Ktm 250 EXC EU 2012 User Manual

OWNER'S MANUAL 2012

125 EXC EU

125 EXC SIX DAYS EU

200 EXC EU

200 EXC AUS

200 XC‑W USA

250 EXC EU

250 EXC AUS

250 EXC SIX DAYS EU

250 XC‑W USA

300 EXC EU

300 EXC AUS

300 EXC SIX DAYS EU

300 XC‑W USA

Art. no. 3211718en

DEAR KTM CUSTOMER 1

DEARKTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

Chassis number ( p. 10) Dealer's stamp

Engine number ( p. 11)

Key number (All EXC models) ( p. 10)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica­tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe­cial equipment that does not belong to the regular scope of delivery.

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.

ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 2

TABLEOF CONTENTS

MEANS OF REPRESENTATION ............................................ 5

IMPORTANT INFORMATION ................................................ 6

VIEW OF VEHICLE............................................................... 8

View of vehicle, front left (example)................................... 8

View of vehicle, rear right (example) .................................. 9

SERIAL NUMBERS............................................................ 10

Chassis number............................................................. 10

Type label..................................................................... 10

Key number (All EXC models) ......................................... 10

Engine number.............................................................. 11

Fork part number........................................................... 11

Shock absorber part number ........................................... 11

CONTROLS....................................................................... 12

Clutch lever .................................................................. 12

Hand brake lever ........................................................... 12

Throttle grip.................................................................. 12

Kill switch (All EXC models) ........................................... 12

Short circuit button (XC-W) ............................................ 13

Light switch (All EXC models) ......................................... 13

Turn signal switch (All EXC models) ................................ 13

Horn button (All EXC models) ......................................... 13

Emergency OFF switch (200 EXC AUS) ........................... 13

Emergency OFF switch (250/300 EXC AUS) .................... 14

Electric starter button (250/300 EXC EU,

EXC SIX DAYS, 250/300 XC‑W) ...................................... 14

Electric starter button (250/300 EXC AUS)...................... 14

Light switch (XC-W) ....................................................... 14

Overview of indicator lamps (All EXC models)................... 14

Speedometer................................................................. 15

Speedometer activation and test ..................................... 15

Tripmaster switch .......................................................... 15

Setting kilometers or miles ............................................. 15

Setting the clock ........................................................... 16

Adjusting the speedometer functions............................... 16

Querying lap time .......................................................... 17

Display mode SPEED (speed) ......................................... 17

Display mode SPEED/H (operating hours) ........................ 17

Display mode SPEED/CLK (clock) ................................... 18

Display mode SPEED/LAP (lap time) ............................... 18

Display mode SPEED/ODO (odometer) ............................. 18

Display mode SPEED/TR1 (trip master 1) ........................ 18

Display mode SPEED/TR2 (trip master 2) ........................ 19

Display mode SPEED/A1 (average speed 1)...................... 19

Display mode SPEED/A2 (average speed 2)...................... 19

Display mode SPEED/S1 (stop watch 1) .......................... 20

Display mode SPEED/S2 (stop watch 2) .......................... 20

Fuel tap........................................................................ 21

Opening the filler cap .................................................... 21

Closing the filler cap...................................................... 22

Shift lever..................................................................... 22

Kickstarter.................................................................... 22

Foot brake lever............................................................. 23

Side stand .................................................................... 23

Steering lock (All EXC models)........................................ 23

Locking the steering (All EXC models) ............................. 23

Unlocking the steering (All EXC models) .......................... 24

PREPARING FOR USE ....................................................... 25

Advice on first use ......................................................... 25

Running in the engine.................................................... 26

Preparing the vehicle for difficult operating conditions...... 26

Preparations for riding on dry sand.................................. 27

Preparations for riding on wet sand ................................. 27

Preparations for riding on wet and muddy surfaces ........... 28

Preparations for riding at high temperatures and low

speeds.......................................................................... 28

Preparing for rides at low temperatures or in snow ............ 29

RIDING INSTRUCTIONS .................................................... 30

Checks and maintenance work when preparing for use ...... 30

Starting ........................................................................ 30

Start off........................................................................ 31

Shifting, riding.............................................................. 31

Braking ........................................................................ 31

Stopping, parking .......................................................... 32

Refueling...................................................................... 32

SERVICE SCHEDULE......................................................... 34

Service schedule ........................................................... 34

Maintenance work (as an additional order) ....................... 35

TUNING THE CHASSIS...................................................... 36

Checking the basic chassis setting with the rider's

weight .......................................................................... 36

Compression damping of shock absorber.......................... 36

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 36

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 37

Adjusting the rebound damping of the shock absorber....... 37

Measuring the sag of the unloaded rear wheel .................. 38

Checking the static sag of the shock absorber .................. 38

Checking the riding sag of the shock absorber .................. 39

Adjusting the spring preload of the shock absorber x ...... 39

Adjusting the riding sag x............................................. 40

Checking the basic setting of the fork.............................. 40

Adjusting the compression damping of the fork ................ 41

Adjusting the rebound damping of the fork....................... 41

Adjusting the spring preload of the fork ........................... 42

Handlebar position ........................................................ 42

Adjusting the handlebar position x................................ 42

SERVICE WORK ON THE CHASSIS ..................................... 44

Raising the motorcycle with the lift stand ........................ 44

Removing the motorcycle from the lift stand .................... 44

Bleeding the fork legs .................................................... 44

Cleaning the dust boots of the fork legs ........................... 45

Loosening the fork protection.......................................... 45

Positioning the fork protection ........................................ 46

Removing the fork legs x.............................................. 46

Installing the fork legs x............................................... 46

Removing the fork protector x....................................... 47

Installing the fork protector x ....................................... 48

Removing the lower triple clamp x (EXC EU/AUS,

XC‑W)........................................................................... 48

Removing the lower triple clamp x (EXC SIX DAYS) ........ 48

Installing the lower triple clamp x (EXC EU/AUS,

XC‑W)........................................................................... 49

Installing the lower triple clamp x (EXC SIX DAYS) ......... 50

Checking the play of the steering head bearing................. 52

Adjusting the play of the steering head bearing x............ 52

Greasing the steering head bearing x............................. 53

Removing the start number plate (XC-W).......................... 53

Installing the start number plate (XC-W) .......................... 53

Removing the front fender .............................................. 54

Installing the front fender............................................... 54

Removing the shock absorber x..................................... 54

Installing the shock absorber x ..................................... 54

TABLE OF CONTENTS 3

Removing the seat ......................................................... 55

Mounting the seat ......................................................... 55

Removing the air filter box lid......................................... 56

Installing the air filter box lid.......................................... 56

Removing the air filter x............................................... 56

Installing the air filter x ............................................... 56

Cleaning the air filter and air filter box x........................ 57

Removing the main silencer............................................ 57

Installing the main silencer ............................................ 58

Changing the glass fiber yarn filling of the main

silencer x ................................................................... 58

Removing the fuel tank x ............................................. 58

Installing the fuel tank x .............................................. 59

Checking the chain for dirt ............................................. 60

Cleaning the chain......................................................... 60

Checking the chain tension ............................................ 61

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 61

Adjusting the chain tension ............................................ 63

Adjusting the chain guide x.......................................... 64

Checking the frame x................................................... 65

Checking the swingarm x ............................................. 65

Checking the throttle cable routing.................................. 65

Checking the rubber grip ................................................ 66

Additionally securing the rubber grip ............................... 66

Adjusting the basic position of the clutch lever................. 66

Checking the fluid level of the hydraulic clutch ................ 67

Changing the hydraulic clutch fluid x ............................ 67

BRAKES........................................................................... 69

Checking free travel of hand brake lever........................... 69

Adjusting the basic position of the hand brake lever

(XC-W).......................................................................... 69

Adjusting free travel of hand brake lever (All EXC

models) ........................................................................ 69

Checking the brake discs................................................ 70

Checking the front brake fluid level ................................. 70

Adding front brake fluid x ............................................ 70

Checking the front brake linings...................................... 71

Changing the front brake linings x................................. 72

Checking the free travel of foot brake lever....................... 73

Adjusting the basic position of the foot brake lever x ...... 73

Checking the rear brake fluid level .................................. 74

Adding brake fluid for the rear brake x .......................... 74

Checking the rear brake linings ....................................... 75

Removing the rear brake linings x ................................. 75

Installing the rear brake linings x.................................. 76

Changing the rear brake linings x.................................. 76

WHEELS, TIRES ............................................................... 78

Removing the front wheel x .......................................... 78

Installing the front wheel x........................................... 78

Removing the rear wheel x ........................................... 79

Installing the rear wheel x ............................................ 79

Checking the tire condition............................................. 80

Checking the tire air pressure ......................................... 81

Checking the spoke tension ............................................ 81

ELECTRICAL SYSTEM ....................................................... 83

Removing the battery x (All 250/300 models) ................ 83

Installing the battery x (All 250/300 models)................. 83

Recharging the battery x (All 250/300 models) .............. 83

Changing the main fuse (All 250/300 models) ................. 84

Removing the headlight mask with the headlight (All EXC

models) ........................................................................ 85

Refitting the headlight mask with the headlight (All EXC

models) ........................................................................ 86

Changing the headlight bulb (All EXC models).................. 86

Checking the headlight setting (All EXC models)............... 87

Adjusting the headlight range (All EXC models) ................ 87

Changing the speedometer battery .................................. 87

COOLING SYSTEM ............................................................ 89

Cooling system .............................................................. 89

Checking the antifreeze and coolant level ........................ 89

Checking the coolant level.............................................. 90

Draining the coolant x.................................................. 90

Refilling with coolant x ................................................ 91

TUNING THE ENGINE ....................................................... 93

Checking the play in the throttle cable............................. 93

Adjusting the play in the throttle cable x ....................... 93

Carburetor .................................................................... 93

Carburetor - adjusting the idle speed x .......................... 94

Emptying the carburetor float chamber x ....................... 95

Checking the basic position of the shift lever.................... 96

Adjusting the basic position of the shift lever x .............. 96

Engine characteristic - auxiliary spring

(All 250/300 models) .................................................... 96

Engine characteristic - adjusting the auxiliary spring x

(All 250/300 models) .................................................... 96

SERVICE WORK ON THE ENGINE ...................................... 98

Checking the gear oil level.............................................. 98

Changing the gear oil x ................................................ 98

Draining the gear oil x ................................................. 99

Refilling with gear oil x ................................................ 99

Adding gear oil x ....................................................... 100

CLEANING, CARE ........................................................... 101

Cleaning the motorcycle ............................................... 101

Checks and maintenance steps for winter operation ........ 102

STORAGE ....................................................................... 103

Storage....................................................................... 103

Preparing for use after storage ...................................... 103

TROUBLESHOOTING....................................................... 104

TECHNICAL DATA - ENGINE ............................................ 106

125 EXC EU, 125 EXC SIX DAYS EU ............................ 106

All 200 models ........................................................... 106

All 250 models ........................................................... 107

All 300 models ........................................................... 107

Capacity - transmission oil............................................ 108

Capacity - coolant........................................................ 108

TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 109

All 125/200 models .................................................... 109

All 250/300 models .................................................... 110

TECHNICAL DATA - CARBURETOR................................... 111

125 EXC EU, 125 EXC SIX DAYS EU ............................ 111

200 EXC EU ............................................................... 111

200 EXC AUS ............................................................. 111

200 XC‑W USA ........................................................... 111

250 EXC EU, 250 EXC SIX DAYS EU ............................ 112

250 EXC AUS ............................................................. 112

250 XC‑W USA ........................................................... 112

300 EXC EU, 300 EXC SIX DAYS EU ............................ 112

300 EXC AUS ............................................................. 113

300 XC‑W USA ........................................................... 113

Carburetor configuration (125 EXC EU,

125 EXC SIX DAYS EU) x .......................................... 113

TABLE OF CONTENTS 4

Carburetor configuration (All 200 models) x................. 115

Carburetor configuration (All 250 models) x................. 116

Carburetor configuration (All 300 models) x................. 117

General carburetor configuration x .............................. 118

TECHNICAL DATA - CHASSIS .......................................... 119

Lighting equipment ..................................................... 120

Tires .......................................................................... 120

Capacity - fuel............................................................. 120

TECHNICAL DATA - FORK................................................ 121

All 125/200 models .................................................... 121

All 250/300 models .................................................... 121

TECHNICAL DATA - SHOCK ABSORBER ........................... 123

All 125/200 models .................................................... 123

All 250/300 models .................................................... 123

TECHNICAL DATA - TIGHTENING TORQUES FOR

CHASSIS ........................................................................ 125

SUBSTANCES................................................................. 126

AUXILIARY SUBSTANCES................................................ 128

STANDARDS................................................................... 130

INDEX ............................................................................ 131

MEANS OF REPRESENTATION 5

Symbols used

The symbols used are explained below.

Indicates an expected reaction (e.g., to a work step or a function).

Indicates an unexpected reaction (e.g., to a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained below.

Specific name Identifies a specific name.

®

Name

Brand™ Identifies a brand available on the open market.

Identifies a protected name.

IMPORTANT INFORMATION 6

Use definition (All EXC models)

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com­ply with currently valid regulations and categories of the top international motorsport organizations.

Info

The motorcycle is authorized for public road traffic in the homologous (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.

Use definition (XC-W)

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com­ply with currently valid regulations and categories of the top international motorsport organizations.

Info

The motorcycle must be used only on closed off property remote from public road traffic.
The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.

Service

A prerequisite for perfect operation and prevention of wear is that the engine and chassis service, care and adjustment work described
in the owner's manual is properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage
of components.
Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of compo­nents such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the
limit specified in the service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com

Work rules

Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parenthe­ses. E.g.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash­ers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

IMPORTANT INFORMATION 7

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from

being run. Always let the vehicle cool first.

– Switch off the engine.
– Turn handle  of the fuel tap to the OFF position.
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob­lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis­play environmental consciousness, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss­ing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
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 appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and

tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle
to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on ser­vicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is

sold.

VIEW OF VEHICLE 8

3.1View of vehicle, front left (example)

1 Hand brake lever ( p. 12)
2 Kill switch ( p. 12)
3 Clutch lever ( p. 12)
4 Air filter box lid
5 Fuel tap ( p. 21)
6 Chain guide
7 Side stand ( p. 23)
8 Shift lever ( p. 22)
9 Fork rebound adjustment
10 Fork compression adjustment

B00784-10

VIEW OF VEHICLE 9

3.2View of vehicle, rear right (example)

1 Filler cap
2 Bleeder screw, fork leg
3 Throttle grip ( p. 12)
4 Chassis number ( p. 10)
5 Kickstarter ( p. 22)
6 Foot brake lever ( p. 23)
7 Shock absorber, compression adjustment
8 Level viewer, rear brake fluid
9 Shock absorber, rebound adjustment

B00783-10

SERIAL NUMBERS 10

4.1Chassis number

(XC-W)

The chassis number  is stamped on the right side of the steering head.

B00015-10

(All EXC models)

The chassis number  is stamped on the right side of the steering head.

303438-10

4.2Type label

4.3Key number (All EXC models)

(XC-W)

The type label  is fixed to the front of the steering head.

400284-10

(All EXC models)

The type label  is fixed to the front of the steering head.

303439-10

The key number  for the steering lock is stamped onto the key connector.

500125-10

SERIAL NUMBERS 11

4.4Engine number

The engine number  is stamped on the left side of the engine under the engine
sprocket.

B00016-10

4.5Fork part number

The fork part number  is stamped on the inner side of the fork stub.

4.6Shock absorber part number

B00265-01

The shock absorber part number  is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

B00786-10

CONTROLS 12

5.1Clutch lever

(All 125/200 models)

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

B00001-10

(All 250/300 models)

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

B00009-10

5.2Hand brake lever

5.3Throttle grip

Hand brake lever  is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.

400196-10

Throttle grip  is fitted on the right side of the handlebar.

B00060-10

5.4Kill switch (All EXC models)

The kill switch  is fitted on the left side of the handlebar.

Possible states

• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.

• Kill switch pressed – In this position, the ignition circuit is interrupted, a run­ning engine stops, and a non-running engine will not start.

B00078-10

CONTROLS 13

5.5Short circuit button (XC-W)

Short circuit button  is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.

• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.

B00002-10

5.6Light switch (All EXC models)

The light switch  is fitted on the left side of the handlebar.

Possible states

Light off – Light switch is turned to the right. In this position, the light
is switched off.

Low beam on – Light switch is in the central position. In this position,
the low beam and tail light are switched on.

High beam on – Light switch is turned to the left. In this position, the

B00082-10

high beam and the tail light are switched on.

5.7Turn signal switch (All EXC models)

101299-10

5.8Horn button (All EXC models)

B00083-10

Turn signal switch  is fitted on the left side of the handlebar.

Possible states

Turn signal off – The turn signal switch is in the central position.
Left turn signal, on – The turn signal switch is turned to the left.

Right turn signal, on – The turn signal switch is turned to the right.

The horn button  is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position

• Horn button pressed – The horn is operated in this position.

5.9Emergency OFF switch (200 EXC AUS)

B00087-10

The emergency OFF switch  is fitted on the right side of the handlebar.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a run­ning engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.

CONTROLS 14

5.10Emergency OFF switch (250/300 EXC AUS)

The emergency OFF switch  is fitted on the right side of the handlebar.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a run­ning engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.

B00079-10

5.11Electric starter button (250/300 EXC EU, EXC SIX DAYS, 250/300 XC‑W)

The electric starter button  is fitted on the right side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed – In this position, the electric starter is actuated.

B00080-10

5.12Electric starter button (250/300 EXC AUS)

The electric starter button  is fitted on the right side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed – In this position, the electric starter is actuated.

B00081-10

5.13Light switch (XC-W)

Light switch  is located to the right of the speedometer.

Possible states

• The light switch has no function when the vehicle is delivered – It can be used to
retrofit the vehicle with a lighting system.

500146-10

5.14Overview of indicator lamps (All EXC models)

Possible states

500147-01

High beam indicator lamp lights up blue – High beam is switched on.

Turn signal indicator lamp flashes green – Turn signal light is switched
on.

CONTROLS 15

5.15Speedometer

– Press the button to change the display mode or change to one of the Setup

menus.

– Press the button to control different functions.
– Press the button to control different functions.

Info

When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.

400312-01

5.16Speedometer activation and test

Activating the speedometer

The speedometer is activated when one of the buttons is pressed or an impulse comes
from the wheel speed sensor.

Display test

For the function test of the display, all display segments light up briefly.

400313-01

WS (wheel size)
After the display function test, the wheel size WS is displayed briefly.

Info

The number 2205 mm equals the circumference of the 21" front wheel with a
series production tire.

The display then changes to the last selected mode.

400314-01

5.17Tripmaster switch

(Option: Tripmaster switch)

You can use the trip master switch to control the functions of the speedometer from the handlebar.

Info

The trip master is an optional accessory.

5.18Setting kilometers or miles

Info

If you change the unit of measure, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

400329-01

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

– Press the button for 3 - 5 seconds.

The Setup menu is displayed and the active functions are shown.

– Press the button repeatedly until the Km/h/Mph display flashes.
Adjusting Km/h

– Press the button .

Adjusting Mph

– Press the button .

CONTROLS 16

– Press the button for 3 - 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.

5.19Setting the clock

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until CLK appears at the bottom right of

the display.

– Press the button for 3 - 5 seconds.

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 same way as the hours by pressing the

400330-01

button and the button .

Info

The seconds can only be set to zero.

– Press the button for 3 - 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if a pulse arrives from the wheel
speed sensor, the settings are stored automatically and the Setup menu is
closed.

5.20Adjusting the speedometer functions

Info

When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

– Press the button for 3 - 5 seconds.

The Setup menu is displayed and the activated functions are shown.

– Change to the desired function by pressing the button briefly.

The selected function flashes.

Activating a function

– Press the button .

400318-01

Deactivating the function

– Press the button .

– All desired functions are activated or deactivated accordingly.
– Press the button for 3 - 5 seconds.

The symbol remains on the screen and the display changes to the next
function.

The symbol on the screen goes out and the display changes to the next
function.

The settings are stored and the Setup menu is closed.

CONTROLS 17

Info

If no button is pressed for 20 seconds, or if a pulse arrives from the wheel
speed sensor, the settings are stored automatically and the Setup menu is
closed.

5.21Querying lap time

Info

This function can be called up only if lap times are measured.

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until LAP appears at the bottom right of

the display.

– Press the button briefly.

LAP 1 appears on the left side of the display.

– Laps 1-10 can be displayed by pressing the button .
– The button has no function.
– Press the button briefly.

Next display mode

400321-01

Info

If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.

5.22Display mode SPEED (speed)

400317-02

5.23Display mode SPEED/H (operating hours)

400316-01

– Press the button briefly and repeatedly until SPEED appears on the left side of

the display.

The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.

Info

Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.

Condition

• The motorcycle is stationary.

– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

In display mode H, the operating hours of the engine are displayed.
The operating hours counter stores the total traveling time.

Info

The operating hours counter is necessary for ensuring that maintenance work is
carried out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automati­cally changes to the ODO display mode.
The H display mode is suppressed during the journey.

Press the button . No function
Press the button . No function
Press the button

for 3 - 5 seconds.
Press the button

The display changes to the Setup menu of the speedometer
functions.

Next display mode

briefly.

CONTROLS 18

5.24Display mode SPEED/CLK (clock)

– Press the button briefly and repeatedly until CLK appears at the bottom right of

the display.

The time is displayed in CLK display mode.

Press the button . No function
Press the button . No function

400319-01

5.25Display mode SPEED/LAP (lap time)

Press the button
for 3 - 5 seconds.

Press the button
briefly.

– Press the button briefly and repeatedly until LAP appears at the bottom right of

the display.

In the LAP display mode, up to 10 lap times can be timed with the stop watch.

Info

If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .

The display changes to the Setup menu of the clock.

Next display mode

400320-01

5.26Display mode SPEED/ODO (odometer)

400317-01

5.27Display mode SPEED/TR1 (trip master 1)

Press the button . Starts or stops the clock.
Press the button . Stops the current lap time and saves it, and the stop watch

starts the next lap.

Press the button

The stop watch and the lap time are reset.

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

– Press the button briefly and repeatedly until ODO appears at the bottom right of

the display.

The total distance traveled is displayed in the ODO display mode.

Press the button . No function
Press the button . No function
Press the button

–

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

– Press the button briefly and repeatedly until TR1 appears at the top right of the

display.

TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

400323-01

Info

If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to

0.0.

Press the button . No function
Press the button . No function
Press the button

for 3 - 5 seconds.
Press the button

briefly.

The TR1, A1 and S1 displays are reset to 0.0.

Next display mode

CONTROLS 19

5.28Display mode SPEED/TR2 (trip master 2)

– Press the button briefly and repeatedly until TR2 appears at the top right of the

display.

TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . This is a
very practical function when riding using the road book.

Info

The TR2 value can also be corrected manually during the journey with the but­ton and the button .

400324-01

5.29Display mode SPEED/A1 (average speed 1)

If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.

Press the button . Increases value of TR2.
Press the button . Reduces value of TR2.
Press the button

Deletes value of TR2.

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

– Press the button briefly and repeatedly until A1 appears at the top right of the

display.

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas­ter 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.

400325-01

5.30Display mode SPEED/A2 (average speed 2)

– Press the button briefly and repeatedly until A2 appears at the top right of the

A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.

400326-01

Press the button . No function
Press the button . No function
Press the button

The TR1, A1 and S1 displays are reset to 0.0.

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

display.

Info

The displayed value can differ from the actual average speed if S2 was not
timed after the ride.

Press the button . No function
Press the button . No function
Press the button

for 3 - 5 seconds.
Press the button

briefly.

–

Next display mode

CONTROLS 20

5.31Display mode SPEED/S1 (stop watch 1)

– Press the button briefly and repeatedly until S1 appears at the top right of the

display.

S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.

Press the button . No function
Press the button . No function

400327-01

5.32Display mode SPEED/S2 (stop watch 2)

400328-01

Press the button
for 3 - 5 seconds.

Press the button
briefly.

– Press the button briefly and repeatedly until S2 appears at the top right of the

display.

S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button . Starts or stops S2.
Press the button . No function
Press the button

for 3 - 5 seconds.
Press the button

briefly.

Displays of TR1, A1 and S1 are reset to 0.0.

Next display mode

Displays of S2 and A2 are reset to 0.0.

Next display mode

Table of functions
Display Press the button . Press the button . Press the button for 3 -

5 seconds.

Display mode SPEED/H
(operating hours)

No function No function The display changes to

the Setup menu of the
speedometer functions.

Display mode SPEED/CLK
(clock)

No function No function The display changes to

the Setup menu of the
clock.

Display mode SPEED/LAP
(lap time)

Starts or stops the
clock.

Stops the current lap
time and saves it, and

The stop watch and the

lap time are reset.
the stop watch starts
the next lap.

Display mode

No function No function – Next display mode

SPEED/ODO (odometer)
Display mode SPEED/TR1

(trip master 1)
Display mode SPEED/TR2

No function No function The TR1, A1 and S1 dis-

plays are reset to 0.0.

Increases value of TR2. Reduces value of TR2. Deletes value of TR2. Next display mode

(trip master 2)
Display mode SPEED/A1

(average speed 1)
Display mode SPEED/A2

No function No function The TR1, A1 and S1 dis-

plays are reset to 0.0.

No function No function – Next display mode

(average speed 2)
Display mode SPEED/S1

(stop watch 1)
Display mode SPEED/S2

(stop watch 2)

No function No function Displays of TR1, A1 and

S1 are reset to 0.0.

Starts or stops S2. No function Displays of S2 and A2

are reset to 0.0.

Press the button
briefly.

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Table of conditions and menu activation
Display The motorcycle is

stationary.

Menu can be acti­vated

Display mode SPEED/H (operating hours) •
Display mode SPEED/CLK (clock) •

CONTROLS 21

Table of conditions and menu activation
Display The motorcycle is

stationary.

Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •

5.33Fuel tap

The fuel tap is on the left side of the fuel tank.
Tap handle  on the fuel tap is used to open or close the supply of fuel to the carbure­tor.

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.

• Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The
fuel tank empties completely.

Menu can be acti­vated

601157-10

5.34Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con­tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

CONTROLS 22

– Press release button , turn the filler cap counterclockwise and lift it free.

303520-10

5.35Closing the filler cap

– Replace the filler cap and turn clockwise until the release button  locks in place.

Info

Run the fuel tank breather hose  without kinks.

303521-10

5.36Shift lever

5.37Kickstarter

Shift lever  is mounted on the left side of the engine.

B00005-10

The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

B00005-12

The kickstarter  is fitted on the right side of the engine. The top part can be
swiveled.

B00787-10

CONTROLS 23

5.38Foot brake lever

Foot brake lever  is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.

B00788-10

5.39Side stand

The side stand  is on the left side of the vehicle.

B00789-10

B00790-10

5.40Steering lock (All EXC models)

B00791-10

The side stand is used to park the motorcycle.

Info

When you are riding, side stand  must be folded up and secured with rubber
band .

Steering lock  is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.

5.41Locking the steering (All EXC models)

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– Park the vehicle.
– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in and turn it to the

right. Remove the key.

Steering is no longer possible.

Info

Never leave the key in the steering lock.

400732-01

CONTROLS 24

5.42Unlocking the steering (All EXC models)

– Insert the key in the steering lock, turn it to the left, pull it out and turn it to the

right. Remove the key.

You can now steer the bike again.

Info

Never leave the key in the steering lock.

400731-01

PREPARING FOR USE 25

6.1Advice on first use

Danger

Danger of accidents Danger arising from the rider's judgement being impaired.

– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally

impaired.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always

wear protective clothing, which must be undamaged and meet legal requirements.

Warning

Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

– Adapt your riding speed to the road conditions and your riding ability.

Warning

Danger of accidents Accident risk caused by presence of a passenger.

– Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidents Failure of brake system.

– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take

your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Unstable riding behavior.

– Do not exceed the maximum permissible weight and axle loads.

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 66)

(XC-W)

– Adjust the basic position of the hand brake lever. ( p. 69)

(All EXC models)

– Adjust the free travel of the hand brake lever. ( p. 69)

–

Adjust the basic position of the foot brake lever. x ( p. 73)

–

Adjust the basic position of the shift lever. x ( p. 96)

– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info

Offroad, you should be accompanied by another person on another machine so that you can help each other.

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.

PREPARING FOR USE 26

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-

tribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

– Do not exceed the overall maximum permitted weight and the axle loads.

Guideline

Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)

– Check the spoke tension. ( p. 81)

Info

The spoke tension must be checked after half an hour of operation.

– Run the engine in.

6.2Running in the engine

– During the running-in phase, do not exceed the specified engine performance.

Guideline

Maximum engine performance

During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %

– Avoid fully opening the throttle!

6.3Preparing the vehicle for difficult operating conditions

Info

Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

–

Seal the air filter box. x

Tip

Seal the air filter box at the edges against dirt.

–

Clean the air filter and air filter box. x ( p. 57)

Info

Check the air filter approx. every 30 minutes.

– Additionally secure the rubber grip. ( p. 66)
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.

» If humidity, corrosion, or damage is found:

– Clean and dry the connector, or change it if necessary.

Difficult operating conditions are:

– Riding on dry sand. ( p. 27)
– Riding on wet sand. ( p. 27)
– Riding on wet and muddy surfaces. ( p. 28)
– Riding at high temperatures and low speeds. ( p. 28)
– Rides at low temperatures or in snow. ( p. 29)

PREPARING FOR USE 27

6.4Preparations for riding on dry sand

– Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)

» If the displayed value does not equal the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling

600872-10

– Change the radiator cap.

– Mount the dust cover for the air filter.

Dust cover for air filter (59006019000)

Info

Read the KTM PowerParts installation instructions.

system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.

600869-01

600871-01

600868-01

– Mount the dust cover for the air filter for sand.

Sand cover for air filter (59006022000)

Info

Read the KTM PowerParts installation instructions.

– Adjust the carburetor jetting and setting.

Info

Recommendations on the carburetor setting are available from your autho­rized KTM workshop.

– Clean the chain.

Chain cleaner ( p. 128)

– Mount the steel sprocket.

Tip

Do not grease the chain.

– Clean the radiator fins.
– Carefully align bent radiator fins.
– If used in sand regularly, replace the piston every 10 operating hours.

6.5Preparations for riding on wet sand

600872-10

– Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)

» If the displayed value does not equal the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling

system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.

PREPARING FOR USE 28

– Change the radiator cap.

– Mount the rain cover for the air filter.

Rain cover for air filter (59006021000)

Info

Read the KTM PowerParts installation instructions.

– Adjust the carburetor jetting and setting.

600870-01

– Clean the chain.

Chain cleaner ( p. 128)

– Mount the steel sprocket.

– Clean the radiator fins.

600868-01

– Carefully align bent radiator fins.
– If used in sand regularly, replace the piston every 10 operating hours.

6.6Preparations for riding on wet and muddy surfaces

– Mount the rain cover for the air filter.

Rain cover for air filter (59006021000)

– Adjust the carburetor jetting and setting.

Info

Recommendations on the carburetor setting are available from your autho­rized KTM workshop.

Tip

Do not grease the chain.

Info

Follow the KTM PowerParts mounting instructions.

600870-01

– Mount the steel sprocket.
– Clean the motorcycle. ( p. 101)
– Carefully align bent radiator fins.

600868-01

6.7Preparations for riding at high temperatures and low speeds

– Check the radiator cap.

The recommended carburetor tuning is available from your authorized KTM
workshop.

Value on the radiator cap 1.8 bar (26 psi)

» If the displayed value does not equal the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling

600872-10

Info

system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.

PREPARING FOR USE 29

– Change the radiator cap.

– Adjust the secondary ratio to the terrain.

Info

The engine oil heats up rapidly if the clutch needs to be operated too fre­quently because the secondary ratio is too long.

– Clean the chain.

Chain cleaner ( p. 128)

600868-01

6.8Preparing for rides at low temperatures or in snow

600870-01

– Clean the radiator fins.
– Carefully align bent radiator fins.
– Check the coolant level. ( p. 90)

– Mount the rain cover for the air filter.

Rain cover for air filter (59006021000)

– Adjust the carburetor jetting and setting.

Info

Follow the KTM PowerParts mounting instructions.

Info

The recommended carburetor tuning is available from your authorized KTM
workshop.

RIDING INSTRUCTIONS 30

7.1Checks and maintenance work when preparing for use

Info

Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.

– Check the gear oil level. ( p. 98)
– Check the electrical system.
– Check the front brake fluid level. ( p. 70)
– Check the rear brake fluid level. ( p. 74)
– Check the front brake linings. ( p. 71)
– Check the rear brake linings. ( p. 75)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 90)
– Check the chain for dirt. ( p. 60)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 61)
– Check the chain tension. ( p. 61)
– Check the tire condition. ( p. 80)
– Check the tire air pressure. ( p. 81)
– Check the spoke tension. ( p. 81)
– Clean the dust boots of the fork legs. ( p. 45)
– Bleed the fork legs. ( p. 44)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts and hose clamps regularly for tightness.
– Check the fuel supply.

7.2Starting

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed

space without an effective exhaust extraction system.

Note

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.

Engine has been out of use for more than 1 week

–

Empty the carburetor float chamber. x ( p. 95)

– Turn handle  of the fuel tap to the ON position. (Figure 601157-10 p. 21)

Fuel can flow from the fuel tank to the carburetor.

– Remove the motorcycle from the stand.
– Shift gear to neutral.

(200 EXC AUS)

– Turn the emergency OFF switch to the position .

(250/300 EXC AUS)

– Turn the emergency OFF switch to the position .

(All 250/300 models)

– Press the electric starter button or press the kick starter robustly through its full range.

RIDING INSTRUCTIONS 31

Info

Do not open the throttle.

(All 125/200 models)

– Press the kick starter forcefully through its full range.

Info

Do not open the throttle.

7.3Start off

Info

Before riding, switch on the lights if your vehicle is equipped with a lighting system. This will make it easier for other road
users to see you.
When you are riding, the side stand must be folded up and secured with the rubber band.

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

7.4Shifting, riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.

– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-

neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

– If the choke function was activated, deactivate it after the engine has warmed up.
– When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces

vehicle speed but lowers fuel consumption considerably.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, brake and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.

Guideline

≥ 2 min

– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

7.5Braking

Warning

Danger of accidents If you brake too hard, the wheels can lock.

– Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.

– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking efficiency due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

RIDING INSTRUCTIONS 32

– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

7.6Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-

nents to cool down before starting work on them.

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from

being run. Always let the vehicle cool first.

Note

Material damage Damage and destruction of components by excessive load.

– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side

stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle.
– Shift gear to neutral.

(All EXC models)

– Press and hold the kill switch while the engine is idling until the engine stops.

(XC-W)

– Press and hold the short circuit button while the engine is idling until the engine stops.
– Turn handle  of the fuel tap to the OFF position.
– Park the motorcycle on firm ground.

7.7Refueling

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– Switch off the engine.
– Open the filler cap. ( p. 21)

RIDING INSTRUCTIONS 33

AA

– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

400382-10

Total fuel tank
capacity, approx.
(EXC EU,
EXC SIX DAYS)

Total fuel tank
capacity, approx.
(EXC AUS, XC‑W)

2-stroke engine oil ( p. 126)

– Close the filler cap. ( p. 22)

9.5 l
(2.51 US gal)

10 l (2.6 US gal) Super unleaded gasoline, mixed with

Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 127)

2-stroke engine oil (1:60) ( p. 127)

SERVICE SCHEDULE 34

8.1Service schedule

S20A S40A

Check that the electrical equipment is functioning properly. • •

Check and charge the battery. x (All 250/300 models)
Change the gear oil. x ( p. 98)

Check the front brake linings. ( p. 71) • •
Check the rear brake linings. ( p. 75) • •
Check the brake discs. ( p. 70) • •
Check the brake lines for damage and leakage. • •
Check the rear brake fluid level. ( p. 74) • •
Check the free travel of the foot brake lever. ( p. 73) • •

Check the frame and swingarm. x
Check the swingarm bearing. x
Check the heim joints at the top and bottom of the shock absorber. x

Check the tire condition. ( p. 80) • •
Check the tire air pressure. ( p. 81) • •

Check the wheel bearing for play. x
Check the wheel hubs. x
Check the rim run-out. x

Check the spoke tension. ( p. 81) • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 61) • •
Check the chain tension. ( p. 61) • •

Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. x

Check the fluid level of the hydraulic clutch. ( p. 67) • •
Check the front brake fluid level. ( p. 70) • •
Check the free travel of the hand brake lever. ( p. 69) • •
Check the play of the steering head bearing. ( p. 52) • •

Change the spark plug and spark plug connector. x
Check the intake diaphragm. x
Check the exhaust control for functioning and smooth operation. x
Check the clutch. x
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing. x

Check the antifreeze and coolant level. ( p. 89) • •

Check the cables for damage and routing without sharp bends. x

Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • •

Clean the air filter and air filter box. x ( p. 57)
Change the glass fiber yarn filling of the main silencer. x ( p. 58)
Check the screws and nuts for tightness. x

Check the headlight setting. (All EXC models) ( p. 87) • •
Check the idle. • •
Final check: Check the vehicle for safe operation and take a test ride. • •

Make the service entry in KTM DEALER.NET and in the service record. x

• •

• •

• •

•

• •

• •

• •

• •

• •

• •

• •

•

•

• •

• •

• •

• •

• •

• •

S20A: Every 20 operating hours
S40A: Every 40 operating hours/after every race

SERVICE SCHEDULE 35

8.2Maintenance work (as an additional order)

S10N S40A S80A J1A

Change the front brake fluid. x
Change the rear brake fluid. x
Change the foot brake cylinder seals. x
Change the hydraulic clutch fluid. x ( p. 67)
Grease the steering head bearing. x ( p. 53)
Check/set the carburetor components. x
Perform a fork service. x
Service the shock absorber. x
Check the starter drive. x (All 250/300 models)
Change the piston and check the cylinder. x (125 EXC EU, 125 EXC SIX DAYS EU)
Change the piston and check the cylinder. x (All 200/250/300 models)
Change the connecting rod, conrod bearing and crank pin. x
Check the transmission and shift mechanism. x
Change all engine bearings. x

S10N: Once after 10 operating hours
S40A: Every 40 operating hours
S80A: Every 80 operating hours/every 40 operating hours when used for motorsports
J1A: Annually

• •

• • •

• •

• •

• •

•

•

•

•

•

•

•

•

•

TUNING THE CHASSIS 36

9.1Checking the basic chassis setting with the rider's weight

Info

When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

– For optimal motorcycle riding characteristics and to avoid damage to forks, shock

absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.

– As delivered, KTM offroad motorcycles are adjusted for a standard rider weight

(with full protective clothing).
Guideline

Standard rider weight 75… 85 kg (165… 187 lb.)

– If the rider's weight is above or below the standard range, the basic setting of the

suspension components must be adjusted accordingly.

– Small weight differences can be compensated by adjusting the spring preload, but

in the case of large weight differences, the springs must be replaced.

401030-01

9.2Compression damping of shock absorber

The compression damping 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-speed setting, for example, affects the compression when landing after a jump: the rear wheel suspension compresses more
quickly.
The low-speed setting, for example, affects the compression when riding over long ground swells: the rear wheel suspension com­presses more slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.

9.3Adjusting the high-speed compression damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop

will be glad to help.)

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

– Turn adjusting screw  all the way clockwise using a socket wrench.

B00793-10

Info

Do not loosen nut !

– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline

(All 125/200 models)

Compression damping, high-speed

Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Full payload 1.25 turns

TUNING THE CHASSIS 37

(All 250/300 models)

Compression damping, high-speed

Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Full payload 1.25 turns

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

9.4Adjusting the low-speed compression damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop

will be glad to help.)

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

B00794-10

– Turn adjusting screw  clockwise with a screwdriver to the last click.

Info

Do not loosen nut !

– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline

(All 125/200 models)

Compression damping, low-speed

Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Full payload 15 clicks

(All 250/300 models)

Compression damping, low-speed

Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Full payload 15 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

9.5Adjusting the rebound damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop

will be glad to help.)

TUNING THE CHASSIS 38

00AA

00AA

0

0

BB

– Turn adjusting screw  clockwise with a screwdriver to the last click.

Info

Do not loosen nut !

– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline

(All 125/200 models)

B00792-10

Rebound damping

Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Sport 22 clicks

(All 250/300 models)

Rebound damping

Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Full payload 22 clicks

9.6Measuring the sag of the unloaded rear wheel

– Raise the motorcycle with the lift stand. ( p. 44)
– Measure the distance – as vertical as possible – between the rear axle and a fixed

point, for example, a mark on the side cover.

– Note down the value as dimension .
– Remove the motorcycle from the lift stand. ( p. 44)

400988-10

9.7Checking the static sag of the shock absorber

– Measure distance  of the unloaded rear wheel. ( p. 38)
– Hold the motorcycle upright with the aid of an assistant.
– Measure the distance between the rear axle and the fixed point again.
– Note down the value as dimension .

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

400989-10

Info

The static sag is the difference between measurements  and .

– Check the static sag.

(All 125/200 models)

Static sag 33… 35 mm (1.3… 1.38 in)

(All 250/300 models)

Static sag 33… 35 mm (1.3… 1.38 in)

» If the static sag is less or more than the specified value:

–

Adjust the spring preload of the shock absorber. x ( p. 39)

TUNING THE CHASSIS 39

00AA

0

0

CC

9.8Checking the riding sag of the shock absorber

– Measure distance  of the unloaded rear wheel. ( p. 38)
– With another person holding the motorcycle, the rider, wearing full protective cloth-

ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.

The rear wheel suspension levels out.

– Another person now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension .

Info

The riding sag is the difference between measurements  and .

– Check the riding sag.

Guideline

(All 125/200 models)

Riding sag 105… 115 mm (4.13… 4.53 in)

(All 250/300 models)

Riding sag 105… 115 mm (4.13… 4.53 in)

400990-10

9.9Adjusting the spring preload of the shock absorber x

» If the riding sag differs from the specified measurement:

–

Adjust the riding sag. x ( p. 40)

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop

will be glad to help.)

Info

Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

–

Remove the shock absorber. x ( p. 54)

– After removing the shock absorber, clean it thoroughly.
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.

Hook wrench (T106S)

– Measure the overall spring length when not under tension.
– Tighten the spring by turning adjusting ring  to measurement .

Guideline

(All 125/200 models)

Spring preload

Comfort 6 mm (0.24 in)
Standard 6 mm (0.24 in)
Sport 6 mm (0.24 in)
Full payload 7 mm (0.28 in)

401026-10

(All 250/300 models)

Spring preload

Comfort 7 mm (0.28 in)
Standard 7 mm (0.28 in)
Sport 7 mm (0.28 in)
Full payload 8 mm (0.31 in)

Info

Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.

TUNING THE CHASSIS 40

– Tighten screw .

Guideline

Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)

–

Install the shock absorber. x ( p. 54)

9.10Adjusting the riding sag x

–

Remove the shock absorber. x ( p. 54)

– After removing the shock absorber, clean it thoroughly.
– Choose and mount a suitable spring.

Guideline

(All 125/200 models)

Spring rate

B00292-10

Weight of rider: 65… 75 kg
(143… 165 lb.)

Weight of rider: 75… 85 kg
(165… 187 lb.)

Weight of rider: 85… 95 kg
(187… 209 lb.)

(All 250/300 models)

Spring rate

Weight of rider: 65… 75 kg
(143… 165 lb.)

Weight of rider: 75… 85 kg
(165… 187 lb.)

Weight of rider: 85… 95 kg
(187… 209 lb.)

63 N/mm (360 lb/in)

66 N/mm (377 lb/in)

69 N/mm (394 lb/in)

66 N/mm (377 lb/in)

69 N/mm (394 lb/in)

72 N/mm (411 lb/in)

Info

The spring rate is shown on the outside of the spring.

–

Install the shock absorber. x ( p. 54)

– Check the static sag of the shock absorber. ( p. 38)
– Check the riding sag of the shock absorber. ( p. 39)
– Adjust the rebound damping of the shock absorber. ( p. 37)

9.11Checking the basic setting of the fork

Info

For various reasons, no exact riding sag can be determined for the forks.

– As with the shock absorber, smaller differences in the rider's weight can be com-

pensated by the spring preload.

– However, if the fork is often overloaded (hard end stop on compression), harder

springs must be fit to avoid damage to the fork and frame.

401000-01

TUNING THE CHASSIS 41

9.12Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

– Remove protection covers .
– Turn adjusting screws  clockwise all the way.

Info

Adjusting screws  are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

100020-10

(All 125/200 models)

Compression damping

Comfort 24 clicks
Standard 22 clicks
Sport 20 clicks
Full payload 20 clicks

(All 250/300 models)

Compression damping

Comfort 24 clicks
Standard 22 clicks
Sport 20 clicks
Full payload 20 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

– Mount protection covers .

9.13Adjusting the rebound damping of the fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screws  clockwise all the way.

Info

Adjusting screws  are located at the top end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

(All 125/200 models)

800017-10

Rebound damping

Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Full payload 18 clicks

(All 250/300 models)

Rebound damping

Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Full payload 18 clicks

TUNING THE CHASSIS 42

00BB 00BB

0

0

AA 00AA

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

9.14Adjusting the spring preload of the fork

– Turn the adjusting screws counterclockwise all the way.

Info

Make the same adjustment on both fork legs.

– Turn back clockwise by the number of turns corresponding to the fork type.

Guideline

(All 125/200 models)

Spring preload - Preload Adjuster

B00795-01

(All 250/300 models)

Comfort 1 turn
Standard 2 turns
Sport 2 turns
Full payload 4 turns

Spring preload - Preload Adjuster

Comfort 1 turn
Standard 2 turns
Sport 2 turns
Full payload 4 turns

Info

Turn clockwise to increase spring preload; turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.

9.15Handlebar position

On the upper triple clamp, there are two holes a distance of  apart.

Hole distance A 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of  from the center.

Hole distance B 3.5 mm (0.138 in)

The handlebar can be mounted in four different positions. In this way, the handlebar
can be mounted in the position that is most comfortable for the rider.

400223-11

9.16Adjusting the handlebar position x

Warning

Danger of accidents Handlebar breakage.

– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-

bar.

TUNING THE CHASSIS 43

0022

0

0

11

0

0

22

0

0

11

– Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it

to one side.

Info

Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.

– Remove screws . Remove the handlebar support.

400223-10

– Place the handlebar support in the required position. Mount and tighten screws .

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Info

Position the left and right handlebar supports evenly.

– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Mount and tighten screws .

Guideline

Screw, handlebar clamp M8 20 Nm

Loctite®243™

(14.8 lbf ft)

SERVICE WORK ON THE CHASSIS 44

10.1Raising the motorcycle with the lift stand

(All 125/200 models)

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

B00796-01

The wheels must no longer touch the ground.

– Secure the motorcycle against falling over.

(All 250/300 models)

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

– Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

B00803-10

The wheels must no longer touch the ground.

– Secure the motorcycle against falling over.

10.2Removing the motorcycle from the lift stand

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

(All 125/200 models)

– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, press side stand  to the ground with your foot and

lean the motorcycle on it.

10.3Bleeding the fork legs

Info

When you are riding, the side stand must be folded up and secured with
the rubber band.

B00789-10

(All 250/300 models)

– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, press side stand  to the ground with your foot and

lean the motorcycle on it.

Info

When you are riding, the side stand must be folded up and secured with
the rubber band.

B00802-10

– Raise the motorcycle with the lift stand. ( p. 44)

SERVICE WORK ON THE CHASSIS 45

(All EXC models)

– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.

303391-10

(XC-W)

– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.

– Remove the motorcycle from the lift stand. ( p. 44)

303637-10

10.4Cleaning the dust boots of the fork legs

– Raise the motorcycle with the lift stand. ( p. 44)
– Loosen the fork protection. ( p. 45)
– Push dust boots  of both fork legs downwards.

10.5Loosening the fork protection

B00797-10

Info

The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the

brake discs.
– Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

– Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray ( p. 129)

– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 46)
– Remove the motorcycle from the lift stand. ( p. 44)

– Remove screws  and take off the clamp.
– Remove screws  on the left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.

B00800-10

SERVICE WORK ON THE CHASSIS 46

10.6Positioning the fork protection

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Position the brake line. Position the clamp and mount and tighten screws .
– Position the fork protection on the right fork leg. Mount and tighten the screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B00800-11

10.7Removing the fork legs x

(All EXC models)

– Remove the headlight mask with the headlight. ( p. 85)

(XC-W)

– Remove the start number plate. ( p. 53)

–

Remove the front wheel. x ( p. 78)

– Remove screws  and take off the clamp.
– Remove cable binder .
– Remove screws  and take off the brake caliper.
– Hang the brake caliper and the brake line loosely to the side.

10.8Installing the fork legs x

B00798-10

(EXC EU/AUS, XC‑W)

– Loosen screws . Remove the fork leg on the left.
– Loosen screws . Remove the fork leg on the right.

B00799-10

(EXC SIX DAYS)

– Loosen screws . Remove the fork leg on the left.
– Loosen screws . Remove the fork leg on the right.

B00804-10

(All EXC models)

– Position the fork legs.

303637-10

Info

The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws  toward the front.

SERVICE WORK ON THE CHASSIS 47

(XC-W)

– Position the fork legs.

Info

The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws  toward the front.

303391-10

(EXC EU/AUS, XC‑W)

– Tighten screws .

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Tighten screws .

Guideline

B00799-11

(EXC SIX DAYS)

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

– Tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

B00804-11

B00798-11

10.9Removing the fork protector x

– Tighten screws .

Guideline

Screw, bottom triple clamp M8 12 Nm

(8.9 lbf ft)

– Position the brake caliper and mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

Loctite®243™

(18.4 lbf ft)

– Mount cable binder .
– Position the brake line and wiring harness. Put the clamp on and mount and

tighten screws .

–

Install the front wheel. x ( p. 78)

(All EXC models)

– Refit the headlight mask with the headlight. ( p. 86)

(XC-W)

– Install the start number plate. ( p. 53)

–

Remove the fork legs. x ( p. 46)

– Remove screws  on the left fork leg. Lift off the fork protector.
– Remove the screws on the right fork leg. Lift off the fork protector.

B00801-10

SERVICE WORK ON THE CHASSIS 48

10.10Installing the fork protector x

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Position the fork protection on the right fork leg. Mount and tighten the screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–

Install the fork legs. x ( p. 46)

B00801-10

10.11Removing the lower triple clamp x (EXC EU/AUS, XC‑W)

–

Remove the fork legs. x ( p. 46)

– Remove the front fender. ( p. 54)
– Remove the handlebar cushion.
– Remove screw . Loosen screw . Take off the upper triple clamp with the han-

dlebar and set it aside.

Info

Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.

B00805-10

– Remove O-ring . Remove protective ring .
– Take out the lower triple clamp with the steering stem.
– Take out the upper steering head bearing.

B00806-10

10.12Removing the lower triple clamp x (EXC SIX DAYS)

–

Remove the fork legs. x ( p. 46)

– Remove the front fender. ( p. 54)
– Remove the handlebar cushion.
– Remove screw . Release screw , take off the top triple clamp with the handle-

bar, and place it on one side.

Info

Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.

B00807-10

B00808-10

– Remove O-ring . Remove protective ring .
– Take out the lower triple clamp with the steering stem.
– Take out the upper steering head bearing.

SERVICE WORK ON THE CHASSIS 49

0022
0011

10.13Installing the lower triple clamp x (EXC EU/AUS, XC‑W)

– Clean the bearing and sealing elements, check for damage, and grease.

High viscosity grease ( p. 128)

– Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

– Check whether the top steering head seal  is correctly positioned.
– Push on protective ring .

500151-10

– Position the upper triple clamp with the steering.
– Position the clutch line and wiring harness.
– Mount screw  but do not tighten yet.

B00805-11

– Position the fork legs.

Info

The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws  toward the front.

B00809-10

– Tighten screws .

Guideline

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

B00799-12

– Tighten screw .

Guideline

Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

B00810-10

SERVICE WORK ON THE CHASSIS 50

0022
0011

0033

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

(14.8 lbf ft)

B00810-11

– Tighten screws .

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

B00799-13

– Position the brake caliper. Mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

Loctite®243™

– Mount cable binder .
– Position the brake line, wiring harness and clamp. Mount and tighten screws .
– Install the front fender. ( p. 54)

B00798-12

10.14Installing the lower triple clamp x (EXC SIX DAYS)

– Mount the handlebar cushion.

(EXC EU/AUS)

– Refit the headlight mask with the headlight. ( p. 86)

(XC-W)

–

Install the start number plate. ( p. 53)

–

Install the front wheel. x ( p. 78)

– 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. 52)

– Clean the bearing and sealing elements, check for damage, and grease.

High viscosity grease ( p. 128)

– Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

– Check whether the top steering head seal  is correctly positioned.
– Slide on protective ring  and O-ring .

303408-01

SERVICE WORK ON THE CHASSIS 51

– Position the upper triple clamp with the steering.
– Mount screw  but do not tighten yet.
– Position the clutch line and wiring harness.

B00807-11

– Position the fork legs.

Info

The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws  toward the front.

B00811-10

– Tighten screws .

Guideline

Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)

B00804-12

B00811-11

B00811-12

– Tighten screw .

Guideline

Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

– Tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

Loctite®243™

(12.5 lbf ft)

– Tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

B00804-13

SERVICE WORK ON THE CHASSIS 52

– Position the brake caliper. Mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

– Mount cable binder .
– Position the brake line, wiring harness and clamp. Mount and tighten screws .
– Install the front fender. ( p. 54)

B00798-13

– Mount the handlebar cushion.
– Refit the headlight mask with the headlight. ( p. 86)

–

Install the front wheel. x ( p. 78)

– 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. 52)

10.15Checking the play of the steering head bearing

Warning

Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.

– Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)

Loctite®243™

Info

If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam­aged over time.

– Raise the motorcycle with the lift stand. ( p. 44)
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

–

Adjust the play of the steering head bearing. x ( p. 52)

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

The handlebar must be able to move easily over the entire steering range. There

400738-11

10.16Adjusting the play of the steering head bearing x

should be no perceptible detent positions.

» If detent positions are noticeable:

–

Adjust the play of the steering head bearing. x ( p. 52)

– Check the steering head bearing and replace if required.

– Remove the motorcycle from the lift stand. ( p. 44)

– Raise the motorcycle with the lift stand. ( p. 44)
(EXC EU/AUS, XC‑W)

– Loosen screws  and .
– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 12 Nm

(8.9 lbf ft)

B00812-10

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Tighten screws .

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

(14.8 lbf ft)

SERVICE WORK ON THE CHASSIS 53

(EXC SIX DAYS)

– Loosen screws . Remove screw .
– Loosen and retighten screw .

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.

B00813-10

10.17Greasing the steering head bearing x

– Tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

(12.5 lbf ft)

– Check the play of the steering head bearing. ( p. 52)

(EXC EU/AUS, XC‑W)

–

Remove the lower triple clamp. x ( p. 48)

–

Install the lower triple clamp. x ( p. 49)

(EXC SIX DAYS)

–

Remove the lower triple clamp. x ( p. 48)

–

Install the lower triple clamp. x ( p. 50)

(12.5 lbf ft)

Loctite®243™

800010-10

10.18Removing the start number plate (XC-W)

500123-10

10.19Installing the start number plate (XC-W)

– Remove screw  and take off the clamp.
– Remove screw . Remove the start number plate.

– Position the start number plate. Mount and tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

Ensure that the holding lugs engage in the fender.

– Position the brake line. Put on the clamp and mount and tighten screw .

500123-11

SERVICE WORK ON THE CHASSIS 54

10.20Removing the front fender

– Remove screws . Remove the front fender.
– Make sure the spacers remain in place.

B00814-10

10.21Installing the front fender

– Ensure that the spacers are mounted in the fender.
– Position the front fender. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

Make sure the holding lugs engage in the start number plate.

B00814-10

10.22Removing the shock absorber x

B00815-10

B00816-10

– Raise the motorcycle with the lift stand. ( p. 44)

(All 125/200 models)

– Remove screw  and lower the rear wheel with the swing arm as far as possible

without blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw , push splash protector  to the side, and remove the shock

absorber.

(All 250/300 models)

– Remove screw  and lower the rear wheel with the swing arm as far as possible

without blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw , push splash protector  to the side, and remove the shock

absorber.

10.23Installing the shock absorber x

B00815-11

(All 125/200 models)

– Push splash protector  to the side and position the shock absorber. Mount

and tighten screw .
Guideline

Screw, top shock
absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

– Mount and tighten screw .

Guideline

Screw, bottom shock
absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

SERVICE WORK ON THE CHASSIS 55

Info

The heim joint for the shock absorber at the swing arm is Teflon
coated. It must not be lubricated with grease or with other lubricants.
Lubricants dissolve the Teflon coating, thereby drastically reducing the
service life.

(All 250/300 models)

– Push splash protector  to the side and position the shock absorber. Mount

and tighten screw .
Guideline

B00816-11

Screw, top shock
absorber

– Mount and tighten screw .

Guideline

Screw, bottom shock
absorber

Info

The heim joint for the shock absorber at the swing arm is Teflon
coated. It must not be lubricated with grease or with other lubricants.
Lubricants dissolve the Teflon coating, thereby drastically reducing the
service life.

M12 80 Nm

(59 lbf ft)

M12 80 Nm

(59 lbf ft)

Loctite®2701

Loctite®2701

10.24Removing the seat

10.25Mounting the seat

– Remove the motorcycle from the lift stand. ( p. 44)

– Remove screw . Lift up the seat at the rear, pull it back and then remove from

above.

B00817-10

– Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear

and simultaneously push forward.

– Make sure that the seat is correctly locked in.

B00818-01

B00817-10

– Mount and tighten screw  of the seat fixation.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

SERVICE WORK ON THE CHASSIS 56

10.26Removing the air filter box lid

– Pull off the air filter box lid in area  sideways and remove it toward the front.

B00819-10

10.27Installing the air filter box lid

– Insert the air filter box lid into the rear area  and clip it into the front area .

B00819-11

10.28Removing the air filter x

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since 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., should be disposed of as stipulated in applicable regulations.

– Remove the air filter box lid. ( p. 56)
– Detach air filter holder  at the bottom and swing it to one side. Remove the air

filter with the air filter support.

– Remove the air filter from the air filter support.

B00820-10

10.29Installing the air filter x

– Mount the clean air filter onto the air filter support.
– Grease the air filter in area .

Long-life grease ( p. 128)

301262-10

SERVICE WORK ON THE CHASSIS 57

– Put in both parts together, position them, and fix them with air filter holder .

Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.

– Install the air filter box lid. ( p. 56)

B00820-10

10.30Cleaning the air filter and air filter box x

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

–

Remove the air filter. x ( p. 56)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 128)

Info

Only press the air filter to dry it; never wring it out.

– Oil the dry air filter with a high quality filter oil.

Oil for foam air filter ( p. 128)

B00325-01

– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.

–

Install the air filter. x ( p. 56)

10.31Removing the main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Remove screws .
– Pull the main silencer off of the manifold at the rubber sleeve .

B00821-10

SERVICE WORK ON THE CHASSIS 58

0033

0

0

22

0

0

44

0

0

11

10.32Installing the main silencer

– Mount the main silencer with rubber sleeve .
– Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B00821-11

10.33Changing the glass fiber yarn filling of the main silencer x

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

Info

Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.

10.34Removing the fuel tank x

– Remove the main silencer. ( p. 57)
– Remove screws . Pull out inner tube .
– Pull the glass fiber yarn filling  from the inner tube.
– Clean the parts that are to be reinstalled.
– Mount the new glass fiber yarn filling  on the inner tube.
– Slide outer tube  over the inner tube with the new glass fiber yarn filling.
– Mount and tighten all screws .
– Install the main silencer. ( p. 58)

401045-10

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con­tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

– Remove the seat. ( p. 55)

SERVICE WORK ON THE CHASSIS 59

– Turn handle  of the fuel tap to the OFF position. (Figure 601157-10 p. 21)
– Pull off the fuel hose.

Info

Remaining fuel may run out of the fuel hose.

– Remove screws  with the collar sleeve.

(All EXC models)

– Hang the horn and horn bracket to one side.

B00090-10

– Remove screw  with the rubber bushing.
– Remove the tube from the fuel tank vent line.

B00822-10

– Pull both spoilers off of the sides of the radiator bracket  and lift off the fuel

tank.

B00032-10

10.35Installing the fuel tank x

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

– Check the throttle cable routing. ( p. 65)
– Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
– Make sure that no cables are trapped or damaged.

B00032-01

SERVICE WORK ON THE CHASSIS 60

– Mount the fuel tank vent hose.
– Mount and tighten screw  with the rubber bushing.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

(All EXC models)

– Position the horn with the horn bracket.

B00822-11

– Mount and tighten screws  with the collar sleeve.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Connect the fuel hose.
– Mount the seat. ( p. 55)

B00090-11

10.36Checking the chain for dirt

– Check the chain for heavy soiling.

» If the chain is very dirty:

– Clean the chain. ( p. 60)

400678-01

10.37Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

The service life of the chain depends largely on its maintenance.

– Clean the chain regularly and then treat with chain spray.

Chain cleaner ( p. 128)
Off-road chain spray ( p. 128)

400725-01

SERVICE WORK ON THE CHASSIS 61

10.38Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces­sary.

– Raise the motorcycle with the lift stand. ( p. 44)
– Push the chain at the end of the chain sliding component upwards to measure

chain tension .

Info

The bottom chain section  must be taut.
When the chain guard is mounted, it must be possible to pull up the chain
at least to the point where it makes contact with chain guard .
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension 55… 58 mm (2.17… 2.28 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension. ( p. 63)

– Remove the motorcycle from the lift stand. ( p. 44)

101430-10

10.39Checking the chain, rear sprocket, engine sprocket and chain guide

– Raise the motorcycle with the lift stand. ( p. 44)
– Shift gear to neutral.
– Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket and engine sprocket are worn:

–

Change the rear sprocket or engine sprocket. x

Info

The engine sprocket, rear sprocket, and chain should always be
changed together.

400227-01

SERVICE WORK ON THE CHASSIS 62

1 2 3 16 17 18

00

0

BB

0

0

AA

– Pull on the upper part of the chain with the specified weight .

Guideline

Weight, chain wear measurement 10… 15 kg (22… 33 lb.)

– Measure the distance  of 18 chain links in the lower chain section.

Info

Chain wear is not always even; repeat this measurement at different chain
positions.

400987-10

Maximum distance  at the longest
chain section

» If the distance  is greater than the specified measurement:

–

Change the chain. x

Info

When you replace the chain, you should also change the rear
sprocket and engine sprocket.
New chains wear out faster on old, worn sprockets.

– Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding

guard:

–

Change the chain sliding guard. x

– Check the chain sliding guard for tightness.

» If the chain sliding guard is loose:

– Tighten the chain sliding guard.

Guideline

Screw, chain sliding
guard

272 mm (10.71 in)

M6 6 Nm

(4.4 lbf ft)

Loctite®243™

B00823-01

B00824-01

– Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding

piece:

–

Change the chain sliding piece. x

– Check the chain sliding piece for tightness.

» If the chain sliding piece is loose:

– Tighten the chain sliding piece.

Guideline

Screw, chain sliding piece M8 15 Nm

(11.1 lbf ft)

SERVICE WORK ON THE CHASSIS 63

– Check the chain guide for wear.

Info

Wear can be seen on the front of the chain guide.

» If the light part of the chain guide is worn:

–

Change the chain guide. x

400985-01

– Check the chain guide for tightness.

» If the chain guide is loose:

– Tighten the chain guide.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

– Remove the motorcycle from the lift stand. ( p. 44)

100865-10

10.40Adjusting the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces­sary.

– Raise the motorcycle with the lift stand. ( p. 44)
– Push the chain at the end of the chain sliding component upwards to measure

chain tension .

Info

The bottom chain section  must be taut.
When the chain guard is mounted, it must be possible to pull up the chain
at least to the point where it makes contact with chain guard .
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

101430-10

SERVICE WORK ON THE CHASSIS 64

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning adjusting screws  to the left and right.

Guideline

Chain tension 55… 58 mm (2.17… 2.28 in)
Turn adjusting screws  on the left and right so that the markings on the left

and right chain adjusters are in the same position relative to reference marks .
The rear wheel is then correctly aligned.

– Tighten nuts .
– Make sure that chain adjusters  are fitted correctly on adjusting screws .
– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary ratios with the same chain length.

B00825-10

– Remove the motorcycle from the lift stand. ( p. 44)

Chain adjusters  can be turned by 180°.

10.41Adjusting the chain guide x

400252-10

– Remove the nut of screw .
– Remove screws  and . Take off the chain guide.

Condition

Number of teeth: ≤ 44 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

– Mount the nut on screw  and tighten.

Guideline

Remaining nuts, chassis M6 10 Nm

(7.4 lbf ft)

Condition

Number of teeth: ≥ 45 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

– Mount the nut on screw  and tighten.

Guideline

Remaining nuts, chassis M6 10 Nm

(7.4 lbf ft)

SERVICE WORK ON THE CHASSIS 65

10.42Checking the frame x

– Check the frame for cracking and deformation.

» If the frame exhibits cracking or deformation due to a mechanical impact:

–

Change the frame. x

Info

A frame that has been damaged due to a mechanical impact must
always be changed. Repair of the frame is not authorized by KTM.

401347-01

10.43Checking the swingarm x

– Check the swingarm for damage, cracking, and deformation.

» If the swingarm shows signs of damage, cracking, or deformation:

–

Change the swingarm. x

Info

A damaged swingarm must always be changed. Repair of the
swingarm is not authorized by KTM.

401341-01

10.44Checking the throttle cable routing

B00826-01

–

Remove the fuel tank. x ( p. 58)

(All 125/200 models)

– Check the throttle cable routing.

The throttle cable must be routed to the carburetor on the left side of the
upper frame tube behind the handlebars.

» If the throttle cable is not routed as specified:

– Correct the throttle cable routing.

SERVICE WORK ON THE CHASSIS 66

(All 250/300 models)

– Check the throttle cable routing.

The throttle cable must be routed to the carburetor on the left side of the
upper frame tube behind the handlebars.

» If the throttle cable is not routed as specified:

– Correct the throttle cable routing.

B00827-01

10.45Checking the rubber grip

– Check the rubber grips on the handlebar for damage and wear and to ensure they

are firmly seated.
» If a rubber grip is damaged, worn, or loose:

– Change and secure the rubber grip.

401197-01

10.46Additionally securing the rubber grip

– Check the rubber grip. ( p. 66)
– Secure the rubber grip at two points using the securing wire.

Securing wire (54812016000)
Wire twister forceps (U6907854)

401198-01

10.47Adjusting the basic position of the clutch lever

(All 125/200 models)

– Adjust the basic setting of the clutch lever to your hand size by turning adjust-

Rubber grip adhesive (00062030051) ( p. 129)

The twisted wire ends face away from the hands and are bent toward the rub­ber grip.

ing screw .

B00001-11

Info

Turn the adjusting screw counterclockwise to increase the distance
between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

SERVICE WORK ON THE CHASSIS 67

(All 250/300 models)

– Adjust the basic setting of the clutch lever to your hand size by turning adjust-

ing screw .

Info

Turn the adjusting screw counterclockwise to decrease the distance
between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.

B00009-11

10.48Checking the fluid level of the hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining discs.

(All 125/200 models)

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-

– Remove screws .
– Remove cover  with membrane .
– Check the fluid level.

The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

tion.

400245-10

B00040-10

10.49Changing the hydraulic clutch fluid x

Fluid level under top edge of con-

4 mm (0.16 in)

tainer

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

Hydraulic fluid (15) ( p. 127)

– Position the cover with the membrane. Mount and tighten the screws.

(All 250/300 models)

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-

tion.

– Remove screws .
– Remove cover  with membrane .
– Check the fluid level.

Fluid level under top edge of con-

4 mm (0.16 in)

tainer

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

Brake fluid DOT 4 / DOT 5.1 ( p. 126)

– Position the cover with the membrane. Mount and tighten the screws.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

SERVICE WORK ON THE CHASSIS 68

(All 125/200 models)

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-

tion.

– Remove screws .
– Remove cover  with membrane .

400245-10

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Hydraulic fluid (15) ( p. 127)

–

On the slave cylinder, remove bleeder screw  and mount bleeding syringe .

B00041-10

– Inject the liquid into the system until it escapes from hole  of the master

cylinder without bubbles.

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
– Correct the fluid level of the hydraulic clutch.

Guideline

400247-10

Fluid level under top edge of con­tainer

– Position the cover with the membrane. Mount and tighten the screws.

(All 250/300 models)

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-

tion.

– Remove screws .
– Remove cover  with membrane .

4 mm (0.16 in)

B00040-10

303440-10

B00042-10

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 126)

– On the slave cylinder, remove bleeder screw  and mount bleeding syringe .

– Inject the liquid into the system until it escapes from hole  of the master

cylinder without bubbles.

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
– Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level under top edge of con-

4 mm (0.16 in)

tainer

– Position the cover with the membrane. Mount and tighten the screws.

BRAKES 69

11.1Checking free travel of hand brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due

to overheating. Adjust free travel on hand brake lever according to specifications.

(XC-W)

– Push the hand brake lever forwards and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– Adjust the basic position of the hand brake lever. ( p. 69)

400196-11

(All EXC models)

– Push the hand brake to the handlebar and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– Adjust the free travel of the hand brake lever. ( p. 69)

400196-13

11.2Adjusting the basic position of the hand brake lever (XC-W)

– Check the free travel of the hand brake lever. ( p. 69)
– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-

ing screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.

400196-12

The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

11.3Adjusting free travel of hand brake lever (All EXC models)

– Check the free travel of the hand brake lever. ( p. 69)
– Adjust the free travel of the hand brake lever with the adjustment screw .

Info

Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.

400196-12

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

BRAKES 70

A

A

11.4Checking the brake discs

Warning

Danger of accidents Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)

– Check the thickness of the front and rear brake discs at several places on the disc

to see if it conforms to measurement .

Info

Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Brake discs - wear limit

Front 2.5 mm (0.098 in)

400257-10

– Check the front and rear brake discs for damage, cracking and deformation.

Rear 3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

» If the brake disc exhibits damage, cracking or deformation:

– Change the brake disc.

11.5Checking the front brake fluid level

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .

» If the brake fluid is below the MIN marking:

–

Add front brake fluid. x ( p. 70)

B00070-10

11.6Adding front brake fluid x

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

BRAKES 71

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Add brake fluid to level .

Guideline

Dimension  (brake fluid level below
top edge of container)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 126)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

11.7Checking the front brake linings

Warning

Danger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings. x ( p. 72)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

–

Change the front brake linings. x ( p. 72)

100394-10

BRAKES 72

11.8Changing the front brake linings x

Warning

Danger of accident Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Press the brake caliper onto the brake disc by hand in order to push back the brake

pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir,
using suction to remove it if it does.

Info

100395-10

– Remove locking split pins , withdraw bolt , and take out the brake linings.
– Clean the brake caliper and brake caliper support.

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

100396-10

BRAKES 73

0

0

77

0

0

66

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

100397-01

– Fit the brake linings, insert the bolt, and mount the locking split pins.
– Operate the hand brake lever several times until the brake linings are lying correctly

against on the brake disc and there is a pressure point.

100398-10

– Correct the brake fluid quantity to level .

Guideline

Dimension  (brake fluid level below
top edge of container)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 126)

– Position the cover with the membrane. Mount and tighten the screws.

100399-10

11.9Checking the free travel of foot brake lever

Info

Clean up overflowed or spilt brake fluid immediately with water.

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to

overheating. Adjust free travel on foot brake lever according to specifications.

– Disconnect spring .
– Move the foot brake lever back and forth between the end stop and the contact to

the foot brake cylinder piston and check free travel .
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the foot brake lever. x ( p. 73)

B00028-10

– Reconnect spring .

11.10Adjusting the basic position of the foot brake lever x

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to

overheating. Adjust free travel on foot brake lever according to specifications.

BRAKES 74

– Disconnect spring .
– Loosen nut  and, with push rod , turn it back until you have maximum free

travel.

– To adjust the basic position of the foot brake lever individually, loosen nut  and

turn screw  accordingly.

Info

The range of adjustment is limited.

B00828-10

– Turn push rod  accordingly until you have free travel . If necessary, adjust the

basic position of the foot brake lever.
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

– Hold screw  and tighten nut .

Guideline

Nut, foot brake lever stop M8 30 Nm

(22.1 lbf ft)

– Hold push rod  and tighten nut .

Guideline

Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)

– Reconnect spring .

11.11Checking the rear brake fluid level

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

– Stand the vehicle upright.
– Check the brake fluid level in the viewer .

» If an air bubble is visible in viewer :

–

Add brake fluid for the rear brake. x ( p. 74)

B00829-10

11.12Adding brake fluid for the rear brake x

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

BRAKES 75

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.
– Add brake fluid to level .

Brake fluid DOT 4 / DOT 5.1 ( p. 126)

– Mount the screw cap with the membrane and the O-ring.

Info

400233-10

11.13Checking the rear brake linings

Clean up overflowed or spilt brake fluid immediately with water.

Warning

Danger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings. x ( p. 76)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

–

Change the rear brake linings. x ( p. 76)

400238-10

11.14Removing the rear brake linings x

Warning

Danger of accident Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)

400236-10

– Press the brake caliper onto the brake disc by hand in order to push back the brake

piston.

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove locking split pins , withdraw bolt , and take out the brake linings.
– Clean the brake caliper and brake caliper support.

BRAKES 76

11.15Installing the rear brake linings x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 70)
– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500122-10

– Insert the brake linings, insert bolt , and mount locking split pins .

Info

Make sure that the decoupling plate  is mounted on the piston side of the
brake lining.

– Operate the foot brake lever several times until the brake linings are lying correctly

against the brake disc and there is a pressure point.

400237-10

11.16Changing the rear brake linings x

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

BRAKES 77

–

Remove the rear brake linings. x ( p. 75)

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Install the rear brake linings. x ( p. 76)

– Add brake fluid to level .

400233-10

Brake fluid DOT 4 / DOT 5.1 ( p. 126)

– Mount the screw cap with the membrane and the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

WHEELS, TIRES 78

12.1Removing the front wheel x

– Raise the motorcycle with the lift stand. ( p. 44)
– Press the brake caliper onto the brake disc by hand in order to push back the brake

pistons.

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

B00055-10

– Remove screw .
– Loosen screws .

500084-10

– Holding the 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 disc is not dam­aged.

500085-10

– Remove spacers .

500086-10

12.2Installing the front wheel x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

500086-11

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

–

Change the wheel bearing. x

– Clean and grease shaft seal rings  and bearing surface  of the spacers.

Long-life grease ( p. 128)

– Insert the spacers.

WHEELS, TIRES 79

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .

Guideline

Screw, front wheel spindle M24x1.5 45 Nm

(33.2 lbf ft)

– Operate the hand brake lever several times until the brake linings are lying correctly

against on the brake disc.

500084-11

12.3Removing the rear wheel x

– Remove the motorcycle from the lift stand. ( p. 44)
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Tighten screws .

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

– Raise the motorcycle with the lift stand. ( p. 44)
– Press the brake caliper onto the brake disc by hand in order to push back the brake

piston.

B00830-10

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove nut .
– Remove chain adjuster . Withdraw wheel spindle  only enough to allow the rear

wheel to be pushed forward.

– Push the rear wheel forward as far as possible. Remove the chain from the rear

sprocket.

– Holding the rear wheel, withdraw the wheel spindle. Take the 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 dam­aged.

– Remove spacers .

400260-11

12.4Installing the rear wheel x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

WHEELS, TIRES 80

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

–

Change the wheel bearing. x

– Clean and grease shaft seal rings  and bearing surface  of the spacers.

Long-life grease ( p. 128)

– Insert the spacers.

400260-10

– Lift the rear wheel into the swing arm, position it, and insert wheel spindle .
– Apply the chain.

B00831-10

– Position chain adjuster . Mount nut , but do not tighten it yet.
– Make sure that chain adjusters  are fitted correctly on adjusting screws .
– Check the chain tension. ( p. 61)
– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm (1.18 in))
enables different secondary ratios with the same chain length.
Chain adjusters  can be turned by 180°.

– Operate the foot brake lever several times until the brake linings are lying correctly

against the brake disc and there is a pressure point.

– Remove the motorcycle from the lift stand. ( p. 44)

B00825-11

12.5Checking the tire condition

Info

Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition and air pressure of the tires all have an important impact on the handling 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 surfaces.

– Check the front and rear tires for cuts, run-in objects and other damage.

» If the tire exhibits cuts, run-in objects or other damage:

– Change the tire.

– Check the depth of the tread.

400602-10

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum permissible depth:

WHEELS, TIRES 81

– Change the tire.

– Check the tire age.

Info

The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits indi­cate the week of manufacture and the last two digits the year of manufac­ture.
KTM recommends that the tires are changed at the latest after 5 years,
regardless of the actual state of wear.

» If the tire is older than five years:

– Change the tire.

12.6Checking the tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove the dust cap.
– Check the tire air pressure when the tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)

Tire air pressure, road (All EXC models)

Front 1.5 bar (22 psi)

400695-01

Rear 1.5 bar (22 psi)

» If the tire pressure does not meet specifications:

– Correct the tire pressure.

– Mount the dust cap.

12.7Checking the spoke tension

Warning

Danger of accidents Instable handling due to incorrect spoke tension.

– Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)

Info

A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

400694-01

– Briefly strike each spoke with the tip of a screwdriver.

Info

The tone frequency depends on the length of the spoke and the spoke diam­eter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.

You should hear a high note.

» If the spoke tension varies:

–

Correct the spoke tension. x

– Check the spoke torque.

WHEELS, TIRES 82

Guideline

Spoke nipple, front wheel M4.5 5… 6 Nm (3.7…

4.4 lbf ft)

Spoke nipple, rear wheel M5 5… 6 Nm (3.7…

4.4 lbf ft)

Torque wrench with various accessories in set (58429094000)

ELECTRICAL SYSTEM 83

13.1Removing the battery x (All 250/300 models)

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 55)
– Disconnect the negative (minus) cable  of the battery.
– Pull back the plus pole cover  and disconnect the positive (plus) cable of the bat-

tery.

– Detach rubber band  at the bottom.
– Lift the battery out.

500069-10

13.2Installing the battery x (All 250/300 models)

– Insert the battery into the battery compartment with the terminals facing to the

front.

– Attach rubber band .
– Connect the positive cable  and negative cable .

Guideline

– Slide positive terminal cover  over the positive terminal.
– Mount the seat. ( p. 55)

101394-10

Battery (YTX4L-BS) ( p. 119)

Screw, battery terminal M5 2.5 Nm

(1.84 lbf ft)

Info

Contact disks  must be mounted between battery terminals  and cable
sockets  with the claws facing up.

13.3Recharging the battery x (All 250/300 models)

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

ELECTRICAL SYSTEM 84

Warning

Environmental hazard The battery contains elements that are harmful to the environment.

– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.

Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 55)
– Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.

– Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat­tery.

Info

Never remove the lid .

400240-10

– Switch off the charger after charging. Disconnect the battery.

– Mount the seat. ( p. 55)

13.4Changing the main fuse (All 250/300 models)

Charge the battery with at most 10% of the capacity specified on the bat­tery .

Guideline

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the

motorcycle is not in use

Warning

Fire hazard The electrical system can be overloaded if the wrong fuses are used.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

3 months

Info

The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the filter box cover.

– Switch off all power consumers and switch off the engine.
– Remove the air filter box lid. ( p. 56)

ELECTRICAL SYSTEM 85

– Remove screw .

101395-10

– Lift rear fairing  slightly and pull starter relay  out of the bracket.

101396-10

– Remove the protection caps.
– Remove the faulty main fuse .

Info

A defective fuse is indicated by a burned-out fuse wire .
A reserve fuse  is located in the starter relay.

– Fit a new main fuse.

Fuse (58011109110)

B00832-10

– Check the functioning of the electrical equipment.

Tip

Insert the spare fuse so that it is available if needed.

– Fit the protection caps.
– Mount the starter relay onto the bracket and lay the cable.
– Position the rear fairing. Mount and tighten the screw.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Install the air filter box lid. ( p. 56)

13.5Removing the headlight mask with the headlight (All EXC models)

– Switch off all power consumers.
– Remove screw  and take off the clamp.
– Release rubber band . Slide the headlight mask up and swing it forward.

B00833-10

303402-10

– Disconnect the electrical plug-in connection  and take off the headlight mask

with the headlight.

ELECTRICAL SYSTEM 86

13.6Refitting the headlight mask with the headlight (All EXC models)

– Connect the electric plug connector .

303402-11

– Position the headlight mask and fix it with the rubber band .

Info

Ensure that the holding lugs engage in the fender.

– Position the brake line and wiring harness. Put on the clamp and mount and

tighten screw .

– Check the headlight setting. ( p. 87)

B00833-11

13.7Changing the headlight bulb (All EXC models)

Note

Damage to reflector Reduced luminance.

– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease

before mounting.

– Remove the headlight mask with the headlight. ( p. 85)
– Turn rubber cap  together with the underlying lamp socket counterclockwise all

the way and remove it.

– Pull lamp socket  of the parking light out of the reflector.

100861-10

–

Press headlight bulb  lightly into the lamp socket, turn it counterclockwise and
pull it out.

– Insert the new headlight bulb.

Headlight (S2 / socket BA20d) ( p. 120)

– Insert the rubber cap with the lamp socket into the reflector and turn it clockwise

all the way.

100862-10

Info

Ensure that the O-ring  is seated properly.

– Insert the lamp socket of the parking light into the reflector.
– Refit the headlight mask with the headlight. ( p. 86)

ELECTRICAL SYSTEM 87

00AA

0

0

BB

13.8Checking the headlight setting (All EXC models)

– Position the vehicle upright on a horizontal surface in front of a light wall and make

a mark at the height of the center of the low beam headlight.

– Make another mark a distance  under the first mark.

Guideline

Distance  5 cm (2 in)

– Position the vehicle vertically a distance  away from the wall.

Guideline

400726-10

13.9Adjusting the headlight range (All EXC models)

Distance  5 m (16 ft)

– The rider now sits down on the motorcycle.
– Switch on the low beam.
– Check the headlight setting.

The boundary between light and dark must be exactly on the lower mark for an
operational motorcycle with a rider.

» If the light-dark border does not meet specifications:

– Adjust the headlight range. ( p. 87)

– Check the headlight setting. ( p. 87)
– Loosen screw .
– Adjust the headlight range by moving the headlight.

Guideline

The boundary between light and dark must be exactly on the lower mark for an
operational motorcycle with a rider (to prepare the mark, see: Checking the head­light setting).

301251-10

13.10Changing the speedometer battery

100859-10

Info

The headlight range may need to be corrected if luggage is carried on the
vehicle.

– Tighten screw .

(All EXC models)

– Remove the headlight mask with the headlight. ( p. 85)

(XC-W)

– Remove the start number plate. ( p. 53)
– Remove screws .
– Pull the speedometer up and out of the holder.

– Turn locking cap  counterclockwise all the way using a coin and remove it.
– Remove speedometer battery .
– Insert the new battery with the lettering facing up.

Speedometer battery (CR 2430)

– Check that the O-Ring of the locking cap is seated properly.

100860-10

ELECTRICAL SYSTEM 88

– Position locking cap  and turn it clockwise all the way using a coin.
– Press any button on the speedometer.

The speedometer is activated.

– Position the speedometer in the holder.
– Mount and tighten the screws with the washers.

(All EXC models)

– Refit the headlight mask with the headlight. ( p. 86)

100864-10

(XC-W)

– Install the start number plate. ( p. 53)
– Set kilometers or miles. ( p. 15)
– Adjust the speedometer functions. ( p. 16)
– Set the clock. ( p. 16)

COOLING SYSTEM 89

14.1Cooling system

(All 125/200 models)

Water pump  in the engine circulates the coolant.

The pressure resulting from the warming of the cooling system is regulated by a

valve in radiator cap . This ensures that operating the vehicle at the specified

coolant temperature will not result in a risk of malfunctions.

120 °C (248 °F)

Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the

B00834-10

B00835-10

cooling effect.

(All 250/300 models)

Water pump  in the engine circulates the coolant.

The pressure resulting from the warming of the cooling system is regulated by a

valve in radiator cap . This ensures that operating the vehicle at the specified

coolant temperature will not result in a risk of malfunctions.

120 °C (248 °F)

Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the

cooling effect.

14.2Checking the antifreeze and coolant level

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the

engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning Coolant is poisonous and a health hazard.

– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition

The engine is cold.

– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant antifreeze.

−25… −45 °C (−13… −49 °F)

» If the coolant antifreeze does not meet specifications:

– Correct the coolant antifreeze.

– Check the coolant level in the radiator.

400243-10

Coolant level  above the radiator fins. 10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 126)

Alternative 2

Coolant (mixed ready to use) ( p. 126)

– Mount the radiator cap.

COOLING SYSTEM 90

14.3Checking the coolant level

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the

engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning Coolant is poisonous and a health hazard.

– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition

The engine is cold.

– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.

Coolant level  above the radiator fins. 10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternative 1

400243-10

Coolant ( p. 126)

Alternative 2

Coolant (mixed ready to use) ( p. 126)

– Mount the radiator cap.

14.4Draining the coolant x

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the

engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning Coolant is poisonous and a health hazard.

– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition

The engine is cold.

– Position the motorcycle upright.
– Place a suitable container under the water pump cover.

(All 125/200 models)

– Remove screw . Remove radiator cap .

– Completely drain the coolant.

– Mount screw  with a new seal ring and tighten it.

Guideline

Drain plug, water pump cover M10x1 15 Nm

(11.1 lbf ft)

B00834-11

COOLING SYSTEM 91

00AA

(All 250/300 models)

– Remove screw . Remove radiator cap .

– Completely drain the coolant.

– Mount screw  with a new seal ring and tighten it.

Guideline

Drain plug, water pump cover M10x1 15 Nm

(11.1 lbf ft)

B00835-11

14.5Refilling with coolant x

Warning

Danger of poisoning Coolant is poisonous and a health hazard.

– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

(All 125/200 models)

– Make sure that screw  is tightened.

– Stand the motorcycle upright.

– Fill the radiator completely with coolant.

B00071-10

B00091-10

B00072-10

Coolant 1.2 l (1.3 qt.) Coolant ( p. 126)

Coolant (mixed ready to use)

( p. 126)

– Loosen screw  until coolant that does not contain any bubbles escapes.

Replace and retighten screw .
Guideline

Bleeder screw, cylinder head M6 10 Nm

(7.4 lbf ft)

(All 250/300 models)

– Make sure that screw  is tightened.

– Stand the motorcycle upright.

– Fill the radiator completely with coolant.

Coolant 1.2 l (1.3 qt.) Coolant ( p. 126)

Coolant (mixed ready to use)

( p. 126)

– Position the vehicle as shown and secure it against rolling away. A height differ-

ence of  must be reached.
Guideline

Height difference  75 cm (29.5 in)

400677-10

Info

To ensure that all of the air can escape from the cooling system, the
front of the vehicle must be jacked up. A poorly bled cooling system is
less effective at cooling and may result in overheating of the engine.

– Place the vehicle back on a level surface.

COOLING SYSTEM 92

– Fill the radiator completely with coolant.
– Mount radiator cap .
– Run the engine until it is warm.
– Check the coolant level. ( p. 90)

B00836-10

TUNING THE ENGINE 93

15.1Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Move 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 play does not meet specifications:

–

Adjust the play in the throttle cable. x ( p. 93)

Danger

400192-10

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

Danger of poisoning Exhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

steering range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the play in the throttle cable. x ( p. 93)

15.2Adjusting the play in the throttle cable x

800216-10

15.3Carburetor

–

Remove the fuel tank. x ( p. 58)

– Expose the throttle cable.
– Move the handlebar to the straight-ahead position.
– Push back sleeve .
– Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster .
– Push back sleeve .
– Loosen nut .
– Turn barrel adjuster  until throttle cable play  exists at the bottom throttle

cable sleeve.

Guideline

Play in throttle cable 3… 5 mm (0.12… 0.2 in)

– Tighten nut .
– Slide on sleeves  and .
– Route the throttle cable and fasten it.

–

Install the fuel tank. x ( p. 59)

– Check the throttle grip for smooth operation.

The idle setting of the carburetor has a big influence on the starting behavior, stable
idling and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.

B00048-11

Info

The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.

The factory setting for the carburetor is set for the following values.

Elevation above sea level 500 m (1,640 ft)
Ambient temperature 20 °C (68 °F)

Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 127)

The idle speed is adjusted with adjusting screw .
The idle mixture is adjusted with the idle air adjusting screw .

TUNING THE ENGINE 94

000DD

0

0

CC

0

0

BB
0

0

AA

Idle air range A

Operation with the throttle slide closed. This range is influenced by adjusting screw 
and the idle air adjusting screw .

Transition range B

Behavior of the engine when the throttle slide is being opened. This range is influenced
by the idling jet and by the form of the throttle slide.
If the engine sputters and smokes heavily when it starts despite a good idle and part­load setting, and if it abruptly reaches full power at a high rpm, the carburetor setting
is too rich, or the float level is too high or the float needle valve is leaky.

500282-01

Part-load range C

Operation with the throttle slide partially open. This range is influenced by the jet
needle (form and position). The idle setting influences the engine tuning in the lower
range, and the main jet influences the engine tuning in the upper range.
If the engine stutters when accelerating with a partially open throttle slide, the jet nee­dle must be lowered by one notch. If the engine knocks when accelerating at the full
power rpm range, the jet needle must be raised. If the above events occur on idle or
just above it, the idle system must be set to a leaner setting if the engine is stuttering
or to a richer setting if the engine is knocking.

Full-load range D

Operation with the throttle slide open (full throttle). This range is influenced by the
main jet and jet needle.
If the insulator of a new spark plug is very light or white after a brief ride at full throt­tle, or if the engine knocks, a larger main jet needs to be used. If the insulator is dark
brown or sooty, a smaller main jet needs to be used.

15.4Carburetor - adjusting the idle speed x

B00048-11

– Screw in idle air adjusting screw  all the way and turn it to the specified basic

position.

Guideline

Idle air adjusting screw (125 EXC EU, 125 EXC SIX DAYS EU)

Open 2.75 turns

Idle air adjusting screw (XC-W)

Open 2.0 turns

Idle air adjusting screw (200 EXC EU)

Open 1.5 turns

Idle air adjusting screw (200 EXC AUS)

Open 1.0 turn

Idle air adjusting screw (250/300 EXC AUS)

Open 3.5 turns

Idle air adjusting screw (250 EXC EU, 250 EXC SIX DAYS EU)

Open 1.5 turns

Idle air adjusting screw (300 EXC EU, 300 EXC SIX DAYS EU)

Open 1.75 turns

– Run the engine until warm.

Guideline

Warm-up time ≥ 5 min

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may

result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Adjust the idle speed with adjusting screw .

Guideline

Idle speed 1,400… 1,500 rpm

TUNING THE ENGINE 95

– Turn idle air adjusting screw  slowly in a clockwise direction until the idle speed

begins to fall.
– Note the position and turn the idle air adjusting screw slowly counterclockwise until

the idle speed falls again.
– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a large engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of
engine speed, you need to install a smaller idling jet.
After changing the idling jet, repeat the adjusting steps from the beginning.
Following extreme air temperature or altitude changes, adjust the idle speed
again.

15.5Emptying the carburetor float chamber x

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con­tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Info

Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.

– Turn handle  of the fuel tap to the OFF position.

No more fuel flows from the tank to the carburetor.

– Place a cloth beneath the carburetor to soak up emerging fuel.
– Remove plug .
– Completely drain the fuel.
– Mount and tighten the plug.

B00047-10

TUNING THE ENGINE 96

000AA

00011

15.6Checking the basic position of the shift lever

– Sit on the vehicle in the riding position and determine the distance  between the

upper edge of your boot and the shift lever.

Distance between shift lever and upper
edge of boot

» If the distance does not meet specifications:

400692-10

15.7Adjusting the basic position of the shift lever x

– Remove screw  and remove shift lever .

B00065-10

– Clean gear teeth  of the shift lever and shift shaft.
– Mount the shift lever on the shift shaft in the required position and engage the

gearing.

10… 20 mm (0.39… 0.79 in)

–

Adjust the basic position of the shift lever. x ( p. 96)

Info

The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle compo­nents during the shift procedure.

B00066-10

– Mount and tighten the screw.

Guideline

Screw, shift lever M6 14 Nm

Loctite®243™

(10.3 lbf ft)

15.8Engine characteristic - auxiliary spring (All 250/300 models)

The auxiliary spring is located on the right side of the engine below the water pump
cover.

Possible states

• Auxiliary spring with yellow marking – Auxiliary spring mounted at the factory with

medium tuning (standard) for good rideability.

• Auxiliary spring with green marking – Auxiliary spring contained in the separate

enclosure for softer performance.

• Auxiliary spring with red marking – Auxiliary spring contained in the separate

enclosure for more aggressive performance.

B00056-10

The engine characteristic can be influenced by different spring strengths of the auxil­iary spring .

15.9Engine characteristic - adjusting the auxiliary spring x (All 250/300 models)

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-

nents to cool down before starting work on them.

– Tilt the motorcycle approx. 45º to the left and secure it in this position to prevent it

from falling over.

TUNING THE ENGINE 97

00044

0033

0

0

55

0

0

22

– Remove screws .

B00057-10

– Take locking cap , adjusting spring , auxiliary spring  and spring insert  out

of the clutch cover.
– Pull both springs off of the spring insert.

B00056-11

– Mount the desired auxiliary spring  and adjusting spring  and slide them into

the clutch cover together.

B00058-10

Auxiliary spring with yellow marking (54637072300)
Auxiliary spring with green marking (54837072100)
Auxiliary spring with red marking (54837072000)

The cut-out of spring insert  engages in the angle lever.

Info

Under no circumstances should screw  be turned as this would have a
negative effect on the engine characteristic.

– Check the O-ring in the locking cap.
– Position the locking cap.
– Mount and tighten the screws.

Guideline

Screw, exhaust control cover M5 6 Nm (4.4 lbf ft)

SERVICE WORK ON THE ENGINE 98

16.1Checking the gear oil level

Info

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

– Stand the motorcycle upright on a horizontal surface.

(All 125/200 models)

– Remove gear oil level check screw .

– Check the gear oil level.

A small amount of gear oil should flow out of the hole.

» If no gear oil flows out:

–

Add gear oil. x ( p. 100)

– Mount and tighten the gear oil level check screw.

B00049-10

Guideline

Screw, gear oil level check M6 10 Nm

(7.4 lbf ft)

(All 250/300 models)

– Remove gear oil level check screw .

– Check the gear oil level.

16.2Changing the gear oil x

B00050-10

400721-01

A small amount of gear oil should flow out of the hole.

» If no gear oil flows out:

–

Add gear oil. x ( p. 100)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 10 Nm

–

Drain the gear oil. x ( p. 99)

–

Refill with gear oil. x ( p. 99)

(7.4 lbf ft)

400722-01