 Screw idle air adjusting screw 1 all the way in Turn the idle air adjusting screw to the specified basic setting Info The basic setting of the carburetor is specified in the technical data Run t...

Страница 137: ...g extreme air temperature or altitude changes adjust the idle speed again 17 6 Ignition curve plug in connector F01061 10 Plug in connector 1 of the ignition timing map adjustment is located on the fr...

Страница 138: ...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 136 17 9 Adjusting the basic position of the shift lever 401950 12 Remove scr...

Страница 139: ...ssive performance at first more aggressive than with the red spring then softer than with the red spring The engine characteristic can be influenced by different spring strengths of auxiliary spring 1...

Страница 140: ...ion them together in the clutch cover Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in sprin...

Страница 141: ...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...

Страница 142: ...4 lbf ft Attach the foot brake lever spring 18 3 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...

Страница 143: ...the oil filler plug 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 eng...

Страница 144: ...ng screw Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft Mount and tighten filler plug 2 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness an...

Страница 145: ...arance will be maintained over a long period Avoid direct sunlight on the motorcycle during cleaning 401061 01 Close off the exhaust system to prevent water from entering Remove coarse dirt particles...

Страница 146: ...alt can be expected on the roads You should therefore take precau tions against aggressive road salt If the vehicle has been used on salted roads use cold water for cleaning after riding Warm water en...

Страница 147: ...ervice 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 40...

Страница 148: ...Because 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 4010...

Страница 149: ...too wide Adjust the plug gap Guideline Spark plug electrode gap 0 60 mm 0 0236 in Fault in ignition system Check the ignition system Kill switch cable in wiring har ness frayed kill switch defec tive...

Страница 150: ...ion coil is loose or oxidized Clean the connector and treat it with contact spray Engine overheats Too little coolant in cooling sys tem Check the cooling system for leakage Check the coolant level p...

Страница 151: ...height of control flap 49 mm 1 93 in Primary transmission 26 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear claw shifted Transmission ratio First gear 14 32 Second...

Страница 152: ...Contactless controlled fully electronic ignition with digital ignition adjustment type Kokusan Spark plug NGK BR 7 ES Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooling permanent circula...

Страница 153: ...bf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 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 start...

Страница 154: ...22 TECHNICAL DATA 152 Nut primary gear M18LHx1 5 150 Nm 110 6 lbf ft Loctite 648...

Страница 155: ...ng jet 17 5 22 5 25 27 5 Starting jet 50 80 Needle jet R 8 S 4 Idle air adjusting screw Open 2 turns Throttle slide 4 Slide stop Present 22 3 2 Carburetor tuning EXC AU Danger Loss of approval for roa...

Страница 156: ...Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet NJ Needle jet Info Do not use on sandy terrain In the derestricted condition the needle jet must be cha...

Страница 157: ...om top Jet needle 6BFY43 75 6BFY42 75 Main jet 450 430 440 460 Idling jet 25 22 5 27 5 Starting jet 80 Needle jet S 4 Idle air adjusting screw Open 1 5 turns Throttle slide 4 22 3 4 Carburetor tuning...

Страница 158: ...dy terrain 22 3 5 EXC BR Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 86 Needle position 3rd position from top Jet needle 6BFY43 73 6BFY42 73 6BFY42 74 6BFY43 74 Main jet 470...

Страница 159: ...A 157 22 3 6 Carburetor tuning EXC BR 402729 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Does not apply o...

Страница 160: ...steel tubing Fork All standard EXC XC W models WP Performance SystemsXplor 48 Fork All Six Days models WP Performance SystemsXplor 48 PA Suspension travel front 300 mm 11 81 in Suspension travel rear...

Страница 161: ...on battery Battery voltage 12 V Nominal capacity 2 0 Ah maintenance free Battery EXC BR YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah maintenance free Combination instrument battery CR 2430 Batt...

Страница 162: ...Fork length 928 mm 36 54 in Fork oil per fork leg 635 10 ml 21 47 0 34 fl oz Fork oil SAE 4 48601166S1 p 165 22 8 2 EXC BR Fork part number 14 18 8Q 63 Fork WP Performance SystemsXplor 48 Compression...

Страница 163: ...in Weight of rider 75 85 kg 165 187 lb 4 2 N mm 24 lb in Weight of rider 85 95 kg 187 209 lb 4 4 N mm 25 1 lb in Fork length 928 mm 36 54 in Fork oil per fork leg 635 10 ml 21 47 0 34 fl oz Fork oil...

Страница 164: ...M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw light switch All EXC mod els M5 1 Nm 0 7 lbf ft Screw shock absorber adjusting ring M...

Страница 165: ...ft Loctite 2701 Screw top steering stem All stan dard EXC XC W models M8 20 Nm 14 8 lbf ft Screw top steering stem All Six Days models M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp All stan...

Страница 166: ...rication properties Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The...

Страница 167: ...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...

Страница 168: ...91 p 166 Recommended supplier Motorex Cross Power 2T Super unleaded type C ROZ 95 RON 95 PON 91 Standard classification ANP Ag ncia Nacional do Petr leo 57 ROZ 95 RON 95 PON 91 Guideline Only use supe...

Страница 169: ...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 Re...

Страница 170: ...ARY SUBSTANCES 168 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...

Страница 171: ...s In most motorcycle engines the transmission and the clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the So...

Страница 172: ...26 LIST OF ABBREVIATIONS 170 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Страница 173: ...iving aids are also represented by yellow or orange symbols Malfunction indicator lamp inoperative Fuel level warning lamp inoperative 27 2 Green and blue symbols Green and blue symbols reflect inform...

Страница 174: ...58 Carburetor float chamber emptying 139 idle 133 idle speed adjusting 134 Carburetor setting 131 Chain checking 86 cleaning 84 Chain guide checking 86 Chain tension adjusting 85 checking 85 Chassis n...

Страница 175: ...e changing 118 G Gear oil adding 141 changing 140 Gear oil level checking 140 H Hand brake lever 17 basic position adjusting 96 free travel adjusting 95 free travel checking 95 Handlebar position 60 a...

Страница 176: ...136 Shock absorber article number 16 compression damping general 51 installing 75 removing 75 riding sag checking 54 spring pretension adjusting 55 static sag checking 54 Side stand 23 Spare parts 11...

Страница 177: ...INDEX 175 Type label 15 U Use definition 7 V View of vehicle front left 13 rear right 14 W Warranty 11 Winter operation checks and maintenance steps 144 Work rules 9...

Страница 178: ...3213644en 3213644en 03 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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