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

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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
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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, EXCF 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
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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, EXCF 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 (XCFW, SXF) .................................. 12
Short circuit button (EXC-F, EXCF SIX DAYS).................. 12
Emergency OFF switch (EXCF AUS) ............................... 12
Electric starter button (EXCF EU, EXCF SIX DAYS,
XCFW)......................................................................... 13
Electric starter button (EXCF AUS)................................. 13
Light switch (EXC-F, EXCF SIX DAYS) ............................ 13
Horn button (EXC-F, EXCF SIX DAYS)............................. 13
Turn signal switch (EXC-F, EXCF SIX DAYS).................... 13
Overview of indicator lamps (EXC-F, EXCF SIX DAYS) ...... 14
CONTROLS (EXCF, EXCF 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 (EXCF, EXCF SIX DAYS, XCF-W)....................... 22
Fuel tap (SXF).............................................................. 22
Opening filler cap.......................................................... 22
Closing filler cap ........................................................... 23
Choke (EXC-F EU, EXCF SIX DAYS)................................ 23
Choke (XCFW, SXF, EXCF AUS) ................................... 23
Shift lever..................................................................... 23
Foot brake lever............................................................. 24
Kick starter................................................................... 24
Side stand (EXCF, EXCF SIX DAYS, XCF-W) ................... 24
Plug-in stand (SXF) ...................................................... 24
Steering lock (EXC-F, EXCF SIX DAYS) ........................... 25
Locking the steering (EXC-F, EXCF SIX DAYS)................. 25
Unlocking the steering (EXC-F, EXCF 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 (EXCF, EXCF 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 (SXF)............................................... 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 (EXCF,
EXCF 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 (EXCF EU,
EXCF AUS, XCFW ZA) .................................................. 49
Adjusting the play of the steering head bearing x (SXF,
250 EXC-F SIX DAYS EU) .............................................. 50
Removing the fork legs................................................... 50
Installing the fork legs x............................................... 51
Removing the fork protector x....................................... 52
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Installing the fork protector x ....................................... 52
Removing the front fender .............................................. 52
Installing the front fender............................................... 53
Removing headlight mask with headlight (EXCF,
EXCF SIX DAYS, XCF-W) ............................................... 53
Refitting the headlight mask with the headlight (EXCF,
EXCF SIX DAYS, XCF-W) ............................................... 53
Removing the start number plate (SXF) .......................... 54
Installing the start number plate (SXF) ........................... 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 (EXCF, EXCF SIX DAYS,
XCF-W)......................................................................... 60
Adjusting the chain guide x (SXF)................................ 61
Checking brake discs ..................................................... 61
Checking free travel of hand brake lever........................... 61
Adjusting basic position of hand brake lever (XCFW,
SXF)............................................................................ 62
Adjusting free travel of hand brake lever
(EXC-F, EXCF 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 (EXCF, EXCF SIX DAYS,
XCF-W)......................................................................... 74
Installing the battery x (EXCF, EXCF SIX DAYS,
XCF-W)......................................................................... 74
Recharging the battery x (EXCF, EXCF SIX DAYS,
XCF-W)......................................................................... 74
Removing a fuse (EXCF, EXCF SIX DAYS, XCF-W)........... 75
Replacing the fuse (EXCF, EXCF SIX DAYS, XCF-W) ....... 75
Adjusting the beam width of the headlight (EXCF,
EXCF SIX DAYS, XCF-W) ............................................... 76
Checking the headlight adjustment (EXCF,
EXCF 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, EXCF SIX DAYS ................................................. 99
XCF-W.......................................................................... 99
SXF............................................................................. 99
TECHNICAL DATA - CHASSIS .......................................... 100
Lighting equipment ..................................................... 100
Tires .......................................................................... 101
Capacity - fuel............................................................. 101
TECHNICAL DATA - FORK................................................ 102
EXCF, EXCF SIX DAYS, XCF-W ................................... 102
SXF EU ..................................................................... 102
SXF USA ................................................................... 103
TECHNICAL DATA - SHOCK ABSORBER ........................... 104
EXCF, EXCF SIX DAYS, XCF-W ................................... 104
SXF........................................................................... 104
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................ 105
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WIRING DIAGRAM .......................................................... 106
Wiring diagram (EXC-F EU, EXCF SIX DAYS)................. 106
Wiring diagram (EXCF AUS) ........................................ 110
Wiring diagram (XCF-W) ............................................... 112
Wiring diagram (SXF).................................................. 114
SUBSTANCES................................................................. 116
AUXILIARY SUBSTANCES................................................ 117
STANDARDS................................................................... 119
INDEX ............................................................................ 120
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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.
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Use definition (EXC-F, EXCF 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 (XCFW, SXF)
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.
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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.
(EXCF, EXCF SIX DAYS, XCF-W)
Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 22)
(SXF)
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.
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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
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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
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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
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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
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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.
Page 15
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.
Page 16
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
Page 17
CONTROLS (EXCF, EXCF 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 .
Page 18
CONTROLS (EXCF, EXCF 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.
Page 19
CONTROLS (EXCF, EXCF 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.
Page 20
CONTROLS (EXCF, EXCF 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.
Page 21
CONTROLS (EXCF, EXCF 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
Page 22
CONTROLS (EXCF, EXCF 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
Page 23
CONTROLS (EXCF, EXCF 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
Page 24

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
Page 25
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
Page 26
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.
Page 27
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.
Page 28

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) (XCFW, SXF)
adjust the basic position of hand brake lever. ( p. 62)
(EXC-F, EXCF 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.
Page 29
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 27
(EXCF, EXCF 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.
(SXF)
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
Page 30
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)
Page 31
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.
Page 32
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.
Page 33

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)
(EXCF, EXCF 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.
(SXF)
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. (EXCF AUS)
Turn the emergency OFF switch to the position .
The engine is cold
(XCFW, SXF, EXCF AUS)
Pull choke lever out as far as possible.
(EXC-F EU, EXCF SIX DAYS)
Pull the choke lever to the stop.
Page 34
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.
Page 35
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. (XCFW, SXF)
Press and hold the short circuit button while the engine is idling until the engine stops.
(EXC-F, EXCF SIX DAYS)
Press and hold the short circuit button while the engine is idling until the engine stops.
(EXCF, EXCF SIX DAYS, XCF-W)
Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 22)
(SXF)
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)
Page 36
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. (EXCF, EXCF SIX DAYS, XCF-W)
Total fuel tank capacity, approx. (SXF)
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)
Page 37
SERVICE SCHEDULE (EXCF, EXCF 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
Page 38
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. (EXCF,
EXCF SIX DAYS, XCF-W) x
Perform a shock absorber service.
(EXCF, EXCF 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
Page 39
SERVICE SCHEDULE (SXF) 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)
Page 40
SERVICE SCHEDULE (SXF) 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. (SXF) x Conduct a minor fork service. (SXF) x Perform a shock absorber service. (SXF) 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
Page 41

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.
Page 42

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.
Page 43
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
(EXCF, EXCF SIX DAYS, XCF-W)
600667-10
Compression damping, high-speed
Comfort 2 turns Standard 1.5 turns Sport 1.25 turns
(SXF)
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
(EXCF, EXCF SIX DAYS, XCF-W)
600667-11
Compression damping, low-speed
Comfort 22 clicks Standard 20 clicks Sport 15 clicks
(SXF)
Compression damping, low-speed
Comfort 17 clicks Standard 15 clicks Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.
Page 44
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
(EXCF, EXCF SIX DAYS, XCF-W)
400210-10
Rebound damping
Comfort 26 clicks Standard 24 clicks Sport 22 clicks
(SXF)
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)
Page 45
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.
(EXCF, EXCF SIX DAYS, XCF-W)
Static sag 35 mm (1.38 in)
(SXF)
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.
(EXCF, EXCF SIX DAYS, XCF-W)
Riding sag 105 mm (4.13 in)
(SXF)
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.
Page 46
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
(EXCF, EXCF SIX DAYS, XCF-W)
Spring preload 8 mm (0.31 in)
(SXF)
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
(EXCF, EXCF 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)
(SXF)
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)
Page 47
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.
Page 48
MAINTENANCE WORK ON CHASSIS AND ENGINE 46
(EXCF, EXCF 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 .
(SXF)
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
(SXF EU)
Compression damping
Comfort 14 clicks Standard 12 clicks Sport 10 clicks
(SXF 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.
(EXCF, EXCF 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
Page 49
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.
(SXF)
Remove protection covers . Turn adjusting screws clockwise all the way.
Guideline
(SXF EU)
Rebound damping
Comfort 14 clicks Standard 12 clicks
100020-10
(SXF 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.
Page 50
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)
(EXCF, EXCF 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)
Page 51
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:
(SXF, 250 EXC-F SIX DAYS EU)
Adjust the play of the steering head bearing. x ( p. 50)
(EXCF EU, EXCF AUS, XCFW 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:
(SXF, 250 EXC-F SIX DAYS EU)
Adjust the play of the steering head bearing. x ( p. 50)
(EXCF EU, EXCF AUS, XCFW 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)
Page 52
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
(SXF)
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.
(EXCF, EXCF 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.
(EXCF EU, EXCF AUS, XCFW ZA)
Loosen screws . Remove the fork leg on the left. Loosen screws . Remove the fork leg on the right.
100804-10
Page 53
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
(SXF)
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.
(EXCF EU, EXCF AUS, XCFW 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)
(SXF)
Fully tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Fully tighten screws .
Page 54
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)
(EXCF, EXCF 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
Page 55
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)
Page 56
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™
Page 57
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)
Page 58
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
Page 59
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.
Page 60
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
Page 61
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°.
Page 62
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)
Page 63
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.
Page 64
MAINTENANCE WORK ON CHASSIS AND ENGINE 62
(XCFW, SXF)
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, EXCF 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.)
Page 65
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.
Page 66
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!
Page 67
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.
Page 68
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.)
Page 69
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.)
Page 70
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.
Page 71
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
Page 72
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)
Page 73
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.
Page 74
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.
Page 75
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, EXCF 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)
Page 76
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.
Page 77
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.
Page 78
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, EXCF 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.
Page 79
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)
(EXCF, EXCF SIX DAYS, XCF-W)
Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 22)
(SXF)
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, EXCF 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
Page 80
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, EXCF 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.
Page 81
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)
Page 82
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)
Page 83
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
Page 84
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.
Page 85
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.
Page 86
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
Page 87
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 (EXCF, EXCF SIX DAYS, SXF)
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. (XCFW, SXF, EXCF AUS) ( p. 23)
Choke function deactivated – The choke lever is pushed back to the stop. (EXC­F EU, EXCF 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.
Page 88
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. (XCFW, SXF, EXCF AUS) ( p. 23)
Choke function deactivated – The choke lever is pushed back to the stop. (EXC­F EU, EXCF 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.
(EXCF, EXCF SIX DAYS, XCF-W)
Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 22)
(SXF)
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.
Page 89
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.
Page 90
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
Page 91
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 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.
Page 92
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.
Page 93

TROUBLESHOOTING 91

Faults Possible cause Action
The engine cannot be cranked (elec­tric starter) (EXCF, EXCF 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
Page 94
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
(EXCF, EXCF SIX DAYS, XCF-W)
Turn handle of the fuel tap to the ON
position. (Figure 500137-10 p. 22)
(SXF)
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.
Page 95

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, EXCF SIX DAYS)
Lubricate the steering lock.
Universal oil spray ( p. 118)
Page 96

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)
(EXCF, EXCF SIX DAYS, XCF-W)
Remove the battery. x ( p. 74)
(EXCF, EXCF 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) (EXCF, EXCF SIX DAYS, XCF-W)
Install the battery. x ( p. 74)
Refuel. ( p. 33) Check before putting into operation. ( p. 31) Take a test ride.
Page 97

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 (EXCF, EXCF 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 (SXF)
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 (EXCF, EXCF SIX DAYS, XCF-W)
Light coil and charging coil 12 V, 80 W Generator (SXF)
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 (EXCF, EXCF SIX DAYS, XCF-W) Electric starter/kickstarter Starting aid (SXF) Kickstarter
Page 98
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)
Page 99

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,
EXCF SIX DAYS, XCF-W) Screw, stator bracket (EXCF,
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)
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
lubricated with engine oil
Loctite®243™
Loctite®243™
Page 100
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)
Loctite®243™
Loctite®243™
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