KTM 250 EXC EU-AUS 2010, EXC-F Six Days 2010, 250 XCF-W 2010, 250 SX-F 2010 Owner's manual

OWNER'S MANUAL 2010

250 EXC-F EU

250 EXC-F AUS

250 EXC-F SIX DAYS EU

250 XCF-W ZA

250 SX-F EU

250 SX-F USA

Art. no. 3211465en

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 riding this vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 10) Dealer's stamp

Engine number ( p. 10)

Key number (EXC-F, EXC‑F SIX DAYS) ( 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 of our motorcycles 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.

© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, 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 the vehicle from the left front (example) ................. 8

View of the vehicle from the right rear (example) ................ 9

LOCATION OF SERIAL NUMBERS ...................................... 10

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

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

Key number (EXC-F, EXC‑F SIX DAYS)............................. 10

Engine number.............................................................. 10

Fork part number........................................................... 10

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

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

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

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

Short circuit button (XCF‑W, SX‑F) .................................. 12

Short circuit button (EXC-F, EXC‑F SIX DAYS).................. 12

Emergency OFF switch (EXC‑F AUS) ............................... 12

Electric starter button (EXC‑F EU, EXC‑F SIX DAYS,

XCF‑W)......................................................................... 13

Electric starter button (EXC‑F AUS)................................. 13

Light switch (EXC-F, EXC‑F SIX DAYS) ............................ 13

Horn button (EXC-F, EXC‑F SIX DAYS)............................. 13

Turn signal switch (EXC-F, EXC‑F SIX DAYS).................... 13

Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS) ...... 14

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) ...................... 15

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 the lap time .................................................... 17

SPEED display mode (speed).......................................... 17

Display mode SPEED/H (service 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

Disply 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

CONTROLS....................................................................... 22

Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF-W)....................... 22

Fuel tap (SX‑F).............................................................. 22

Opening filler cap.......................................................... 22

Closing filler cap ........................................................... 23

Choke (EXC-F EU, EXC‑F SIX DAYS)................................ 23

Choke (XCF‑W, SX‑F, EXC‑F AUS) ................................... 23

Shift lever..................................................................... 23

Foot brake lever............................................................. 24

Kick starter................................................................... 24

Side stand (EXC‑F, EXC‑F SIX DAYS, XCF-W) ................... 24

Plug-in stand (SX‑F) ...................................................... 24

Steering lock (EXC-F, EXC‑F SIX DAYS) ........................... 25

Locking the steering (EXC-F, EXC‑F SIX DAYS)................. 25

Unlocking the steering (EXC-F, EXC‑F SIX DAYS).............. 25

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION...................................................................... 26

Advice on first use ......................................................... 26

Running-in the engine ................................................... 27

Preparing vehicle for arduous riding conditions................. 27

Preparing for riding on dry sand ...................................... 27

Preparing for riding on wet sand...................................... 28

Preparing for riding on wet and muddy surfaces................ 29

Preparing for rides at high temperature and slow speed ..... 30

Preparing for rides at low temperatures or in snow ............ 30

RIDING INSTRUCTIONS .................................................... 31

Checks before putting into operation ............................... 31

Starting ........................................................................ 31

Starting up ................................................................... 32

Shifting, riding.............................................................. 32

Braking ........................................................................ 32

Stopping, parking .......................................................... 33

Refueling...................................................................... 33

SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)........ 35

Important maintenance work to be carried out by an

authorized KTM workshop .............................................. 35

Important maintenance work to be carried out by an

authorized KTM workshop (as additional order)................. 36

SERVICE SCHEDULE (SX‑F)............................................... 37

Important maintenance work to be carried out by an

authorized KTM workshop .............................................. 37

Important maintenance work to be carried out by an

authorized KTM workshop (as additional order)................. 38

SERVICE SCHEDULE FOR RIDER....................................... 39

Important checks and maintenance work to be carried

out by the rider ............................................................. 39

MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 40

Jacking up the motorcycle .............................................. 40

Removing the motorcycle from the work stand.................. 40

Checking the basic suspension setting with the rider's

weight .......................................................................... 40

Compression damping of shock absorber.......................... 40

Adjusting high-speed compression damping of the shock

absorber ....................................................................... 40

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 41

Adjusting the rebound damping of the shock absorber....... 42

Measuring rear wheel sag unloaded ................................. 42

Checking the static sag of the shock absorber .................. 43

Checking the riding sag of the shock absorber .................. 43

Adjusting the spring preload of the shock absorber x ...... 43

Adjusting the riding sag x............................................. 44

Removing the shock absorber x..................................... 45

Installing the shock absorber x ..................................... 45

Checking basic setting of fork ......................................... 45

Adjusting the compression damping of the fork ................ 45

Adjusting the rebound damping of the fork....................... 46

Adjusting the spring preload of the fork (EXC‑F,

EXC‑F SIX DAYS, XCF-W) ............................................... 47

Bleeding fork legs.......................................................... 48

Cleaning the dust boots of the fork legs ........................... 48

Loosening the fork protector ........................................... 48

Positioning the fork protection ........................................ 48

Checking steering head bearing play................................ 49

Adjusting play of steering head bearing x (EXC‑F EU,

EXC‑F AUS, XCF‑W ZA) .................................................. 49

Adjusting the play of the steering head bearing x (SX‑F,

250 EXC-F SIX DAYS EU) .............................................. 50

Removing the fork legs................................................... 50

Installing the fork legs x............................................... 51

Removing the fork protector x....................................... 52

TABLE OF CONTENTS 3

Installing the fork protector x ....................................... 52

Removing the front fender .............................................. 52

Installing the front fender............................................... 53

Removing headlight mask with headlight (EXC‑F,

EXC‑F SIX DAYS, XCF-W) ............................................... 53

Refitting the headlight mask with the headlight (EXC‑F,

EXC‑F SIX DAYS, XCF-W) ............................................... 53

Removing the start number plate (SX‑F) .......................... 54

Installing the start number plate (SX‑F) ........................... 54

Handlebar position ........................................................ 54

Adjusting handlebar position x...................................... 54

Checking throttle cable route .......................................... 55

Checking the play in the throttle cable............................. 55

Adjusting the play in the throttle cable x ....................... 56

Checking for chain dirt accumulation .............................. 56

Cleaning the chain......................................................... 56

Checking the chain tension ............................................ 57

Checking chain tension when fitting rear wheel ................ 57

Checking the rear sprocket/engine sprocket for wear ......... 57

Checking chain wear...................................................... 58

Adjusting chain tension.................................................. 58

Adjusting chain tension - after checking .......................... 59

Adjusting chain tension - fitting rear wheel ...................... 60

Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS,

XCF-W)......................................................................... 60

Adjusting the chain guide x (SX‑F)................................ 61

Checking brake discs ..................................................... 61

Checking free travel of hand brake lever........................... 61

Adjusting basic position of hand brake lever (XCF‑W,

SX‑F)............................................................................ 62

Adjusting free travel of hand brake lever

(EXC-F, EXC‑F SIX DAYS)............................................... 62

Checking the brake fluid level of the front brake ............... 62

Topping up the front brake fluid x................................. 63

Checking the front brake linings...................................... 64

Changing the front brake linings x................................. 64

Checking free travel of foot brake lever ............................ 66

Adjusting basic position of footbrake lever x................... 66

Checking rear brake fluid level ........................................ 66

Adding brake fluid to the rear brake circuit x ................. 67

Checking rear brake linings ............................................ 67

Changing the rear brake linings x.................................. 68

Removing front wheel x................................................ 69

Installing the front wheel x........................................... 70

Removing the rear wheel x ........................................... 71

Installing the rear wheel x ............................................ 71

Tire condition checking.................................................. 72

Checking tire air pressure ............................................... 73

Checking spoke tension.................................................. 73

Removing the battery x (EXC‑F, EXC‑F SIX DAYS,

XCF-W)......................................................................... 74

Installing the battery x (EXC‑F, EXC‑F SIX DAYS,

XCF-W)......................................................................... 74

Recharging the battery x (EXC‑F, EXC‑F SIX DAYS,

XCF-W)......................................................................... 74

Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W)........... 75

Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W) ....... 75

Adjusting the beam width of the headlight (EXC‑F,

EXC‑F SIX DAYS, XCF-W) ............................................... 76

Checking the headlight adjustment (EXC‑F,

EXC‑F SIX DAYS, XCF-W) ............................................... 76

Removing the seat ......................................................... 76

Mounting the seat ......................................................... 77

Dismounting the fuel tank x ......................................... 77

Installing the fuel tank x .............................................. 78

Cooling system .............................................................. 78

Checking the anti-freeze and coolant level ....................... 79

Checking the coolant level.............................................. 79

Draining the coolant x.................................................. 80

Refilling coolant x ....................................................... 80

Glass fiber yarn filling of main silencer ............................ 81

Removing main silencer ................................................. 81

Installing the main silencer ............................................ 81

Removing the air filter box lid......................................... 81

Installing the air filter box lid.......................................... 81

Removing the air filter x............................................... 82

Installing the air filter x ............................................... 82

Cleaning air filter x...................................................... 82

Adjusting basic position of clutch lever............................ 83

Checking the fluid level of hydraulic clutch...................... 83

Changing the hydraulic clutch fluid x ............................ 83

Checking the basic position of the shift lever.................... 84

Adjusting the basic position of the shift lever x .............. 84

Carburetor - idle ............................................................ 85

Carburetor - adjusting idle x ......................................... 85

Emptying the carburetor float chamber x ....................... 86

Checking the engine oil level .......................................... 87

Changing the engine oil and oil filter, cleaning the oil

screen x ..................................................................... 87

Draining the engine oil x .............................................. 87

Cleaning the oil screens x ............................................ 88

Removing the oil filter x............................................... 89

Installing the oil filter x ............................................... 89

Filling up with engine oil x........................................... 90

Adding engine oil .......................................................... 90

TROUBLESHOOTING......................................................... 91

CLEANING........................................................................ 93

Cleaning the motorcycle ................................................. 93

STORAGE ......................................................................... 94

Storage......................................................................... 94

Putting into operation after storage ................................. 94

TECHNICAL DATA - ENGINE .............................................. 95

Capacity - engine oil ...................................................... 96

Capacity - coolant.......................................................... 96

TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 97

TECHNICAL DATA - CARBURETOR..................................... 99

EXC-F, EXC‑F SIX DAYS ................................................. 99

XCF-W.......................................................................... 99

SX‑F............................................................................. 99

TECHNICAL DATA - CHASSIS .......................................... 100

Lighting equipment ..................................................... 100

Tires .......................................................................... 101

Capacity - fuel............................................................. 101

TECHNICAL DATA - FORK................................................ 102

EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 102

SX‑F EU ..................................................................... 102

SX‑F USA ................................................................... 103

TECHNICAL DATA - SHOCK ABSORBER ........................... 104

EXC‑F, EXC‑F SIX DAYS, XCF-W ................................... 104

SX‑F........................................................................... 104

TECHNICAL DATA - TIGHTENING TORQUES FOR

CHASSIS ........................................................................ 105

TABLE OF CONTENTS 4

WIRING DIAGRAM .......................................................... 106

Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)................. 106

Wiring diagram (EXC‑F AUS) ........................................ 110

Wiring diagram (XCF-W) ............................................... 112

Wiring diagram (SX‑F).................................................. 114

SUBSTANCES................................................................. 116

AUXILIARY SUBSTANCES................................................ 117

STANDARDS................................................................... 119

INDEX ............................................................................ 120

MEANS OF REPRESENTATION 5

Symbols used

The symbols used are explained in the following.

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

Indicates an unexpected reaction (e.g. of 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 in the following.

Specific name Identifies a specific name.

®

Name

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT INFORMATION 6

Use definition (EXC-F, EXC‑F SIX DAYS)

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 off-road sport endurance competition (Enduro) and not for the use predominantly in motocross.

Use definition (XCF‑W, SX‑F)

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 secluded property remote from public road traffic.

Maintenance

A prerequisite for trouble free operation and avoiding premature wear is that the engine and suspension are maintained and adjusted
as described in this manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of compo­nents.
Using a motorcycle in difficult conditions such as on sand or very wet and muddy ground 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.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. Observing these rules will vastly
increase the service life of 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; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation
and/or other changes 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.
Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy 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 necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.

IMPORTANT INFORMATION 7

Transport

Note

Danger of damage The parked vehicle can 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.

– Switch off the engine.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

– 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.

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 useful infor-

mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motor­cycle for your own use and how you can 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 the vehicle from the left front (example)

1 Hand brake lever
2 Filler cap
3 Clutch lever
4 Fuel tap
5 Shift lever
6 Air filter box lid
7 Chain guide

600874-10

VIEW OF VEHICLE 9

3.2View of the vehicle from the right rear (example)

1 Rubber band for the side stand
2 Shock absorber, compression adjustment
3 Chassis number
4 Fork protector
5 Shock absorber, rebound adjustment
6 Level viewer, rear brake fluid
7 Level viewer, engine oil
8 Kickstarter

600873-10

LOCATION OF SERIAL NUMBERS 10

4.1Chassis number

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

500127-10

4.2Type label

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

500128-10

4.3Key number (EXC-F, EXC‑F SIX DAYS)

500125-10

4.4Engine number

The key number  is stamped on the key strap.

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

4.5Fork part number

600661-12

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

500082-10

LOCATION OF SERIAL NUMBERS 11

4.6Shock absorber part number

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

500129-10

CONTROLS 12

5.1Clutch lever

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

600659-10

5.2Hand brake lever

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

5.3Short circuit button (XCF‑W, SX‑F)

The 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

• Short circuit button pressed – In this position, the ignition circuit is interrupted,

500132-10

5.4Short circuit button (EXC-F, EXC‑F SIX DAYS)

The 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

• Short circuit button pressed – In this position, the ignition circuit is interrupted,

closed, and the engine can be started.

a running engine stops, and a non-running engine will not start.

closed, and the engine can be started.

a running engine stops, and a non-running engine will not start.

500134-10

5.5Emergency OFF switch (EXC‑F AUS)

500131-10

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 13

5.6Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑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.

400198-10

5.7Electric starter button (EXC‑F 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.

500131-11

5.8Light switch (EXC-F, EXC‑F SIX DAYS)

500134-12

5.9Horn button (EXC-F, EXC‑F SIX DAYS)

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
high beam and the tail light are switched on.

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.

500134-11

5.10Turn signal switch (EXC-F, EXC‑F SIX DAYS)

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

Possible states

500145-10

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

Turn signal light, right, on – Turn signal switch turned to the right.

CONTROLS 14

5.11Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS)

Possible states

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

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

500147-01

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 15

6.1Speedometer

– Press the key 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

In its condition at delivery, the display mode SPEED/H andSPEED/ODO is acti­vated.

400312-01

6.2Speedometer activation and test

Activating the speedometer:
The speedometer is activated when one of the keys is pressed or a signal is received
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

2205 mm corresponds to the size of the 21" front wheel with a series produc­tion tire.

The display then changes to the last selected mode.

400314-01

6.3Tripmaster 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.

6.4Setting 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 opens and the active functions are displayed.

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

– Press the button .

Adjusting Mph

– Press the button .

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 16

– Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu 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.

6.5Setting 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.

400330-01

– You can set the following segments in the same way as the hours by pressing the

button and the button .

Info

The seconds can only be set to zero.

– Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu 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.

6.6Adjusting the speedometer functions

Info

Upon delivery, 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 opens and the active functions are displayed.

– Switch to the function you require by briefly pressing the button .

The selected function flashes.

Activating a function

– Press the button .

400318-01

Deactivating a function

– Press the button .

– Activate or deactivate all functions accordingly.
– Press the button for 3 - 5 seconds.

The icon remains in the display and the display changes to the next func­tion.

The icon disappears from the display and the display changes to the next
function.

The settings are saved and the Setup menu closed.

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 17

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.

6.7Querying the lap time

Info

This function can be called 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.

400321-01

Next display mode

Info

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

6.8SPEED display mode (speed)

400317-02

6.9Display mode SPEED/H (service 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 service hours of the engine are displayed.
The service hour counter stores the total traveling time.

Info

The service hour counter is necessary for ensuring that 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 (EXC‑F, EXC‑F SIX DAYS, XCF-W) 18

6.10Display 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

6.11Display 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

6.12Display mode SPEED/ODO (odometer)

400317-01

6.13Display 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.

In ODO display mode, the total number of kilometers ridden is displayed.

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 up to 999.9.
You can use it to measure trips or the distance between refuelling 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 automaticallt reset to

0.0.

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

for 3 - 5 seconds.

Displays of TR1, A1 and S1 are reset to 0,0.

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 19

6.14Display mode SPEED/TR2 (trip master 2)

400324-01

6.15Disply mode SPEED/A1 (average speed 1)

Press the button

Next display mode

briefly.

– 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 . 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 .
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

for 3 - 5 seconds.
Press the button

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 using TR1 (trip master 1) and
S1 (stop watch 1).

The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.

Deletes value of TR2.

Next display mode

400325-01

6.16Display 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

Displays of TR1, A1 and S1 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 (EXC‑F, EXC‑F SIX DAYS, XCF-W) 20

6.17Display 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

400327-01

6.18Display mode SPEED/S2 (stop watch 2)

Press the button . No function
Press the button

Displays of TR1, A1 and S1 are reset to 0,0.

for 3 - 5 seconds.
Press the button

Next display mode

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

400328-01

Press the button
for 3 - 5 seconds.

Press the button

Displays of S2 and A2 are reset to 0.0.

Next display mode

briefly.

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

5 seconds.

Display mode SPEED/H
(service 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 Displays of TR1, A1 and

S1 are reset to 0,0.

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

(trip master 2)
Disply mode SPEED/A1

(average speed 1)
Display mode SPEED/A2

No function No function Displays of TR1, A1 and

S1 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 activability
Display The motorcycle is

stationary

Display mode SPEED/H (service hours) •

Menu can be acti­vated

CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W) 21

Table of conditions and activability
Display The motorcycle is

stationary

Display mode SPEED/CLK (clock) •
Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Disply 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) •

Menu can be acti­vated

CONTROLS 22

7.1Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF-W)

The fuel tap is on the left side of the fuel tank.
Using tap handle  on the fuel tap, you can 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.

500137-10

7.2Fuel tap (SX‑F)

7.3Opening filler cap

The fuel tap is on the left side of the fuel tank.
Using tap handle  on the fuel tap, you can 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 completely.

500178-10

– Press release button , turn filler cap counterclockwise and lift it upwards and

remove.

400199-10

CONTROLS 23

7.4Closing filler cap

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

Info

Route the fuel tank breather hose  without kinking.

400199-11

7.5Choke (EXC-F EU, EXC‑F SIX DAYS)

The choke lever  is fitted on the left side of the handlebar.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

500136-10

• Choke function activated – The choke lever is pulled to the stop.

• Choke function deactivated – The choke lever is pushed back to the stop.

7.6Choke (XCF‑W, SX‑F, EXC‑F AUS)

600660-10

7.7Shift lever

600661-13

Choke  is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

• Choke function activated – The choke lever is pulled out to the stop.

• Choke function deactivated – The choke lever is pushed in to the stop.

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

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

600661-10

CONTROLS 24

7.8Foot brake lever

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

600664-10

7.9Kick starter

The kick starter  is fitted on the right of the engine.
The engine can be started with either the kick starter or the electric starter.
The upper part of the kick starter can be swung out.

Info

Before riding, swing the upper part of the kick starter inwards towards the
engine.

600664-11

7.10Side stand (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Note

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

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

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

500140-10

To park the motorcycle, press the side stand  to the ground with your foot and lean
the motorcycle on it.

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

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.

7.11Plug-in stand (SX‑F)

600665-10

400203-10

Note

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

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

To park the motorcycle, insert plug-in stand  into the left side of the wheel spindle.

Info

Remove the plug-in stand before starting on a trip.

CONTROLS 25

7.12Steering lock (EXC-F, EXC‑F SIX DAYS)

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.

500126-10

7.13Locking the steering (EXC-F, EXC‑F SIX DAYS)

Note

Danger of damage The parked vehicle can 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.

400732-01

7.14Unlocking the steering (EXC-F, EXC‑F SIX DAYS)

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

right. Remove the key.

400731-01

Info

Never leave the key in the steering lock.

You can now steer the bike again.

Info

Never leave the key in the steering lock.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 26

8.1Advice on first use

Danger

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

– Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

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 handling characteristic due to inappropriate riding style.

– Adapt your riding speed to the road conditoins 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 permanently. The rear brake can fail due to overheating. Take

your foot off the foot brake lever if you do not want to brake.

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 clutch lever. ( p. 83)
(XCF‑W, SX‑F)

– adjust the basic position of hand brake lever. ( p. 62)

(EXC-F, EXC‑F SIX DAYS)

– Adjust the free travel of the hand brake lever. ( p. 62)

–

Adjust the basic position of the footbrake lever. x ( p. 66)

–

Adjust the basic position of the shift lever. x ( p. 84)

– 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.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 27

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– 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

distribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

(SX‑F)

– Do not transport luggage.

– 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. 73)

Info

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

– Run the engine in.

8.2Running-in the engine

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

Guideline

Maximum engine speed

During the first 3 service hours 7,000 rpm

Maximum engine performance

During the first 3 service hours ≤ 50 %
During the next 12 service hours ≤ 75 %

– Avoid fully opening the throttle!

8.3Preparing vehicle for arduous riding conditions

– Using a motorcycle in arduous 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.

Arduous riding conditions are:

– Riding on dry sand. ( p. 27)
– Riding on wet sand. ( p. 28)
– Riding on wet and muddy surfaces. ( p. 29)
– Rides at high temperature and slow speed. ( p. 30)
– Rides at low temperatures or in snow. ( p. 30)

8.4Preparing for riding on dry sand

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does not correspond to specifications:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.

600872-10

– 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.

– Change the radiator cap.

–

Seal the air filter box. x

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 28

Tip

Seal the air filter box on the edges against dirt.

–

Clean the air filter. x ( p. 82)

Info

Check the air filter approx. every 30 minutes.

– Fit a dust protection device on the air filter.

Dust protection device for air filter (59006019000)

Info

See the KTM PowerParts fitting instructions.

600869-01

– Fit a sand screen device on the air filter.

Sand protection device for air filter (59006022000)

Info

See the KTM PowerParts fitting instructions.

600871-01

600868-01

8.5Preparing for riding on wet sand

600872-10

– Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning set­tings.

– Clean the chain.

Chain cleaner ( p. 117)

– Fit the steel sprocket.

Tip

Do not grease the chain.

– Clean radiator fins.
– Straighten bent radiator fins carefully.

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does not correspond to specifications:

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.

– Change the radiator cap.

–

Seal the air filter box. x

Tip

Seal the air filter box on the edges against dirt.

–

Clean the air filter. x ( p. 82)

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 29

Info

Check the air filter approx. every 30 minutes.

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (59006021000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and settings.

600870-01

– Clean the chain.

Chain cleaner ( p. 117)

– Fit the steel sprocket.

– Clean radiator fins.

600868-01

8.6Preparing for riding on wet and muddy surfaces

– Straighten bent radiator fins carefully.

–

Seal the air filter box. x

–

Clean the air filter. x ( p. 82)

Info

Your authorized KTM workshop has the recommended carburetor tuning set­tings.

Tip

Do not grease the chain.

Tip

Seal the air filter box along the edges to prevent the ingress of dirt.

Info

Check the air filter approx. every 30 minutes.

600870-01

600868-01

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (59006021000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning set­tings.

– Fit the steel sprocket.
– Clean the motorcycle. ( p. 93)
– Straighten bent radiator fins carefully.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 30

8.7Preparing for rides at high temperature and slow speed

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does not correspond to specifications:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.

600872-10

– Change the radiator cap.

–

Seal the air filter box. x

–

Clean the air filter. x ( p. 82)

– 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.

Tip

Seal the air filter box on the edges against dirt.

Info

Check the air filter approx. every 30 minutes.

– Adjust the secondary drive to the road conditions.

– Clean the chain.

Chain cleaner ( p. 117)

600868-01

– Clean radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 79)

8.8Preparing for rides at low temperatures or in snow

–

Seal the air filter box. x

–

Clean the air filter. x ( p. 82)

– Fit a waterproofing device on the air filter.

Info

The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.

Tip

Seal the air filter box on the edges against dirt.

Info

Check the air filter approx. every 30 minutes.

600870-01

Waterproofing device for air filter (59006021000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning set­tings.

RIDING INSTRUCTIONS 31

9.1Checks before putting into operation

Info

Make sure that the motorcycle is in a perfect technical condition before use.

Info

In the interests of riding safety, make a habit of making a general check before you ride.

– Check the engine oil level. ( p. 87)
– Check the chain tension. ( p. 57)
– Check for chain dirt accumulation. ( p. 56)
– Check the tire condition. ( p. 72)
– Check the tire air pressure. ( p. 73)
– Check the brake fluid level of the front brake. ( p. 62)
– Check the rear brake fluid level. ( p. 66)
– Check the front brake linings. ( p. 64)
– Check the rear brake linings. ( p. 67)
– Check the brake system function.
– Check the coolant level. ( p. 79)
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check the functioning of the electrical equipment.

9.2Starting

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.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

Engine has been out of use for more than 1 week

–

Empty the carburetor float chamber. x ( p. 86)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn handle  of the fuel tap to the ON position. (Figure 500137-10 p. 22)

Fuel can flow from the fuel tank to the carburetor.

(SX‑F)

– Turn handle  of the fuel tap to the ON position. (Figure 500178-10 p. 22)

Fuel can flow from the fuel tank to the carburetor.

400733-01

– Remove the motorcycle from the stand.
– Shift transmission to neutral.
(EXC‑F AUS)

– Turn the emergency OFF switch to the position .

The engine is cold

(XCF‑W, SX‑F, EXC‑F AUS)

– Pull choke lever out as far as possible.

(EXC-F EU, EXC‑F SIX DAYS)

– Pull the choke lever to the stop.

RIDING INSTRUCTIONS 32

– Press the electric starter button or press the kickstarter robustly through its full

range.

Info

Do not open the throttle.

9.3Starting up

Info

If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists.
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.

9.4Shifting, 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 overspeeds and the rear wheel can block.

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 stationary for a long time.

Guideline

≥ 2 min

– Avoid frequent and prolonged slipping of the clutch. This causes heat build-up in the engine oil, the engine and the cooling sys-

tem.

– Ride at lower engine speeds instead of high revs and a slipping clutch.

9.5Braking

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.

– 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.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.

In this way, you have to brake far less and the brakes do not overheat.

RIDING INSTRUCTIONS 33

9.6Stopping, 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 get very hot when the vehicle is in use.

– 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 can 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 transmission to neutral.
(XCF‑W, SX‑F)

– Press and hold the short circuit button while the engine is idling until the engine stops.

(EXC-F, EXC‑F SIX DAYS)

– Press and hold the short circuit button while the engine is idling until the engine stops.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

– Park the motorcycle on firm ground.

9.7Refueling

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 engine.
– Open the filler cap. ( p. 22)

RIDING INSTRUCTIONS 34

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‑F,
EXC‑F SIX DAYS,
XCF-W)

Total fuel tank
capacity, approx.
(SX‑F)

– Close the filler cap. ( p. 23)

9.2 l
(2.43 US gal)

8.0 l
(2.11 US gal)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 116)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 116)

SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) 35

10.1Important maintenance work to be carried out by an authorized KTM workshop

S3N S20A S30A

Engine

Carburetor Check the carburetor connection boots for cracks and leakage. •

Attachments Check the cooling system for leakage. • •

Brakes Check the front brake linings. ( p. 64) • •

Chassis

Wheels Check the spoke tension. ( p. 73) • •

Change the engine oil and oil filter, clean the oil screen. x ( p. 87)

Replace the spark plug. •

Check the valve clearance. x

Check the engine mounting screws for tightness. • •
Clean the spark plug connectors and check for tightness. • •
Check that the screws in the shift lever and the kickstarter are tight. • •

Check the vent hoses for damage and routing without sharp bends. • •
Check the idle. • •

Check the anti-freeze and coolant level. ( p. 79) • •
Check the exhaust system for leakage and looseness. •
Check the throttle cables for damage, smooth operation and routing without sharp

bends.
Check the fluid level of the hydraulic clutch. ( p. 83) • •

Clean the air filter. x ( p. 82)

Check the cables for damage and routing without sharp bends. •
Check the functioning of the electrical equipment. • •
Check the headlight setting. •

Check the rear brake linings. ( p. 67) • •
Check the brake discs. ( p. 61) • •
Check the brake fluid level of the front brake. ( p. 62) • •
Check the rear brake fluid level. ( p. 66) • •
Check the brake lines for damage and leakage. • •
Check the free travel of the hand brake lever. ( p. 61) • •
Check the free travel of the foot brake lever. ( p. 66) • •
Check the brake system function. • •
Check the screws and guide bolts of the rake system for tightness. • •

Check the shock absorber and fork for leakage and functioning. x

Clean the dust boots of the fork legs. ( p. 48) •
Bleed fork legs. ( p. 48) •
Check the frame and swingarm for damage. •
Check the swingarm bearing. •
Check the steering head bearing play. ( p. 49) • •
Check all screws to see if they are tight. • •

Check the wheel hubs for damage. •
Check the rim run-out. • •
Check the tire condition. ( p. 72) • •
Check the tire air pressure. ( p. 73) • •
Check the chain wear. ( p. 58) • •
Check the chain tension. ( p. 57) • •
Clean the chain. ( p. 56) • •
Check the wheel bearing for play. • •
Clean and grease the adjusting screws of the chain adjuster. • •

• •

• •

• •

• •

• •

S3N: once after three operating hours
S20A: every 20 service hours / after every race
S30A: every 30 service hours

SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W) 36

10.2Important maintenance work to be carried out by an authorized KTM workshop (as additional order)

Competition use Hobby use S10N J1A

S10A S20A S40A S80A S20A S40A S60A S80A

Perform a fork service. (EXC‑F,

EXC‑F SIX DAYS, XCF-W) x

Perform a shock absorber service.

(EXC‑F, EXC‑F SIX DAYS, XCF-W) x
Grease the steering head bearing. x

Treat electric contacts with contact
spray.

Change the hydraulic clutch fluid. x

( p. 83)

Change the front brake fluid. x
Change the rear brake fluid. x
Check the clutch discs for wear. x
Check the clutch. x

Check the cylinder and piston for

wear. x
Check the camshafts. x
Check the valve spring seat. x
Check the valves. x
Change the valves. x
Check wear of valve guides. x
Change the valve springs. x

Check the timing-chain tensioner

function. x

Check the crankshaft run-out at the

bearing pin. x
Change the conrod bearing. x

Change the crankshaft main bear-

ing. x
Fully check the transmission. x
Check the shift mechanism. x

Check the spring length of the oil pres-

sure regulator valve. x

Change the glass fiber yarn filling of

the main silencer. x

Change the foot brake cylinder

seals. x

Check/adjust the carburetor compo-

nents. x

• • • • •

• • • • •

• • • • • • • •

• • • • •

• • • • •

• • •

•

•

•

•

•

• • •

• • •

• • •

• • •

• •

• •

• • •

• • •

• • •

• • •

• •

• • •

• • •

• • •

• • • • •

S10A: every 10 service hours
S20A: every 20 service hours / after every race
S40A: every 40 service hours
S60A: every 60 service hours
S80A: every 80 service hours
S10N: once after 10 operating hours
J1A: annually

SERVICE SCHEDULE (SX‑F) 37

11.1Important maintenance work to be carried out by an authorized KTM workshop

S3N S10A S30A

Engine

Carburetor Check the carburetor connection boots for cracks and leakage. • •

Attachments Check the cooling system for leakage. • • •

Brakes Check the front brake linings. ( p. 64) • • •

Chassis

Wheels Check the spoke tension. ( p. 73) • • •

Change the engine oil and oil filter, clean the oil screen. x ( p. 87)

Replace the spark plug. •

Check the valve clearance. x

Check the engine mounting screws for tightness. • • •
Clean the spark plug connectors and check for tightness. • • •
Check that the screws in the shift lever and the kickstarter are tight. • • •

Check the vent hoses for damage and routing without sharp bends. • • •
Check the idle. • • •

Check the anti-freeze and coolant level. ( p. 79) • • •
Check the exhaust system for leakage and looseness. • •
Check the throttle cables for damage, smooth operation and routing without sharp

bends.
Check the fluid level of the hydraulic clutch. ( p. 83) • • •

Clean the air filter. x ( p. 82)

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

Check the rear brake linings. ( p. 67) • • •
Check the brake discs. ( p. 61) • • •
Check the brake fluid level of the front brake. ( p. 62) • • •
Check the rear brake fluid level. ( p. 66) • • •
Check the brake lines for damage and leakage. • • •
Check the free travel of the hand brake lever. ( p. 61) • • •
Check the free travel of the foot brake lever. ( p. 66) • • •
Check the brake system function. • • •
Check the screws and guide bolts of the brake system for tightness. • • •

Check the shock absorber and fork for leakage and functioning. x

Clean the dust boots of the fork legs. ( p. 48) • •
Bleed fork legs. ( p. 48) • •
Check the frame and swingarm for damage. • •
Check the swingarm bearing. • •
Check the steering head bearing play. ( p. 49) • • •
Check all screws to see if they are tight. • • •

Check the wheel hubs for damage. • •
Check the rim run-out. • • •
Check the tire condition. ( p. 72) • • •
Check the tire air pressure. ( p. 73) • • •
Check the chain wear. ( p. 58) • • •
Check the chain tension. ( p. 57) • • •
Clean the chain. ( p. 56) • • •
Check the wheel bearing for play. • • •
Clean and grease the adjusting screws of the chain adjuster. • • •

• • •

• • •

• • •

• • •

• • •

S3N: Once after 3 service hours - corresponds to about 21 liters of fuel (5.55 US gal)
S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)

SERVICE SCHEDULE (SX‑F) 38

11.2Important maintenance work to be carried out by an authorized KTM workshop (as additional order)

S10A S20N S20A S30A S40A S80A J1A

Conduct a major fork service. (SX‑F) x
Conduct a minor fork service. (SX‑F) x
Perform a shock absorber service. (SX‑F) x
Grease the steering head bearing. x

Treat electric contacts with contact spray. •

Change the hydraulic clutch fluid. x ( p. 83)
Change the front brake fluid. x
Change the rear brake fluid. x
Check the clutch discs for wear. x
Check the clutch. x
Check the cylinder and piston for wear. x
Check the camshafts. x
Check the valve spring seat. x
Check the valves. x
Change the valves. x

Check wear of valve guides. •

Change the valve springs. x
Check the timing-chain tensioner function. x
Check the crankshaft run-out at the bearing pin. x
Change the conrod bearing. x
Change the crankshaft main bearing. x
Fully check the transmission. x
Check the shift mechanism. x
Check the spring length of the oil pressure regulator valve. x
Change the glass fiber yarn filling of the main silencer. x
Change the foot brake cylinder seals. x
Check/adjust the carburetor components. x

• • • • •

• • •

• • •

• • •

• • • • •

• • •

•

•

•

•

•

• •

• •

• •

• •

•

• •

• •

• •

• •

•

• •

• •

• •

• • •

S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S20N: Once after 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)
S80A: Every 80 service hours - corresponds to about 560 liters of fuel (148 US gal)
J1A: annually

SERVICE SCHEDULE FOR RIDER 39

12.1Important checks and maintenance work to be carried out by the rider

NB1A

Check the engine oil level. ( p. 87) •
Check the brake fluid level of the front brake. ( p. 62) •
Check the rear brake fluid level. ( p. 66) •
Check the front brake linings. ( p. 64) •
Check the rear brake linings. ( p. 67) •
Check and adjust the cables. •
Bleed fork legs. ( p. 48) •
Clean the dust boots of the fork legs. ( p. 48) •
Clean the chain. ( p. 56) •
Check the chain tension. ( p. 57) •
Check the chain wear. ( p. 58) •
Check rear sprocket/engine sprocket for wear. ( p. 57) •

Clean the air filter. x ( p. 82)

Check the tire air pressure. ( p. 73) •
Check the tire condition. ( p. 72) •
Check the coolant level. ( p. 79) •

Empty the carburetor float chamber. x ( p. 86)

Check all controls for smooth operation. •
Check braking. •
Check all screws, nuts and hose clamps regularly for tightness. •

•

•

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE 40

13.1Jacking up the motorcycle

Note

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

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

– Jack up the motorcycle underneath the engine. The wheels should no longer touch

the ground.

Work stand (54829055000)

600697-01

13.2Removing the motorcycle from the work stand

– Secure the motorcycle against falling over.

Note

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

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

– Remove the motorcycle from the work stand.
– Remove the work stand.

13.3Checking the basic suspension setting with the rider's weight

Info

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

– For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set-

tings of the suspension components must match your body weight.

– As delivered, KTM off-road motorcycles are adjusted for a standard rider weight (with full protective clothing).

Guideline

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

– If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accord-

ingly.

– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the

springs must be replaced.

13.4Compression damping of shock absorber

The shock absorber can regulate compression damping separately in the low-speed and high-speed ranges (Dual Compression Control).
The terms low-speed and high-speed refers to the movement of the shock absorber during compression and not to the riding speed of
the motorcycle.
Changes in the settings in the low-speed range have an impact on the high-speed range and vice versa.

13.5Adjusting high-speed compression damping of the shock absorber

Danger

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE 41

– Turn adjusting screw  all the way clockwise with a ring wrench.

Info

Do not loosen nut !

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

absorber type.
Guideline

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

600667-10

Compression damping, high-speed

Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns

(SX‑F)

Compression damping, high-speed

Comfort 2 turns
Standard 1.5 turns
Sport 1 turn

Info

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

13.6Adjusting the low-speed compression damping of the shock absorber

Danger

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.

– 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

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

600667-11

Compression damping, low-speed

Comfort 22 clicks
Standard 20 clicks
Sport 15 clicks

(SX‑F)

Compression damping, low-speed

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 42

00AA

13.7Adjusting the rebound damping of the shock absorber

Danger

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.)

– 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

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

400210-10

Rebound damping

Comfort 26 clicks
Standard 24 clicks
Sport 22 clicks

(SX‑F)

Rebound damping

Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks

13.8Measuring rear wheel sag unloaded

400220-10

Info

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

– Jack up the motorcycle. ( p. 40)
– Measure the distance – as vertical as possible – between the rear axle and a fixed

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

– Make a note of the value as measurement .
– Remove the motorcycle from the work stand. ( p. 40)

MAINTENANCE WORK ON CHASSIS AND ENGINE 43

000BB

0

0

AA

CC

0

0

AA

13.9Checking the static sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 42)
– Ask someone to help you by holding the motorcycle upright.
– Measure the distance between the rear axle and the fixed point again.
– Make a note of the value as measurement .

Info

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

– Check the static sag.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

Static sag 35 mm (1.38 in)

(SX‑F)

Static sag 33 mm (1.3 in)

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

–

Adjust the spring preload of the shock absorber. x ( p. 43)

400221-10

13.10Checking the riding sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 42)
– With the help of a second person to steady the motorcycle, the rider wearing a full

set of protective clothing sits on the motorcycle in the normal seating position (with
feet on the footrests). Then depress and release the rear of the motorcycle repeat­edly so that the rear suspension is returned to the normal operating position.

– The other person now measures the distance between the rear axle and the fixed

point again.

– Make a note of the value as measurement .

Info

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

– Check the riding sag.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

Riding sag 105 mm (4.13 in)

(SX‑F)

Riding sag 105 mm (4.13 in)

» If the riding sag differs from the specified measurement:

400222-10

13.11Adjusting the spring preload of the shock absorber x

–

Adjust the riding sag. x ( p. 44)

Danger

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 shock absorber. x ( p. 45)

– After removing the shock absorber, clean it thoroughly.

MAINTENANCE WORK ON CHASSIS AND ENGINE 44

AA

22
11

– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.

Combination wrench (50329080000)
Hook wrench (T106S)

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

Guideline

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

Spring preload 8 mm (0.31 in)

(SX‑F)

Spring preload 6 mm (0.24 in)

Info

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

– Tighten screw .

400216-10

Guideline

Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft)

–

Install the shock absorber. x ( p. 45)

13.12Adjusting the riding sag x

–

Remove shock absorber. x ( p. 45)

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

Guideline

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in)

(SX‑F)

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in)

Info

The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.

–

Install the shock absorber. x ( p. 45)

– Check the static sag of the shock absorber. ( p. 43)
– Check the riding sag of the shock absorber. ( p. 43)
– Adjust the rebound damping of the shock absorber. ( p. 42)

MAINTENANCE WORK ON CHASSIS AND ENGINE 45

13.13Removing the shock absorber x

– Jack up the motorcycle. ( p. 40)
– 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.

600668-10

13.14Installing the shock absorber x

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

tighten screw .
Guideline

600668-11

Screw, top shock absorber M12 80 Nm

– Mount and tighten screw .

Guideline

Screw, bottom shock

M12 80 Nm

absorber

(59 lbf ft)

(59 lbf ft)

Loctite®243™

Loctite®243™

Info

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

– Remove the motorcycle from the work stand. ( p. 40)

13.15Checking basic setting of fork

Info

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

– As with the shock absorber, smaller weight differences can be compensated by the

spring preload.

– However, if your fork is often overloaded (hits the bump stops on compression), it is

recommended to fit stiffer springs to avoid damage to the fork and frame.

400189-01

13.16Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

MAINTENANCE WORK ON CHASSIS AND ENGINE 46

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– 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

100020-10

type.
Guideline

Compression damping

Comfort 26 clicks
Standard 22 clicks
Sport 18 clicks

Info

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

– Mount protection covers .

(SX‑F)

– Turn adjusting screws  clockwise all the way.

600669-10

13.17Adjusting the rebound damping of the fork

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

(SX‑F EU)

Compression damping

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

(SX‑F USA)

Compression damping

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

Info

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

Info

The hydraulic rebound damping determines the fork suspension behavior.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– 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.

600670-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 47

Guideline

Rebound damping

Comfort 24 clicks
Standard 20 clicks
Sport 20 clicks

Info

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

(SX‑F)

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

Guideline

(SX‑F EU)

Rebound damping

Comfort 14 clicks
Standard 12 clicks

100020-10

(SX‑F USA)

Sport 10 clicks

Rebound damping

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

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.

Info

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

– Mount protection covers .

13.18Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– 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

Spring preload - Preload Adjuster

600671-01

Comfort 0 turn
Standard 2 turns
Sport 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.

MAINTENANCE WORK ON CHASSIS AND ENGINE 48

13.19Bleeding fork legs

– Jack up the motorcycle. ( p. 40)
– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.
– Remove the motorcycle from the work stand. ( p. 40)

100021-10

13.20Cleaning the dust boots of the fork legs

– Jack up the motorcycle. ( p. 40)
– Loosen the fork protector. ( p. 48)
– Push dust boots  of both fork legs downwards.

Info

The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, there is an ingress of dirt inside the boots. If this dirt is
not removed, it may cause the oil seals to leak.

13.21Loosening the fork protector

600691-10

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. 118)

– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 48)
– Remove the motorcycle from the work stand. ( p. 40)

– Remove screws  and remove the clamp.
– Remove screws  on the left fork leg. Push the fork protector downwards.
– Remove the screws on the right fork leg. Push the fork protector downwards.

600875-11

13.22Positioning the fork protection

600875-10

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

Guideline

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

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Position the wiring harness.

– Position the brake line. Put the clamp on, 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)

MAINTENANCE WORK ON CHASSIS AND ENGINE 49

13.23Checking steering head bearing play

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.)

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can
be damaged after time.

– Jack up the motorcycle. ( p. 40)
– 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:

(SX‑F, 250 EXC-F SIX DAYS EU)

–

Adjust the play of the steering head bearing. x ( p. 50)

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

–

400387-10

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

Adjust play of the steering head bearing. x ( p. 49)

The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.

» If click positions are noticeable:

(SX‑F, 250 EXC-F SIX DAYS EU)

–

Adjust the play of the steering head bearing. x ( p. 50)

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

–

Adjust play of the steering head bearing. x ( p. 49)

– Check the steering head bearing and replace if required.

– Remove the motorcycle from the work stand. ( p. 40)

13.24Adjusting play of steering head bearing x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Jack up the motorcycle. ( p. 40)
– Loosen screws  and .
– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw .

Guideline

100022-10

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

– Check the steering head bearing play. ( p. 49)

(14.8 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 50

13.25Adjusting the play of the steering head bearing x (SX‑F, 250 EXC-F SIX DAYS EU)

– Jack up the motorcycle. ( p. 40)

(250 EXC-F SIX DAYS EU)

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

Guideline

Screw, top steering head M20x1.5 10 Nm

(7.4 lbf ft)

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

800022-10

– Fully tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

(SX‑F)

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

Guideline

Screw, top steering head M20x1.5 10 Nm

(12.5 lbf ft)

Loctite®243™

(12.5 lbf ft)

(7.4 lbf ft)

13.26Removing the fork legs

600876-10

100802-10

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

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

Loctite®243™

(12.5 lbf ft)

– Check the steering head bearing play. ( p. 49)

–

Remove front wheel. x ( p. 69)

– Remove screws  and take off the clamp.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Remove cable clip .

– Remove screws  and take off the brake caliper.
– Hang the brake caliper and the brake line loosely to the side.

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

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

100804-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 51

(250 EXC-F SIX DAYS EU)

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

100803-10

(SX‑F)

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

600877-10

13.27Installing the fork legs x

– Position the fork legs.

100021-10

100804-11

Info

The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position bleeder screws  toward the front.

(EXC‑F EU, EXC‑F AUS, XCF‑W ZA)

– Fully tighten screws .

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Fully tighten screws .

Guideline

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

(250 EXC-F SIX DAYS EU)

– Fully tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

100803-11

600877-11

– Fully tighten screws .

Guideline

Screw, bottom triple clamp M8 12 Nm

(8.9 lbf ft)

(SX‑F)

– Fully tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

– Fully tighten screws .

MAINTENANCE WORK ON CHASSIS AND ENGINE 52

Guideline

Screw, bottom triple clamp M8 12 Nm

(8.9 lbf ft)

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

Guideline

100802-11

13.28Removing the fork protector x

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Mount cable clip .
– Position the wiring harness.

– Position the brake line. Put the clamp on and mount and tighten screws .

–

Install the front wheel. x ( p. 70)

– Remove the fork legs. ( p. 50)
– Remove screws  on the left fork leg. Remove the fork protector upwards.
– Remove the screws on the right fork leg. Remove the fork protector upwards.

Loctite®243™

600878-10

13.29Installing the fork protector x

600878-10

13.30Removing the front fender

– 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. 51)

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

600692-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 53

13.31Installing 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 or headlight
mask.

600692-10

13.32Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Switch off all electrical equipment.
– Remove screw  and take off clamp.
– Loosen the rubber band . Push up the headlight mask and swing it forwards.

600703-10

– Pull out the electric plug connector  and remove the headlight mask with the

headlight.

600702-10

13.33Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Connect the electric plug connector .

600702-11

– Position the headlight mask and fix it with the rubber band .

600703-11

Info

Ensure that the retaining lugs engage in the fender.

– Position the brake line and wiring harness. Put the clamp on, mount and tighten

screw .

– Check the headlight adjustment. ( p. 76)

MAINTENANCE WORK ON CHASSIS AND ENGINE 54

00BB 00BB

0

0

AA 00AA

0022

0

0

11

0

0

22

0

0

11

13.34Removing the start number plate (SX‑F)

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

500101-10

13.35Installing the start number plate (SX‑F)

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

Guideline

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

Info

Take care with the contact of the holding lug at the fender.

– Position the brake line and wiring harness. Put the clamp on, mount and tighten

500101-11

screw .

13.36Handlebar position

On the upper triple clamp, there are 2 holes at a distance of  to each other.

Distance  between holes 15 mm (0.59 in)

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

Distance  between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.

400223-11

13.37Adjusting 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.

– Remove the four screws . Remove the handlebar clamps. 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.

400223-10

– Remove the two screws . Remove the handlebar support.
– Place the handlebar support in the required position. Fit and tighten the two screws

.

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Info

Position the left and right handlebar supports evenly.

Loctite®243™

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

– Position the handlebars.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamps. Fit and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

13.38Checking throttle cable route

– The two throttle cables must run parallel behind the handlebar down to the frame.

They must be routed directly to the right of the frame above the tank bracket
towards the carburetor.

600672-10

13.39Checking the play in the throttle cable

400192-10

– 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. 56)

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.

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

steering range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the play in the throttle cable. x ( p. 56)

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

13.40Adjusting the play in the throttle cable x

–

Dismount the fuel tank. x ( p. 77)

– Check throttle cable route. ( p. 55)
– Move the handlebar to the straight-ahead position.
– Push back bellows .
– Loosen nut . Turn adjusting screw  in as far as possible.
– Loosen nut . Turn adjusting screw  so that there is play in the gas throttle

cable at the throttle grip.
Guideline

Play in throttle cable 3… 5 mm (0.12… 0.2 in)

600673-10

– Tighten nut .
– Press and hold the throttle grip in the closed setting. Turn adjusting screw  out

until there is no play in the throttle cable .

– Tighten nut .
– Push bellows  on. Check the throttle grip for smooth operation.

–

Install the fuel tank. x ( p. 78)

– Check the play in the throttle cable. ( p. 55)

13.41Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 56)

400678-01

13.42Cleaning 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. 117)
Off-road chain spray ( p. 117)

400725-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

13.43Checking 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.

– Jack up the motorcycle. ( p. 40)
– Push the chain up at the rear edge of the chain guide to measure the chain ten-

sion .

Info

The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension 8… 10 mm (0.31… 0.39 in)

400213-10

» If the chain tension does not meet specifications:

– Adjusting chain tension - after checking. ( p. 59)

– Remove the motorcycle from the work stand. ( p. 40)

13.44Checking chain tension when fitting rear wheel

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.

– Make sure that the chain adjusters are fitted correctly on the adjusting screws.
– Push the chain up at the rear edge of the chain guide to measure the chain ten-

sion .

Info

The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

400213-10

13.45Checking the rear sprocket/engine sprocket for wear

Chain tension 8… 10 mm (0.31… 0.39 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension when fitting rear wheel. ( p. 60)

– Check rear sprocket/engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Replace the rear sprocket/engine sprocket.

400227-01

Info

When fitting the split link, always make sure that the closed side of
the locking clip faces forward (riding direction).
The engine sprocket, rear sprocket and chain should always be
replaced together.

– Check the chain guide for tightness and wear.

MAINTENANCE WORK ON CHASSIS AND ENGINE 58

00

0

BB

0

0

AA

1 2 3 16 17 18

13.46Checking chain wear

– Jack up the motorcycle. ( p. 40)
– Shift transmission to neutral.
– Pull on the upper part of the chain with the specified weight .

Guideline

Weight of 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, so you should repeat this measurement at
different chain positions.

Maximum distance  at the longest
chain section

» If the distance  is greater than the specified measurement:

– Replace the chain.

Info

When you replace the chain, you should also replace rear sprocket
and engine sprocket.

400226-10

– Remove the motorcycle from the work stand. ( p. 40)

13.47Adjusting 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.

– Jack up the motorcycle. ( p. 40)
– Push the chain up at the rear edge of the chain guide to measure the chain ten-

sion .

New chains wear out faster on old, worn sprockets.

272 mm (10.71 in)

Info

The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

400213-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 59

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 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 the 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 transmissions with the same chain length.

400225-10

– Remove the motorcycle from the work stand. ( p. 40)

Chain adjusters  can be turned by 180°.

13.48Adjusting chain tension - after checking

400225-13

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws  left and right so that the markings on the left and

right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.

– Tighten nuts .
– Make sure that the chain adjusters  are fitted correctly on the 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 transmissions with the same chain length.
The chain adjusters  can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

13.49Adjusting chain tension - fitting rear wheel

– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws  left and right so that the markings on the left and

right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.

– Tighten nuts .

400225-11

13.50Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– 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

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

400252-10

(7.4 lbf ft)

(7.4 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 61

A

A

13.51Adjusting the chain guide x (SX‑F)

– Loosen screw . Remove screw . Push the chain guide down.

Condition

Number of teeth: ≤ 44 teeth
– Insert collar sleeve  in hole . Position the chain guide.
– Mount and tighten screw . Tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

Condition

Number of teeth: ≥ 45 teeth
– Insert collar sleeve  in hole . Position the chain guide.
– Mount and tighten screw . Tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

400224-10

13.52Checking 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 disk

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.

13.53Checking free travel of hand brake lever

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 shows signs of damage, cracking or deformation:

– Change the brake disc.

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

(XCF‑W, SX‑F)

– 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 hand brake lever. ( p. 62)

400196-11

(EXC-F, EXC‑F SIX DAYS)

– 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. 62)

400196-13

13.54Adjusting basic position of hand brake lever (XCF‑W, SX‑F)

– Check the free travel of the hand brake lever. ( p. 61)
– 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!

13.55Adjusting free travel of hand brake lever (EXC-F, EXC‑F SIX DAYS)

– Check the free travel of the hand brake lever. ( p. 61)
– Adjust the free travel of the hand brake lever with adjusting 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

13.56Checking the brake fluid level of the front brake

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

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 brakes according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

MAINTENANCE WORK ON CHASSIS AND ENGINE 63

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in viewer .

» If the brake fluid is below the MIN mark:

–

Top up the brake fluid of the front brake. x ( p. 63)

400231-10

13.57Topping up the 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 gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brakes 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 user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
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

Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

100395-10

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE WORK ON CHASSIS AND ENGINE 64

13.58Checking 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. 64)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

–

Change the front brake linings. x ( p. 64)

100394-10

13.59Changing 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 gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brakes 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 user DOT 5 brake fluid! This is based on silicone oil and is colored purple. 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!

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

0

0

77

0

0

66

0

0

– 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.

100396-10

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

caliper support are seated correctly.

100397-01

100398-10

100399-10

– Fit the brake linings, insert the bolt, and mount the locking split pins.
– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc

and there is a pressure point.

– Correct the brake fluid quantity to level .

Guideline

Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE WORK ON CHASSIS AND ENGINE 66

13.60Checking free travel of foot brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to

overheating. Adjust free travel on foot brake lever according to specifications.

– Disconnect spring .
– Move the foot brake lever backwards and forwards between the end stop and the

foot brake cylinder piston bracket 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 footbrake lever. x ( p. 66)

600704-10

13.61Adjusting basic position of footbrake 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.

– Reconnect spring .

600705-10

– 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, lossen nut  and

turn screw  accordingly.

Info

The range of adjustment is limited.

– Turn push rod  accordingly until you have free travel . If necessary, adjust the

basic position of the footbrake lever.
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

– Hold screw  and tighten nut .

Guideline

Remaining nuts, chassis M8 30 Nm

(22.1 lbf ft)

– Hold push rod  and tighten nut .

Guideline

Remaining nuts, chassis M6 15 Nm

(11.1 lbf ft)

– Reconnect spring .

13.62Checking 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 brakes according to the service schedule. (Your authorized KTM workshop will

be glad to help.)

MAINTENANCE WORK ON CHASSIS AND ENGINE 67

– Stand the vehicle upright.
– Check the brake fluid level in the sight glass .

» If there is an air bubble in the sight glass  visible:

–

Add brake fluid to the rear brake circuit. x ( p. 67)

400234-10

13.63Adding brake fluid to the rear brake circuit 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 gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brakes 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 user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
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 up to level .

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Mount the screw cap with the membrane and the O-ring.

Info

400233-10

Clean up overflowed or spilt brake fluid immediately with water.

13.64Checking rear 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.)

MAINTENANCE WORK ON CHASSIS AND ENGINE 68

– 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. 68)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

–

Change the rear brake linings. x ( p. 68)

400238-10

13.65Changing 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.)

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 gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brakes 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 user DOT 5 brake fluid! This is based on silicone oil and is colored purple. 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!

100807-10

– 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.

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

MAINTENANCE WORK ON CHASSIS AND ENGINE 69

– Remove locking split pins , withdraw bolt , and take out the brake linings.
– Clean the brake caliper and brake caliper support.

100808-10

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

100407-10

– Fit the brake linings, insert the bolt, and mount the locking split pins.
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a pressure point.

13.66Removing front wheel x

100408-01

– Correct the brake fluid quantity to marking .

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– Mount screw cap  with membrane  and the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

400233-10

– Jack up the motorcycle. ( p. 40)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

100809-01

– Remove screw .
– Loosen screw .

500084-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 70

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

the fork.

Info

Do not operate 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

13.67Installing 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.

– Clean and grease shaft seal rings  and bearing surface  of the spacers.

Long-life grease ( p. 117)

– Insert the spacers.

500086-11

– 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

– Operate the hand brake lever several times until the brake pads are lying correctly

on the brake disc.

500084-11

– Remove the motorcycle from the work stand. ( p. 40)
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Fully tighten screws .

Guideline

Screw, fork stub M8 15 Nm

(33.2 lbf ft)

(11.1 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 71

13.68Removing the rear wheel x

– Jack up the motorcycle. ( p. 40)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove nut .
– Remove chain adjuster . Withdraw wheel spindle  only enough to allow the rear

wheel to be pushed forward.

– Push the rear wheel forward 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.

400258-10

– Remove spacers .

400260-11

13.69Installing 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.

– Clean and grease shaft seal rings  and bearing surface  of the spacers.

Long-life grease ( p. 117)

– Insert the spacers.

400260-10

400259-10

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
– Put the chain on.

MAINTENANCE WORK ON CHASSIS AND ENGINE 72

– Position the chain adjuster . Mount nut , but do not tighten it yet.
– Check chain tension when fitting rear wheel. ( p. 57)
– Make sure that the chain adjusters  are fitted correctly on the 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 transmissions with the same chain length.
The chain adjusters  can be turned by 180°.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a pressure point.

– Remove the motorcycle from the work stand. ( p. 40)

400225-12

13.70Tire condition checking

Info

Only mount tires approved or recommended by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.

– Examine the front and rear tires for cuts, foreign bodies and other damage.

» If you find cuts, foreign bodies or other damage on a tire:

– Change the tires.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

400602-10

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum allowable depth:

– Change the tires.

– Check the age of the tires.

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 refer
to the week of manufacture and last two digits refer to the year of manufac­ture.
KTM recommends that the tires be changed after five years at the latest,
regardless of the actual state of wear.

» If a tire is more than 5 years old:

– Change the tires.

MAINTENANCE WORK ON CHASSIS AND ENGINE 73

13.71Checking 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 tire air pressure when tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)

Road tire pressure (EXC-F, EXC‑F SIX DAYS)

400695-01

– Fit the dust cap.

13.72Checking spoke tension

Front 1.5 bar (22 psi)
Rear 2.0 bar (29 psi)

» If the tire pressure does not meet specifications:

– Correct the tire air pressure.

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 can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– Tap each spoke with a screwdriver.

Info

The sound frequency depends on the length and thickness of the spoke.
If there are different sound frequencies in spokes with the same length and
thickness, this indicates different spoke tensions.

You should hear a high note.

400694-01

» If the spoke tension varies:

–

Correct the spoke tension. x

– Check the spoke torque.

Guideline

Spoke nipple, front wheel M4.5 5… 6 Nm (3.7…

Spoke nipple, rear wheel M5 5… 6 Nm (3.7…

4.4 lbf ft)

4.4 lbf ft)

Torque wrench with various accessories in set (58429094000)

MAINTENANCE WORK ON CHASSIS AND ENGINE 74

13.73Removing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Warning

Risk of injury Battery acid and battery gases cause serious cauterization.

– 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 fire. Charge only in well ventilated rooms.
– 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 doctor.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 76)
– Disconnect the negative (minus) cable  of the battery.
– Pull back the plus pole cover  and disconnect the positive (plus) cable of the bat-

tery.

– Hang the rubber band  out to the bottom.
– Lift the battery up.

500069-10

13.74Installing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Place the battery in the battery holder.

4Ah battery (YTX5L-BS) ( p. 100)

– Reconnect the rubber band .
– Attach the plus cable and replace the plus pole cover .
– Attach the minus cable .
– Mount the seat. ( p. 77)

500069-11

13.75Recharging the battery x (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Warning

Risk of injury Battery acid and battery gases cause serious cauterization.

– 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 fire. Charge only in well ventilated rooms.
– 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 doctor.

Warning

Environmental hazard Battery parts and acid 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.

MAINTENANCE WORK ON CHASSIS AND ENGINE 75

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. 76)
– 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 generator. With this device, you cannot overcharge the bat­tery.

400240-10

– Switch off the charger after charging. Disconnect 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

– Mount the seat. ( p. 77)

13.76Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Switch off all power consumers and switch off the engine.
– Remove the air filter box lid. ( p. 81)
– Remove the protection cover .

– Remove the fuse .

Info

Never remove the lid .
Charge the battery with at most 10% of the capacity specified on the bat­tery .

3 months

Info

The fuse  is located in the starter relay  under the filter box cover.

400270-10

13.77Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Warning

Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

MAINTENANCE WORK ON CHASSIS AND ENGINE 76

00AA

0

0

BB

– Refit the fuse.

Fuse (58011109110)

Info

A reserve fuse  is located in the starter relay.
Replace a burned-out fuse  only by an equivalent fuse.
If the new fuse burns out, contact an authorized KTM workshop.

400273-10

13.78Adjusting the beam width of the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Replace the protection cover.
– Install the air filter box lid. ( p. 81)

– Check the headlight adjustment. ( p. 76)
– Loosen screw .
– Adjust the light range by swiveling the headlight.

Guideline

The boundary between light and dark must be exactly on the lower mark for a
motorcycle with a rider (mark is applied under: Checking the headlight adjust­ment).

Info

301251-10

– Tighten screw .

13.79Checking the headlight adjustment (EXC‑F, EXC‑F SIX DAYS, XCF-W)

– On a light-colored wall behind a horizontal area, make a mark as high as the center

– Make a second mark at distance of  under the first mark.

If you have a payload, you may have to correct the headlight beam width.

of the headlight.

Guideline

Distance  5 cm (2 in)

13.80Removing the seat

400726-10

500080-10

– Stand the motorcycle upright in front of the wall at distance . The driver, in full

protective clothing, should now sit on the motorcycle in a normal sitting position
(feet on the footrests).

Guideline

Distance  5 m (16 ft)

– Switch on low beam. Check the headlight adjustment.

The border between light and dark must be exactly at the lower mark when the
motorcycle is operational and complete with rider.

» If the boundary between light and dark does not meet specifications:

– Adjust the beam width of the headlight. ( p. 76)

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

above.

MAINTENANCE WORK ON CHASSIS AND ENGINE 77

13.81Mounting the seat

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

and simultaneously push it forward.

– Make sure that the seat is correctly locked in.
– Mount and tighten the screw of the seat fixing.

Guideline

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

600674-01

13.82Dismounting 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 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.

600678-10

600675-11

– Remove the seat. ( p. 76)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

– Pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

– Remove screws  with the collar sleeve.

(EXC-F, EXC‑F SIX DAYS)

– Hang the horn and horn bracket to one side.

– Remove screw  with the collar sleeve.
– Remove the tube from the fuel tank vent line.

– Pull both spoilers to the side of the radiator bracket  and take the fuel tank away

upward.

600677-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 78

13.83Installing 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.

– 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.

13.84Cooling system

600676-01

– Mount the fuel tank vent hose.
– Mount and tighten screw  with the collar sleeve.

Guideline

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

(EXC-F, EXC‑F SIX DAYS)

– Position the horn with the horn bracket.

600675-10

– 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. 77)

600678-11

The water pump  in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve
in the radiator cap . This ensures that operating the vehicle at the specified coolant
temperature will not result in a risk of malfunctions.

600679-10

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.

(XCF-W, 250 EXC-F SIX DAYS EU)

The radiator fan provides extra cooling. It is controlled by a thermoswitch.

MAINTENANCE WORK ON CHASSIS AND ENGINE 79

13.85Checking the anti-freeze 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

Engine is cold.

– Stand the motorcycle upright on a horizontal surface.
– Remove radiator cap.
– Check the anti-freeze of the coolant.

−25… −45 °C (−13… −49 °F)

» If the anti-freeze of the coolant does not meet specifications:

– Correct the anti-freeze of the coolant.

– Check the coolant level in the radiator.

400243-10

Coolant level  above 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. 116)

Alternative 2

Coolant (mixed ready to use) ( p. 116)

– Refit the radiator cap.

13.86Checking 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 radiator cap.
– Check the coolant level in the radiator.

400243-10

Coolant level  above the radiator fins. 10 mm (0.39 in)

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 116)

MAINTENANCE WORK ON CHASSIS AND ENGINE 80

Alternative 2

Coolant (mixed ready to use) ( p. 116)

– Mount the radiator cap.

13.87Draining 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.

– Stand the vehicle upright.
– Place a suitable container under the water pump cover.
– Remove screw . Remove radiator cap .
– Completely drain the coolant.
– Mount screw  with a new seal and tighten it.

Guideline

Screw, water pump cover M6 10 Nm (7.4 lbf ft)

600679-11

13.88Refilling 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.

– Make sure that the screw  is tightened.
– Stand the vehicle upright.
– Pour coolant in up to measurement  above the radiator fins.

Guideline

10 mm (0.39 in)

Coolant 1.2 l (1.3 qt.) Coolant ( p. 116)

Coolant (mixed ready to use)

600680-10

– Refit the radiator cap.
– Make a short test ride.
– Check the coolant level. ( p. 79)

( p. 116)

MAINTENANCE WORK ON CHASSIS AND ENGINE 81

13.89Glass fiber yarn filling of main silencer

The main silencer is filled with glass fiber yarn.
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.

13.90Removing 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.

– Disconnect spring .
– Remove screws  and take off main silencer.

600681-11

13.91Installing the main silencer

13.92Removing the air filter box lid

– Mount the main silencer. Mount and tighten screws .

Guideline

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

– Reconnect spring .

600681-10

– Pull off the air filter box lid in area  to the side and remove to the front.

600682-10

13.93Installing the air filter box lid

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

600682-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 82

13.94Removing 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. 81)
– 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.

500107-10

13.95Installing the air filter x

– Mount the clean air filter onto the air filter support.
– Apply grease to the section  of the air filter.

Long-life grease ( p. 117)

301262-10

– 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. 81)

500107-10

13.96Cleaning air filter 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 gasoline since these substances attack the foam.

–

Remove the air filter. x ( p. 82)

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

Air filter cleaner ( p. 117)

Info

Only squeeze the air filter when drying it out, never wring it out.

MAINTENANCE WORK ON CHASSIS AND ENGINE 83

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

Oil for foam air filter ( p. 117)

– Clean the air filter box.
– Check carburetor connection boot for damage and tightness.

–

Install the air filter. x ( p. 82)

13.97Adjusting basic position of clutch lever

– Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.

500133-11

13.98Checking the fluid level of hydraulic clutch

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

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 gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Check the fluid level.

Fluid level under top level of container 4 mm (0.16 in)

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

400339-10

– Position the cover with the membrane. Mount and tighten the screws.

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

Info

Clean up overflowed or spilt fluid immediately with water.

13.99Changing the hydraulic clutch fluid 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 gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE 84

000AA

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .

400339-10

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 116)

– On the slave cylinder, remove bleeder screw  and mount bleeding syringe .

600683-10

– Inject the liquid into the system until it escapes from bore hole  of the master

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.

400340-10

13.100Checking the basic position of the shift lever

– Position the cover with the membrane. Mount and tighten the screws.

– Sit on the vehicle (facing the direction of travel) and measure the gap between the

cylinder without bubbles.

Guideline

Fluid level under top level of container 4 mm (0.16 in)

Info

Clean up overflowed or spilt fluid immediately with water.

top of the boot and shift lever .

Gap between the shift lever and the top
of the boot

» If the distance does not meet the specifications:

–

Adjust the basic position of the shift lever. x ( p. 84)

10… 20 mm (0.39… 0.79 in)

400692-10

13.101Adjusting the basic position of the shift lever x

– Remove screw  and remove shift lever .

100805-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 85

– 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.

– Mount and tighten the screw.

Guideline

Screw, shift lever M6 10 Nm

(7.4 lbf ft)

Loctite®243™

13.102Carburetor - idle

13.103Carburetor - adjusting idle x

100806-10

600684-10

Info

The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle compo­nents during the shift procedure.

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.

Info

The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with the adjustment screw .
The idle mixture is adjusted with the idle mixture adjustment screw .

– Screw in the idle adjusting screw  until it stops and then to the prescribed basic

setting.
Guideline

Idle mixture adjusting screw (EXC‑F, EXC‑F SIX DAYS, SX‑F)

Open 1.25 turns

Idle mixture adjusting screw (XCF-W)

Open 1.0 turn

600684-10

Adjustment tool for mixture control screw (77329034000)

– 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

Choke function deactivated – The choke lever is pushed in to the stop. (XCF‑W,
SX‑F, EXC‑F AUS) ( p. 23)

Choke function deactivated – The choke lever is pushed back to the stop. (EXC­F EU, EXC‑F SIX DAYS) ( p. 23)

Idle speed 1,400… 1,500 rpm

– Turn the idle adjusting screw  slowly until the idle speed begins to fall.
– Note the position and turn the idle adjusting screw slowly counterclockwise until

the idle speed falls.

MAINTENANCE WORK ON CHASSIS AND ENGINE 86

– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extreme sport motorcyclist will set the mixture about ¼ of a turn back
from this ideal value (leaner, in a clockwise direction) since the engine
becomes hotter in sporting use.
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 adjusting screw to the end without any change of
engine speed, you have to mount a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.

– Adjust the idle speed with adjusting screw .

Guideline

Choke function deactivated – The choke lever is pushed in to the stop. (XCF‑W,
SX‑F, EXC‑F AUS) ( p. 23)

Choke function deactivated – The choke lever is pushed back to the stop. (EXC­F EU, EXC‑F SIX DAYS) ( p. 23)

Idle speed 1,400… 1,500 rpm

Info

Following extreme air temperature or altitude changes, adjust the idle speed
again.

13.104Emptying 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.

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the OFF position. (Figure 500178-10 p. 22)

No more fuel flows from the tank to the carburetor.

MAINTENANCE WORK ON CHASSIS AND ENGINE 87

– Guide the hose coming down behind the engine into a suitable container.

Info

Water in the float chamber results in malfunctioning.

– Undo screw  (turn it counterclockwise) a few turns and drain the fuel from the

float chamber.

– Tighten screw .

600684-11

13.105Checking the engine oil level

– Stand the motorcycle upright on a horizontal surface.

Condition

The engine is cold.
– Check the engine oil level.

The engine oil level is at the bottom edge of level viewer .

» If the engine oil level is below the specified level:

– Add engine oil. ( p. 90)

Condition

600685-11

The engine is warm.
– Check the engine oil level.

The engine oil level is at the top edge of level viewer .

» If the engine oil level is below the specified level:

– Add engine oil. ( p. 90)

13.106Changing the engine oil and oil filter, cleaning the oil screen x

–

Drain the engine oil. x ( p. 87)

–

Clean the oil screens. x ( p. 88)

–

Remove the oil filter. x ( p. 89)

–

Install the oil filter. x ( p. 89)

–

Fill up with engine oil. x ( p. 90)

301489-10

13.107Draining the engine oil x

Warning

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

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

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

Drain the engine oil only when the engine is warm.

– Stand the motorcycle on its side stand on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 88

– Place a suitable container under the engine.
– Remove oil drain plug .
– Completely drain the engine oil.
– Thoroughly clean the oil drain plug with the magnet.
– Clean the sealing area on the engine.
– Mount and tighten oil drain plug  with the seal ring.

Guideline

600686-10

13.108Cleaning the oil screens x

Warning

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

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

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.

Oil drain plug with magnet M12x1.5 20 Nm

(14.8 lbf ft)

600693-10

600694-10

– Place a suitable container under the engine.
– Remove plug  with oil screen  and the O-rings.

– Remove plug  with oil screen  and the O-rings.
– Drain the remaining engine oil.
– Thoroughly clean parts and sealing area.

– Position oil screen  with the O-rings.
– Mount and tighten plug  with the O-ring.

Guideline

Plug for oil screen, long M20x1.5 15 Nm

(11.1 lbf ft)

600695-10

600696-10

– Position the oil screen with the O-rings.
– Mount and tighten plug  with the O-ring.

Guideline

Plug for oil screen, short M16x1.5 10 Nm

(7.4 lbf ft)

lubricated with
engine oil

MAINTENANCE WORK ON CHASSIS AND ENGINE 89

13.109Removing the oil filter x

Warning

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

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

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.

– Place a suitable container under the engine.
– Remove screws . Remove oil filter cover  with the O-ring.

600687-10

– Pull the oil filter insert  out of the oil filter casing.

13.110Installing the oil filter x

Circlip pliers reverse (51012011000)

– Completely drain the engine oil.
– Thoroughly clean parts and sealing surface.

600688-10

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with

engine oil.

– Fill oil filter  with engine oil and place it in the oil filter container.
– Lubricate O-ring  of the oil filter cover.

600689-10

– Mount oil filter cover .
– Mount and tighten screws .

Guideline

Screw, oil filter cover M5 6 Nm (4.4 lbf ft)

600687-11

– Stand the motorcycle up.

MAINTENANCE WORK ON CHASSIS AND ENGINE 90

13.111Filling up with engine oil x

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove screw connection  on the clutch cover and fill up with engine oil.

Engine oil 1.10 l (1.16 qt.) Engine oil (SAE 10W/50) ( p. 116)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may

result in unconsciousness and/or death.

600690-10

– Start the engine and check that it is oil-tight.
– Check the engine oil level. ( p. 87)

13.112Adding engine oil

– 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.

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove screw cap  from the clutch cover and fill up with engine oil.

Engine oil (SAE 10W/50) ( p. 116)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may

result in unconsciousness and/or death.

600690-10

– Start the engine and check that it is oil-tight.
– Check the engine oil level. ( p. 87)

– 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.

TROUBLESHOOTING 91

Faults Possible cause Action

The engine cannot be cranked (elec­tric starter)
(EXC‑F, EXC‑F SIX DAYS, XCF-W)

Engine turns but does not start Operating error – Go through the steps of starting the engine.

Engine has no idle Idling jet blocked –

Engine does not speed up Carburetor running over because float

Engine has a lack of power Fuel feed interrupted – Check the fuel tank breather.

Operating error – Go through the steps of starting the engine.

( p. 31)

Battery discharged –

Fuse blown – Remove the fuse. ( p. 75)

Starter relay defective –
Starter motor defective –

Motorcycle was out of use for a long
time and there is old fuel in the float
chamber

Fuel feed interrupted – Check the fuel tank breather.

Engine flooded – Clean and dry the spark plug or replace if nec-

Spark plug oily or wet – Clean and dry the spark plug or replace if nec-

Electrode distance (plug gap) of spark
plug too wide

Defect in ignition system –
Short-circuit cable in wiring harness

frayed, short-circuit button or emer­gency OFF switch defective

Plug connector of CDI control device,
pulse generator or ignition coil oxi­dized.

Water in carburetor or jets blocked –

Adjusting screws on carburetor dis­torted

Spark plug defective – Change spark plug.
Ignition system defective –

needle dirty or worn.
Loose carburetor jets –
Ignition system defective –

Recharge the battery. x ( p. 74)

–

Check the charging voltage. x

–

Check the stall current. x

–

Check the generator. x

– Replace the fuse. ( p. 75)

Check the starter relay. x
Check the starter motor. x

( p. 31)

–

Empty the carburetor float chamber. x

( p. 86)

– Clean the fuel tap.

–

Check/adjust the carburetor components. x

essary.

essary.

– Adjust the plug gap.

Guideline
Spark plug electrode gap

0.7 mm (0.028 in)

Check the ignition system. x

– Check the wiring harness. (visual check)
– Check the electrical system.

– Clean the plug connector and treat it with con-

tact spray.

Check/adjust the carburetor components. x
Check/adjust the carburetor components. x

–

Carburetor - adjust the idle speed. x

( p. 85)

Check the ignition coil. x

–

Check the CDI controller. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

–

Check/adjust the carburetor components. x
Check/adjust the carburetor components. x

Check the ignition coil. x

–

Check the CDI controller. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

– Clean the fuel tap.

–

Check/adjust the carburetor components. x

TROUBLESHOOTING 92

Faults Possible cause Action

Engine has a lack of power Air filter severly contaminated –

Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer

Valve clearance too little –
Ignition system defective –

Engine stalls or pops back into the
carburetor

Engine overheats Coolant level low in cooling system – Check the cooling system for leaks.

High oil consumption Engine vent hose bent – Route the vent hose without bends or replace it

Battery discharged The battery does not charge –

Speedometer values deleted (time,
stop watch, lap times)

Lack of fuel

The intake system has an air leak – Check rubber sleeves and carburetor for tight-

Insufficient airflow – Switch off engine when stationary.
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system –

Bent radiator hose –
Thermostat defective –

Defect in radiator fan system (XCF-W,
250 EXC-F SIX DAYS EU)

Engine oil level too high – Check the engine oil level. ( p. 87)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter, clean the

Piston or cylinder is worn – Piston/cylinder - determine the mounting clear-

Undesired power consumer –
The battery in the speedometer is

empty.

Clean the air filter. x ( p. 82)

– Check exhaust system for damage.
– Change glass fiber yarn filling of main

silencer. x
Adjust the valve clearance. x
Check the ignition coil. x

–

Check the CDI controller. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

– Turn handle  of the fuel tap to the ON

position. (Figure 500137-10 p. 22)

(SX‑F)

– Turn handle  of the fuel tap to the ON

position. (Figure 500178-10 p. 22)

– Refuel. ( p. 33)

ness.

– Check the coolant level. ( p. 79)

Drain the coolant. x ( p. 80)

–

Refill the coolant. x ( p. 80)
Change the radiator hose. x
Check the thermostat. x

Guideline
Opening temperature: 70 °C (158 °F)

– Check the radiator fan fuse.

–

Check the radiator fan. x

–

Check the thermostat. x

if necessary.

oil screen. x ( p. 87)
ance x

Check the charging voltage. x

–

Check the charging current. x

–

Check the generator. x
Check the stall current. x

– Change the battery in the speedometer.

CLEANING 93

15.1Cleaning the motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-

cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.

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

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunlight on the motorcycle during cleaning.

– Close off the exhaust system to prevent water from entering.
– First remove coarse dirt particles with a gentle water spray.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft brush.

Motorcycle cleaner ( p. 117)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

–

Empty the carburetor float chamber. x ( p. 86)

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.

– After cleaning, take a short ride until the engine reaches operating temperature.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

– Push back the protective covers from the handlebar armatures to allow any water that may have entered there to evaporate.
– After the motorcycle has cooled off, oil or grease all moving parts and bearings.
– Clean the chain. ( p. 56)
– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 117)

– Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

Cleaning and polishing materials for metal, rubber and plastic ( p. 117)

– To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( p. 117)

(EXC-F, EXC‑F SIX DAYS)

– Lubricate the steering lock.

Universal oil spray ( p. 118)

STORAGE 94

16.1Storage

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.

Info

If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– Clean the motorcycle. ( p. 93)

–

Change the engine oil and oil filter, clean the oil screen. x ( p. 87)

– Check the anti-freeze and coolant level. ( p. 79)
– Drain the fuel from the tank into a suitable container.

–

Empty the carburetor float chamber. x ( p. 86)

– Check the tire air pressure. ( p. 73)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

–

Remove the battery. x ( p. 74)

(EXC‑F, EXC‑F SIX DAYS, XCF-W)

–

Recharge the battery. x ( p. 74)

Guideline

Storage temperature of battery without direct sunlight. 0… 35 °C (32… 95 °F)

– The storage place should be dry and not subject to large temperature fluctuations.

Info

KTM recommends jacking up the motorcycle.

– Jack up the motorcycle. ( p. 40)
– Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Info

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.

16.2Putting into operation after storage

– Remove the motorcycle from the work stand. ( p. 40)
(EXC‑F, EXC‑F SIX DAYS, XCF-W)

–

Install the battery. x ( p. 74)

– Refuel. ( p. 33)
– Check before putting into operation. ( p. 31)
– Take a test ride.

TECHNICAL DATA - ENGINE 95

Design 1-cylinder 4-stroke engine, water-cooled
Displacement 248.60 cm³ (15.1706 cu in)
Stroke 54.80 mm (2.1575 in)
Bore 76 mm (2.99 in)
Compression ratio 12.8:1
Idle speed 1,400… 1,500 rpm
Control DOHC, four valves controlled via cam lever, drive via tooth-wheel

chain
Valve diameter, intake 30.0 mm (1.181 in)
Valve diameter, exhaust 26.0 mm (1.024 in)
Valve clearance

Exhaust at: 20 °C (68 °F) 0.12… 0.17 mm (0.0047… 0.0067 in)

Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with two rotary pumps
Primary transmission 22:68
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission ratio (EXC‑F, EXC‑F SIX DAYS, XCF-W)

1st gear 13:33

2nd gear 17:33

3rd gear 19:29

4th gear 23:28

5th gear 23:23

6th gear 26:22
Transmission ratio (SX‑F)

1st gear 13:32

2nd gear 15:30

3rd gear 17:28

4th gear 19:26

5th gear 21:25

6th gear 22:24
Generator (EXC‑F, EXC‑F SIX DAYS, XCF-W)

Light coil and charging coil 12 V, 80 W
Generator (SX‑F)

Light coil and charging coil none
Ignition Contactless controlled fully electronic ignition with digital igni-

tion adjustment, type Kokusan
Spark plug NGK CR 9 EKB
Spark plug electrode gap 0.7 mm (0.028 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid (EXC‑F, EXC‑F SIX DAYS, XCF-W) Electric starter/kickstarter
Starting aid (SX‑F) Kickstarter

TECHNICAL DATA - ENGINE 96

17.1Capacity - engine oil

Engine oil 1.10 l (1.16 qt.) Engine oil (SAE 10W/50) ( p. 116)

17.2Capacity - coolant

Coolant 1.2 l (1.3 qt.) Coolant ( p. 116)

Coolant (mixed ready to use) ( p. 116)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 97

Oil jet, conrod lubrication M4
Oil jet for cam lever lubrication M5 4 Nm (3 lbf ft)
Screw, freewheel hub M5 7 Nm (5.2 lbf ft)
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft)
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft)
Screw, stator bracket (SX‑F) M5 6 Nm (4.4 lbf ft)
Locking screw for bearing M6 6 Nm (4.4 lbf ft)
Screw, cable holder in generator cover M6 6 Nm (4.4 lbf ft)
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, cover plate of valve cover M6 3 Nm (2.2 lbf ft)
Screw, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, engine housing M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 10 Nm (7.4 lbf ft)
Screw, generator cover M6 10 Nm (7.4 lbf ft) –
Screw, kickstarter stop M6 10 Nm (7.4 lbf ft)
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Screw, shift lever M6 10 Nm (7.4 lbf ft)
Screw, starter motor (EXC‑F,

EXC‑F SIX DAYS, XCF-W)
Screw, stator bracket (EXC‑F,

EXC‑F SIX DAYS, XCF-W)
Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft)
Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft)
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft)
Nut, camshaft bearing bridge M7 15 Nm (11.1 lbf ft) lubricated with engine oil
Screw, camshaft bearing bridge M7 15 Nm (11.1 lbf ft) lubricated with engine oil
Stud, camshaft bearing bridge M7
Plug, crankshaft location M8 20 Nm (14.8 lbf ft) –
Screw, kickstarter M8 25 Nm (18.4 lbf ft)
Screw, timing chain guide rail M8 10 Nm (7.4 lbf ft)
Screw, cylinder head M10 Tightening sequence:

Screw, engine sprocket M10 60 Nm (44.3 lbf ft)
Spark plug M10 10… 12 Nm (7.4…

Screw, unlocking of timing chain ten­sioner

Nut, rotor M12x1 60 Nm (44.3 lbf ft) –
Screw, camshaft gear M12x1 80 Nm (59 lbf ft)
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) –
Plug for oil screen, short M16x1.5 10 Nm (7.4 lbf ft) lubricated with engine oil

M6 10 Nm (7.4 lbf ft) –

M6 8 Nm (5.9 lbf ft)

Tighten diagonally, begin­ning with the rear screw on
the chain shaft.
Step 1
40 Nm (29.5 lbf ft)
Step 2
50 Nm (36.9 lbf ft)

8.9 lbf ft)

M10x1 10 Nm (7.4 lbf ft) –

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lubricated with engine oil

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TECHNICAL DATA - ENGINE TIGHTENING TORQUES 98

Nut, inner clutch hub M18x1.5 120 Nm (88.5 lbf ft)
Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft)
Plug for oil screen, long M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –

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