KTM 250 EXC (2013) manual

OWNER'S MANUAL 2013 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AUS 200 XC ‑ W USA 250 EXC EU 250 EXC AUS 250 EXC SIX DAYS EU 250 XC ‑ W USA 300 EXC EU 300 EXC AUS 300 EXC SIX DAYS EU 300 XC ‑ W USA Art. no. 3211861en[...]

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DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Ch[...]

TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 5 1.1 Symbols used ....................................... ............ 5 1.2 Formats used ................................ .................... 5 2 SAFETY ADVICE ...................................... ..................... 6 2.1 Use definition -[...]

TABLE OF CONTENTS 3 10.14 Adjusting the spring preload of the fork (EXC EU/AUS, XC ‑ W).............. ......................... 44 10.15 Handlebar position ............ ............................ .. 44 10.16 Adjusting the handlebar position x ................. 45 11 SERVICE WORK ON THE CHASSIS .............................. 46 11.1 Raising the [...]

TABLE OF CONTENTS 4 16.6 Checking the basic position of the shift lever ... 101 16.7 Adjusting the basic position of the shift lever x .................................... ................... 101 16.8 Engine characteristic - auxiliary spring (All 250/300 models) .............................. ...... 101 16.9 Engine characteristic - setting the auxi[...]

1 MEANS OF REPRESENTATIO N 5 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 you[...]

2 SAFETY ADVICE 6 2.1 Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public road traffic in the[...]

2 SAFETY ADVICE 7 2.5 Safe operation Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result [...]

3 IMPORTA NT NOTES 8 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net ; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulatio ns and[...]

4 VIEW OF VEHICLE 9 4.1 View of vehicle, front left (example) B01138-10 1 Hand brake lever ( p. 13) 2 Kill switch ( p. 13) 3 Clutch lever ( p. 13) 4 Air filter box lid 5 Fuel tap ( p. 23) 6 Chain guide 7 Side stand ( p. 24) 8 Shift lever ( p. 23)[...]

4 VIEW OF VEHICLE 10 4.2 View of vehicle, rear right (example) B01137-10 1 Filler cap 2 Bleeder screw, fork leg 3 Throttle grip ( p. 13) 4 Chassis number ( p. 11) 5 Kick starter ( p. 24) 6 Foot brake lever ( p. 24) 7 Level viewer for brake fluid, rear[...]

5 SERIAL NUMBERS 11 5.1 Chassis number 303438-10 The chassis number 1 is stamped on the right side of the steering head. 5.2 Type label 303439-10 The type label 1 is fixed to the front of the steering head. 5.3 Key number (All EXC models) 500125-10 The key number 1 for the steering lock is stamped onto the key connector. 5.4 Engine number B01139-10[...]

5 SERIAL NUMBERS 12 5.6 Shock absorber part number B00786-10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side.[...]

6 CONTROL S 13 6.1 Clutch lever B01140-10 (All 125/200 models) The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01146-10 (All 250/300 models) The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 6.2 Hand brake[...]

6 CONTROL S 14 6.5 Kill switch (XC-W) B01144-10 The kill switch 1 is fitted on the left side of the handlebar. Possible states • Kill switch in basic position – In this position, the ignition circuit is closed and the engine can be started. • Kill switch pressed – In this position, the ignition circuit is interrupted , a run- ning engine st[...]

6 CONTROL S 15 6.10 Emergency OFF switch (EXC AUS) B01148-10 The emergency OFF switch 1 is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a run- ning engine stops, and a non-running engine will not start. Ignition on – In this position, the ignition circuit is clo[...]

6 CONTROL S 16 6.14.2 Activation and test 400313-01 Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. Display test To enable you to check that the display is functioning properly, all display segments light up briefly. 400314-01 WS (wheel size) After the displ[...]

6 CONTROL S 17 Condition The motorcycle is stationary. 400318-01 – Press the button briefly and repeatedly until H appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The Setup menu is displayed and the activated functions are shown. – Change to the desired function by pressing the button briefly. The selected fu[...]

6 CONTROL S 18 400321-01 – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. – Press the button briefly. LAP 1 appears on the left side of the display. – Laps 1-10 can be displayed by pressing the button . – The button has no function. – Press the button briefly. Next display mode Info If an imp[...]

6 CONTROL S 19 6.14.11 Display mode SPEED/LAP (lap time) 400320-01 – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. In the LAP display mode, up to 10 lap times can be timed with the stop watch. Info If the lap time continues after you press the button , 9 memory locations are already occupied. Lap 10[...]

6 CONTROL S 20 Press the button . Reduces value of TR2 . Press the button for 3 - 5 seconds. Deletes value of TR2 . Press the button briefly. Next display mode 6.14.15 Display mode SPEED/A1 (average speed 1) 400325-01 – Press the button briefly and repeatedly until A1 appears at the top right of the display. A1 (average speed 1) shows the average[...]

6 CONTROL S 21 6.14.18 Display mode SPEED/S2 (stop watch 2) 400328-01 – Press the button briefly and repeatedly until S2 appears at the top right of the display. S2 (stop watch 2) is a manual stop watch. If S2 is running in the background, the S2 display flashes in the speedometer display. Press the button . Starts or stops S2 . Press the button [...]

6 CONTROL S 22 6.15 Opening the filler cap Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm[...]

6 CONTROL S 23 6.17 Fuel tap 601157-10 The fuel tap is on the left side of the fuel tank. Tap handle 1 on the fuel tap is used to open or close the supply of fuel to the carbure- tor. 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 [...]

6 CONTROL S 24 6.20 Kick starter B00787-10 The kick starter 1 is fitted on the right side of the engine. The top part can be swiveled. 6.21 Foot brake lever B00788-10 Foot brake lever 1 is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 6.22 Side stand B00789-10 The side stand 1 is on the left side o[...]

6 CONTROL S 25 6.24 Locking the steering (All EXC models) Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. 400732-01 – 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 [...]

7 PREPARIN G FOR USE 26 7.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Missing or poor protective clothing presents a[...]

7 PREPARIN G FOR USE 27 – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes[...]

7 PREPARIN G FOR USE 28 7.4 Preparations for riding on dry sand 600872-10 – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value: Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap,[...]

7 PREPARIN G FOR USE 29 – Change the radiator cap. 600870-01 – Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. 600868-01 – Clean th[...]

7 PREPARIN G FOR USE 30 – Change the radiator cap. 600868-01 – Adjust the secondary ratio to the terrain. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive. – Clean the chain. Chain cleaner ( p. 131) – Clean the radiator fins. – Carefully align bent radiator fins. – Ch[...]

8 RIDING INSTRUCTIO NS 31 8.1 Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 103) – Check the electrical system. – Check the front brake fluid level. ( p. 74) – C[...]

8 RIDING INSTRUCTIO NS 32 Info Do not turn the throttle. (125 EXC EU, 125 EXC SIX DAYS EU) – Press the kick starter robustly through its full range. Info Do not turn the throttle. 8.3 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. Whe[...]

8 RIDING INSTRUCTIO NS 33 – 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. 8.6 Stopping, parking Warning Risk of misappropriation   Usage by unauthorize d persons. – Never leave the vehicle while the engine is[...]

8 RIDING INSTRUCTIO NS 34 8.8 Refueling Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm an[...]

9 SERVICE SCHEDUL E 35 9.1 Service schedule S20A S40A Check that the electrical equipment is functioning properly. • • Check and charge the battery. x (All 200/250/300 models) • • Check the front brake linings. ( p. 75) • • Check the rear brake linings. ( p. 79) • • Check the brake discs. ( p. 74) • • Check the brake lines for d[...]

9 SERVICE SCHEDUL E 36 9.2 Service work (as addition al order) S10N S40A S80A J1A Change the front brake fluid. x • Change the rear brake fluid. x • Change the hydraulic clutch fluid. x ( p. 71) • Grease the steering head bearing. x ( p. 56) • Check/set the carburetor components. x • • Perform a fork service. (EXC SIX DAYS) x • • ?[...]

10 TUNING THE CHASSIS 37 10.1 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. 401030-01 – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspe[...]

10 TUNING THE CHASSIS 38 (All 250/300 models) Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 10.4 Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents   Disassembly of pressurized parts[...]

10 TUNING THE CHASSIS 39 B00792-10 – Turn adjusting screw 1 clockwise with a screwdriver to the last click. Info Do not loosen nut 2 ! – Turn back counterclockwi se by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks (All 250/300 mo[...]

10 TUNING THE CHASSIS 40 10.8 Checking the riding sag of the shock absorber 400990-10 – Measure distance A of the unloaded rear wheel. ( p. 39) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times. The re[...]

10 TUNING THE CHASSIS 41 Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw 1 . Guideline Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) Finishing work – Install the shock absorber. x ( p. 57) – Remove the motorcycle from the lift stand. ( p. 46) 1[...]

10 TUNING THE CHASSIS 42 401000-01 – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression), harder springs must be fit to avoid damage to the fork and frame. 10.12 Adjusting the compression damping of the fo[...]

10 TUNING THE CHASSIS 43 (250/300 EXC SIX DAYS EU) Compression damping Comfort 24 clicks Standard 22 clicks Sport 16 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. 800017-10 (EXC EU/AU[...]

10 TUNING THE CHASSIS 44 (250/300 EXC SIX DAYS EU) Rebound damping Comfort 20 clicks Standard 18 clicks Sport 18 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.14 Adjusting the spring preload of the fork (EXC EU/AUS, XC ‑ W) B00795-01 – Turn the adjusting screws counterclockwise all the way. Info Mak[...]

10 TUNING THE CHASSIS 45 10.16 Adjusting the handlebar position x Warning Danger of accidents   Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. 400223-10 – Remove screws 1 . Remove the handlebar clamp. Remove the handlebar and lay it to one[...]

11 SERVICE WORK ON THE CHASSIS 46 11.1 Raising the motorcycle with the lift stand B00796-01 (All 125/200 models) Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels must no lo[...]

11 SERVICE WORK ON THE CHASSIS 47 303391-10 Main work – Remove bleeder screws 1 briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Finishing work – Remove the motorcycle from the lift stand. ( p. 46) 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle wit[...]

11 SERVICE WORK ON THE CHASSIS 48 11.6 Positioning the fork protection B00800-11 – Position the fork protection on the left fork leg. Mount and tighten screws 1 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line. Position the clamp and mount and tighten screws 2 . – Position the fork protection on the right [...]

11 SERVICE WORK ON THE CHASSIS 49 B01215-10 (EXC SIX DAYS) – Position the fork legs. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from th[...]

11 SERVICE WORK ON THE CHASSIS 50 B00801-10 Main work – Remove screws 1 on the left fork leg. Lift off the fork protector. – Remove the screws on the right fork leg. Lift off the fork protector. 11.10 Installing the fork protector x B00801-10 Main work – Position the fork protection on the left fork leg. Mount and tighten screws 1 . Guideline[...]

11 SERVICE WORK ON THE CHASSIS 51 11.12 Removing the lower triple clamp x (EXC SIX DAYS) Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) – Remove the front wheel. x ( p. 82) – Remove the headlight mask with the headlight. ( p. 90) – Remove the fork legs. x ( p. 48) – Remove the front fender. ( p. 56) – Remove the h[...]

11 SERVICE WORK ON THE CHASSIS 52 B00809-10 – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. Position bleeder screws 4 toward the front. B00799-12 – Tighten screws 5 . Guideline Screw, bottom tri[...]

11 SERVICE WORK ON THE CHASSIS 53 Finishing work – Mount the handlebar cushion. – Install the front fender. ( p. 56) – Install the front wheel. x ( p. 82) – Refit the headlight mask with the headlight. ( p. 90) – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly. – Check t[...]

11 SERVICE WORK ON THE CHASSIS 54 B01214-12 – Tighten screws 6 . Guideline Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) B01215-12 – Tighten screw 4 . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B01220-10 – Mount and tighten screw 7 . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ B01214-13 ?[...]

11 SERVICE WORK ON THE CHASSIS 55 11.15 Checking the play of the steering head bearing Warning Danger of accidents   Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering[...]

11 SERVICE WORK ON THE CHASSIS 56 – Tighten screws 1 . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Mount and tighten screw 2 . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ Finishing work – Check the play of the steering head bearing. ( p. 55) – Remove the motorcycle from the lift stand. ( p. 46)[...]

11 SERVICE WORK ON THE CHASSIS 57 B00815-10 Main work (All 125/200 models) – Remove screw 1 and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. – Remove screw 2 , push splash protector 3 to the side, and remove the shock absorber. B00816-10 (All 250/300 models) –[...]

11 SERVICE WORK ON THE CHASSIS 58 11.22 Removing the seat B00817-10 – Remove screw 1 . Lift up the seat at the rear, pull it back and then remove from above. 11.23 Mounting the seat B00818-01 – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. – Make sure that the seat is [...]

11 SERVICE WORK ON THE CHASSIS 59 11.26 Removing the air filter x Note Engine failure   Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard   Hazardous substances caus[...]

11 SERVICE WORK ON THE CHASSIS 60 S00044-10 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 131) Info Only squeeze the air filter to dry it; never wring it out. – Oil the dry air filter with a high quality filter oil. Oil for foam air filter ( p. 132) – Clean the air [...]

11 SERVICE WORK ON THE CHASSIS 61 11.32 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns   The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns&quo[...]

11 SERVICE WORK ON THE CHASSIS 62 B00090-10 Main work – Turn handle 1 of the fuel tap to the OFF position. (Figure 601157-10 p. 23) – Pull off the fuel hose. Info Remaining fuel may run out of the fuel hose. – Remove screws 1 with the collar sleeve. (All EXC models) – Hang the horn and horn bracket to one side. B00822-10 – Remove screw 2 [...]

11 SERVICE WORK ON THE CHASSIS 63 B00822-11 – Mount the fuel tank vent hose. – Mount and tighten screw 1 with the rubber bushing. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) (All EXC models) – Position the horn with the horn bracket. B00090-11 – Mount and tighten screws 2 with the collar sleeve. Guideline Remaining screws, cha[...]

11 SERVICE WORK ON THE CHASSIS 64 400725-01 – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 131) Off-road chain spray ( p. 131) 11.37 Checking the chain tension Warning Danger of accidents   Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train[...]

11 SERVICE WORK ON THE CHASSIS 65 101430-10 Main work – Push the chain at the end of the chain sliding component upwards to measure chain tension A . Info The bottom chain section 1 must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard B . Chain wear i[...]

11 SERVICE WORK ON THE CHASSIS 66 400987-10 – Pull on the upper part of the chain with the specified weight A . Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance B of 18 chain links in the lower chain section. Info Chain wear is not always even; repeat this measurement at different chain positions. Maxim[...]

11 SERVICE WORK ON THE CHASSIS 67 400985-01 – 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. x 100865-10 – Check the chain guide for tightness. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining scre[...]

11 SERVICE WORK ON THE CHASSIS 68 11.41 Checking the frame x 401347-01 – Check the frame for cracking and deformation. » If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. x Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by K[...]

11 SERVICE WORK ON THE CHASSIS 69 B01151-01 (All 250/300 models) – Check the routing of the throttle cable. The throttle cable must be routed behind the handlebar, on the right of the upper frame tube, and to the carburetor. » If the throttle cable is not routed as specified: – Correct the routing of the throttle cable. Finishing work – Inst[...]

11 SERVICE WORK ON THE CHASSIS 70 Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any [...]

11 SERVICE WORK ON THE CHASSIS 71 11.48 Changing the hydraulic clutch fluid x Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. 400245-10 (All 125/200 models) – Move the clutch fluid reservoir[...]

11 SERVICE WORK ON THE CHASSIS 72 B00042-10 – Inject the liquid into the system until it escapes from hole 6 of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. – Correct the fluid level of the hydrauli[...]

12 BRAKE SYSTEM 73 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. B01[...]

12 BRAKE SYSTEM 74 12.4 Checking the brake discs Warning Danger of accidents   Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) 400257-10 – Check the thickness of the front and rear brake discs at several places on the disc to see if it co[...]

12 BRAKE SYSTEM 75 Warning Danger of accidents   Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filter[...]

12 BRAKE SYSTEM 76 12.8 Changing the front brake linings x Warning Danger of accident   Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation   Br ake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes,[...]

12 BRAKE SYSTEM 77 100397-01 – Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly. 100398-10 – Insert the brake linings, insert the pin, and mount the cotter pins. – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc and[...]

12 BRAKE SYSTEM 78 B00828-10 – Disconnect spring 1 . – Loosen nut 4 and, with push rod 5 , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever individually, loosen nut 2 and turn screw 3 accordingly. Info The range of adjustment is limited. – Turn push rod 5 accordingly until you have free[...]

12 BRAKE SYSTEM 79 Warning Danger of accidents   Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filter[...]

12 BRAKE SYSTEM 80 Warning Danger of accidents   Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from[...]

12 BRAKE SYSTEM 81 400233-10 – Correct the brake fluid level to marking A . Brake fluid DOT 4 / DOT 5.1 ( p. 129) – Mount screw cap 1 with membrane 2 and the O-ring. Info Wash off overflowed or spilled brake fluid immediately with water.[...]

13 WHEELS, TIRES 82 13.1 Removing the front wheel x Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) B00055-10 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes[...]

13 WHEELS, TIRES 83 500084-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw 2 . Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. – Remove the motorcycle[...]

13 WHEELS, TIRES 84 400260-10 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. x – Clean and grease shaft seal rings 1 and bearing surface A of the spacers. Long-life grease ( p. 131) – Insert the spacers. B00831-10 – Lift the rear wheel into the swing arm, po[...]

13 WHEELS, TIRES 85 » If the tread depth is less than the minimum permissible depth: – Change the tire. – Check the tire age. Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indi- cate the week of manufacture and the last two digits [...]

13 WHEELS, TIRES 86 Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (584290940 00)[...]

14 ELECTRIC AL SYSTEM 87 14.1 Removing the battery x (All 200/250/300 models) Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away fro[...]

14 ELECTRIC AL SYSTEM 88 14.3 Recharging the battery x (All 200/250/300 models) Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away f[...]

14 ELECTRIC AL SYSTEM 89 14.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard   The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay [...]

14 ELECTRIC AL SYSTEM 90 14.5 Removing the headlight mask with the headlight B00833-10 – Switch off all power consumers. – Remove screw 1 and take off the clamp. – Release rubber band 2 . Slide the headlight mask up and swing it forward. 303402-10 – Disconnect the electrical plug-in connection 3 and take off the headlight mask with the head[...]

14 ELECTRIC AL SYSTEM 91 100861-10 Main work – Turn rubber cap 1 together with the underlying lamp socket counterclockwise all the way and remove it. – Pull lamp socket 2 of the parking light out of the reflector. 100862-10 – Press headlight bulb 3 lightly into the lamp socket, turn it counterclockwi se and pull it out. – Insert the new hea[...]

14 ELECTRIC AL SYSTEM 92 14.9 Checking the headlight setting 400726-10 – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark a distance B under the first mark. Guideline Distance B 5 cm (2 in) – Position the vehicle vertically [...]

14 ELECTRIC AL SYSTEM 93 100864-10 – Position protection cap 2 and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with the washers. Finishing work – Refit the headlight mask with the headlight. ( p. 90) ?[...]

15 COOLING SYSTEM 94 15.1 Cooling system B00834-10 (All 125/200 models) Water pump 1 in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap 2 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. 1[...]

15 COOLING SYSTEM 95 15.3 Checking the coolant level Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse i[...]

15 COOLING SYSTEM 96 B00835-11 (All 250/300 models) – Remove screw 1 . Take off radiator cap 2 . – Completely drain the coolant. – Mount and tighten screw 1 with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 15.5 Refilling with coolant x Warning Danger of poisoning   Coolant is poisonous and a health haza[...]

15 COOLING SYSTEM 97 B00836-10 – Fill the radiator completely with coolant. – Mount radiator cap 2 . – Run the engine until it is warm. Finishing work – Check the coolant level. ( p. 95)[...]

16 TUNING THE ENGINE 98 16.1 Checking the play in the throttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3… 5 mm (0.12… 0.2 in) » If the throttle cabl[...]

16 TUNING THE ENGINE 99 The idle speed is adjusted with adjusting screw 1 . The idle mixture is adjusted with the idle air adjusting screw 2 . 500282-01 Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw 1 and the idle air adjusting screw 2 . Transition range B Behavior of the engine when the thro[...]

16 TUNING THE ENGINE 100 Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 23) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw 2 slowly in a clockwise direction until the idle speed begins to fall. – Note the position and turn the idle air adjusting screw slowly counterclock wise until the idl[...]

16 TUNING THE ENGINE 101 16.6 Checking the basic position of the shift lever 400692-10 – Sit on the vehicle in the riding position and determine the distance A between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot 10… 20 mm (0.39… 0.79 in) » If the distance does not meet specification s:[...]

16 TUNING THE ENGINE 102 B00057-10 Main work – Remove screws 1 . B00056-11 – Take cap 2 , adjusting spring 3 , auxiliary spring 4 , and spring insert 5 out of the clutch cover. – Pull both springs off of the spring insert. B00058-10 – Mount the required auxiliary spring 4 and adjusting spring 3 and slide them into the clutch cover together.[...]

17 SERVICE WORK ON THE ENGINE 103 17.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. B00049-10 Main work (All 125/200 models) – Remove screw 1 from the opening used to check the gear oil level. – Check the gear oil level. A[...]

17 SERVICE WORK ON THE ENGINE 104 17.3 Draining the gear oil x Warning Danger of scalding   Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediatel y with lukewarm water. Warning Environmental hazard   Hazardous substances cause environmen[...]

17 SERVICE WORK ON THE ENGINE 105 – Mount and tighten the screw cap. Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exha[...]

17 SERVICE WORK ON THE ENGINE 106 – Start the engine and check that it is oil-tight.[...]

18 CLEANING , CARE 107 18.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between [...]

18 CLEANING , CARE 108 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of [...]

19 STORAGE 109 19.1 Storage Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swallowed, c[...]

20 TROUBLE SHOOTING 110 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) (All 200/250/300 models) Operating error – Carry out the start procedure. ( p. 31) Battery discharged – Recharge the battery. x ( p. 88) – Check the charging voltage. x – Check the closed current. x – Check the alternator. x Main fuse is[...]

20 TROUBLE SHOOTING 111 Faults Possible cause Action Engine stalls or is popping into the carburetor Lack of fuel – Turn handle 1 of the fuel tap to the ON posi- tion. – Refuel. ( p. 34) Engine takes in bad air – Check the intake flange and carburetor for tightness. The connector or ignition coil is loose or oxidized – Clean the connector a[...]

21 TECHNICA L DATA 112 21.1 Engine 21.1.1 125 EXC EU, 125 EXC SIX DAYS EU Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin beari[...]

21 TECHNICA L DATA 113 5th gear 17:19 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 21.1.3 All 250 models Design 1-cyli[...]

21 TECHNICA L DATA 114 Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48.5 mm (1.909 in) Primary transmission 2[...]

21 TECHNICA L DATA 115 Axle for control flap, exhaust control M8 Step 1 3 Nm (2.2 lbf ft) Step 2 (loosen, counter- clockwise) 1/4 turn – Nut, cylinder base M8 30 Nm (22.1 lbf ft) – Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, shift drum locating M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Stud, cylinder base M8 35 Nm (25.8 l[...]

21 TECHNICA L DATA 116 Nut, inner clutch hub M18x1.5 120 Nm (88.5 lbf ft) Loctite ® 2701 Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite ® 648™ 21.3 Capacities 21.3.1 Gear oil Gear oil (All 125/200 models) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 129) Gear oil (All 250/300 models) 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 129) 21.3[...]

21 TECHNICA L DATA 117 Secondary ratio (200 XC ‑ W USA) 14:48 Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase (All 125/200 models) 1,471±10 mm (57.91±0.39 in) Wheelbase (All 250/300 models) 1,482±10 mm (58.35±0.39 in) Seat height unloaded 960 mm (37.8 in) Ground clearance [...]

21 TECHNICA L DATA 118 21.7 Fork 21.7.1 125 EXC EU, all 200 models Fork part number 14.18.7L.61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload - Preload Adjuster Comfort 1 turn Standard 2 turns S[...]

21 TECHNICA L DATA 119 Weight of rider: 85… 95 kg (187… 209 lb.) 4.4 N/mm (25.1 lb/in) Fork length 940 mm (37.01 in) Air chamber length 110 +10 − 20 mm (4.33 +0.39 − 0.79 in) Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 129) 21.7.3 125 EXC SIX DAYS EU Fork part number 24.18.7M.61 Fork WP Suspension Up Side[...]

21 TECHNICA L DATA 120 21.8 Shock absorber 21.8.1 All 125/200 models Shock absorber part number 12.18.7L.61 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 28 click[...]

21 TECHNICA L DATA 121 Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in) Spring length 250 mm (9.84 in) Gas pressure 10 bar (145 psi) Static sag 33… 35 mm (1.3… 1.38 in) Riding sag 105… 115 mm (4.[...]

21 TECHNICA L DATA 122 Screw, bottom shock absorber M1 2 80 Nm (59 lbf ft) Loctite ® 2701 Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite ® 2701 Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) – Screw, top steering head M20x1.5 12 Nm (8[...]

21 TECHNICA L DATA 123 Carburetor identification number BM9 0 Needle position 3rd position from top Jet needle N1EI (N1EH / N1EJ) Main jet 158 (160) Idling jet 40 Starting jet 85 Idle air adjusting screw Open 2.0 turns Throttle slide 7 with cut-out Slide stop - 21.10.5 250 EXC EU, 250 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG Carburetor ide[...]

21 TECHNICA L DATA 124 21.10.8 300 EXC EU, 300 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N2ZJ / N2ZK / N2ZL) Main jet 115 (162/165) Idling jet 38X38 (35) Starting jet 50 (85) Idle air adjusting screw Open 1.75 turns Throttle slide 7 with cut-out Sl[...]

21 TECHNICA L DATA 125 401348-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.10.11 Carburetor tuning (All 200 models) x Danger Loss of approval for road use and insurance coverage   The motorcycle is authorized for pub[...]

21 TECHNICA L DATA 126 401526-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.10.12 Carburetor tuning (All 250 models) x Danger Loss of approval for road use and insurance coverage   The motorcycle is authorized for pub[...]

21 TECHNICA L DATA 127 401043-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.10.13 Carburetor tuning (All 300 models) x Danger Loss of approval for road use and insurance coverage   The motorcycle is authorized for pub[...]

21 TECHNICA L DATA 128 401044-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.10.14 General carburetor tuning x 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075-10 1... 5 Needle position from above The five needle positions[...]

22 SUBSTAN CES 129 2-stroke engine oil According to – JASO FC ( p. 133) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the[...]

22 SUBSTAN CES 130 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (5018[...]

23 AUXILIAR Y SUBSTANCES 131 Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ?[...]

23 AUXILIAR Y SUBSTANCES 132 Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcy cle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic[...]

24 STANDAR DS 133 JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustio n is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions req[...]

INDEX 134 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 A[...]

INDEX 135 Fork basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 41 Fork legs bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 47 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 removing . . . . . .[...]

INDEX 136 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 40 spring preload, setting . . . . . . . . . . . . . . . . . . . . . . . . 40 static sag, checking . . . . . . [...]

*321 186 1en* 3211861en 06/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]