KTM 250 XC-W 2018, 250 EXC 2018, 300 EXC 2018, 300 XC-W 2018, 300 XC-W Six Day 2018 Owner's Manual
...
OWNER'S MANUAL 2018
250 EXC
250 XC‑W
300 EXC
300 XC‑W
300 XC‑W Six Days
Art. no. 3213644en
DEAR KTM CUSTOMER
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 properly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 15) Dealer's stamp
Engine number ( p. 15)
Key number (All EXC models) ( p. 15)
The Owner's Manual contained the latest information for this model series at the time of going to print. However,
minor differences due to further developments in design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle GmbH 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 figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2017 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
250 EXC AU (F7360R6)
250 XC‑W US (F7375R3)
300 EXC AU (F7460R6)
300 EXC BR (F7440R6)
300 XC‑W US (F7475R3)
300 XC‑W Six Days US (F7475R2)
*3213644en*
3213644en
03/2017
TABLE OF CONTENTS
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ...................... 6
1.1 Symbols used .................................... 6
1.2 Formats used..................................... 6
2 SAFETY ADVICE............................................ 7
2.1 Use definition – intended use.............. 7
2.2 Misuse.............................................. 7
2.3 Safety advice..................................... 7
2.4 Degrees of risk and symbols ................ 8
2.5 Tampering warning............................. 8
2.6 Safe operation ................................... 8
2.7 Protective clothing ............................. 9
2.8 Work rules......................................... 9
2.9 Environment...................................... 9
2.10 Owner's Manual ............................... 10
3 IMPORTANT NOTES.................................... 11
3.1 Manufacturer and implied warranty.... 11
3.2 Operating and auxiliary substances .... 11
3.3 Spare parts, accessories ................... 11
3.4 Service ........................................... 11
3.5 Figures ........................................... 11
3.6 Customer service.............................. 12
4 VIEW OF VEHICLE ...................................... 13
4.1 View of vehicle, front left (example) ... 13
4.2 View of vehicle, rear right
(example)........................................ 14
5 SERIAL NUMBERS ..................................... 15
5.1 Chassis number ............................... 15
5.2 Type label ....................................... 15
5.3 Key number (All EXC models)............ 15
5.4 Engine number ................................ 15
5.5 Fork part number ............................. 16
5.6 Shock absorber article number .......... 16
6 CONTROLS................................................. 17
6.1 Clutch lever..................................... 17
6.2 Hand brake lever.............................. 17
6.3 Throttle grip .................................... 17
6.4 Kill switch (All EXC models) .............. 17
6.5 Kill switch (All XC‑W models) ............ 18
6.6 Horn button (All EXC models)............ 18
6.7 Light switch (All EXC models) ........... 18
6.8 Light switch (All XC‑W models).......... 18
6.9 Turn signal switch (All EXC
models)........................................... 19
6.10 Emergency OFF switch (EXC AU)....... 19
6.11 Electric starter button....................... 19
6.12 Map switch (All Six Days models) ...... 19
6.13 Indicator lamps overview (All EXC
models)........................................... 20
6.14 Indicator lamps overview (All XC‑W
models)........................................... 20
6.15 Opening the filler cap....................... 20
6.16 Closing the filler cap ........................ 21
6.17 Fuel tap .......................................... 21
6.18 Choke............................................. 22
6.19 Shift lever ....................................... 22
6.20 Kick starter ..................................... 22
6.21 Foot brake lever ............................... 23
6.22 Side stand....................................... 23
6.23 Steering lock (All EXC models) .......... 23
6.24 Locking the steering (All EXC
models)........................................... 24
6.25 Unlocking the steering (All EXC
models)........................................... 24
7 COMBINATION INSTRUMENT ..................... 25
7.1 Combination instrument overview ...... 25
7.2 Activation and test ........................... 25
7.3 Setting the kilometers or miles .......... 25
7.4 Adjusting the combination
instrument function.......................... 26
7.5 Setting the clock.............................. 27
7.6 Viewing the lap time......................... 27
7.7 Display mode SPEED (speed) ............ 28
7.8 Display mode SPEED/H (operating
hours)............................................. 28
7.9 Setup menu .................................... 28
7.10 Setting the unit of measurement ....... 29
7.11 Display mode SPEED/CLK (time)....... 30
7.12 Setting the clock.............................. 30
7.13 Display mode SPEED/LAP (lap
time) .............................................. 30
7.14 Viewing the lap time......................... 31
7.15 Display mode SPEED/ODO
(odometer) ...................................... 31
7.16 Display mode SPEED/TR1 (trip
master 1) ........................................ 32
7.17 Display mode SPEED/TR2 (trip
master 2) ........................................ 32
7.18 Setting TR2 (trip master 2) ............... 32
7.19 Display mode SPEED/A1 (average
speed 1) ......................................... 33
7.20 Display mode SPEED/A2 (average
speed 2) ......................................... 33
7.21 Display mode SPEED/S1 (stop
watch 1) ......................................... 34
7.22 Display mode SPEED/S2 (stop
watch 2) ......................................... 34
7.23 Table of functions ............................ 35
7.24 Table of conditions and menu
activation ........................................ 36
2
TABLE OF CONTENTS
8 PREPARING FOR USE................................. 37
8.1 Advice on first use ........................... 37
8.2 Running in the engine ...................... 38
8.3 Starting power of lithium-ion
batteries at low temperatures (All
AU/US models)................................ 39
8.4 Preparing the vehicle for difficult
riding conditions.............................. 39
8.5 Preparing for rides on dry sand.......... 40
8.6 Preparing for rides on wet sand ......... 41
8.7 Preparations for riding on wet and
muddy surfaces ............................... 42
8.8 Preparing for rides at high
temperature and slow speed.............. 42
8.9 Preparing for riding at low
temperatures or in snow.................... 43
9 RIDING INSTRUCTIONS.............................. 44
9.1 Checks and maintenance measures
when preparing for use ..................... 44
9.2 Starting the vehicle .......................... 44
9.3 Start off .......................................... 45
9.4 Shifting, riding ................................ 45
9.5 Braking........................................... 46
9.6 Stopping, parking............................. 46
9.7 Transporting.................................... 47
9.8 Refueling ........................................ 48
10 SERVICE SCHEDULE .................................. 49
10.1 Additional information ...................... 49
10.2 Required work ................................. 49
10.3 Recommended work ......................... 50
11 TUNING THE CHASSIS ............................... 51
11.1 Checking the basic chassis setting
with the rider's weight ...................... 51
11.2 Compression damping of the shock
absorber.......................................... 51
11.3 Adjusting the low-speed
compression damping of the shock
absorber.......................................... 51
11.4 Adjusting the high-speed
compression damping of the shock
absorber.......................................... 52
11.5 Adjusting the rebound damping of
the shock absorber ........................... 53
11.6 Measuring the rear wheel dimension
unloaded......................................... 53
11.7 Checking the static sag of the shock
absorber.......................................... 54
11.8 Checking the riding sag of the shock
absorber.......................................... 54
11.9 Adjusting the spring pretension of
the shock absorber ....................... 55
11.10 Adjusting the riding sag ................ 56
11.11 Checking the basic setting of the
fork ................................................ 56
11.12 Adjusting the compression damping
of the fork ....................................... 57
11.13 Adjusting the rebound damping of
the fork........................................... 58
11.14 Adjusting the spring pretension of
the fork (All Six Days models)............ 59
11.15 Handlebar position........................... 60
11.16 Adjusting the handlebar position .... 61
12 SERVICE WORK ON THE CHASSIS............... 63
12.1 Raising the motorcycle with a lift
stand .............................................. 63
12.2 Removing the motorcycle from the
lift stand ......................................... 63
12.3 Bleeding the fork legs....................... 63
12.4 Cleaning the dust boots of the fork
legs ................................................ 64
12.5 Removing the fork protector .............. 64
12.6 Installing the fork protector............... 65
12.7 Removing the fork legs .................. 65
12.8 Installing the fork legs .................. 66
12.9 Removing the lower triple clamp
(All standard EXC/XC-W models) ........ 67
12.10 Removing the lower triple clamp
(All Six Days models)........................ 68
12.11 Installing the lower triple clamp
(All standard EXC/XC-W models) ........ 68
12.12 Installing the lower triple clamp
(All Six Days models)........................ 70
12.13 Checking the play of the steering
head bearing ................................... 72
12.14 Adjusting the steering head bearing
play ............................................ 73
12.15 Lubricating the steering head
bearing ........................................ 74
12.16 Removing front fender ...................... 74
12.17 Installing front fender....................... 74
12.18 Removing the shock absorber ........ 75
12.19 Installing the shock absorber ......... 75
12.20 Removing the seat ........................... 76
12.21 Mounting the seat ............................ 76
12.22 Removing the air filter box cover ....... 76
12.23 Installing the air filter box cover ........ 77
12.24 Removing the air filter .................. 77
12.25 Installing the air filter ................... 78
12.26 Cleaning the air filter and air filter
box ............................................. 78
12.27 Securing the air filter box cover ..... 79
12.28 Sealing the air filter box ................ 79
12.29 Removing the main silencer .............. 80
12.30 Installing the main silencer............... 80
12.31 Changing the glass fiber yarn filling
in the main silencer ...................... 80
3
TABLE OF CONTENTS
12.32 Removing the fuel tank ................. 81
12.33 Installing the fuel tank .................. 82
12.34 Checking the chain for dirt................ 84
12.35 Cleaning the chain ........................... 84
12.36 Checking the chain tension ............... 85
12.37 Adjusting the chain tension............... 85
12.38 Checking the chain, rear sprocket,
motor sprocket, and chain guide........ 86
12.39 Checking the frame ...................... 89
12.40 Checking the swingarm ................. 89
12.41 Checking throttle cable routing.......... 89
12.42 Checking the rubber grip .................. 90
12.43 Adjusting the basic position of the
clutch lever ..................................... 91
12.44 Checking/correcting the fluid level of
the hydraulic clutch ......................... 91
12.45 Changing the hydraulic clutch
fluid ............................................ 92
12.46 Removing the engine guard (All
Six Days models, EXC AU) ................ 93
12.47 Installing the engine guard (All
Six Days models, EXC AU) ................ 94
13 BRAKE SYSTEM ......................................... 95
13.1 Checking the free travel of the hand
brake lever ...................................... 95
13.2 Adjusting free travel of hand brake
lever (All EXC models) ...................... 95
13.3 Adjusting the basic position of the
hand brake lever (All XC‑W models) ... 96
13.4 Checking the brake discs .................. 96
13.5 Checking the front brake fluid level ... 97
13.6 Adding front brake fluid ................ 97
13.7 Checking the front brake linings ........ 98
13.8 Changing the front brake linings .... 99
13.9 Checking the free travel of foot
brake lever .................................... 101
13.10 Adjusting the basic position of the
foot brake lever .......................... 101
13.11 Checking the rear brake fluid
level ............................................. 102
13.12 Adding rear brake fluid ............... 103
13.13 Checking the brake linings of the
rear brake...................................... 104
13.14 Changing the rear brake linings .... 104
14 WHEELS, TIRES ....................................... 107
14.1 Removing the front wheel ............ 107
14.2 Installing the front wheel ............ 108
14.3 Removing the rear wheel ............. 108
14.4 Installing the rear wheel .............. 109
14.5 Checking the tire condition ............. 111
14.6 Checking the tire air pressure.......... 111
14.7 Checking spoke tension .................. 112
15 ELECTRICAL SYSTEM ............................... 113
15.1 Removing the battery .................. 113
15.2 Installing the battery ................... 114
15.3 Recharging the battery ................ 115
15.4 Changing the main fuse.................. 118
15.5 Removing the headlight mask with
the headlight ................................. 119
15.6 Installing the headlight mask with
the headlight ................................. 120
15.7 Changing the headlight bulb ........... 121
15.8 Changing the turn signal bulb (All
EXC models).................................. 121
15.9 Checking the headlight setting ........ 122
15.10 Adjusting the headlight range.......... 123
15.11 Changing the combination
instrument .................................... 123
16 COOLING SYSTEM .................................... 125
16.1 Cooling system .............................. 125
16.2 Checking the antifreeze and
coolant level.................................. 125
16.3 Checking the coolant level .............. 126
16.4 Draining the coolant ................... 126
16.5 Refilling with coolant .................. 127
17 TUNING THE ENGINE............................... 129
17.1 Checking the play in the throttle
cable ............................................ 129
17.2 Adjusting the play in the throttle
cable ......................................... 129
17.3 Carburetor setting .......................... 131
17.4 Carburetor - idle............................. 133
17.5 Carburetor – adjusting the idle
speed ........................................ 134
17.6 Ignition curve plug-in connector ...... 135
17.7 Changing the ignition timing map .... 135
17.8 Checking the basic position of the
shift lever...................................... 136
17.9 Adjusting the basic position of the
shift lever .................................. 136
17.10 Engine characteristic – auxiliary
spring ........................................... 137
17.11 Engine characteristic – setting the
auxiliary spring ........................... 137
18 SERVICE WORK ON THE ENGINE .............. 139
18.1 Emptying the carburetor float
chamber .................................... 139
18.2 Checking the gear oil level .............. 140
18.3 Changing the gear oil .................. 140
18.4 Adding gear oil ........................... 141
19 CLEANING, CARE ..................................... 143
19.1 Cleaning the motorcycle ................. 143
4
19.2 Checks and maintenance steps for
winter operation............................. 144
20 STORAGE................................................. 145
20.1 Storage ......................................... 145
20.2 Preparing for use after storage......... 146
21 TROUBLESHOOTING ................................ 147
22 TECHNICAL DATA..................................... 149
22.1 Engine .......................................... 149
22.1.1 All 250 models.......................... 149
22.1.2 All 300 models.......................... 149
22.2 Engine tightening torques ............... 150
22.3 Carburetor ..................................... 153
22.3.1 EXC AU .................................... 153
22.3.2 Carburetor tuning (EXC AU) ..... 153
22.3.3 All XC‑W models ........................ 154
22.3.4 Carburetor tuning (All XC‑W
models) ................................. 155
22.3.5 EXC BR .................................... 156
22.3.6 Carburetor tuning (EXC BR) ..... 157
22.4 Capacities ..................................... 158
22.4.1 Gear oil..................................... 158
22.4.2 Coolant..................................... 158
22.4.3 Fuel ......................................... 158
22.5 Chassis ......................................... 158
22.6 Electrical system............................ 159
22.7 Tires ............................................. 159
22.8 Fork.............................................. 160
22.8.1 All 250 models, EXC AU,
300 XC‑W US............................ 160
22.8.2 EXC BR .................................... 160
22.8.3 All Six Days models.................... 161
22.9 Shock absorber .............................. 161
22.10 Chassis tightening torques .............. 162
TABLE OF CONTENTS
23 SUBSTANCES .......................................... 164
24 AUXILIARY SUBSTANCES ......................... 167
25 STANDARDS ............................................ 169
26 LIST OF ABBREVIATIONS.......................... 170
27 LIST OF SYMBOLS.................................... 171
27.1 Yellow and orange symbols.............. 171
27.2 Green and blue symbols.................. 171
INDEX ............................................................. 172
5
1 MEANS OF REPRESENTATION
1.1 Symbols used
The meaning of specific symbols is described below.
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 performed by an authorized KTM workshop!
Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary
tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates the end of an activity including potential reworking.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
®
Name
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
Indicates a protected name.
are explained in the glossary.
6
2 SAFETY ADVICE
2.1 Use definition – intended use
(All EXC models)
This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations.
Info
This vehicle is only authorized for operation on public roads in the homologated (restricted) version.
The derestricted version of this vehicle must only be operated in closed off areas away from public
highway traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in
motocross.
(All XC‑W models)
This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations.
Info
This vehicle is not approved for use on public roads.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in
motocross.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the
respective use.
2.3 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual
carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be
injured.
7
2 SAFETY ADVICE
2.4 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.5 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing
thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replace-
ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any
person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct
exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those
specified by the manufacturer.
2.6 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
8
2 SAFETY ADVICE
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a
safe and environmentally compatible manner.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle
on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.7 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.8 Work rules
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals,
sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a thread locker (e.g. Loctite®) is required. Apply according to the manufacturer's
instructions.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the
future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and
regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no
legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad
to advise you.
9
2 SAFETY ADVICE
2.10 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle.
Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself
from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an
authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the
vehicle is sold.
10
3 IMPORTANT NOTES
3.1 Manufacturer and implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be
recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will
become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not
covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the
Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM
and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any
resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM
dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work
on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and
tuning of the engine and chassis can lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this
reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly,
you will ensure a much longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
11
3 IMPORTANT NOTES
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
12
4.1 View of vehicle, front left (example)
4 VIEW OF VEHICLE
Hand brake lever ( p. 17)
1
Light switch ( p. 18) (All EXC models)
2
Kill switch ( p. 17) (All EXC models)
2
Turn signal switch ( p. 19) (All EXC models)
2
Horn button ( p. 18) (All EXC models)
2
Clutch lever ( p. 17)
3
Chain guide
4
Air filter box cover
5
Side stand ( p. 23)
6
Shift lever ( p. 22)
7
Fuel tap ( p. 21)
8
E00815-10
13
4 VIEW OF VEHICLE
4.2 View of vehicle, rear right (example)
Filler cap
1
Throttle grip ( p. 17)
2
Chassis number ( p. 15)
3
Kick starter ( p. 22)
4
Foot brake lever ( p. 23)
5
Level viewer for brake fluid, rear
6
E00816-10
14
5.1 Chassis number
5.2 Type label
5 SERIAL NUMBERS
The chassis number1is stamped on the right side of the steering head.
401945-10
Type label1is fixed to the front of the steering head.
401946-10
5.3 Key number (All EXC models)
402247-10
5.4 Engine number
The key number1for the steering lock is stamped onto the key
connector.
The engine number1is located on the left side of the engine
over the engine sprocket.
H01047-10
15
5 SERIAL NUMBERS
0011
5.5 Fork part number
5.6 Shock absorber article number
The fork part number1is stamped on the inside of the axle
clamp.
401947-10
Shock absorber article number1is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.
401948-10
16
6.1 Clutch lever
6.2 Hand brake lever
6 CONTROLS
Clutch lever1is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
E00817-10
Hand brake lever1is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
E00818-10
6.3 Throttle grip
E00819-10
6.4 Kill switch (All EXC models)
Throttle grip1is fitted on the right side of the handlebar.
The kill switch1is fitted on the left side of the handlebar.
Possible states
• Kill switch in the basic position – In this position, the ignition circuit is closed and the engine can be started.
• Kill switch is pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running
engine will not start.
E00820-10
17
6 CONTROLS
6.5 Kill switch (All XC‑W models)
6.6 Horn button (All EXC models)
The kill switch1is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition
circuit is closed and the engine can be started.
• Kill switch pressed – In this position, the ignition circuit
is interrupted, a running engine stops, and a non-running
engine will not start.
E00821-10
The horn button1is 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.
E00820-11
6.7 Light switch (All EXC models)
E00822-10
6.8 Light switch (All XC‑W models)
Light switch1is fitted on the left side of the handlebar.
Possible states
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 light switch1is located to the left of the combination
instrument.
Possible states
• Light off – Light switch is pressed in up to the stop. In this
position, the light is switched off.
• Light on – Light switch is pulled out to the stop. In this position, the low beam and tail light are switched on.
18
E00317-10
6.9 Turn signal switch (All EXC models)
Turn signal switch1is fitted on the left side of the handlebar.
Possible states
E00820-12
6.10 Emergency OFF switch (EXC AU)
The emergency OFF switch1is fitted on the right side of the
handlebar.
Possible states
E00823-10
6 CONTROLS
Turn signal off – The turn signal switch is in the central position.
Left turn signal, on – The turn signal switch is turned
to the left.
Right turn signal, on – The turn signal switch is
turned to the right.
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.
6.11 Electric starter button
The electric starter button1is fitted on the right side of the
handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the elec-
E00824-10
6.12 Map switch (All Six Days models)
The map switch1is fitted on the right side of the handlebar.
Possible states
• Map switch in position I – The ignition timing map Perfor-
• Map switch in position II – The ignition timing map Soft is
E00825-10
tric starter is actuated.
mance is active in this position.
active in this position.
Warning
Voiding of the government approval for road use and the
insurance coverage If the map switch is installed, the
vehicle's approval for road use is invalidated.
– Only operate the vehicle in closed-off areas away from
public road traffic if the map switch is installed.
The engine characteristic can be altered with the map switch.
19
6 CONTROLS
6.13 Indicator lamps overview (All EXC models)
Possible states
The high beam indicator lamp lights up blue – The
high beam is switched on.
Malfunction indicator lamp – inoperative
Fuel level warning lamp – inoperative
E00314-01
Turn signal indicator lamp flashes green – The turn
signal is switched on.
6.14 Indicator lamps overview (All XC‑W models)
Possible states
High beam indicator lamp – inoperative
Malfunction indicator lamp – inoperative
Fuel level warning lamp – inoperative
E00371-01
6.15 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
20
6.16 Closing the filler cap
V00325-10
6 CONTROLS
–
Press release button1, turn the filler cap counterclockwise
and lift it free.
– Replace the filler cap and turn clockwise until the release but-
ton1locks in place.
Info
Run the fuel tank breather hose2without kinks.
6.17 Fuel tap
V00325-11
The fuel tap is on the left side of the fuel tank.
Open or close the supply of fuel to the carburetor using tap handle1on the fuel tap.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank
to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the
carburetor. The fuel tank empties down to the reserve level.
• Fuel reserve supply open RES – Fuel can flow from the fuel
tank to the carburetor. The fuel tank empties completely.
E00826-10
21
6 CONTROLS
0011
6.18 Choke
Choke1is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor
through which the engine can draw extra fuel. This results in a
richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
6.19 Shift lever
E00827-10
401950-10
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 lever1is 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.
6.20 Kick starter
22
401950-11
Kick starter1is fitted on the right side of the engine.
The top part of the kick starter pivots.
Info
Before riding, swing the top part of the kick starter inward
toward the engine.
401954-10
6.21 Foot brake lever
6.22 Side stand
6 CONTROLS
Foot brake lever1is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
401956-10
Side stand1is located on the left side of the vehicle.
401943-10
401944-10
6.23 Steering lock (All EXC models)
V00328-10
The side stand is used for parking the motorcycle.
Info
When you are riding, side stand1must be folded up and
secured with rubber band2.
Steering lock1is 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.
23
6 CONTROLS
6.24 Locking the steering (All EXC models)
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
6.25 Unlocking the steering (All EXC models)
– Park the vehicle.
– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in
and turn it to the right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
400732-01
– Insert the key in the steering lock, turn it to the left, pull it out
and turn it to the right. Remove the key.
You can now steer the bike again.
400731-01
Info
Never leave the key in the steering lock.
24
7.1 Combination instrument overview
– Press the button to control different functions.
– Press the button to control different functions.
V00799-01
7.2 Activation and test
Activating combination instrument
The combination instrument is activated when one of the buttons
is pressed or an impulse comes from the wheel speed sensor.
Display test
To enable you to check that the display is functioning properly, all
display segments light up briefly.
7 COMBINATION INSTRUMENT
Info
When the vehicle is delivered, only the SPEED/H and
SPEED/ODO display modes are activated.
400313-01
WS (wheel size)
After the display function check, the wheel circumference WS is
displayed briefly.
Info
The number 2205 equals the circumference of the 21"
front wheel with standard tires.
The display then changes to the last selected mode.
400314-01
7.3 Setting the kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
– Repeatedly press the button briefly until Km/h/Mph flashes.
Setting the Km/h
– Press the button .
400329-01
25
7 COMBINATION INSTRUMENT
7.4 Adjusting the combination instrument function
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Setting the Mph
–
Press the button .
– Wait 3 - 5 seconds.
The settings are stored.
Info
If no button is pressed for 10 -12 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
400318-01
Info
If no button is pressed for 10–12 seconds, the settings
are automatically saved.
If no button is pressed for 20 seconds, or if an impulse
comes from the wheel speed sensor, the settings are
automatically saved and the setup menu is closed.
– Repeatedly press the button briefly until the desired func-
tion flashes.
The selected function flashes.
Activating the function
– Press the button .
The symbol continues to appear in the display and the
next function appears.
Deactivating a function
– Press the button .
The symbol disappears in the display and the next
function appears.
26
7.5 Setting the clock
400330-01
7 COMBINATION INSTRUMENT
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The hour display flashes.
– Set the hour display with the button and/or button .
– Wait 3 - 5 seconds.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the
hours by pressing the button and the button .
Info
The seconds can only be set to zero.
If no button is pressed for 15 - 20 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
7.6 Viewing the lap time
Info
This function can only be opened if lap times have actually been timed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until LAP appears at the
bottom right of the display.
– Briefly press the button .
LAP 1 appears on the left side of the display.
– The laps 1–10 can be viewed with the button .
– Press and hold the button for 3-5 seconds.
The lap times are deleted.
400321-01
– Briefly press the button .
Next display mode
Info
When an impulse is received from the wheel speed sensor, the left side of the display changes back to the
SPEED mode.
27
7 COMBINATION INSTRUMENT
7.7 Display mode SPEED (speed)
400317-02
7.8 Display mode SPEED/H (operating hours)
– Repeatedly press the button briefly 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
Make the setting according to the country.
When an impulse comes from the front wheel, the left side
of the combination instrument display changes to the
SPEED mode and the current speed is shown.
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly 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.
7.9 Setup menu
400316-01
Info
The service hour counter is necessary for ensuring that
service work is carried out at the right intervals.
If the combination instrument is in Hdisplay mode when
starting off, it automatically changes to the ODO display
mode.
The H display mode is suppressed during the journey.
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu displays the active functions.
The display changes to the setup menu for the
combination instrument functions.
Next display mode
No function
No function
28
400344-01
7 COMBINATION INSTRUMENT
Info
Repeatedly press the button briefly until the desired
function is reached.
If no button is pressed for 20 seconds, the settings are
automatically saved.
7.10 Setting the unit of measurement
400329-01
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
– Repeatedly press the button briefly until Km/h/Mph flashes.
In measurement unit mode, you can change the unit of measurement.
Activates the flashing display and changes to
the next display
No function
Deactivates the flashing display and changes to
the next display
No function
Changes to the next display without changes
Setup menu starts, stores the settings, and
changes to H or ODO.
Info
If no button is pressed for 5 seconds, the settings are automatically saved.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Starts selection, activates Km/h display
No function
Activates Mph display
No function
Changes to the next display, changes from
selection to the Setup menu
Stores and closes the Setup menu
29
7 COMBINATION INSTRUMENT
7.11 Display mode SPEED/CLK (time)
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
The time is shown in display mode CLK.
7.12 Setting the clock
400319-01
400319-01
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
The display changes to the Setup menu of the
clock.
Next display mode
No function
No function
Increases the value
Increases the value
Reduces the value
Reduces the value
Changes to the next value
Closes the SETUP menu
7.13 Display mode SPEED/LAP (lap time)
– Repeatedly press the button briefly until LAP appears at the
In the LAP display mode, up to 10 lap times can be timed with the
stop watch.
400320-01
30
bottom right of the display.
Info
If the lap time continues running after the button is
pressed, 9 memory locations are occupied.
Lap 10 must be timed using the button .
7 COMBINATION INSTRUMENT
7.14 Viewing the lap time
400321-01
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until LAP appears at the
bottom right of the display.
– Briefly press the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
The stop watch and the lap time are reset.
Next display mode
Stops the clock.
Starts the stop watch or stop the current lap
time measurement, stores it and the stop watch
starts the next lap.
The stop watch and the lap time are reset.
Select a lap from 1–10
No function
View the next lap time.
7.15 Display mode SPEED/ODO (odometer)
– Repeatedly press the button briefly until ODO appears at the
bottom right of the display.
The total traveled distance is shown in display mode ODO.
Press the button for 2–3
seconds.
Briefly press
400317-01
the button .
Press the but-
ton for 2–3
seconds.
Briefly press
the button .
No function
Next display mode
No function
No function
31
7 COMBINATION INSTRUMENT
7.16 Display mode SPEED/TR1 (trip master 1)
400323-01
– Repeatedly press the button briefly 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 refueling
stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are
automatically reset to 0.0.
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
7.17 Display mode SPEED/TR2 (trip master 2)
– Repeatedly press the button briefly until TR2 appears at the
top right of the display.
TR2 (trip master 2) runs constantly and counts up to 999.9.
Press the button for 2–3
seconds.
Briefly press
400324-01
the button .
Press the but-
ton for 2–3
seconds.
Briefly press
the button .
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
No function
No function
Clears the values TR2 and A2.
Next display mode
Reduces value of TR2.
Reduces value of TR2.
7.18 Setting TR2 (trip master 2)
400324-01
32
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until TR2 appears at the
top right of the display.
– Press the button for 2–3 seconds until TR2 flashes.
The displayed value can be set manually with the button and
the button . This is a very practical function when riding using
the road book.
7 COMBINATION INSTRUMENT
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 for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Wait 10 - 12
seconds.
7.19 Display mode SPEED/A1 (average speed 1)
– Repeatedly press the button briefly 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.
Press the button for 2–3
400325-01
seconds.
Briefly press
the button .
Press the but-
ton for 2–3
seconds.
Briefly press
the button .
Increases value of TR2.
Increases value of TR2.
Reduces value of TR2.
Reduces value of TR2.
Stores and closes the Setup menu.
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
No function
No function
7.20 Display mode SPEED/A2 (average speed 2)
– Repeatedly press the button briefly until A2 appears at the
top right of the display.
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.
Info
The displayed value can differ from the actual average
speed if S2 was not stopped after the ride.
400326-01
33
7 COMBINATION INSTRUMENT
Briefly press
the button .
Press the button for 2–3
seconds.
Press the button for 2–3
seconds.
Briefly press
the button .
7.21 Display mode SPEED/S1 (stop watch 1)
– Repeatedly press the button briefly until S1 appears at the
top right of the display.
S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed
sensor.
The calculation of this value starts with the first impulse from the
wheel speed sensor and ends 3 seconds after the last impulse.
Press the but-
400327-01
ton for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Next display mode
No function
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
No function
No function
7.22 Display mode SPEED/S2 (stop watch 2)
– Repeatedly press the button briefly 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 in the combination instrument flashes.
Press the button for 2–3
seconds.
400328-01
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
The displays of S2 and A2 are set to 0,0.
Next display mode
No function
Starts or stops S2.
34
7.23 Table of functions
7 COMBINATION INSTRUMENT
Display Press the but-
ton for 2–3
seconds.
Display mode
SPEED/H (operating hours)
Setup menu No function Activates
Setting the unit
of measurement
Display mode
SPEED/CLK
(time)
Setting the
clock
Display mode
SPEED/LAP (lap
time)
Viewing the lap
time
Display mode
SPEED/ODO
(odometer)
The display
changes to
the setup
menu for the
combination
instrument
functions.
No function Starts selec-
The display
changes to
the Setup
menu of the
clock.
Increases the
value
The stop
watch and
the lap time
are reset.
The stop
watch and
the lap time
are reset.
No function Next display
Briefly press
the button .
Next display
mode
the flashing display
and changes
to the next
display
tion, activates Km/h
display
Next display
mode
Increases the
value
Next display
mode
Select a lap
from 1–10
mode
Press the button for 2–3
seconds.
No function No function
No function Deactivates
No function Activates
No function No function
Reduces the
value
Stops the
clock.
No function View the next
No function No function
Briefly press
the button .
the flashing
display and
changes to
the next display
Mph display
Reduces the
value
Starts the
stop watch or
stop the current lap time
measurement, stores
it and the
stop watch
starts the
next lap.
lap time.
Wait 3 - 5
seconds.
Changes to
the next display without
changes
Changes to
the next display, changes
from selection to the
Setup menu
Changes
to the next
value
Wait 10 - 12
seconds.
Setup menu
starts, stores
the settings,
and changes
to H or ODO.
Stores and
closes the
Setup menu
Closes the
SETUP menu
35
7 COMBINATION INSTRUMENT
Display Press the but-
ton for 2–3
seconds.
Display mode
SPEED/TR1 (trip
master 1)
Display mode
SPEED/TR2 (trip
master 2)
Setting TR2
(trip master 2)
Display mode
SPEED/A1 (average speed 1)
Display mode
SPEED/A2 (average speed 2)
Display mode
SPEED/S1 (stop
watch 1)
Display mode
SPEED/S2 (stop
watch 2)
Displays of
TR1, A1 and
S1 are reset
to 0,0.
Clears the
values TR2
and A2.
Increases
value of TR2.
Displays of
TR1, A1 and
S1 are reset
to 0,0.
No function Next display
Displays of
TR1, A1 and
S1 are reset
to 0,0.
The displays
of S2 and
A2 are set to
0,0.
Briefly press
the button .
Next display
mode
Next display
mode
Increases
value of TR2.
Next display
mode
mode
Next display
mode
Next display
mode
Press the button for 2–3
seconds.
No function No function
Reduces
value of TR2.
Reduces
value of TR2.
No function No function
No function No function
No function No function
No function Starts or
Briefly press
the button .
Reduces
value of TR2.
Reduces
value of TR2.
stops S2.
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Stores and
closes the
Setup menu.
7.24 Table of conditions and menu activation
Display The motorcycle is
stationary.
Display mode SPEED/H (operating hours) •
Setup menu •
Setting the unit of measurement •
Setting the clock •
Display mode SPEED/LAP (lap time) •
Viewing the lap time •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Setting TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •
Menu can be activated
36
8 PREPARING FOR USE
8.1 Advice on first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
teristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access 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 and Warranty Booklet at vehicle handover.
– Before your first trip, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 91)
37
8 PREPARING FOR USE
(All EXC models)
–
Adjust the free travel of the hand brake lever. ( p. 95)
(All XC‑W models)
– Adjust the basic position of the hand brake lever. ( p. 96)
– Adjust the basic position of the foot brake lever. ( p. 101)
– Adjust the basic position of the shift lever. ( p. 136)
– Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip.
Info
When off road, it is recommended that you are accompanied by another person on another vehicle 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 motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and
ensure even weight distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded.
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. 112)
Info
The spoke tension must be checked after half an hour of operation.
– Run in the engine. ( p. 38)
8.2 Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
– Avoid fully opening the throttle!
38
8 PREPARING FOR USE
8.3 Starting power of lithium-ion batteries at low temperatures (All AU/US models)
Lithium-ion batteries are far lighter than lead batteries, have a low
self-discharge rate, and have more starting power at temperatures
over 15 °C (60 °F). At low temperatures, however, the starting
power of lithium-ion batteries drops to below that of lead batteries.
Multiple starting attempts may be needed. Press the electric
starter button for 5 seconds, and wait 30 seconds between
attempts. The pauses are necessary so that the created heat can
402555-01
8.4 Preparing the vehicle for difficult riding conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to
considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
distribute through the lithium-ion battery and the battery is not
damaged.
If the charged lithium-ion battery does not or only weakly turns
over the electric starter when temperatures are below 15 °C
(60 °F), then the battery is not faulty, but needs to be warmed up
internally to increase its starting power (current output).
The starting power increases as the battery warms up.
– Seal the air filter box. ( p. 79)
– Clean the air filter and air filter box. ( p. 78)
Info
Check the air filter approx. every 30 minutes.
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult riding conditions are:
– Rides on dry sand. ( p. 40)
– Rides on wet sand. ( p. 41)
– Riding on wet and muddy surfaces. ( p. 42)
– Rides at high temperature and slow speed. ( p. 42)
– Riding at low temperatures or in snow. ( p. 43)
39
8 PREPARING FOR USE
8.5 Preparing for rides on dry sand
M01129-01
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the required
value:
Warning
Danger of scalding During motorcycle oper-
ation, the coolant gets very hot and is under
pressure.
– Do not open the radiator, the radiator hoses
or other cooling system components if the
engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to
cool down before you open the radiator, the
radiator hoses or other components of the
cooling system.
– In the event of scalding, rinse the area
affected immediately with lukewarm water.
M01104-01
M01105-01
– Change the radiator cap.
– Fit a dust cover on the air filter.
Dust cover for air filter (79006920000)
Info
See the KTM PowerParts fitting instructions.
– Fit a sand cover on the air filter.
Sand cover for air filter (79006922000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and setting.
Info
Your authorized KTM workshop can recommend the
right carburetor tuning.
40
600868-01
8.6 Preparing for rides on wet sand
8 PREPARING FOR USE
– Clean the chain.
Chain cleaner ( p. 167)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the required
value:
M01129-01
Warning
Danger of scalding During motorcycle oper-
ation, the coolant gets very hot and is under
pressure.
– Do not open the radiator, the radiator hoses
or other cooling system components if the
engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to
cool down before you open the radiator, the
radiator hoses or other components of the
cooling system.
– In the event of scalding, rinse the area
affected immediately with lukewarm water.
– Change the radiator cap.
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and setting.
M01106-01
Info
Your authorized KTM workshop can recommend the
right carburetor tuning.
41
8 PREPARING FOR USE
8.7 Preparations for riding on wet and muddy surfaces
600868-01
– Clean the chain.
Chain cleaner ( p. 167)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
– Mount the rain cover for the air filter.
Waterproofing device for air filter (79006921000)
Info
Follow the KTM PowerParts mounting instructions.
– Adjust the carburetor jetting and setting.
M01106-01
– Mount the steel sprocket.
– Clean the motorcycle. ( p. 143)
– Carefully align bent radiator fins.
600868-01
Info
Your authorized KTM workshop can recommend the
right carburetor tuning.
8.8 Preparing for rides at high temperature and slow speed
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
42
» If the displayed value does not correspond to the setpoint
value:
M01129-01
8 PREPARING FOR USE
Warning
Danger of scalding During motorcycle oper-
ation, the coolant gets very hot and is under
pressure.
– Do not open the radiator, the radiator hoses
or other cooling system components if the
engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to
cool down before you open the radiator, the
radiator hoses or other components of the
cooling system.
– In the event of scalding, rinse the area
affected immediately with lukewarm water.
– Change the radiator cap.
– Adjust the secondary drive to the road conditions.
Info
The transmission oil heats up quickly when the clutch
is operated frequently due to an excessively high secondary drive.
– Clean the chain.
600868-01
Chain cleaner ( p. 167)
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 126)
8.9 Preparing for riding at low temperatures or in snow
– Mount the rain cover for the air filter.
Waterproofing device for air filter (79006921000)
Info
Follow the KTM PowerParts mounting instructions.
– Adjust the carburetor jetting and setting.
M01106-01
Info
Your authorized KTM workshop can recommend the
right carburetor tuning.
43
9 RIDING INSTRUCTIONS
9.1 Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
H02217-01
– Check the gear oil level. ( p. 140)
– Check the electrical system.
– Check the front brake fluid level. ( p. 97)
– Check the rear brake fluid level. ( p. 102)
– Check the front brake linings. ( p. 98)
– Check the brake linings of the rear brake. ( p. 104)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 126)
– Check the chain for dirt. ( p. 84)
– Check the chain, rear sprocket, motor sprocket, and chain
guide. ( p. 86)
– Check the chain tension. ( p. 85)
– Check the tire condition. ( p. 111)
– Check the tire air pressure. ( p. 111)
– Check the spoke tension. ( p. 112)
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
– Clean the dust boots of the fork legs. ( p. 64)
– Bleed the fork legs. ( p. 63)
– Check the air filter.
– Check the settings of all controls and ensure that they can be
operated smoothly.
– Check all screws, nuts, and hose clamps regularly for tight-
ness.
– Check the fuel level.
9.2 Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
44
9 RIDING INSTRUCTIONS
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.
Condition
The motorcycle was stationary for more than 1 week.
– Empty the carburetor float chamber. ( p. 139)
–
Turn handle1of the fuel tap to the ON position. (Figure E00826-10 p. 21)
Fuel can flow from the fuel tank to the carburetor.
– Remove the motorcycle from the stand.
– Shift gear to neutral.
Condition
The engine is cold.
– Pull the choke lever out as far as possible.
– Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not open the throttle.
9.3 Start off
Info
Before riding, switch on the lights if your vehicle is equipped with a lighting system. This will make it easier for other road users to see you.
When you are riding, the side stand must be folded up and secured with the rubber band.
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle
carefully.
9.4 Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine
races.
– Do not change into a low gear at high engine speed.
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 and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle
while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the
throttle.
– If the choke function was activated, deactivate the choke function after the engine has warmed up.
45
9 RIDING INSTRUCTIONS
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This
will barely reduce the speed but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel con-
sumption.
– To shift down, apply the brakes and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or
shift again.
– Switch off the engine if running at idle or standing for a long time.
Guideline
≥ 2 min
– Avoid frequent and longer slipping of the clutch. As a result the gear oil, engine and cooling system heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
9.5 Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– 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.
9.6 Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
46
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Apply the brakes on the motorcycle.
– Shift gear to neutral.
(All EXC models)
– Press and hold the kill switch while the engine is idling until the engine stops.
(All XC‑W models)
– Press and hold the kill switch while the engine is idling until the engine stops.
–
Turn handle1of the fuel tap to the OFF position. (Figure E00826-10 p. 21)
– Park the motorcycle on firm ground.
9 RIDING INSTRUCTIONS
9.7 Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Switch off the engine.
– Use tension belts or other suitable devices to secure the
motorcycle against falling over or rolling away.
401475-01
47
9 RIDING INSTRUCTIONS
9.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
– Switch off the engine.
– Open the filler cap. ( p. 20)
–
Fill the fuel tank with fuel up to measurementA.
Guideline
35 mm (1.38 in)
9.5 l
(2.51 US gal)
400382-10
Measurement of
Total fuel tank capacity, approx.
Total fuel tank capacity, approx.
A
Super unleaded
(95 octane) mixed
with 2-stroke
engine oil (1:60)
( p. 165) (All
AU/US models)
Super unleaded,
type C (ROZ
95/RON 95/PON
91 mixed with
2-stroke engine oil,
1:60) ( p. 166)
(EXC BR)
48
Engine oil, 2-stroke ( p. 165)
– Close the filler cap. ( p. 21)
10 SERVICE SCHEDULE
10.1 Additional information
Any further work that results from the required work or from the recommended work must be ordered separately
and can be invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
10.2 Required work
Every 10 operating hours when used for motorsports
Every 40 operating hours
Every 20 operating hours
Once after 5 operating hours
Once after 1 operating hour
Check that the electrical system is functioning properly. ○ ● ● ●
Check and charge the battery. ● ● ●
Check the front brake linings. ( p. 98) ● ● ●
Check the brake linings of the rear brake. ( p. 104) ● ● ●
Check the brake discs. ( p. 96) ● ● ●
Check the brake lines for damage and leakage. ● ● ●
Check the rear brake fluid level. ( p. 102) ● ● ●
Check the free travel of the foot brake lever. ( p. 101) ● ● ●
Check the frame. ( p. 89) ● ● ●
Check the swingarm. ( p. 89) ● ● ●
Check the swingarm bearing for play. ● ●
Check the heim joint for play. ● ●
Check the tire condition. ( p. 111) ○ ● ● ●
Check the tire air pressure. ( p. 111) ○ ● ● ●
Check the wheel bearing for play. ● ● ●
Check the wheel hubs. ● ● ●
Check the rim run-out. ○ ● ●
Check the spoke tension. ( p. 112) ○ ● ● ●
Check the chain, rear sprocket, motor sprocket, and chain guide. ( p. 86) ● ● ●
Check the chain tension. ( p. 85) ○ ● ● ●
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth
operation.
Check/correct the fluid level of the hydraulic clutch. ( p. 91) ● ● ●
Check the front brake fluid level. ( p. 97) ● ● ●
Check the free travel of the hand brake lever. ( p. 95) ● ● ●
Check the play of the steering head bearing. ( p. 72) ○ ● ●
Change the spark plug and spark plug connector. ●
Check the reed valve housing, reed valve, and intake flange. ● ●
Change the gear oil. ( p. 140) ○ ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking,
leaks, and incorrect routing.
Check the antifreeze and coolant level. ( p. 125) ○ ● ● ●
Check the cables for damage and for routing without kinks. ● ● ●
○ ● ● ●
● ● ●
49
10 SERVICE SCHEDULE
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
Clean the air filter and air filter box. ( p. 78) ● ● ●
Change glass fiber yarn filling in the main silencer. ( p. 80) ● ●
Service the fork. ●
Service the shock absorber. ●
Check the screws and nuts for tightness. ○ ● ● ●
Check the headlight setting. ( p. 122) ○ ● ● ●
Check idle. ● ● ●
Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ●
Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ ○ ● ● ●
○ One-time interval
● Periodic interval
Every 10 operating hours when used for motorsports
Every 40 operating hours
Every 20 operating hours
Once after 5 operating hours
Once after 1 operating hour
○ ● ● ●
10.3 Recommended work
Every 40 operating hours when used for motorsports
Every 10 operating hours when used for motorsports
Annually
Every 80 operating hours
Every 40 operating hours
Once after 20 operating hours
Once after 10 operating hours
Change the front brake fluid. ●
Change the rear brake fluid. ●
Change the hydraulic clutch fluid. ( p. 92) ●
Lubricate the steering head bearing. ( p. 74) ●
Service the fork. ○
Service the shock absorber. ○
Check the electric starter drive. ● ●
Change the piston and check the cylinder. ● ●
Check/adjust the carburetor components. ● ● ●
Perform minor engine service. (Check the exhaust control for functioning and
smooth operation. Check the clutch.)
Perform major engine service including removing and installing engine.
(Change the connecting rod, conrod bearing, and crank pin. Check the
transmission and shift mechanism. Change all engine bearings.)
● ● ● ●
● ●
○ One-time interval
● Periodic interval
50
11.1 Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid
damage to forks, shock absorbers, swingarm and frame, the
basic settings of the suspension components must match the
rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for a stan-
dard rider weight (with full protective clothing).
Guideline
Standard rider weight 75 … 85 kg (165 …
– If the rider's weight is above or below the standard range, the
basic setting of the suspension components must be adjusted
accordingly.
– Small weight differences can be compensated by adjusting the
spring preload, but in the case of large weight differences, the
springs must be replaced.
11 TUNING THE CHASSIS
187 lb.)
401030-01
11.2 Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle
speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension
compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice
versa.
11.3 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.
51
11 TUNING THE CHASSIS
E00828-10
–
Turn adjusting screw1clockwise with a screwdriver as far as
the last perceptible click.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
Compression damping, low-speed
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
11.4 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed setting can be seen in fast compression of the shock absorber.
–
Using an open end wrench, turn adjusting screw1clockwise
all the way.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of turns corresponding
to the shock absorber type.
E00829-10
Guideline
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
52
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
11 TUNING THE CHASSIS
11.5 Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
–
Turn adjusting screw1clockwise up to the last perceptible
click.
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
Rebound damping
Comfort 18 clicks
V00331-10
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
11.6 Measuring the rear wheel dimension unloaded
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
– Position the sag gauge in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090100)
Pin for sag gauge (00029990010)
–
Note down the value as dimensionA.
402415-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
53
11 TUNING THE CHASSIS
11.7 Checking the static sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 53)
– Hold the motorcycle upright with the aid of an assistant.
– Again measure the distance between the rear axle and mark-
ing SAG on the rear fender using the sag gauge.
–
Note down the value as dimensionB.
Info
The static sag is the difference between
measurementsAandB.
– Check the static sag.
Static sag 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring pretension of the shock absorber.
( p. 55)
402416-10
11.8 Checking the riding sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 53)
– With another person holding the motorcycle, the rider, wear-
ing full protective clothing, sits on the seat in a normal sitting
position (feet on footrests) and bounces up and down a few
times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear
axle and marking SAG on the rear fender using the sag gauge.
–
Note down the value as dimensionC.
Info
The riding sag is the difference between
measurementsAandC.
– Check the riding sag.
Riding sag 110 mm (4.33 in)
» If the riding sag differs from the specified measurement:
402417-10
– Adjust the riding sag. ( p. 56)
54
11 TUNING THE CHASSIS
11.9 Adjusting the spring pretension of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
Before changing the spring pretension, make a note of the present setting, e.g., by measuring the length
of the spring.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Remove the shock absorber. ( p. 75)
– After removing the shock absorber, clean it thoroughly.
Main work
–
Loosen screw1.
–
Turn adjusting ring2until the spring is no longer under tension.
402405-10
Hook wrench (90129051000)
– Measure the overall spring length while the spring is not under
tension.
–
Tighten the spring by turning adjusting ring2to measurementA.
Guideline
Spring preload
Comfort 8 mm (0.31 in)
Standard 8 mm (0.31 in)
Sport 8 mm (0.31 in)
Info
Depending on the static sag and/or the riding sag, it
may be necessary to increase or decrease the spring
pretension.
–
Tighten screw1.
Guideline
Screw, shock absorber
adjusting ring
Finishing work
– Install the shock absorber. ( p. 75)
– Remove the motorcycle from the lift stand. ( p. 63)
M5 5 Nm (3.7 lbf ft)
55
11 TUNING THE CHASSIS
11.10 Adjusting the riding sag
B00292-10
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Remove the shock absorber. ( p. 75)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65 …
75 kg (143 … 165 lb.)
Weight of rider: 75 …
85 kg (165 … 187 lb.)
Weight of rider: 85 …
95 kg (187 … 209 lb.)
60 N/mm (343 lb/in)
63 N/mm (360 lb/in)
66 N/mm (377 lb/in)
Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber. ( p. 75)
– Remove the motorcycle from the lift stand. ( p. 63)
– Check the static sag of the shock absorber. ( p. 54)
– Check the riding sag of the shock absorber. ( p. 54)
– Adjust the rebound damping of the shock absorber. ( p. 53)
11.11 Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
– As with the shock absorber, smaller differences in the rider's
weight can be compensated by the spring preload.
– However, if the fork frequently bottoms out (hard end stop on
compression), harder springs must be fitted to avoid damage
to the fork and frame.
– If the fork feels unusually hard after extended periods of oper-
ation, the fork legs need to be bled.
401000-01
56
11.12 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
(All standard EXC/XC-W models)
–
Turn white adjusting screw1clockwise as far as it will
go.
Info
Adjusting screw1is located at the upper end of
the left fork leg.
The compression damping is located in left fork
E00323-10
– Turn counterclockwise by the number of clicks correspond-
leg COMP (white adjusting screw). The rebound
damping is located in right fork leg REB (red adjusting screw).
ing to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
11 TUNING THE CHASSIS
E00830-10
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
(All Six Days models)
–
Turn white adjusting screw1clockwise as far as it will
go.
Info
Adjusting screw1is located at the upper end of
the left fork leg.
The compression damping is located in left fork
leg COM (white adjusting screw). The rebound
damping is located in right fork leg REB (red
adjusting screw).
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
57
11 TUNING THE CHASSIS
11.13 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
(All standard EXC/XC-W models)
–
Turn red adjusting screw1clockwise as far as it will go.
E00326-10
Info
Adjusting screw1is located at the upper end of
the right fork leg.
The rebound damping is located in right fork
leg REB (red adjusting screw). The compression
damping is located in left fork leg COMP (white
adjusting screw).
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
58
E00831-10
11 TUNING THE CHASSIS
(All Six Days models)
–
Turn red adjusting screw1clockwise as far as it will go.
Info
Adjusting screw1is located at the upper end of
the right fork leg.
The rebound damping is located in right fork
leg REB (red adjusting screw). The compression
damping is located in left fork leg COM (white
adjusting screw).
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
11.14 Adjusting the spring pretension of the fork (All Six Days models)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
–
Turn the adjusting wings1counterclockwise all the way.
The marking +0 aligns with the right wing on both fork
legs.
Info
Make the adjustment by hand only. Do not use a tool.
Make the same adjustment on both fork legs.
E00832-10
– Turn the adjusting wings clockwise.
Guideline
Spring preload - Preload Adjuster
Comfort +0
Standard +0
Sport +3
The adjusting wings engage noticeably at the numerical
values.
59
11 TUNING THE CHASSIS
11.15 Handlebar position
Info
Adjust the spring preload to the numerical values only
as the preload will not engage between the numerical
values.
Turn clockwise to increase the spring preload; turn
counterclockwise to reduce the spring preload.
Adjusting the spring pretension has no influence on the
absorption setting of the rebound.
Basically, however, you should set the rebound damping higher with a higher spring pretension.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
(All standard EXC/XC-W models)
On the upper triple clamp, there are 2 holes at a distance
ofAto each other.
M00993-10
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance
ofBfrom the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This
allows the handlebar to be mounted in the most comfortable
position for the rider.
60
M00987-10
11 TUNING THE CHASSIS
(All Six Days models)
On the upper triple clamp, there are 2 holes at a distance
ofAto each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance
ofBfrom the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This
allows the handlebar to be mounted in the most comfortable
position for the rider.
11.16 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
– Change the handlebar if the handlebar is damaged or bent.
(All standard EXC/XC-W models)
–
Remove screws1. Take off the handlebar clamps.
Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove screws2. Take off the handlebar supports.
– Place the handlebar supports in the required position.
Mount and tighten screws2.
Guideline
Screw, handlebar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
M00993-11
Info
Position the left and right handlebar supports
evenly.
– Position the handlebar.
61
11 TUNING THE CHASSIS
Info
Make sure the cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount screws1and
tighten evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm
Info
Make sure the gap widths are even.
(All Six Days models)
–
Remove screws1. Take off the handlebar clamps.
Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
(14.8 lbf ft)
M00987-11
–
Remove screws2. Take off the handlebar supports.
– Place the handlebar supports in the required position.
Mount and tighten screws2.
Guideline
Screw, handlebar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount screws1and
tighten evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.
62
12.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall
over.
– Park the vehicle on a firm and level surface.
– Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
401942-01
– Secure the motorcycle against falling over.
Neither wheel is in contact with the ground.
12.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
12 SERVICE WORK ON THE CHASSIS
401943-10
12.3 Bleeding the fork legs
H01595-10
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
–
To park the motorcycle, press side stand1to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with the rubber band.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
–
Release bleeder screws1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
63
12 SERVICE WORK ON THE CHASSIS
12.4 Cleaning the dust boots of the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Remove the fork protector. ( p. 64)
Main work
–
K00070-10
Push dust boots1of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles
from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when nec-
essary.
12.5 Removing the fork protector
V00332-10
– Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray ( p. 168)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 65)
– Remove the motorcycle from the lift stand. ( p. 63)
–
Remove screws1and take off the clamp.
–
Remove screws2and take off the left fork protector.
–
Remove screws3and take off the right fork protector.
64
12.6 Installing the fork protector
V00332-11
12.7 Removing the fork legs
12 SERVICE WORK ON THE CHASSIS
– Position the fork protector on the left fork leg. Mount and
tighten screws1.
Guideline
Remaining screws,
chassis
– Position the brake line, wiring harness, and clamp. Mount and
tighten screws2.
– Position the fork protector on the right fork leg. Mount and
tighten screws3.
Guideline
Remaining screws,
chassis
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Remove the front wheel. ( p. 107)
– Remove the headlight mask with the headlight. ( p. 119)
Main work
–
Remove screws1and take off the clamp.
– Remove the cable tie(s).
–
Remove screws2and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the
side.
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
E00375-10
E00376-10
(All standard EXC/XC-W models)
–
Loosen screws3. Take out the left fork leg.
–
Loosen screws4. Take out the right fork leg.
65
12 SERVICE WORK ON THE CHASSIS
(All Six Days models)
E00377-10
12.8 Installing the fork legs
Main work
– Position the fork legs.
H01595-10
–
Loosen screws3. Take out the left fork leg.
–
Loosen screws4. Take out the right fork leg.
Bleeder screws1are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjusting screw). The compression damping is
located in left fork leg COM (white adjusting screw).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the top edge of the upper triple clamp.
V00334-11
V00355-11
(All standard EXC/XC-W models)
–
Tighten screws2.
Guideline
Screw, top triple
clamp
–
Tighten screws3.
Guideline
Screw, bottom triple
clamp
(All Six Days models)
–
Tighten screws2.
Guideline
Screw, top triple
clamp
–
Tighten screws3.
Guideline
Screw, bottom triple
clamp
M8 20 Nm
(14.8 lbf ft)
M8 15 Nm
(11.1 lbf ft)
M8 17 Nm
(12.5 lbf ft)
M8 15 Nm
(11.1 lbf ft)
66
12 SERVICE WORK ON THE CHASSIS
–
Position the brake caliper, and mount and tighten screws4.
Guideline
Screw, front
brake caliper
– Mount the cable tie(s).
– Position the brake line, wiring harness, and clamp. Mount and
tighten screws5.
E00375-11
Finishing work
– Install the front wheel. ( p. 108)
– Install the headlight mask with the headlight. ( p. 120)
– Check the headlight setting. ( p. 122)
12.9 Removing the lower triple clamp (All standard EXC/XC-W models)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Remove the front wheel. ( p. 107)
– Remove the headlight mask with the headlight. ( p. 119)
– Remove the fork legs. ( p. 65)
– Remove front fender. ( p. 74)
– Remove the handlebar cushion.
Main work
–
Remove screw1. Loosen screw2. Pull off the upper triple
clamp with the handlebar and hang it to one side.
M8 25 Nm (18.4 lbf ft)
Loctite®243™
V00336-10
V00335-10
Info
Protect the components against damage by covering
them.
Do not bend the cables and lines.
–
Remove O-ring3. Remove protective ring4.
– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
67
12 SERVICE WORK ON THE CHASSIS
12.10 Removing the lower triple clamp (All Six Days models)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Remove the front wheel. ( p. 107)
– Remove the headlight mask with the headlight. ( p. 119)
– Remove the fork legs. ( p. 65)
– Remove front fender. ( p. 74)
– Remove the handlebar cushion.
Main work
–
V00357-10
Remove screw1. Remove screw2. Pull off the upper triple
clamp with the handlebar and hang it to one side.
Info
Protect the components against damage by covering
them.
Do not bend the cables and lines.
–
Remove O-ring3. Remove protective ring4.
– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
V00358-10
12.11 Installing the lower triple clamp (All standard EXC/XC-W models)
Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 167)
– Insert the lower triple clamp with the steering stem. Mount the
upper steering head bearing.
–
Check whether upper steering head seal1is correctly positioned.
–
Mount protective ring2and O-ring3.
68
V00359-10
V00336-11
H01637-10
12 SERVICE WORK ON THE CHASSIS
– Position the upper triple clamp with the handlebar.
– Position the clutch line and wiring harness.
–
Mount screw4but do not tighten yet.
– Position the fork legs.
Bleeder screws5are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjusting screw). The compression damping is
located in left fork leg COMP (white adjusting screw).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the top edge of the upper triple clamp.
V00338-10
V00337-10
–
Tighten screws6.
Guideline
Screw, top triple
clamp
–
Tighten screws7.
Guideline
Screw, bottom triple
clamp
–
Tighten screw4.
Guideline
Screw, top steering
head
–
Tighten screw8.
Guideline
Screw, top steering
stem
M8 20 Nm (14.8 lbf ft)
M8 15 Nm (11.1 lbf ft)
M20x1.5 12 Nm (8.9 lbf ft)
M8 20 Nm (14.8 lbf ft)
V00337-11
69
12 SERVICE WORK ON THE CHASSIS
–
– Mount the cable tie(s).
– Position the brake line, wiring harness, and clamp. Mount and
E00375-12
Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 74)
– Install the front wheel. ( p. 108)
– Install the headlight mask with the headlight. ( p. 120)
– Check that the wiring harness, throttle cables, and brake and
– Check the play of the steering head bearing. ( p. 72)
– Remove the motorcycle from the lift stand. ( p. 63)
– Check the headlight setting. ( p. 122)
Position the brake caliper, and mount and tighten screws9.
Guideline
Screw, front
brake caliper
tighten screwsbk.
clutch lines can move freely and are routed correctly.
M8 25 Nm (18.4 lbf ft)
Loctite®243™
12.12 Installing the lower triple clamp (All Six Days models)
Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 167)
– Insert the lower triple clamp with the steering stem. Mount the
upper steering head bearing.
–
Check whether upper steering head seal1is correctly positioned.
–
Mount protective ring2and O-ring3.
B01218-10
70
V00356-10
H01637-10
12 SERVICE WORK ON THE CHASSIS
– Position the upper triple clamp with the handlebar.
–
Mount screw4but do not tighten yet.
– Position the clutch line and wiring harness.
– Position the fork legs.
Bleeder screws5are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjusting screw). The compression damping is
located in left fork leg COMP (white adjusting screw).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the top edge of the upper triple clamp.
V00353-10
V00360-10
–
Tighten screws6.
Guideline
Screw, top triple
clamp
–
Tighten screws7.
Guideline
Screw, bottom triple
clamp
–
Tighten screw4.
Guideline
Screw, top steering
head
–
Mount and tighten screw8.
Guideline
Screw, top
steering stem
M8 17 Nm (12.5 lbf ft)
M8 15 Nm (11.1 lbf ft)
M20x1.5 12 Nm (8.9 lbf ft)
M8 17 Nm (12.5 lbf ft)
Loctite®243™
V00361-10
71
12 SERVICE WORK ON THE CHASSIS
–
– Mount the cable tie(s).
– Position the brake line, wiring harness, and clamp. Mount and
E00375-12
Finishing work
– Install front fender. ( p. 74)
– Mount the handlebar cushion.
– Install the headlight mask with the headlight. ( p. 120)
– Check the headlight setting. ( p. 122)
– Install the front wheel. ( p. 108)
– Check that the wiring harness, throttle cables, and brake and
– Check the play of the steering head bearing. ( p. 72)
– Remove the motorcycle from the lift stand. ( p. 63)
Position the brake caliper, and mount and tighten screws9.
Guideline
Screw, front
brake caliper
tighten screwsbk.
clutch lines can move freely and are routed correctly.
M8 25 Nm (18.4 lbf ft)
Loctite®243™
12.13 Checking the play of the steering head bearing
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad
to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play. ( p. 73)
H01167-01
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over
the entire steering range. There should be no detectable
detent positions.
72
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 73)
– Check the steering head bearing and change if neces-
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
12.14 Adjusting the steering head bearing play
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
(All standard EXC/XC-W models)
–
Loosen screws1and2.
–
Loosen and retighten screw3.
Guideline
Screw, top steering
head
12 SERVICE WORK ON THE CHASSIS
sary.
M20x1.5 12 Nm (8.9 lbf ft)
V00339-10
E00833-10
– Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screws1.
Guideline
Screw, top triple
clamp
–
Tighten screw2.
Guideline
Screw, top steering
stem
(All Six Days models)
–
Loosen screws1. Remove screw2.
–
Loosen and retighten screw3.
Guideline
Screw, top steering
head
– Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screws1.
Guideline
Screw, top triple
clamp
M8 20 Nm
(14.8 lbf ft)
M8 20 Nm
(14.8 lbf ft)
M20x1.5 12 Nm (8.9 lbf ft)
M8 17 Nm
(12.5 lbf ft)
–
Mount and tighten screw2.
Guideline
Screw, top
steering stem
Finishing work
– Check the play of the steering head bearing. ( p. 72)
– Remove the motorcycle from the lift stand. ( p. 63)
M8 17 Nm (12.5 lbf ft)
Loctite®243™
73
12 SERVICE WORK ON THE CHASSIS
12.15 Lubricating the steering head bearing
(All standard EXC/XC-W models)
(All Six Days models)
H02387-01
12.16 Removing front fender
Preparatory work
– Remove the headlight mask with the headlight. ( p. 119)
Main work
–
– Remove the lower triple clamp. ( p. 67)
– Install the lower triple clamp. ( p. 68)
– Remove the lower triple clamp. ( p. 68)
– Install the lower triple clamp. ( p. 70)
Remove screws1.
12.17 Installing front fender
V00340-10
V00341-10
V00341-11
–
Remove screws2. Take off front fender.
Main work
–
Position front fender. Mount and tighten screws1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
74
V00340-11
12.18 Removing the shock absorber
12 SERVICE WORK ON THE CHASSIS
–
Mount and tighten screws2.
Guideline
Remaining screws,
chassis
Finishing work
– Install the headlight mask with the headlight. ( p. 120)
– Check the headlight setting. ( p. 122)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
–
Remove screw1and lower the rear wheel with the swingarm
as far as possible without blocking the rear wheel. Secure the
rear wheel in this position.
–
Remove screw2, push splash protector3to the side, and
remove the shock absorber.
M6 10 Nm (7.4 lbf ft)
E00834-11
12.19 Installing the shock absorber
E00834-10
Main work
–
Push splash protector1to the side and position the shock
absorber. Mount and tighten screw2.
Guideline
Screw, top
shock absorber
–
Mount and tighten screw3.
Guideline
Screw, bottom
shock absorber
M12 80 Nm (59 lbf ft)
Loctite®2701™
M12 80 Nm (59 lbf ft)
Loctite®2701™
Info
The heim joint for the shock absorber at the swingarm
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.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
75
12 SERVICE WORK ON THE CHASSIS
12.20 Removing the seat
–
– Raise the rear of the seat, pull the seat back, and lift it off.
V00342-10
12.21 Mounting the seat
– Hook in the front of the seat on the collar bushing of the fuel
– Make sure that the seat is correctly locked in.
Remove screws1.
tank, lower it at the rear and push it forward.
V00343-10
–
V00342-10
12.22 Removing the air filter box cover
Condition
V00346-10
Mount and tighten screws1.
Guideline
Remaining screws,
chassis
The air filter box cover is secured.
–
Remove screw1.
M6 10 Nm (7.4 lbf ft)
76
V00346-11
12.23 Installing the air filter box cover
12 SERVICE WORK ON THE CHASSIS
–
Pull off the air filter box cover in areaAsideways and take
off toward the front.
–
Insert the air filter box cover in areaAand clip it into
areaB.
V00346-12
Condition
The air filter box cover is secured.
–
Mount and tighten screw1.
Guideline
Screw, air filter box
cover
V00346-10
®
EJOT PT
K60x20-Z
3 Nm (2.2 lbf ft)
12.24 Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
– Remove the air filter box cover. ( p. 76)
77
12 SERVICE WORK ON THE CHASSIS
Main work
–
– Remove air filter from air filter support.
E00835-10
12.25 Installing the air filter
Main work
– Mount the clean air filter on the air filter support.
–
Detach retaining tab1. Remove air filter with air filter support.
Grease the air filter in areaA.
Long-life grease ( p. 167)
102178-10
–
Insert air filter and position retaining pin1in bushingB.
The air filter is correctly positioned.
–
Insert retaining tab2.
Retaining pin3is secured by retaining tab2.
Info
If the air filter is not mounted correctly, dust and dirt
may enter the engine and result in damage.
E00836-10
Finishing work
– Install the air filter box cover. ( p. 77)
12.26 Cleaning the air filter and air filter box
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
78
Preparatory work
– Remove the air filter box cover. ( p. 76)
– Remove the air filter. ( p. 77)
12 SERVICE WORK ON THE CHASSIS
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner ( p. 167)
Info
Only squeeze the air filter to dry it; never wring it out.
102191-01
12.27 Securing the air filter box cover
S00846-10
– Oil the dry air filter with a high quality filter oil.
Oil for foam air filter ( p. 167)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Finishing work
– Install the air filter. ( p. 78)
– Install the air filter box cover. ( p. 77)
Preparatory work
– Remove the air filter box cover. ( p. 76)
Main work
–
Drill a hole at markingA.
Guideline
Diameter 6 mm (0.24 in)
12.28 Sealing the air filter box
S00847-10
Finishing work
– Install the air filter box cover. ( p. 77)
Preparatory work
– Remove the air filter box cover. ( p. 76)
Main work
–
Seal the air filter box in the marked areaA.
Finishing work
– Install the air filter box cover. ( p. 77)
79
12 SERVICE WORK ON THE CHASSIS
12.29 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
–
–
E00837-10
12.30 Installing the main silencer
–
–
Remove screws1.
Pull off the main silencer at the rubber sleeve2and the
spring ring from the manifold.
Mount the main silencer with the rubber sleeve1and spring
ring.
Mount and tighten screws2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E00837-11
12.31 Changing the glass fiber yarn filling in the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
– Remove the main silencer. ( p. 80)
80
H01759-10
12 SERVICE WORK ON THE CHASSIS
Main work
–
Remove screws1.
–
Pull out inner tube2.
–
Remove the glass fiber yarn filling3from the inner tube.
– Clean the parts that need to be reinstalled and check for dam-
age.
–
Fit the new glass fiber yarn filling3into the inner tube.
–
Position outer tube4over the inner tube with the new glass
fiber yarn filling.
–
Mount and tighten screws1.
Guideline
Screws on the main
silencer
M5 7 Nm (5.2 lbf ft)
Finishing work
– Install the main silencer. ( p. 80)
12.32 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
– Remove the seat. ( p. 76)
81
12 SERVICE WORK ON THE CHASSIS
Main work
–
– Pull off the fuel hose.
V00350-10
–
(All EXC models)
–
– Remove the tube from the fuel tank breather.
Turn handle1of the fuel tap to the OFF position.
(Figure E00826-10 p. 21)
Info
Remaining fuel may flow out of the fuel hose.
Remove screws1with the collar bushings.
– Hang the horn and horn bracket to one side.
Remove screw2with the rubber bushing.
V00351-10
– Pull both spoilers off the sides of the radiator bracket and lift
off the fuel tank.
V00352-10
12.33 Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
82
12 SERVICE WORK ON THE CHASSIS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Main work
– Check throttle cable routing. ( p. 89)
– Position the fuel tank and fit the two spoilers to the sides of
the radiator bracket.
– Make sure that no cables or throttle cables are trapped or dam-
aged.
V00352-11
V00351-11
V00350-11
– Attach the fuel tank breather hose.
–
Mount and tighten screw1with the rubber bushing.
Guideline
Remaining screws,
chassis
(All EXC models)
– Position the horn with the horn bracket.
–
Mount and tighten screws2with the collar bushings.
Guideline
Remaining screws,
chassis
– Connect the fuel hose.
Finishing work
– Mount the seat. ( p. 76)
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
83
12 SERVICE WORK ON THE CHASSIS
12.34 Checking the chain for dirt
– Check the chain for heavy soiling.
400678-01
12.35 Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
– Remove the lubricant from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
» If the chain is very dirty:
– Clean the chain. ( p. 84)
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 167)
– After drying, apply chain spray.
Off-road chain spray ( p. 167)
400725-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
84
12 SERVICE WORK ON THE CHASSIS
12.36 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
– Pull the chain at the end of the chain sliding piece upward to
measure chain tensionA.
Info
The bottom chain section1must be taut.
When the chain guard is mounted, it must be possible
to pull up the chain at least to the point where it makes
contact with chain guardB.
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
Chain tension 55 … 58 mm (2.17 …
2.28 in)
» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 85)
V00354-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
12.37 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
– Check the chain tension. ( p. 85)
85
12 SERVICE WORK ON THE CHASSIS
Main work
–
–
–
–
–
–
E00330-10
Loosen nut1.
Loosen nuts2.
Adjust the chain tension by turning adjusting screws3left
and right.
Guideline
Chain tension 55 … 58 mm (2.17 …
2.28 in)
Turn adjusting screws3on the left and right so that the
markings on the left and right chain adjusters are in the
same position relative to reference marksA. The rear
wheel is then correctly aligned.
Tighten nuts2.
Make sure that chain adjusters4are fitted correctly on
adjusting screws3.
Tighten nut1.
Guideline
Nut, rear wheel spindle
M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters
(32 mm (1.18 in)) enables different secondary ratios
with the same chain length.
Chain adjusters4can be turned by 180°.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
12.38 Checking the chain, rear sprocket, motor sprocket, and chain guide
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 63)
Main work
– Shift the transmission to idle.
– Check the rear sprocket and motor sprocket for wear.
» If the rear sprocket and motor sprocket are worn:
– Change the drivetrain kit.
Info
The motor sprocket, rear sprocket, and chain
400227-01
should always be replaced together.
86
12 SERVICE WORK ON THE CHASSIS
–
Pull at the top part of the chain with the specified weightA.
Guideline
Weight, chain wear measurement
–
Measure the distanceBof 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.
10 … 15 kg (22 … 33 lb.)
400987-10
Maximum distanceBat
the longest chain section
»
If distanceBis greater than the specified measurement:
– Change the drivetrain kit.
272 mm (10.71 in)
Info
When the chain is replaced, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on old, worn sprockets.
– Check the chain sliding guard for wear.
» If the lower edge of the chain pin is at the level of or below
the chain sliding guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screws on the chain sliding guard.
Guideline
Screw, chain
sliding guard
M6 14 Nm (10.3 lbf ft)
Loctite®243™
E00838-10
87
12 SERVICE WORK ON THE CHASSIS
– Check the chain sliding piece for wear.
– Check that the chain sliding piece is firmly seated.
E00839-10
» If the lower edge of the chain pins is in line with or below
the chain sliding piece:
– Change the chain sliding piece.
» If the chain sliding piece is loose:
– Tighten the screw on the chain sliding piece.
Guideline
Screw, chain sliding piece
M8 15 Nm
(11.1 lbf ft)
400985-01
E00333-01
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:
– Change the chain guide.
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws,
chassis
Finishing work
– Remove the motorcycle from the lift stand. ( p. 63)
M6 10 Nm
(7.4 lbf ft)
88
12.39 Checking the frame
S01316-10
12.40 Checking the swingarm
12 SERVICE WORK ON THE CHASSIS
– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a
mechanical impact:
– Change the frame.
Info
Always replace a frame that has been damaged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or defor-
mation:
– Change the swingarm.
Info
Always change a damaged swingarm. Repair of
the swingarm is not authorized by KTM.
S01317-10
12.41 Checking throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-
tion.
Preparatory work
– Remove the seat. ( p. 76)
– Remove the fuel tank. ( p. 81)
89
12 SERVICE WORK ON THE CHASSIS
Main work
– Check throttle cable routing.
E00841-10
The throttle cable must be routed behind the handlebar, on the right of the frame, and to the carburetor. The
throttle cable must be secured behind the fuel tank contact area rubber band.
» If the throttle cable routing is not as specified:
– Correct throttle cable routing.
12.42 Checking the rubber grip
401197-01
Finishing work
– Install the fuel tank. ( p. 82)
– Mount the seat. ( p. 76)
– Check the rubber grips on the handlebar for damage, wear,
and looseness.
Info
The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
» If a rubber grip is damaged or worn:
– Change the rubber grip.
–
Check that screw1is firmly seated.
Guideline
Screw, fixed
grip
M4 5 Nm (3.7 lbf ft)
Loctite®243™
90
DiamondAmust be located at the top.
K00547-10
12 SERVICE WORK ON THE CHASSIS
12.43 Adjusting the basic position of the clutch lever
– Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw1.
Info
Turn the adjusting screw counterclockwise to decrease
the distance between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase the
E00842-10
12.44 Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
91
12 SERVICE WORK ON THE CHASSIS
– Move the clutch fluid reservoir mounted on the handlebar to a
–
–
– Check the fluid level.
horizontal position.
Remove screws1.
Remove cover2with membrane3.
E00337-10
Fluid level below container
rim
» If the level of the fluid does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 164)
– Position the cover with the membrane. Mount and tighten the
screws.
4 mm (0.16 in)
Info
Clean up overflowed or spilled brake fluid immediately
with water.
12.45 Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
92
E00337-10
E00843-10
12 SERVICE WORK ON THE CHASSIS
– Move the clutch fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
–
Fill bleeding syringe4with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 164)
–
On the clutch slave cylinder, remove bleeder screw5and
mount bleeding syringe4.
– Now inject the fluid into the system until it emerges from drill
hole6of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir
to prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws
bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
E00339-10
Fluid level below container
rim
– Position the cover with the membrane. Mount and tighten the
screws.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
12.46 Removing the engine guard (All Six Days models, EXC AU)
–
Remove screws1and engine guard.
4 mm (0.16 in)
H01638-10
93
12 SERVICE WORK ON THE CHASSIS
12.47 Installing the engine guard (All Six Days models, EXC AU)
– Attach the engine guard on the frame at the rear and swing up
–
H01638-10
at the front.
Mount and tighten screws1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
94
13.1 Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
(All EXC models)
– Push the hand brake lever to the handlebar and check free
travelA.
13 BRAKE SYSTEM
Free travel of hand brake
lever
» If the free travel does not match the specification:
– Adjust the free travel of the hand brake lever.
E00844-11
(All XC‑W models)
– Push the hand brake lever forward and check free
E00844-10
( p. 95)
travelA.
Free travel of hand brake
lever
» If the free travel does not match the specification:
– Adjust the basic position of the hand brake lever.
( p. 96)
13.2 Adjusting free travel of hand brake lever (All EXC models)
– Check the free travel of the hand brake lever. ( p. 95)
– Adjust the free travel of the hand brake lever with the adjust-
ment screw1.
Info
Turn the adjusting screw clockwise to reduce free
travel. The pressure point moves away from the
handlebar.
E00844-12
Turn the adjusting screw counterclockwise to increase
free travel. The pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding!
≥ 3 mm (≥ 0.12 in)
≥ 3 mm (≥ 0.12 in)
95
13 BRAKE SYSTEM
13.3 Adjusting the basic position of the hand brake lever (All XC‑W models)
13.4 Checking the brake discs
E00844-12
– Check the free travel of the hand brake lever. ( p. 95)
– Adjust the basic setting of the hand brake lever to your hand
size by turning adjusting screw1.
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.
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!
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will
be glad to help.)
– Check the front and rear brake disc thickness at multiple
points for the dimensionA.
Info
Wear reduces the thickness of the brake disc around
the contact surface of the brake linings.
Brake discs - wear limit (All standard EXC/XC-W models)
400257-10
» If the brake disc thickness is less than the specified value:
– Check the front and rear brake discs for damage, cracking, and
deformation.
» If the brake disc exhibits damage, cracking, or deforma-
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
Brake discs - wear limit (All Six Days models)
front 2.5 mm (0.098 in)
rear 3.7 mm (0.146 in)
– Change the front brake disc.
– Change the rear brake disc.
tion:
– Change the front brake disc.
– Change the rear brake disc.
96
13.5 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Check the brake fluid level in level viewer1.
» If an air bubble is visible in upper range of the level
viewerA:
– Add front brake fluid. ( p. 97)
13 BRAKE SYSTEM
E00845-10
13.6 Adding front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
97
13 BRAKE SYSTEM
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
–
Add brake fluid to levelA.
Guideline
LevelA(brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 164)
– Position the cover with the membrane. Mount and tighten the
screws.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
E00846-10
13.7 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
E00342-10
Minimum thickness
» If the minimum thickness is less than specified:
– Change the front brake linings. ( p. 99)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the front brake linings. ( p. 99)
A
98
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