Мануал ктм 300 exc 2017

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Manuals and User Guides for KTM 300 EXC. We have 14 KTM 300 EXC manuals available for free PDF download: Repair Manual, Owner’s Manual, Owner’s Handbook Manual, Manual

KTM 300 EXC Repair Manual

KTM 300 EXC Repair Manual (289 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 12.59 MB

Table of Contents
  • Table of Contents

    4

  • Table of Contents 2

    4

  • 1 Means of Representation

    8

    • Symbols Used

      8

    • Formats Used

      8

  • 2 Safety Advice

    9

    • Repair Manual

      9

    • Degrees of Risk and Symbols

      9

    • Work Rules

      9

  • 3 Important Information

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Figures

      10

  • 4 Serial Numbers

    11

    • Chassis Number

      11

    • Type Label

      11

    • Engine Number

      11

    • Fork Part Number

      11

    • Shock Absorber Part Number

      11

  • 5 Motorcycle

    12

    • Raising the Motorcycle with the Lift Stand

      12

    • Removing the Motorcycle from the Lift Stand

      12

    • Starting

      12

    • Starting the Motorcycle for Checking

      13

  • 6 Fork, Triple Clamp

    14

    • Exc Eu/Aus, XC-W

      14

    • Adjusting the Compression Damping of the Fork

      14

    • Adjusting the Rebound Damping of the Fork

      14

    • Adjusting the Spring Preload of the Fork

      14

    • Bleeding the Fork Legs

      15

    • Cleaning the Dust Boots of the Fork Legs

      15

    • Loosening the Fork Protection

      16

    • Positioning the Fork Protection

      16

    • Removing the Fork Legs

      16

    • Installing the Fork Legs

      16

    • Removing the Fork Protector

      17

    • Installing the Fork Protector

      17

    • Performing a Fork Service

      18

    • Disassembling the Fork Legs

      18

    • Cartridge Disassembly

      21

    • Disassembling the Compression Damping Fitting

      23

    • Checking the Fork Legs

      23

    • Assembling the Compression Damping Fitting

      24

    • Assembling the Cartridge

      25

    • Assembling the Fork Legs

      26

    • Greasing the Steering Head Bearing

      31

    • Removing the Lower Triple Clamp

      31

    • Installing the Lower Triple Clamp

      32

    • Checking the Play of the Steering Head Bearing

      33

    • Adjusting the Play of the Steering Head Bearing

      34

    • 250/300 Six Days

      34

    • Adjusting the Compression Damping of the Fork

      34

    • Adjusting the Rebound Damping of the Fork

      35

    • Bleeding the Fork Legs

      35

    • Cleaning the Dust Boots of the Fork Legs

      35

    • Loosening the Fork Protection

      36

    • Positioning the Fork Protection

      36

    • Removing the Fork Legs

      36

    • Installing the Fork Legs

      37

    • Removing the Fork Protector

      37

    • Installing the Fork Protector

      38

    • Performing a Fork Service

      38

    • Disassembling the Fork Legs

      38

    • Removing the Spring

      40

    • Disassembling the Cartridge

      41

    • Disassembling the Piston Rod

      42

    • Disassembling the Hydrostop Unit

      43

    • Disassembling the Seal Ring Retainer

      44

    • Checking the Fork Legs

      44

    • Assembling the Seal Ring Retainer

      45

    • Assembling the Hydrostop Unit

      46

    • Assembling the Piston Rod

      46

    • Assembling the Cartridge

      48

    • Assembling the Fork Legs

      49

    • Greasing the Steering Head Bearing

      52

    • Removing the Lower Triple Clamp

      53

    • Installing the Lower Triple Clamp

      53

    • Checking the Play of the Steering Head Bearing

      55

    • Adjusting the Play of the Steering Head Bearing

      55

  • 7 Handlebar, Controls

    56

    • Handlebar Position

      56

    • Adjusting the Handlebar Position

      56

    • Adjusting the Basic Position of the Clutch Lever

      56

    • Checking the Routing of the Throttle Cable

      57

    • Checking the Play in the Throttle Cable

      57

    • Adjusting the Play in the Throttle Cable

      58

  • 8 Frame

    59

    • Removing the Engine Guard (250/300 SIX DAYS)

      59

    • Installing the Engine Guard (250/300 SIX DAYS)

      59

  • 9 Shock Absorber, Swingarm

    60

    • Adjusting the High-Speed Compression Damping of the Shock Absorber

      60

    • Adjusting the Low-Speed Compression Damping of the Shock Absorber

      60

    • Adjusting the Rebound Damping of the Shock Absorber

      61

    • Measuring the Sag of the Unloaded Rear Wheel

      61

    • Checking the Static Sag of the Shock Absorber

      61

    • Checking the Riding Sag of the Shock Absorber

      62

    • Adjusting the Spring Preload of the Shock Absorber

      62

    • Adjusting the Riding Sag

      63

    • Removing the Shock Absorber

      63

    • Installing the Shock Absorber

      63

    • Servicing the Shock Absorber

      64

    • Removing the Spring

      64

    • Disassembling the Damper

      65

    • Disassembling the Piston Rod

      66

    • Disassembling the Seal Ring Retainer

      67

    • Replacing the Pilot Bushing

      68

    • Checking the Damper

      69

    • Disassembling the Rebound Adjuster

      69

    • Removing the Heim Joint

      70

    • Installing the Heim Joint

      71

    • Assembling the Rebound Adjuster

      72

    • Assembling the Seal Ring Retainer

      72

    • Assembling the Piston Rod

      73

    • Assembling the Damper

      74

    • Bleeding and Filling the Damper

      77

    • Filling the Damper with Nitrogen

      79

    • Installing the Spring

      80

    • Changing the Heim Joint

      81

  • 10 Exhaust

    83

    • Removing the Main Silencer

      83

    • Installing the Main Silencer

      83

    • Changing the Glass Fiber Yarn Filling of the Main Silencer

      83

  • 11 Air Filter

    85

    • Removing the Air Filter Box Lid

      85

    • Installing the Air Filter Box Lid

      85

    • Removing the Air Filter

      85

    • Installing the Air Filter

      85

    • Cleaning the Air Filter and Air Filter Box

      86

    • Sealing the Air Filter Box

      86

  • 12 Fuel Tank, Seat, Trim

    87

    • Opening the Filler Cap

      87

    • Closing the Filler Cap

      87

    • Removing the Seat

      87

    • Mounting the Seat

      88

    • Removing the Fuel Tank

      88

    • Installing the Fuel Tank

      89

    • Fuel Tap

      90

  • 13 Mask, Fender

    91

    • Removing the Front Fender

      91

    • Installing the Front Fender

      91

    • Removing the Headlight Mask with the Headlight

      91

    • Refitting the Headlight Mask with the Headlight

      92

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KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (150 pages)

2014

Brand: KTM
|
Category: Motorcycle
|
Size: 3.99 MB

Table of Contents
  • Table of Contents

    4

  • 1 Means of Representation

    7

    • Symbols Used

      7

    • Formats Used

      7

  • 2 Safety Advice

    8

    • Use Definition — Intended Use

      8

    • Degrees of Risk and Symbols

      8

    • Tampering Warning

      8

    • Safe Operation

      9

    • Protective Clothing

      9

    • Work Rules

      9

    • Environment

      9

    • Owner’s Manual

      9

  • 3 Important Notes

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Service

      10

    • Figures

      10

    • Customer Service

      10

  • 4 View of Vehicle

    11

    • View of Vehicle, Front Left (Example)

      11

    • View of Vehicle, Rear Right (Example)

      12

  • 5 Serial Numbers

    13

    • Chassis Number

      13

    • Type Label

      13

    • Key Number (All EXC Models)

      13

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      14

  • 6 Controls

    15

    • Clutch Lever

      15

    • Hand Brake Lever

      15

    • Throttle Grip

      15

    • Kill Switch (All EXC Models)

      15

    • Kill Switch (All XC-W Models)

      16

    • Horn Button (All EXC Models)

      16

    • Light Switch (All EXC Models)

      16

    • Light Switch (All XC-W Models)

      16

    • Turn Signal Switch (All EXC Models)

      16

    • Emergency off Switch (EXC AUS)

      17

    • Electric Starter Button (200/250/300 EXC EU, 250/300 SIX DAYS, XC-W)

      17

    • Electric Starter Button (EXC AUS)

      17

    • Overview of Indicator Lamps (EXC EU/AUS)

      17

    • Overview of Indicator Lamps (SIX DAYS EU)

      17

    • Overview of Indicator Lamps (300 XC-W SIX DAYS USA)

      18

    • Opening the Filler Cap

      18

    • Closing the Filler Cap

      18

    • Fuel Tap

      19

    • Choke

      19

    • Shift Lever

      19

    • Kick Starter

      20

    • Foot Brake Lever

      20

    • Side Stand

      20

    • Steering Lock (All EXC Models)

      20

    • Locking the Steering (All EXC Models)

      21

    • Unlocking the Steering (All EXC Models)

      21

  • 7 Speedometer

    22

    • Exc, XC-W

      22

    • Speedometer Overview

      22

    • Activation and Test

      22

    • Setting Kilometers or Miles

      22

    • Adjusting the Speedometer Functions

      23

    • Setting the Clock

      23

    • Querying Lap Time

      23

    • Display Mode SPEED (Speed)

      24

    • Display Mode SPEED/H (Service Hours)

      24

    • Setup Menu

      24

    • Unit of Measurement Menu

      25

    • Display Mode SPEED/CLK (Time)

      25

    • Setting the Clock

      25

    • Display Mode SPEED/LAP (Lap Time)

      26

    • Viewing the Lap Time

      26

    • Display Mode SPEED/ODO (Odometer)

      26

    • Display Mode SPEED/TR1 (Trip Master 1)

      26

    • Display Mode SPEED/TR2 (Trip Master 2)

      27

    • Setting TR2 (Trip Master 2)

      27

    • Display Mode SPEED/A1 (Average Speed 1)

      27

    • Display Mode SPEED/A2 (Average Speed 2)

      28

    • Display Mode SPEED/S1 (Stop Watch 1)

      28

    • Display Mode SPEED/S2 (Stop Watch 2)

      28

    • Table of Functions

      28

    • Table of Conditions and Menu Activation

      29

    • Six Days

      29

    • Speedometer Overview

      29

    • Activation and Test

      30

    • Setting Kilometers or Miles

      30

    • Setting the Speedometer Functions

      30

    • Setting the Clock

      31

    • Viewing the Lap Time

      31

    • Display Mode SPEED (Speed)

      32

    • Display Mode SPEED/H (Service Hours)

      32

    • Setup Menu

      32

    • Setting the Unit of Measurement

      33

    • Display Mode SPEED/CLK (Time)

      33

    • Setting the Clock

      33

    • Display Mode SPEED/LAP (Lap Time)

      34

    • Viewing the Lap Time

      34

    • Display Mode SPEED/ODO (Odometer)

      34

    • Display Mode SPEED/TR1 (Trip Master 1)

      34

    • Display Mode SPEED/TR2 (Trip Master 2)

      35

    • Setting TR2 (Trip Master 2)

      35

    • Display Mode SPEED/A1 (Average Speed 1)

      35

    • Display Mode SPEED/A2 (Average Speed 2)

      36

    • Display Mode SPEED/S1 (Stop Watch 1)

      36

    • Display Mode SPEED/S2 (Stop Watch 2)

      36

    • Table of Functions

      37

    • Table of Conditions and Menu Activation

      38

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (154 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 7.42 MB

Table of Contents
  • Table of Contents

    4

  • 1 Means of Representation

    7

    • Symbols Used

      7

    • Formats Used

      7

  • 2 Safety Advice

    8

    • Use Definition — Intended Use

      8

    • Degrees of Risk and Symbols

      8

    • Tampering Warning

      8

    • Safe Operation

      9

    • Protective Clothing

      9

    • Work Rules

      9

    • Environment

      9

    • Owner’s Manual

      9

  • 3 Important Notes

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Service

      10

    • Figures

      10

    • Customer Service

      10

  • 4 View of Vehicle

    11

    • View of Vehicle, Front Left (Example)

      11

    • View of Vehicle, Rear Right (Example)

      12

  • 5 Serial Numbers

    13

    • Chassis Number

      13

    • Type Label

      13

    • Key Number (All EXC Models)

      13

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      14

  • 6 Controls

    15

    • Clutch Lever

      15

    • Hand Brake Lever

      15

    • Throttle Grip

      15

    • Kill Switch (All EXC Models)

      15

    • Kill Switch (All XC-W Models)

      16

    • Horn Button (All EXC Models)

      16

    • Light Switch (All EXC Models)

      16

    • Light Switch (All XC-W Models)

      16

    • Turn Signal Switch (All EXC Models)

      16

    • Emergency off Switch (EXC AU)

      17

    • Electric Starter Button (All 200/250/300 EU/US Models, 300 EXC BR)

      17

    • Electric Starter Button (EXC AU)

      17

    • Overview of Indicator Lamps (All EXC Models)

      17

    • Overview of Indicator Lamps (All XC-W Models)

      17

    • Opening the Filler Cap

      18

    • Closing the Filler Cap

      18

    • Fuel Tap

      19

    • Choke

      19

    • Shift Lever

      19

    • Kick Starter

      20

    • Foot Brake Lever

      20

    • Side Stand

      20

    • Steering Lock (All EXC Models)

      20

    • Locking the Steering (All EXC Models)

      21

    • Unlocking the Steering (All EXC Models)

      21

  • 7 Speedometer

    22

    • Speedometer Overview

      22

    • Activation and Test

      22

    • Setting Kilometers or Miles

      22

    • Setting the Speedometer Functions

      23

    • Setting the Clock

      23

    • Viewing the Lap Time

      23

    • Display Mode SPEED (Speed)

      24

    • Display Mode SPEED/H (Service Hours)

      24

    • Setup Menu

      25

    • Setting the Unit of Measurement

      25

    • Display Mode SPEED/CLK (Time)

      26

    • Setting the Clock

      26

    • Display Mode SPEED/LAP (Lap Time)

      26

    • Viewing the Lap Time

      27

    • Display Mode SPEED/ODO (Odometer)

      27

    • Display Mode SPEED/TR1 (Trip Master 1)

      27

    • Display Mode SPEED/TR2 (Trip Master 2)

      28

    • Setting TR2 (Trip Master 2)

      28

    • Display Mode SPEED/A1 (Average Speed 1)

      28

    • Display Mode SPEED/A2 (Average Speed 2)

      29

    • Display Mode SPEED/S1 (Stop Watch 1)

      29

    • Display Mode SPEED/S2 (Stop Watch 2)

      29

    • Table of Functions

      30

    • Table of Conditions and Menu Activation

      31

  • 8 Preparing for Use

    32

    • Advice on First Use

      32

    • Running in the Engine

      33

    • Preparing the Vehicle for Difficult Riding Conditions

      33

    • Preparations for Riding on Dry Sand

      34

    • Preparations for Riding on Wet Sand

      34

    • Preparations for Riding on Wet and Muddy Surfaces

      35

    • Preparations for Riding at High Temperatures and Low Speeds

      35

    • Preparing for Riding at Low Temperatures or in Snow

      36

  • 9 Riding Instructions

    37

    • Checks and Maintenance Work When Preparing for Use

      37

    • Starting

      37

    • Start off

      38

    • Shifting, Riding

      38

    • Braking

      38

    • Stopping, Parking

      39

    • Transport

      39

    • Refueling

      40

  • 10 Service Schedule

    41

    • Service Work (as Additional Order)

      42

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KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (145 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 7.05 MB

Table of Contents
  • Table of Contents

    4

  • Table of Contents 2

    4

  • 1 Means of Representation

    7

    • Symbols Used

      7

    • Formats Used

      7

  • 2 Safety Advice

    8

    • Use Definition — Intended Use

      8

    • Degrees of Risk and Symbols

      8

    • Tampering Warning

      8

    • Safe Operation

      9

    • Protective Clothing

      9

    • Work Rules

      9

    • Environment

      9

    • Owner’s Manual

      9

  • 3 Important Notes

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Service

      10

    • Figures

      10

    • Customer Service

      10

  • 4 View of Vehicle

    11

    • View of Vehicle, Front Left (Example)

      11

    • View of Vehicle, Rear Right (Example)

      12

  • 5 Serial Numbers

    13

    • Chassis Number

      13

    • Type Label

      13

    • Key Number (All EXC Models)

      13

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      14

  • 6 Controls

    15

    • Clutch Lever

      15

    • Hand Brake Lever

      15

    • Throttle Grip

      15

    • Kill Switch (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

      15

    • Kill Switch (Six Days EU)

      16

    • Kill Switch (All XC-W Models)

      16

    • Horn Button (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

      16

    • Horn Button (Six Days EU)

      16

    • Light Switch (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

      16

    • Light Switch (Six Days EU)

      17

    • Light Switch (All XC-W Models)

      17

    • Turn Signal Switch (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

      17

    • Turn Signal Switch (Six Days EU)

      17

    • Emergency off Switch (EXC AU)

      17

    • Electric Starter Button (All 200/250/300 EU/US Models, 300 EXC BR)

      18

    • Electric Starter Button (EXC AU)

      18

    • Overview of Indicator Lamps (All EXC Models)

      18

    • Overview of Indicator Lamps (All XC-W Models)

      18

    • Opening the Filler Cap

      18

    • Closing the Filler Cap

      19

    • Fuel Tap

      19

    • Choke

      20

    • Shift Lever

      20

    • Kick Starter

      20

    • Foot Brake Lever

      20

    • Side Stand

      21

    • Steering Lock (All EXC Models)

      21

    • Locking the Steering (All EXC Models)

      21

    • Unlocking the Steering (All EXC Models)

      22

  • 7 Speedometer

    23

    • Speedometer Overview

      23

    • Activation and Test

      23

    • Setting Kilometers or Miles

      23

    • Setting the Speedometer Functions

      24

    • Setting the Clock

      24

    • Viewing the Lap Time

      24

    • Display Mode SPEED (Speed)

      25

    • Display Mode SPEED/H (Service Hours)

      25

    • Setup Menu

      25

    • Setting the Unit of Measurement

      26

    • Display Mode SPEED/CLK (Time)

      26

    • Setting the Clock

      27

    • Display Mode SPEED/LAP (Lap Time)

      27

    • Viewing the Lap Time

      27

    • Display Mode SPEED/ODO (Odometer)

      28

    • Display Mode SPEED/TR1 (Trip Master 1)

      28

    • Display Mode SPEED/TR2 (Trip Master 2)

      28

    • Setting TR2 (Trip Master 2)

      28

    • Display Mode SPEED/A1 (Average Speed 1)

      29

    • Display Mode SPEED/A2 (Average Speed 2)

      29

    • Display Mode SPEED/S1 (Stop Watch 1)

      30

    • Display Mode SPEED/S2 (Stop Watch 2)

      30

    • Table of Functions

      30

    • Table of Conditions and Menu Activation

      31

  • 8 Preparing for Use

    32

    • Advice on First Use

      32

    • Running in the Engine

      33

    • Preparing the Vehicle for Difficult Riding Conditions

      33

    • Preparations for Riding on Dry Sand

      34

    • Preparations for Riding on Wet Sand

      34

    • Preparations for Riding on Wet and Muddy Surfaces

      35

    • Preparations for Riding at High Temperatures and Low Speeds

      35

    • Preparing for Riding at Low Temperatures or in Snow

      36

  • 9 Riding Instructions

    37

    • Checks and Maintenance Work When Preparing for Use

      37

    • Starting

      37

    • Start off

      38

    • Shifting, Riding

      38

    • Braking

      38

    • Stopping, Parking

      39

    • Transport

      39

    • Refueling

      40

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (139 pages)

201 year

Brand: KTM
|
Category: Motorcycle
|
Size: 4.41 MB

Table of Contents
  • Table of Contents

    4

  • 1 Means of Representation

    7

    • Symbols Used

      7

    • Formats Used

      7

  • 2 Safety Advice

    8

    • Use Definition — Intended Use

      8

    • Degrees of Risk and Symbols

      8

    • Tampering Warning

      8

    • Safe Operation

      9

    • Protective Clothing

      9

    • Work Rules

      9

    • Environment

      9

    • Owner’s Manual

      9

  • 3 Important Notes

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Service

      10

    • Figures

      10

    • Customer Service

      10

  • 4 View of Vehicle

    11

    • View of Vehicle, Front Left (Example)

      11

    • View of Vehicle, Rear Right (Example)

      12

  • 5 Serial Numbers

    13

    • Chassis Number

      13

    • Type Label

      13

    • Key Number (All EXC Models)

      13

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      14

  • 6 Controls

    15

    • Clutch Lever

      15

    • Hand Brake Lever

      15

    • Throttle Grip

      15

    • Kill Switch (All EXC Models)

      15

    • Kill Switch (XC-W)

      16

    • Horn Button (All EXC Models)

      16

    • Light Switch (All EXC Models)

      16

    • Light Switch (XC-W)

      16

    • Turn Signal Switch (All EXC Models)

      16

    • Emergency off Switch (EXC AUS)

      17

    • Electric Starter Button (200/250/300 EXC EU, 250/300 EXC SIX DAYS EU, XC-W)

      17

    • Electric Starter Button (EXC AUS)

      17

    • Overview of Indicator Lamps (All EXC Models)

      17

    • Speedometer

      17

    • Overview

      17

    • Activation and Test

      18

    • Tripmaster Switch

      18

    • Setting Kilometers or Miles

      18

    • Adjusting the Speedometer Functions

      18

    • Setting the Clock

      19

    • Querying Lap Time

      19

    • Display Mode SPEED (Speed)

      20

    • Display Mode SPEED/H (Operating Hours)

      20

    • Display Mode SPEED/CLK (Clock)

      20

    • Display Mode SPEED/LAP (Lap Time)

      21

    • Display Mode SPEED/ODO (Odometer)

      21

    • Display Mode SPEED/TR1 (Trip Master 1)

      21

    • Display Mode SPEED/TR2 (Trip Master 2)

      21

    • Display Mode SPEED/A1 (Average Speed 1)

      22

    • Display Mode SPEED/A2 (Average Speed 2)

      22

    • Display Mode SPEED/S1 (Stop Watch 1)

      22

    • Display Mode SPEED/S2 (Stop Watch 2)

      23

    • 6.14.19 Table of Functions

      23

    • 6.14.20 Table of Conditions and Menu Activation

      23

    • Opening the Filler Cap

      24

    • Closing the Filler Cap

      24

    • Fuel Tap

      25

    • Choke

      25

    • Shift Lever

      25

    • Kick Starter

      26

    • Foot Brake Lever

      26

    • Side Stand

      26

    • Steering Lock (All EXC Models)

      26

    • Locking the Steering (All EXC Models)

      27

    • Unlocking the Steering (All EXC Models)

      27

  • 7 Preparing for Use

    28

    • Advice on First Use

      28

    • Running in the Engine

      29

    • Preparing the Vehicle for Difficult Riding Conditions

      29

    • Preparations for Riding on Dry Sand

      30

    • Preparations for Riding on Wet Sand

      30

    • Preparations for Riding on Wet and Muddy Surfaces

      31

    • Preparations for Riding at High Temperatures and Low Speeds

      31

    • Preparing for Riding at Low Temperatures or in Snow

      32

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (136 pages)

2012 Motorcycle

Brand: KTM
|
Category: Motorcycle
|
Size: 4.26 MB

Table of Contents
  • Table of Contents

    4

  • Means of Representation

    7

  • Important Information

    8

  • View of Vehicle

    10

    • View of Vehicle, Front Left (Example)

      10

    • View of Vehicle, Rear Right (Example)

      11

  • Serial Numbers

    12

    • Chassis Number

      12

    • Type Label

      12

    • Key Number (All EXC Models)

      12

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      13

  • Controls

    14

    • Clutch Lever

      14

    • Hand Brake Lever

      14

    • Throttle Grip

      14

    • Kill Switch (All EXC Models)

      14

    • Short Circuit Button (XC-W)

      15

    • Light Switch (All EXC Models)

      15

    • Turn Signal Switch (All EXC Models)

      15

    • Horn Button (All EXC Models)

      15

    • Emergency off Switch (200 EXC AUS)

      15

    • Emergency off Switch (250/300 EXC AUS)

      16

    • Electric Starter Button (250/300 EXC EU, EXC SIX DAYS, 250/300 XC-W)

      16

    • Electric Starter Button (250/300 EXC AUS)

      16

    • Light Switch (XC-W)

      16

    • Overview of Indicator Lamps (All EXC Models)

      16

    • Speedometer

      17

    • Speedometer Activation and Test

      17

    • Tripmaster Switch

      17

    • Setting Kilometers or Miles

      17

    • Setting the Clock

      18

    • Adjusting the Speedometer Functions

      18

    • Querying Lap Time

      19

    • Display Mode SPEED (Speed)

      19

    • Display Mode SPEED/H (Operating Hours)

      19

    • Display Mode SPEED/CLK (Clock)

      20

    • Display Mode SPEED/LAP (Lap Time)

      20

    • Display Mode SPEED/ODO (Odometer)

      20

    • Display Mode SPEED/TR1 (Trip Master 1)

      20

    • Display Mode SPEED/TR2 (Trip Master 2)

      21

    • Display Mode SPEED/A1 (Average Speed 1)

      21

    • Display Mode SPEED/A2 (Average Speed 2)

      21

    • Display Mode SPEED/S1 (Stop Watch 1)

      22

    • Display Mode SPEED/S2 (Stop Watch 2)

      22

    • Fuel Tap

      23

    • Opening the Filler Cap

      23

    • Closing the Filler Cap

      24

    • Shift Lever

      24

    • Kickstarter

      24

    • Foot Brake Lever

      25

    • Side Stand

      25

    • Steering Lock (All EXC Models)

      25

    • Locking the Steering (All EXC Models)

      25

    • Unlocking the Steering (All EXC Models)

      26

  • Preparing for Use

    27

    • Advice on First Use

      27

    • Running in the Engine

      28

    • Preparing the Vehicle for Difficult Operating Conditions

      28

    • Preparations for Riding on Dry Sand

      29

    • Preparations for Riding on Wet Sand

      29

    • Preparations for Riding on Wet and Muddy Surfaces

      30

    • Preparations for Riding at High Temperatures and Low Speeds

      30

    • Preparing for Rides at Low Temperatures or in Snow

      31

  • Riding Instructions

    32

    • Checks and Maintenance Work When Preparing for Use

      32

    • Starting

      32

    • Start off

      33

    • Shifting, Riding

      33

    • Braking

      33

    • Stopping, Parking

      34

    • Refueling

      34

  • Service Schedule

    36

    • Maintenance Work (as an Additional Order)

      37

KTM 300 EXC Repair Manual

KTM 300 EXC Repair Manual (154 pages)

KTM Automobile Parts User Manual

Brand: KTM
|
Category: Engine
|
Size: 5.51 MB

Table of Contents
  • Table of Contents

    5

  • Updating Instructions

    7

  • Explanation — Updating

    9

  • General Information

    14

  • Operating Ranges of the Carburetor

    16

    • Basic Information on a Change of the Carburetor Setting

      17

    • Basic Information on the Original Carburetor Setting

      17

  • Carburetor Adjustment

    17

    • Bleeding of the Hydraulic Clutch

      18

      • Checking the Setting of the TVC System

        18

      • Special Tools — Engine 250/300/380

        19

    • Cleaning

      20

    • Conservartion for Winter Operation

      20

    • Storage

      20

    • Removing and Refitting Engine

      22

      • Dismounting the Engine

        24

      • Filling in of Cooling Liquid

        26

      • Filling in of Transmission Oil

        26

      • Refitting the Engine

        26

    • Disassembling the Engine

      28

      • Dismounting of Cylinder Head, Cylinder and Piston

        30

      • Dismounting of Sprocket and Shift Lever

        30

      • Draining Gear Oil

        30

      • Dismounting of Clutch Cover

        31

      • Dismounting of Pressure Cap and Clutch Discs

        32

      • Dismounting of the Primary Drive

        32

      • Dismounting of Ignition Cover

        33

      • Dismounting of Kickstarter

        33

      • Dismounting of the Shift Lock

        33

      • Dismounting of the Ignition (Kokusan)

        34

      • Dismounting of the Ignition (SEM)

        34

      • Dismounting of Gearshift Mechanism and Transmission

        35

      • Dismounting of Intake Flange and Reed Valve Housing

        35

      • Parting of Engine Housing Halves

        35

      • Dismounting the Crankshaft

        36

      • Servicing of Individual Components

        37

      • Working on the Right-Hand Housing Half

        39

      • Working on the Left-Hand Housing Half

        40

    • Crankshaft

      41

    • Crankshaft Webs – Measure Outer Dimension

      41

    • Piston

      41

    • Piston Ring End Gap

      41

    • Checking Cylinder for Wear

      42

    • Nikasil Coating of Cylinder

      42

    • Recoated Cylinder

      42

    • Cylinder Exhaust Control System

      43

    • Cylinder Preassembly

      43

    • Exhaust Control, Clutch Cover

      45

    • Preassembly of Clutch Cover

      45

    • Reed Valve Housing, Intake Flange

      46

    • Clutch

      47

    • Replace Outer Clutch Hub

      48

    • Preassembly of Shift Shaft

      49

    • Shift Mechanism

      49

    • Check Stator and Pulse Generator (Kokusan)

      50

    • Ignition (Kokusan)

      50

    • Kokusan Ignition & Spark Plug

      50

    • Check Stator (SEM)

      51

    • Ignition (SEM)

      51

    • SEM Ignition & Spark Plug

      51

    • Assembly Mainshaft

      52

    • Transmission

      52

    • Assembly Countershaft

      53

    • Assemble of Kickstarter Shaft

      54

    • Assembling the Engine

      55

    • Assembling the Engine Housing

      58

    • Mounting Kickstarter

      59

    • Mounting Shift Mechanism

      59

    • Mount Primary Drive and Clutch

      60

    • Mounting Clutch Discs and Pressure Cap

      61

    • Adjusting Dimension „X“

      62

    • Mounting Piston and Cylinder

      62

    • Adjusting Control Flap (Dimension “Z“)

      63

    • Mounting Cylinder Head

      64

    • Mounting Reed Valve Housing and Intake Flange

      64

    • Mounting Steering Covers

      64

    • Mounting Engine Sprocket

      65

    • Mounting the Ignition (Kokusan)

      65

    • Adjusting Ignition Point (SEM)

      66

    • Mounting Starting Lever and Shift Lever

      66

    • Mounting the Ignition (SEM)

      66

      • Electrical

        67

      • Checking the Voltage Regulator (Kokusan)

        69

      • Checking the Voltage Regulator (Tympanium)

        69

      • Checking the Voltage Regulator-Rectifier (Shindengen)

        69

      • CDI Unit

        70

      • Checking the Capacitor

        70

      • Ignition Coil (Kokusan)

        70

      • Ignition Coil (SEM)

        70

      • Checking the Voltage Regulator

        71

      • Static Ignition Values 250-380 SX, EXC (Kokusan 2K-1, 2K-3, 2K-4)

        72

      • Static Generator Values 250-380 EXC (Kokusan 2K-3) (Except 250 USA)

        74

      • Static Ignition Values 250 MXC, EXC USA (Kokusan 2K-2)

        76

      • Troubleshooting

        79

    • Trouble Shooting

      81

    • Technical Specifications

      83

      • Technical Specifications — Engine 250/300/380 SX/MXC/EXC ‘99 (Only for USA)

        85

      • Basic Carburetor Setting

        86

      • Gasket Thicknesses

        86

      • Tightening Torques

        86

      • Tolerances and Fitting Clearances

        86

      • Technical Specifications — Engine 250/300/380 SX/EXC/EGS ‘99 (All Models out of USA)

        87

      • Standard Adjustment — Fork

        89

      • Standard Adjustment — Shock Absorber

        89

      • Technical Specifications Chassis 250/300/380 SX/MXC/EXC/EGS ‘99

        89

      • Carburetor Setting KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38

        90

      • Carburetor Setting KTM 250 SX Europe, USA ‘99 KEIHIN PWK 38

        91

      • Carburetor Setting KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38

        92

      • Technical Data — Engine 250/300/380 SX/MXC/EXC 2000 (Only USA)

        93

      • Technical Data — Engine 250/300/380 SX/EXC 2000 (All Models out of USA)

        95

      • Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2000

        97

      • Carburetor Setting G KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ

        98

      • Carburetor Setting KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG

        99

      • Carburetor Setting KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG

        100

      • Carburetor Setting KTM 380 SX/MXC/ EXC/EUR/USA 2000 KEIHIN PWK 38 AG

        101

      • Technical Data — Engine 250/300/380 SX/MXC EXC 2001 (Only USA)

        103

      • Technical Data — Engine 250/300/380 SX / EXC 2001 (All Models out of USA)

        105

      • Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2001

        107

      • Carburetor Setting KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ

        108

      • Carburetor Setting KTM 250 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG

        109

      • Carburetor Setting KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG

        110

      • Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2001 KEIHIN PWK 38 AG

        111

      • Technical Data — Engine 250/300/380 SX / MXC / EXC 2002 (Only USA)

        112

      • Technical Data — Engine 250/300/380 SX / EXC 2002 (All Models out of USA)

        114

      • Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2002

        116

      • Carburetor Setting KTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG

        117

      • Carburetor Setting KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG

        118

      • Carburetor Setting KTM 300 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG

        119

      • Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2002 KEIHIN PWK 38 AG

        120

      • Technical Data — Engine 250/300 MXC/EXC 2003

        121

      • Periodic Lubrication and Maintenance Schedule

        131

      • Periodic Maintenance Schedule 2001/02

        132

      • Important Chacks and Maintenance to be Carried by the Rider

        133

      • Periodic Maintenance Schedule 2003

        134

      • Recommended Inspection of the 250/300 EXC and MXC Engine Used for Enduro Competitions by Your KTM Workshop

        136

      • Recommended Inspection of the 250/300 EXC and MXC Engine Used for Hobby Enduro by Your KTM Workshop

        136

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (74 pages)

KTM Owner’s Manual Motorcycle 125 EXC, EXC SIX DAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXC SIX DAYS 300 XC, XC-W, EXC-E, EXC-E SIX DAYS

Brand: KTM
|
Category: Motorcycle
|
Size: 9.08 MB

Table of Contents
  • Table of Contents

    5

  • Serial Number Locations

    6

    • Chassis Number

      6

    • Engine Number, Engine Type

      6

  • Operation Instruments

    6

    • Clutch Lever

      6

    • Hand Brake Lever

      6

    • Electronic Speedometer

      7

    • Indicator Lamps (EXC)

      11

    • Short Circuit Button

      11

    • Combination Switch (EXC)

      12

    • Headlamp Switch (XC-W)

      12

    • Flasher Switch

      12

    • Starter Button

      12

    • Emergency off Switch (Australia)

      12

    • Filler Cap

      13

    • Fuel Tap

      13

    • Choke Knob

      13

    • Shift Lever

      14

    • Kickstarter

      14

    • Foot Brake Pedal

      14

    • Side Stand

      14

    • Steering Lock

      14

    • Compression Damping of Fork

      15

    • Rebound Damping of Fork

      15

    • Spring Preload of the Fork

      15

    • Shock Absorber Compression Damping

      16

    • Shock Absorber Rebound Damping

      16

  • General Tips and Warnings for Starting the Motorcycle

    17

    • Instructions for Your First Ride

      17

    • Running in

      17

  • Driving Instructions

    18

    • What You Should Check before each Start

      18

    • Starting When the Engine Is Cold

      19

    • Starting When the Engine Is Warm

      19

    • What to Do When the Engine Is „Flooded

      19

    • Starting off

      19

    • Shifting/Riding

      20

    • Braking

      20

    • Stopping and Parking

      20

    • Refueling, Fuel

      20

  • Periodic Maintenance Schedule

    21

  • Maintenance Work on Chassis and Engine

    25

    • Changing the Spring Preloading of the Shock Absorber

      25

    • Pivot Bearing

      25

    • Basic Suspension Setup for the Weight of the Driver

      26

    • Checking the Shock Absorber and Spring

      26

    • Determining the Static Sag of the Shock Absorber

      26

    • Determining the Riding Sag of the Shock Absorber

      26

    • Changing the Spring Preload on the Telescopic Fork

      27

    • Checking the Basic Setup of the Telescopic Fork

      27

    • Breather Plug Front Fork

      27

    • Cleaning the Dust Sleeves of the Telescopic Fork

      28

    • Checking and Adjusting the Steering Head Bearing

      28

    • Changing the Fork Offset (Caster) XC/EXC Six Days

      29

    • How to Change the Handlebar Position

      30

    • Adapting Chain Guide to the Rear Sprocket

      31

    • Check Chain Tension

      32

    • Correct Chain Tension

      32

    • Chain Maintenance

      32

    • Chain Wear

      32

    • General Information about KTM Disc Brakes

      33

    • Changing Basic Position of the Hand Brake Lever

      34

    • Checking the Brake Fluid Level — Front Brake

      34

    • Refilling the Front Brake Fluid Reservoir

      34

    • Checking the Front Brake Pads

      34

    • Replacing the Front Brake Pads

      35

    • Checking the Rear Brake Fluid Level

      35

    • Refilling the Rear Brake Fluid Reservoir

      35

    • Changing the Basic Position of the Foot Brake Pedal

      36

    • Checking the Rear Brake Pads

      36

    • Replacing the Rear Brake Pads

      36

    • Dismounting and Mounting the Front Wheel

      37

    • Dismounting and Mounting the Rear Wheel

      38

    • Tires, Air Pressure

      38

    • Checking Spoke Tension

      39

    • Replacing the Battery of the Digital Speedometer

      39

    • Replacing the Headlight Lamp/Parking Light Lamp

      39

    • Battery

      40

    • Charging the Battery

      40

    • Fuse

      41

    • Cooling System

      41

    • Checking the Coolant Level

      42

    • Refilling/Bleeding the Cooling System

      42

    • Cleaning the Air Filter

      42

    • Checking the Oil Level of the Hydraulic Clutch

      43

    • Exhaust System

      43

    • Changing the Original Position of the Clutch Lever

      43

    • Bleeding the Hydraulic Clutch

      44

    • Carburetor Adjustment

      44

    • Draining the Float Chamber of the Carburetor

      46

    • Checking the Float Level

      46

    • Adjusting the Engine Characteristic Via the Ignition Curve

      46

    • Adjusting the Engine Characteristic Via the Auxiliary Spring

      47

    • Check Transmission Oil Level

      48

    • Changing the Transmission Oil

      48

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (71 pages)

2007

Brand: KTM
|
Category: Motorcycle
|
Size: 5.14 MB

Table of Contents
  • Table of Contents

    5

  • Serial Number Locations

    6

    • Chassis Number

      6

    • Engine Number, Engine Type

      6

  • Operation Instruments

    6

    • Clutch Lever

      6

    • Hand Brake Lever

      6

    • Electronic Speedometer

      7

    • Indicator Lamps (EXC)

      11

    • Combination Switch (EXC)

      12

    • Headlamp Switch (XC-W)

      12

    • Flasher Switch

      12

    • Emergency off Switch (Australia)

      12

    • Filler Cap

      13

    • Filler Cap (XC, XC-W)

      13

    • Fuel Tap

      13

    • Choke Knob

      13

    • Shift Lever

      13

    • Kickstarter

      14

    • Foot Brake Pedal

      14

    • Side Stand

      14

    • Steering Lock

      14

    • Compression Damping of Fork

      15

    • Rebound Damping of Fork

      15

    • Spring Preload of the Fork(XC/EXC Six Days)

      15

    • Compression Damping of Shock Absorber (XC-W, EXC)

      16

    • Shock Absorber Compression Damping (XC-W/EXC)

      16

    • Shock Absorber Rebound Damping XC-W, EXC)

      16

  • General Tips and Warnings for Starting the Motorcycle

    17

    • Instructions for Your First Ride

      17

    • Running in

      17

  • Driving Instructions

    18

    • What You Should Check before each Start

      18

    • Starting When the Engine Is Cold

      19

    • Starting When the Engine Is Warm

      19

    • What to Do When the Engine Is „Flooded

      19

    • Starting off

      19

    • Shifting/Riding

      20

    • Braking

      20

    • Stopping and Parking

      20

    • Refueling, Fuel

      20

  • Periodic Maintenance Schedule

    21

  • Maintenance Work on Chassis and Engine

    25

    • Changing the Spring Preloading of the Shock Absorber

      25

    • Pivot Bearing

      25

    • Basic Suspension Setup for the Weight of the Driver

      26

    • Checking the Shock Absorber and Spring

      26

    • Determining the Static Sag of the Shock Absorber

      26

    • Determining the Riding Sag of the Shock Absorber

      26

    • Changing the Spring Preload on the Telescopic Fork

      27

    • Checking the Basic Setup of the Telescopic Fork

      27

    • Replacing Fork Springs

      28

    • Breather Plug Front Fork

      28

    • Cleaning the Dust Sleeves of the Telescopic Fork

      28

    • Changing the Fork Offset (Caster) (XC)

      29

    • Checking and Adjusting the Steering Head Bearing

      30

    • How to Change the Handlebar Position

      31

    • Check Chain Tension

      31

    • Correct Chain Tension

      32

    • Chain Maintenance

      32

    • Chain Wear

      32

    • General Information about KTM Disc Brakes

      33

    • Adjusting the Free Travel at the Hand Brake Lever

      34

    • Checking the Brake Fluid Level — Front Brake

      34

    • Refilling the Front Brake Fluid Reservoir

      34

    • Checking the Front Brake Pads

      34

    • Replacing the Front Brake Pads

      35

    • Changing the Basic Position of the Foot Brake Pedal

      35

    • Checking the Rear Brake Fluid Level

      35

    • Refilling the Rear Brake Fluid Reservoir

      35

    • Checking the Rear Brake Pads

      36

    • Replacing the Rear Brake Pads

      36

    • Dismounting and Mounting the Front Wheel

      36

    • Dismounting and Mounting the Rear Wheel

      37

    • Tires, Air Pressure

      38

    • Checking Spoke Tension

      38

    • Replacing the Battery of the Digital Speedometer

      39

    • Check/Set Distance of the Magnetic Sensor

      39

    • Replacing the Headlight Lamp/Parking Light Lamp

      39

    • Cooling System

      40

    • Checking the Coolant Level

      40

    • Refilling/Bleeding the Cooling System

      41

    • Cleaning the Air Filter

      41

    • Checking the Oil Level of the Hydraulic Clutch

      42

    • Exhaust System

      42

    • Changing the Original Position of the Clutch Lever

      42

    • Bleeding the Hydraulic Clutch

      43

    • Carburetor Adjustment

      43

    • Draining the Float Chamber of the Carburetor

      45

    • Checking the Float Level

      45

    • Adjusting the Engine Characteristic Via the Ignition Curve

      45

    • Adjusting the Engine Characteristic Via the Auxiliary Spring

      46

    • Check Transmission Oil Level (125/200)

      47

    • Changing the Transmission Oil (125/200)

      47

    • Check Transmission Oil Level (250/300)

      47

    • Changing the Transmission Oil (250/300)

      47

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (67 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 5.12 MB

Table of Contents
  • Table of Contents

    5

  • Serial Number Locations

    6

    • Chassis Number

      6

    • Engine Number, Engine Type

      6

  • Operation Instruments

    6

    • Clutch Lever

      6

    • Hand Brake Lever

      6

    • Electronic Speedometer

      7

    • Indicator Lamps (EXC)

      11

    • Short Circuit Button (SX)

      12

    • Combination Switch (EXC)

      12

    • Headlamp Switch (EXC USA)

      12

    • Flasher Switch

      12

    • Emergency off Switch (Australia)

      12

    • Filler Cap

      13

    • Fuel Tap

      13

    • Choke Knob

      13

    • Shift Lever

      13

    • Kickstarter

      14

    • Foot Brake Pedal

      14

    • Side Stand

      14

    • Steering Lock

      14

    • Compression Damping of Fork

      15

    • Rebound Damping of Fork

      15

    • Damping Action During Compression of Shock Absorber (SX)

      15

    • Compression Damping of Shock Absorber (MXC, EXC)

      16

    • Rebound Damping of Shock Absorber (SX, MXC, EXC)

      16

  • General Tips and Warnings for Starting the Motorcycle

    17

    • Instructions for Your First Ride

      17

    • Running in

      17

  • Driving Instructions

    18

    • What You Should Check before each Start

      18

    • Starting When the Engine Is Cold

      19

    • Starting When the Engine Is Warm

      19

    • What to Do When the Engine Is „Flooded

      19

    • Starting off

      19

    • Shifting/Riding

      19

    • Braking

      20

    • Stopping and Parking

      20

    • Refueling, Fuel

      20

  • Periodic Maintenance Schedule

    21

  • Maintenance Work on Chassis and Engine

    24

    • Changing the Spring Preload of the Shock Absorber

      24

    • Pivot Bearing

      24

    • Basic Suspension Setup for the Weight of the Driver

      25

    • Checking the Shock Absorber and Spring

      25

    • Determining the Static Sag of the Shock Absorber

      25

    • Determining the Riding Sag of the Shock Absorber

      25

    • Checking the Basic Setup of the Telescopic Fork

      26

    • Changing the Spring Preload on the Telescopic Fork

      26

    • Replacing Fork Springs

      27

    • Breather Plug Front Fork

      27

    • Cleaning the Dust Sleeves of the Telescopic Fork

      27

    • Changing the Fork Offset (SX)

      28

    • Checking and Adjusting the Steering Head Bearing

      29

    • How to Change the Handlebar Position

      30

    • Check Chain Tension

      30

    • Correct Chain Tension

      31

    • Chain Maintenance

      31

    • Chain Wear

      31

    • General Information about KTM Disc Brakes

      32

    • Adjusting the Free Travel at the Hand Brake Lever

      33

    • Checking the Brake Fluid Level — Front Brake

      33

    • Refilling the Front Brake Fluid Reservoir

      33

    • Checking the Front Brake Pads

      33

    • Replacing the Front Brake Pads

      34

    • Changing the Basic Position of the Foot Brake Pedal

      34

    • Checking the Rear Brake Fluid Level

      34

    • Refilling the Rear Brake Fluid Reservoir

      34

    • Checking the Rear Brake Pads

      35

    • Replacing the Rear Brake Pads

      35

    • Dismounting and Mounting the Front Wheel

      35

    • Dismounting and Mounting the Rear Wheel

      36

    • Tires, Air Pressure

      37

    • Checking Spoke Tension

      37

    • Replacing the Battery of the Digital Speedometer

      37

    • Check/Set Distance of the Magnetic Sensor

      38

    • Replacing the Headlight Lamp/Parking Light Lamp

      38

    • Cooling System

      39

    • Radiator Cover for the Cold Season

      39

    • Checking the Coolant Level

      39

    • Refilling/Bleeding the Cooling System

      40

    • Cleaning the Air Filter

      40

    • Changing the Original Position of the Clutch Lever

      41

    • Checking the Oil Level of the Hydraulic Clutch

      41

    • Bleeding of the Hydraulic Clutch

      41

    • Exhaust System

      41

    • Cleaning the Spark Arrestor (EXC USA)

      42

    • Carburetor Adjustment

      42

    • Draining the Float Chamber of the Carburetor

      43

    • Checking the Float Level

      43

    • Engine Characteristic 250/300 SX/MXC/EXC

      44

    • Check Transmission Oil Level (125/200)

      45

    • Changing the Transmission Oil (125/200)

      45

    • Check Transmission Oil Level (250/300)

      45

    • Changing the Transmission Oil (250/300)

      45

KTM 300 EXC Owner's Handbook Manual

KTM 300 EXC Owner’s Handbook Manual (45 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 3.46 MB

Table of Contents
  • Chassis Number

    3

  • Engine Number

    3

  • Table of Contents

    5

  • Serial Number Locations

    6

    • Chassis Number

      6

    • Engine Number, Engine Type (125/200)

      6

    • Engine Number, Engine Type (250/300/380)

      6

  • Operation Instruments

    6

    • Clutch Lever

      6

    • Hand Brake Lever

      6

    • Digital Speedometer, Indicator Lamp (EXC)

      7

    • Digital Speedometer

      7

    • Odometer (EXC USA)

      7

    • Speedometer, Indicator Lamps (EXC — Australia)

      7

    • Short Circuit Button (SX)

      7

    • Combination Switch (EXC)

      8

    • Headlamp Switch (EXC USA)

      8

    • Flasher Switch

      8

    • Emergency off Switch (Australia)

      8

    • Filler Cap

      8

    • Refueling, Fuel

      9

    • Fuel Tap

      9

    • Choke Knob

      9

    • Shift Lever

      10

    • Kickstarter

      10

    • Foot Brake Pedal

      10

    • Compression Damping of Fork

      10

    • Rebound Damping of Fork

      10

    • Compression Damping of Shock Absorber

      11

    • Rebound Damping of Shock Absorber

      11

    • Steering Lock

      11

    • Side Stand

      11

  • Driving Instructions

    12

    • Starting off

      13

    • Periodic Maintenance Schedule

      14

  • Maintenance Work on Chassis and Engine

    16

    • Changing the Original Position of the Clutch Lever

      16

    • Checking and Adjusting the Steering Head Bearing

      16

    • Breather Plug Front Fork

      17

    • Cleaning the Dust Sleeves of the Telescopic Fork

      17

    • How to Change the Handlebar Position

      17

    • Changing the Spring Preloading of the Shock Absorber

      18

    • Pivot Bearing

      18

    • Check Chain Tension

      18

    • Correct Chain Tension

      19

    • Chain Maintenance

      19

    • Chain Wear

      19

    • General Informations about KTM Disc Brakes

      20

    • Adjusting of Free Travel at the Hand Brake Lever

      20

    • WIRING DIAGRAMME, CARBURETOR SETTING . . .Appendix

      21

    • Checking of Brake Fluid Level — Front Brake

      21

    • Refilling the Front Brake Fluid Reservoir

      21

    • Checking the Front Brake Pads

      21

    • Replacing the Front Brake Pads

      21

    • Changing the Basic Position of the Foot Brake Pedal

      22

    • Checking Rear Brake Fluid Level

      22

    • Refilling the Rear Brake Fluid Reservoir

      22

    • Checking the Rear Brake Pads

      23

    • Replacing the Rear Brake Pads

      23

    • Dismounting and Mounting the Front Wheel

      23

    • Dismounting and Mounting the Rear Wheel

      24

    • Tires-Air Pressure

      25

    • Checking Spoke Tension

      25

    • Replacing the Battery of the Digital Speedometer

      25

    • Adjustin Digital Speedometer

      27

    • Check/Set Distance of Magnetic Sensor

      27

    • Replacing Headlight Lamp (H4)

      28

    • Cooling System

      28

    • Radiator Cover for the Cold Season

      29

    • Checking the Coolant Level

      29

    • Refilling/Bleeding the Cooling System

      29

    • Cleaning the Air Filter

      30

    • Exhaust System

      30

    • Cleaning the Spark Arrestor (EXC USA)

      30

    • Draining of Float Chamber of the Carburetor

      30

    • Carburetor Adjustment

      31

    • Checking the Float Level

      32

    • Checking the Oil Level of the Hydraulic Clutch

      32

    • Bleeding of the Hydraulic Clutch

      32

    • Check Transmission Oil Level (125/200)

      33

    • Changing the Transmission Oil (125/200)

      33

    • Check Transmission Oil Level (250/300/380)

      33

    • Changing the Transmission Oil (250/300/380)

      33

KTM 300 EXC Owner's Manual

KTM 300 EXC Owner’s Manual (39 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 4.82 MB

Table of Contents
  • Serial Number Locations

    6

  • Frame Number

    6

  • Engine Number, Engine Type (125/200)

    6

  • Engine Number, Engine Type (250/300/380)

    6

  • Operation Instruments

    6

  • Clutch Control Lever (125/200)

    6

  • Clutch Control Lever (250/300/380)

    6

  • Table of Contents

    5

  • Hand Brake Lever

    7

  • Speedometer, Indicator Lamps (EXC)

    7

  • Odometer (EXC USA)

    7

  • Speedometer, Indicator Lamps (EGS)

    7

  • Ignition Lock

    7

  • Short Circuit Button (SX)

    8

  • Combination Switch (EXC)

    8

  • Headlamp Switch (EXC USA)

    8

  • Flasher Switch

    8

  • Emergency off Switch (Australia)

    8

  • Filler Cap

    9

  • Refueling, Fuel

    9

  • Fuel Tap

    9

  • Choke Knob

    10

  • Shift Lever

    10

  • Kickstarter

    10

  • Foot Brake Pedal

    10

  • Compression Damping of Fork

    10

  • Rebound Damping of Fork

    11

  • Compression Damping of Shock Absorber

    11

  • Rebound Damping of Shock Absorber

    11

  • Steering Lock

    11

  • Side Stand

    11

  • Driving Instructions

    12

  • Starting When the Engine Is Cold

    13

  • Starting When the Engine Is Warm

    13

  • Starting off

    13

  • Stopping and Parking

    13

  • Periodic Lubrication and Maintenance Schedule

    14

  • Maintenance Work on Chassis and Engine

    15

  • Changing the Original Position of the Clutch Lever (125/200)

    15

  • Checking and Adjusting the Steering Head Bearing

    15

  • Check Chain Tension

    16

  • Correct Chain Tension

    16

  • Chain Maintenance

    16

  • Chain Wear

    17

  • General Informations about KTM Disc Brakes

    17

  • Adjusting of Free Travel at the Hand Brake Lever

    17

  • Checking of Brake Fluid Level — Front Brake

    18

  • Refilling the Front Brake Fluid Reservoir

    18

  • Checking the Front Brake Pads

    18

  • Replacing the Front Brake Pads

    18

KTM 300 EXC Owner's Handbook Manual

KTM 300 EXC Owner’s Handbook Manual (37 pages)

1999

Brand: KTM
|
Category: Motorcycle
|
Size: 5.75 MB

Table of Contents
  • Serial Number Locations

    6

  • Chassis Number

    6

  • Engine Number, Engine Type (125/200)

    6

  • Engine Number, Engine Type (250/300/380)

    6

  • Operation Instruments

    6

  • Clutch Lever

    6

  • Hand Brake Lever

    6

  • Table of Contents

    5

  • Speedometer, Indicator Lamp (EXC)

    7

  • Odometer (EXC USA)

    7

  • Speedometer, Indicator Lamps (EGS)

    7

  • Ignition Lock

    7

  • Short Circuit Button (SX)

    8

  • Combination Switch (EXC)

    8

  • Headlamp Switch (EXC USA)

    8

  • Flasher Switch

    8

  • Emergency off Switch (Australia)

    8

  • Filler Cap

    9

  • Refueling, Fuel

    9

  • Fuel Tap

    9

  • Choke Knob

    10

  • Shift Lever

    10

  • Kickstarter

    10

  • Foot Brake Pedal

    10

  • Compression Damping of Fork

    10

  • Rebound Damping of Fork

    11

  • Compression Damping of Shock Absorber

    11

  • Rebound Damping of Shock Absorber

    11

  • Steering Lock

    11

  • Center Stand

    11

  • Driving Instructions

    12

  • Starting off

    13

  • Periodic Lubrication and Maintenance Schedule

    14

  • Maintenance Work on Chassis and Engine

    15

  • Changing the Original Position of the Clutch Lever

    15

  • Checking and Adjusting the Steering Head Bearing

    15

  • Pivot Bearing

    16

  • Check Chain Tension

    16

  • Correct Chain Tension

    16

  • Chain Maintenance

    16

  • Chain Wear

    17

  • General Informations about KTM Disc Brakes

    17

  • Adjusting of Free Travel at the Hand Brake Lever

    17

  • Checking of Brake Fluid Level — Front Brake

    18

  • Refilling the Front Brake Fluid Reservoir

    18

  • Checking the Front Brake Pads

    18

  • Replacing the Front Brake Pads

    18

  • Changing the Basic Position of the Brake Pedal

    19

  • Checking Rear Brake Fluid Level

    19

  • Refilling the Rear Brake Fluid Reservoir

    19

KTM 300 EXC Manual

KTM 300 EXC Manual (12 pages)

motor type 546

Brand: KTM
|
Category: Engine
|
Size: 10.69 MB

Table of Contents
  • Technical Data

    1

  • Gear Ratios

    2

  • Basic Carburetor Setting

    2

  • Tolerances and Fitting Clearances

    2

  • Gasket Thicknesses

    2

  • Crank Case

    3

  • Clutch Cover

    4

  • Crankshaft, Piston

    4

  • Cylinder

    5

  • Twin Valve Control

    5

  • Carburettor

    6

  • Clutch

    7

  • Kickstarter

    7

  • Ignition System

    8

  • Transmission

    9

  • Shifting Mechanism

    10

  • Cooling System

    10

  • Special Tools

    11

Advertisement

Related Products

  • KTM 300 EXC AUS

  • KTM 300 EXC EU 2010

  • KTM 300 EXC SIX DAYS EU 2010

  • KTM 300 EXC AUS 2010

  • KTM 300 EXC Six days eu

  • KTM 300 EXC Factory Edition

  • KTM 300 EXC SIX DAYS

  • KTM 300 EXC 2004

  • KTM 300 EXC-E SIX DAYS 2008

  • KTM 300 EXC 2006

KTM Categories

Motorcycle

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Manuals and User Guides for KTM 300 EXC AUS. We have 3 KTM 300 EXC AUS manuals available for free PDF download: Repair Manual, Owner’s Manual

KTM 300 EXC AUS Repair Manual

KTM 300 EXC AUS Repair Manual (289 pages)

Brand: KTM
|
Category: Motorcycle
|
Size: 12.59 MB

Table of Contents
  • Table of Contents

    4

  • Table of Contents 2

    4

  • 1 Means of Representation

    8

    • Symbols Used

      8

    • Formats Used

      8

  • 2 Safety Advice

    9

    • Repair Manual

      9

    • Degrees of Risk and Symbols

      9

    • Work Rules

      9

  • 3 Important Information

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Figures

      10

  • 4 Serial Numbers

    11

    • Chassis Number

      11

    • Type Label

      11

    • Engine Number

      11

    • Fork Part Number

      11

    • Shock Absorber Part Number

      11

  • 5 Motorcycle

    12

    • Raising the Motorcycle with the Lift Stand

      12

    • Removing the Motorcycle from the Lift Stand

      12

    • Starting

      12

    • Starting the Motorcycle for Checking

      13

  • 6 Fork, Triple Clamp

    14

    • Exc Eu/Aus, XC-W

      14

    • Adjusting the Compression Damping of the Fork

      14

    • Adjusting the Rebound Damping of the Fork

      14

    • Adjusting the Spring Preload of the Fork

      14

    • Bleeding the Fork Legs

      15

    • Cleaning the Dust Boots of the Fork Legs

      15

    • Loosening the Fork Protection

      16

    • Positioning the Fork Protection

      16

    • Removing the Fork Legs

      16

    • Installing the Fork Legs

      16

    • Removing the Fork Protector

      17

    • Installing the Fork Protector

      17

    • Performing a Fork Service

      18

    • Disassembling the Fork Legs

      18

    • Cartridge Disassembly

      21

    • Disassembling the Compression Damping Fitting

      23

    • Checking the Fork Legs

      23

    • Assembling the Compression Damping Fitting

      24

    • Assembling the Cartridge

      25

    • Assembling the Fork Legs

      26

    • Greasing the Steering Head Bearing

      31

    • Removing the Lower Triple Clamp

      31

    • Installing the Lower Triple Clamp

      32

    • Checking the Play of the Steering Head Bearing

      33

    • Adjusting the Play of the Steering Head Bearing

      34

    • 250/300 Six Days

      34

    • Adjusting the Compression Damping of the Fork

      34

    • Adjusting the Rebound Damping of the Fork

      35

    • Bleeding the Fork Legs

      35

    • Cleaning the Dust Boots of the Fork Legs

      35

    • Loosening the Fork Protection

      36

    • Positioning the Fork Protection

      36

    • Removing the Fork Legs

      36

    • Installing the Fork Legs

      37

    • Removing the Fork Protector

      37

    • Installing the Fork Protector

      38

    • Performing a Fork Service

      38

    • Disassembling the Fork Legs

      38

    • Removing the Spring

      40

    • Disassembling the Cartridge

      41

    • Disassembling the Piston Rod

      42

    • Disassembling the Hydrostop Unit

      43

    • Disassembling the Seal Ring Retainer

      44

    • Checking the Fork Legs

      44

    • Assembling the Seal Ring Retainer

      45

    • Assembling the Hydrostop Unit

      46

    • Assembling the Piston Rod

      46

    • Assembling the Cartridge

      48

    • Assembling the Fork Legs

      49

    • Greasing the Steering Head Bearing

      52

    • Removing the Lower Triple Clamp

      53

    • Installing the Lower Triple Clamp

      53

    • Checking the Play of the Steering Head Bearing

      55

    • Adjusting the Play of the Steering Head Bearing

      55

  • 7 Handlebar, Controls

    56

    • Handlebar Position

      56

    • Adjusting the Handlebar Position

      56

    • Adjusting the Basic Position of the Clutch Lever

      56

    • Checking the Routing of the Throttle Cable

      57

    • Checking the Play in the Throttle Cable

      57

    • Adjusting the Play in the Throttle Cable

      58

  • 8 Frame

    59

    • Removing the Engine Guard (250/300 SIX DAYS)

      59

    • Installing the Engine Guard (250/300 SIX DAYS)

      59

  • 9 Shock Absorber, Swingarm

    60

    • Adjusting the High-Speed Compression Damping of the Shock Absorber

      60

    • Adjusting the Low-Speed Compression Damping of the Shock Absorber

      60

    • Adjusting the Rebound Damping of the Shock Absorber

      61

    • Measuring the Sag of the Unloaded Rear Wheel

      61

    • Checking the Static Sag of the Shock Absorber

      61

    • Checking the Riding Sag of the Shock Absorber

      62

    • Adjusting the Spring Preload of the Shock Absorber

      62

    • Adjusting the Riding Sag

      63

    • Removing the Shock Absorber

      63

    • Installing the Shock Absorber

      63

    • Servicing the Shock Absorber

      64

    • Removing the Spring

      64

    • Disassembling the Damper

      65

    • Disassembling the Piston Rod

      66

    • Disassembling the Seal Ring Retainer

      67

    • Replacing the Pilot Bushing

      68

    • Checking the Damper

      69

    • Disassembling the Rebound Adjuster

      69

    • Removing the Heim Joint

      70

    • Installing the Heim Joint

      71

    • Assembling the Rebound Adjuster

      72

    • Assembling the Seal Ring Retainer

      72

    • Assembling the Piston Rod

      73

    • Assembling the Damper

      74

    • Bleeding and Filling the Damper

      77

    • Filling the Damper with Nitrogen

      79

    • Installing the Spring

      80

    • Changing the Heim Joint

      81

  • 10 Exhaust

    83

    • Removing the Main Silencer

      83

    • Installing the Main Silencer

      83

    • Changing the Glass Fiber Yarn Filling of the Main Silencer

      83

  • 11 Air Filter

    85

    • Removing the Air Filter Box Lid

      85

    • Installing the Air Filter Box Lid

      85

    • Removing the Air Filter

      85

    • Installing the Air Filter

      85

    • Cleaning the Air Filter and Air Filter Box

      86

    • Sealing the Air Filter Box

      86

  • 12 Fuel Tank, Seat, Trim

    87

    • Opening the Filler Cap

      87

    • Closing the Filler Cap

      87

    • Removing the Seat

      87

    • Mounting the Seat

      88

    • Removing the Fuel Tank

      88

    • Installing the Fuel Tank

      89

    • Fuel Tap

      90

  • 13 Mask, Fender

    91

    • Removing the Front Fender

      91

    • Installing the Front Fender

      91

    • Removing the Headlight Mask with the Headlight

      91

    • Refitting the Headlight Mask with the Headlight

      92

  • 14 Wheels

    93

    • Checking the Tire Air Pressure

      93

    • Checking the Tire Condition

      93

    • Checking the Brake Discs

      94

    • Checking the Spoke Tension

      94

    • Front Wheel

      95

    • Removing the Front Wheel

      95

    • Installing the Front Wheel

      95

    • Removing the Brake Disc of the Front Brake

      96

    • Installing the Brake Disc of the Front Brake

      96

    • Rear Wheel

      96

    • Removing the Rear Wheel

      96

    • Installing the Rear Wheel

      97

    • Removing the Brake Disc of the Rear Brake

      98

    • Installing the Brake Disc of the Rear Brake

      98

    • Checking the Chain for Dirt

      98

    • Cleaning the Chain

      99

    • Checking the Chain Tension

      99

    • Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide

      100

    • Adjusting the Chain Tension

      101

  • 15 Wiring Harness, Battery

    103

    • Plug-In Connection, Ignition Timing Map

      103

    • Removing the Main Fuse

      103

    • Installing the Main Fuse

      103

    • Recharging the Battery

      103

    • Disconnecting the Negative Cable of the Battery

      104

    • Connecting the Negative Cable of the Battery

      105

    • Removing the Battery

      105

    • Installing the Battery

      106

    • Checking the Charging Voltage

      106

    • Checking the Closed Current

      106

    • Checking the Starter Relay

      107

  • 16 Brake System

    108

    • Checking the Front Brake Linings

      108

    • Changing the Front Brake Linings

      108

    • Checking the Free Travel of the Hand Brake Lever

      110

    • Adjusting Free Travel of Hand Brake Lever (All 250/300 EXC Models)

      110

    • Adjusting the Basic Position of the Hand Brake Lever (All 250/300 XC-W)

      110

    • Checking the Front Brake Fluid Level

      111

    • Adding Front Brake Fluid

      111

    • Changing the Front Brake Fluid

      112

    • Checking the Rear Brake Linings

      113

    • Changing the Brake Linings of the Rear Brake

      114

    • Checking the Free Travel of Foot Brake Lever

      115

    • Adjusting the Basic Position of the Foot Brake Lever

      115

    • Checking the Rear Brake Fluid Level

      116

    • Adding Brake Fluid for the Rear Brake

      116

    • Changing the Rear Brake Fluid

      117

  • 17 Lighting System, Instruments

    119

    • Checking the Headlight Setting

      119

    • Adjusting the Headlight Range

      119

    • Exc Eu/Aus, XC-W

      119

    • Speedometer Overview

      119

    • Activation and Test

      120

    • Setting Kilometers or Miles

      120

    • Adjusting the Speedometer Functions

      120

    • Setting the Clock

      121

    • Activating the Additional Functions

      121

    • Setting the Wheel Circumference

      122

    • Querying Lap Time

      122

    • 250/300 Six Days

      123

    • Speedometer Overview

      123

    • Activation and Test

      123

    • Setting Kilometers or Miles

      123

    • Setting the Speedometer Functions

      124

    • Setting the Clock

      124

    • Setting the Wheel Circumference

      125

    • Viewing the Lap Time

      125

  • 18 Engine

    126

    • Removing the Engine

      126

    • Installing the Engine

      130

    • Engine Disassembly

      135

    • Clamping the Engine into the Engine Work Stand

      135

    • Draining the Gear Oil

      135

    • Removing the Clutch Push Rod

      135

    • Removing the Shift Lever

      135

    • Removing the Engine Sprocket

      135

    • Removing the Spacer

      136

    • Removing the Starter Motor

      136

    • Removing the Kick Starter

      137

    • Removing the Cylinder Head

      138

    • Removing the Cylinder

      138

    • Removing the Piston

      139

    • Removing the Water Pump Cover

      140

    • Removing the Clutch Cover

      140

    • Removing the Clutch Discs

      140

    • Removing the Clutch Basket

      141

    • Removing the Kick Starter Shaft

      142

    • Removing the Intermediate Kick Starter Gear

      142

    • Removing the Shift Shaft

      143

    • Removing the Shift Drum Locating Unit

      143

    • Removing the Locking Lever

      143

    • Removing the Rotor

      143

    • Removing the Reed Valve Housing

      144

    • Removing the Left Engine Case Section

      144

    • Removing the Shift Rails

      144

    • Removing the Shift Drum

      145

    • Removing the Shift Forks

      145

    • Removing the Transmission Shafts

      145

    • Removing the Crankshaft

      145

    • Work on Individual Parts

      146

    • Work on the Right Section of the Engine Case

      146

    • Work on the Left Section of the Engine Case

      147

    • Removing the Crankshaft Bearing Inner Race

      147

    • Installing the Crankshaft Bearing Inner Race

      148

    • Changing the Connecting Rod, Conrod Bearing, and Crank Pin

      148

    • Checking the Crankshaft Run-Out at the Bearing Pin

      149

    • Checking/Measuring the Cylinder

      149

    • Removing the Exhaust Control

      150

    • Checking the Exhaust Control

      152

    • Installing the Exhaust Control

      152

    • Cylinder — Nikasil ® Coating

      154

    • Checking/Measuring the Piston

      155

    • Checking the Piston Ring End Gap

      156

    • Piston/Cylinder — Measuring the Mounting Clearance

      156

    • Checking the Reed Valve Housing, Reed Valve, and Intake Flange

      157

    • Work on the Clutch Cover

      157

    • Checking the Clutch

      161

    • Preassembling the Shift Shaft

      162

    • Checking the Shift Mechanism

      163

    • Disassembling the Main Shaft

      164

    • Disassembling the Countershaft

      165

    • Checking the Transmission

      165

    • Assembling the Main Shaft

      166

    • Assembling the Countershaft

      167

    • Checking the Kick Starter

      169

    • Preassembling the Kick Starter Shaft

      169

    • Checking the Electric Starter Drive

      171

    • Engine Assembly

      172

    • Installing the Crankshaft

      172

    • Installing the Transmission Shafts

      172

    • Installing the Shift Forks

      173

    • Installing the Shift Drum

      173

    • Installing the Shift Rails

      173

    • Installing the Left Engine Case Section

      173

      • Installing the Reed Valve Housing

        174

      • Installing the Rotor

        174

      • Installing the Locking Lever

        175

      • Installing the Shift Drum Locating Unit

        175

      • Installing the Shift Shaft

        175

      • Installing the Intermediate Kick Starter Gear

        175

      • Installing the Kick Starter Shaft

        175

      • Installing the Clutch Basket

        176

      • Installing the Clutch Discs

        177

      • Installing the Clutch Cover

        178

      • Installing the Water Pump Cover

        179

      • Installing the Piston

        179

      • Installing the Cylinder

        180

      • Checking the X-Distance

        181

      • Adjusting the X-Distance

        182

      • Adjusting the Z-Distance

        182

      • Installing the Cylinder Head

        184

      • Installing the Kick Starter

        184

      • Installing the Starter Motor

        184

      • Installing the Spacer

        186

      • Installing the Engine Sprocket

        186

      • Installing the Shift Lever

        186

      • Installing the Clutch Push Rod

        187

      • Installing the Gear Oil Drain Plug

        187

      • Removing the Engine from the Work Stand

        187

  • 19 Carburetor

    188

    • Choke

      188

    • Carburetor — Adjusting the Idle Speed

      188

    • Emptying the Carburetor Float Chamber

      189

    • Removing the Carburetor

      189

    • Installing the Carburetor

      190

    • Checking/Adjusting the Carburetor Components

      191

    • Disassembling the Carburetor

      192

    • Checking the Choke Slide

      193

    • Checking the Jet Needle

      193

    • Checking the Throttle Slide

      193

    • Checking the Float Needle Valve

      194

    • Assembling the Carburetor

      194

    • Checking/Adjusting the Float Level

      195

  • 20 Clutch

    196

    • Checking/Correcting the Fluid Level of the Hydraulic Clutch

      196

    • Changing the Hydraulic Clutch Fluid

      196

  • 21 Water Pump, Cooling System

    197

    • Cooling System

      197

    • Checking the Antifreeze and Coolant Level

      197

    • Checking the Coolant Level

      197

    • Draining the Coolant

      198

    • Refilling with Coolant

      198

  • 22 Exhaust Control

    200

    • Engine Characteristic — Setting the Auxiliary Spring

      200

  • 23 Lubrication System

    201

    • Changing the Gear Oil

      201

    • Draining the Gear Oil

      201

    • Refilling with Gear Oil

      202

    • Checking the Gear Oil Level

      202

    • Adding Gear Oil

      202

  • 24 Ignition System

    204

    • Checking the Ignition System

      204

    • Ignition Coil — Checking the Primary Winding

      204

    • Ignition Coil — Checking the Secondary Winding

      205

    • Checking the Spark Plug Connector

      205

    • Alternator — Checking the Charging Coil of the Ignition

      206

    • Alternator — Checking the Battery Winding

      206

    • Alternator — Checking the Light Winding

      207

    • Checking the Ignition Pulse Generator

      207

    • Removing the Stator and Crankshaft Position Sensor

      208

    • Installing the Stator and Crankshaft Position Sensor

      208

  • 25 Electric Starter

    209

    • Checking the Starter Motor

      209

  • 26 Technical Data

    210

    • Engine

      210

    • All 250 Models

      210

    • All 300 Models

      210

    • Engine Tolerance, Wear Limits

      211

    • Engine Tightening Torques

      212

    • Capacities

      212

    • Gear Oil

      212

    • Coolant

      212

    • Fuel

      213

    • Chassis

      213

    • Electrical System

      214

    • Tires

      214

    • Fork

      214

    • Exc Eu/Aus, XC-W

      214

    • 250/300 Six Days

      215

    • Shock Absorber

      215

    • Chassis Tightening Torques

      216

    • Carburetor

      217

    • Exc Eu, 250 Exc Six Days Eu

      217

    • Exc aus

      217

    • XC-W Usa

      217

    • Exc Eu, 300 Exc Six Days Eu

      217

    • Exc aus

      218

    • XC-W Usa, 300 XC-W Six Days Usa

      218

    • Carburetor Tuning

      219

    • Carburetor Tuning (All 250 Models)

      219

    • Carburetor Tuning (All 300 Models)

      220

    • General Carburetor Tuning

      221

  • 27 Cleaning, Care

    222

    • Cleaning the Motorcycle

      222

    • Checks and Maintenance Steps for Winter Operation

      223

  • 28 Storage

    224

    • Preparing for Use after Storage

      224

  • 29 Service Schedule

    225

    • Service Work (as Additional Order)

      226

Advertisement

KTM 300 EXC AUS Owner's Manual

KTM 300 EXC AUS Owner’s Manual (150 pages)

2014

Brand: KTM
|
Category: Motorcycle
|
Size: 3.99 MB

Table of Contents
  • Table of Contents

    4

  • 1 Means of Representation

    7

    • Symbols Used

      7

    • Formats Used

      7

  • 2 Safety Advice

    8

    • Use Definition — Intended Use

      8

    • Degrees of Risk and Symbols

      8

    • Tampering Warning

      8

    • Safe Operation

      9

    • Protective Clothing

      9

    • Work Rules

      9

    • Environment

      9

    • Owner’s Manual

      9

  • 3 Important Notes

    10

    • Guarantee, Warranty

      10

    • Operating and Auxiliary Substances

      10

    • Spare Parts, Accessories

      10

    • Service

      10

    • Figures

      10

    • Customer Service

      10

  • 4 View of Vehicle

    11

    • View of Vehicle, Front Left (Example)

      11

    • View of Vehicle, Rear Right (Example)

      12

  • 5 Serial Numbers

    13

    • Chassis Number

      13

    • Type Label

      13

    • Key Number (All EXC Models)

      13

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      14

  • 6 Controls

    15

    • Clutch Lever

      15

    • Hand Brake Lever

      15

    • Throttle Grip

      15

    • Kill Switch (All EXC Models)

      15

    • Kill Switch (All XC-W Models)

      16

    • Horn Button (All EXC Models)

      16

    • Light Switch (All EXC Models)

      16

    • Light Switch (All XC-W Models)

      16

    • Turn Signal Switch (All EXC Models)

      16

    • Emergency off Switch (EXC AUS)

      17

    • Electric Starter Button (200/250/300 EXC EU, 250/300 SIX DAYS, XC-W)

      17

    • Electric Starter Button (EXC AUS)

      17

    • Overview of Indicator Lamps (EXC EU/AUS)

      17

    • Overview of Indicator Lamps (SIX DAYS EU)

      17

    • Overview of Indicator Lamps (300 XC-W SIX DAYS USA)

      18

    • Opening the Filler Cap

      18

    • Closing the Filler Cap

      18

    • Fuel Tap

      19

    • Choke

      19

    • Shift Lever

      19

    • Kick Starter

      20

    • Foot Brake Lever

      20

    • Side Stand

      20

    • Steering Lock (All EXC Models)

      20

    • Locking the Steering (All EXC Models)

      21

    • Unlocking the Steering (All EXC Models)

      21

  • 7 Speedometer

    22

    • Exc, XC-W

      22

    • Speedometer Overview

      22

    • Activation and Test

      22

    • Setting Kilometers or Miles

      22

    • Adjusting the Speedometer Functions

      23

    • Setting the Clock

      23

    • Querying Lap Time

      23

    • Display Mode SPEED (Speed)

      24

    • Display Mode SPEED/H (Service Hours)

      24

    • Setup Menu

      24

    • Unit of Measurement Menu

      25

    • Display Mode SPEED/CLK (Time)

      25

    • Setting the Clock

      25

    • Display Mode SPEED/LAP (Lap Time)

      26

    • Viewing the Lap Time

      26

    • Display Mode SPEED/ODO (Odometer)

      26

    • Display Mode SPEED/TR1 (Trip Master 1)

      26

    • Display Mode SPEED/TR2 (Trip Master 2)

      27

    • Setting TR2 (Trip Master 2)

      27

    • Display Mode SPEED/A1 (Average Speed 1)

      27

    • Display Mode SPEED/A2 (Average Speed 2)

      28

    • Display Mode SPEED/S1 (Stop Watch 1)

      28

    • Display Mode SPEED/S2 (Stop Watch 2)

      28

    • Table of Functions

      28

    • Table of Conditions and Menu Activation

      29

    • Six Days

      29

    • Speedometer Overview

      29

    • Activation and Test

      30

    • Setting Kilometers or Miles

      30

    • Setting the Speedometer Functions

      30

    • Setting the Clock

      31

    • Viewing the Lap Time

      31

    • Display Mode SPEED (Speed)

      32

    • Display Mode SPEED/H (Service Hours)

      32

    • Setup Menu

      32

    • Setting the Unit of Measurement

      33

    • Display Mode SPEED/CLK (Time)

      33

    • Setting the Clock

      33

    • Display Mode SPEED/LAP (Lap Time)

      34

    • Viewing the Lap Time

      34

    • Display Mode SPEED/ODO (Odometer)

      34

    • Display Mode SPEED/TR1 (Trip Master 1)

      34

    • Display Mode SPEED/TR2 (Trip Master 2)

      35

    • Setting TR2 (Trip Master 2)

      35

    • Display Mode SPEED/A1 (Average Speed 1)

      35

    • Display Mode SPEED/A2 (Average Speed 2)

      36

    • Display Mode SPEED/S1 (Stop Watch 1)

      36

    • Display Mode SPEED/S2 (Stop Watch 2)

      36

    • Table of Functions

      37

    • Table of Conditions and Menu Activation

      38

  • 8 Preparing for Use

    39

    • Advice on First Use

      39

    • Running in the Engine

      40

    • Preparing the Vehicle for Difficult Riding Conditions

      40

    • Preparations for Riding on Dry Sand

      41

    • Preparations for Riding on Wet Sand

      41

    • Preparations for Riding on Wet and Muddy Surfaces

      42

    • Preparations for Riding at High Temperatures and Low Speeds

      42

    • Preparing for Riding at Low Temperatures or in Snow

      43

  • 9 Riding Instructions

    44

    • Checks and Maintenance Work When Preparing for Use

      44

    • Starting

      44

    • Start off

      45

    • Shifting, Riding

      45

    • Braking

      45

    • Stopping, Parking

      46

    • Transport

      46

    • Refueling

      47

  • 10 Service Schedule

    48

    • Service Work (as Additional Order)

      49

  • 11 Tuning the Chassis

    50

    • Checking the Basic Chassis Setting with the Rider’s Weight

      50

    • Compression Damping of Shock Absorber

      50

    • Adjusting the Low-Speed Compression Damping of the Shock Absorber

      50

    • Adjusting the High-Speed Compression Damping of the Shock Absorber

      51

    • Adjusting the Rebound Damping of the Shock Absorber

      51

    • Measuring the Sag of the Unloaded Rear Wheel

      52

    • Checking the Static Sag of the Shock Absorber

      52

    • Checking the Riding Sag of the Shock Absorber

      53

    • Adjusting the Spring Preload of the Shock Absorber

      53

    • Adjusting the Riding Sag

      54

    • Checking the Basic Setting of the Fork

      54

    • Adjusting the Compression Damping of the Fork

      55

    • Adjusting the Rebound Damping of the Fork

      56

    • Adjusting the Spring Preload of the Fork (EXC, XC-W)

      57

    • Handlebar Position

      57

    • Adjusting the Handlebar Position

      58

  • 12 Service Work on the Chassis

    59

    • Raising the Motorcycle with the Lift Stand

      59

    • Removing the Motorcycle from the Lift Stand

      59

    • Bleeding the Fork Legs

      59

    • Cleaning the Dust Boots of the Fork Legs

      60

    • Loosening the Fork Protection

      60

    • Positioning the Fork Protection

      61

    • Removing the Fork Legs

      61

    • Installing the Fork Legs

      61

    • Removing the Fork Protector

      62

    • Installing the Fork Protector

      63

    • Removing the Lower Triple Clamp (EXC, XC-W)

      63

    • Removing the Lower Triple Clamp (SIX DAYS)

      64

    • Installing the Lower Triple Clamp (EXC, XC-W)

      64

    • Installing the Lower Triple Clamp

      66

    • Six Days)

      66

    • Checking the Play of the Steering Head Bearing

      68

    • Adjusting the Play of the Steering Head Bearing

      68

    • Greasing the Steering Head Bearing

      69

    • Removing the Front Fender

      69

    • Installing the Front Fender

      69

    • Removing the Shock Absorber

      70

    • Installing the Shock Absorber

      70

    • Removing the Seat

      71

    • Mounting the Seat

      71

    • Removing the Air Filter Box Lid

      72

    • Installing the Air Filter Box Lid

      72

    • Removing the Air Filter

      72

    • Installing the Air Filter

      72

    • Cleaning the Air Filter and Air Filter Box

      73

    • Sealing the Air Filter Box

      73

    • Removing the Main Silencer

      74

    • Installing the Main Silencer

      74

    • Changing the Glass Fiber Yarn Filling of the Main Silencer

      74

    • Removing the Fuel Tank

      75

    • Installing the Fuel Tank

      76

    • Checking the Chain for Dirt

      77

    • Cleaning the Chain

      77

    • Checking the Chain Tension

      77

    • Adjusting the Chain Tension

      78

    • Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide

      79

    • Checking the Frame

      80

    • Checking the Swingarm

      81

    • Checking the Routing of the Throttle Cable

      81

    • Checking the Rubber Grip

      82

    • Additionally Securing the Rubber Grip

      82

    • Adjusting the Basic Position of the Clutch Lever

      82

    • Checking/Correcting the Fluid Level of the Hydraulic Clutch

      83

    • Changing the Hydraulic Clutch Fluid

      83

    • Removing the Engine Guard (SIX DAYS)

      84

    • Installing the Engine Guard (SIX DAYS)

      85

  • 13 Brake System

    86

    • Checking the Free Travel of the Hand Brake Lever

      86

    • Adjusting Free Travel of Hand Brake Lever (All EXC Models)

      86

    • Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)

      86

    • Checking the Brake Discs

      87

    • Checking the Front Brake Fluid Level

      87

    • Adding Front Brake Fluid

      87

    • Checking the Front Brake Linings

      88

    • Changing the Front Brake Linings

      89

    • Checking the Free Travel of Foot Brake Lever

      90

    • Adjusting the Basic Position of the Foot Brake Lever

      90

    • Checking the Rear Brake Fluid Level

      91

    • Adding Brake Fluid for the Rear Brake

      91

    • Checking the Rear Brake Linings

      92

    • Changing the Brake Linings of the Rear Brake

      92

  • 14 Wheels, Tires

    95

    • Removing the Front Wheel

      95

    • Installing the Front Wheel

      95

    • Removing the Rear Wheel

      96

    • Installing the Rear Wheel

      96

    • Checking the Tire Condition

      97

    • Checking the Tire Air Pressure

      98

    • Checking the Spoke Tension

      98

  • 15 Electrical System

    100

    • Removing the Battery (All 200/250/300 Models)

      100

    • Installing the Battery (All 200/250/300 Models)

      100

    • Recharging the Battery (All 200/250/300 Models)

      101

    • Changing the Main Fuse (All 200/250/300 Models)

      102

    • Removing the Headlight Mask with the Headlight

      103

    • Refitting the Headlight Mask with the Headlight

      103

    • Changing the Headlight Bulb

      103

    • Changing the Turn Signal Bulb (All EXC Models)

      104

    • Checking the Headlight Setting

      105

    • Adjusting the Headlight Range

      105

    • Changing the Speedometer Battery

      105

  • 16 Cooling System

    107

    • Checking the Antifreeze and Coolant Level

      107

    • Checking the Coolant Level

      108

    • Draining the Coolant

      108

    • Refilling with Coolant

      109

  • 17 Tuning the Engine

    111

    • Checking the Play in the Throttle Cable

      111

    • Adjusting the Play in the Throttle Cable

      111

    • Carburetor — Idle

      111

    • Carburetor — Adjusting the Idle Speed

      112

    • Emptying the Carburetor Float Chamber

      113

    • Checking the Basic Position of the Shift Lever

      114

    • Adjusting the Basic Position of the Shift Lever

      114

    • Engine Characteristic — Auxiliary Spring (All 250/300 Models)

      114

    • Engine Characteristic — Setting the Auxiliary Spring X (All 250/300 Models)

      114

  • 18 Service Work on the Engine

    116

    • Checking the Gear Oil Level

      116

    • Changing the Gear Oil

      116

    • Draining the Gear Oil

      117

    • Refilling with Gear Oil

      117

    • Adding Gear Oil

      118

  • 19 Cleaning, Care

    120

    • Cleaning the Motorcycle

      120

    • Checks and Maintenance Steps for Winter Operation

      121

  • 20 Storage

    122

    • Preparing for Use after Storage

      122

  • 21 Troubleshooting

    123

  • 22 Technical Data

    125

    • Engine

      125

    • All 125 Models

      125

    • All 200 Models

      125

    • All 250 Models

      126

    • All 300 Models

      126

    • Engine Tightening Torques

      127

    • All 125/200 Models

      127

    • All 250/300 Models

      128

    • Capacities

      129

    • Gear Oil

      129

    • Coolant

      129

    • Fuel

      129

    • Chassis

      129

    • Electrical System

      130

    • Tires

      131

    • Fork

      131

    • EXC EU, All 200 Models

      131

    • 250/300 Exc Eu/Aus, XC-W Usa

      131

    • Exc Six Days Eu

      132

    • 250/300 Six Days

      132

    • Shock Absorber

      133

    • All 125/200 Models

      133

    • All 250/300 Models

      133

    • Chassis Tightening Torques

      134

    • Carburetor

      135

    • 22.10.1 All 125 Models

      135

    • 22.10.2 200 Exc Eu

      135

    • 22.10.3 200 Exc aus

      135

    • 22.10.4 200 XC-W Usa

      135

    • 22.10.5 250 Exc Eu, 250 Exc Six Days Eu

      136

    • 22.10.6 250/300 Exc aus

      136

    • 22.10.7 250 XC-W Usa

      136

    • 22.10.8 300 Exc Eu, 300 Exc Six Days Eu

      137

    • 22.10.9 300 XC-W Usa, 300 XC-W Six Days Usa

      137

    • Carburetor Tuning (All 125 Models)

      137

    • Carburetor Tuning (All 200 Models)

      138

    • Carburetor Tuning (All 250 Models)

      139

    • Carburetor Tuning (All 300 Models)

      140

    • General Carburetor Tuning

      141

KTM 300 EXC AUS Owner's Manual

KTM 300 EXC AUS Owner’s Manual (136 pages)

2012 Motorcycle

Brand: KTM
|
Category: Motorcycle
|
Size: 4.26 MB

Table of Contents
  • Table of Contents

    4

  • Means of Representation

    7

  • Important Information

    8

  • View of Vehicle

    10

    • View of Vehicle, Front Left (Example)

      10

    • View of Vehicle, Rear Right (Example)

      11

  • Serial Numbers

    12

    • Chassis Number

      12

    • Type Label

      12

    • Key Number (All EXC Models)

      12

    • Engine Number

      13

    • Fork Part Number

      13

    • Shock Absorber Part Number

      13

  • Controls

    14

    • Clutch Lever

      14

    • Hand Brake Lever

      14

    • Throttle Grip

      14

    • Kill Switch (All EXC Models)

      14

    • Short Circuit Button (XC-W)

      15

    • Light Switch (All EXC Models)

      15

    • Turn Signal Switch (All EXC Models)

      15

    • Horn Button (All EXC Models)

      15

    • Emergency off Switch (200 EXC AUS)

      15

    • Emergency off Switch (250/300 EXC AUS)

      16

    • Electric Starter Button (250/300 EXC EU, EXC SIX DAYS, 250/300 XC-W)

      16

    • Electric Starter Button (250/300 EXC AUS)

      16

    • Light Switch (XC-W)

      16

    • Overview of Indicator Lamps (All EXC Models)

      16

    • Speedometer

      17

    • Speedometer Activation and Test

      17

    • Tripmaster Switch

      17

    • Setting Kilometers or Miles

      17

    • Setting the Clock

      18

    • Adjusting the Speedometer Functions

      18

    • Querying Lap Time

      19

    • Display Mode SPEED (Speed)

      19

    • Display Mode SPEED/H (Operating Hours)

      19

    • Display Mode SPEED/CLK (Clock)

      20

    • Display Mode SPEED/LAP (Lap Time)

      20

    • Display Mode SPEED/ODO (Odometer)

      20

    • Display Mode SPEED/TR1 (Trip Master 1)

      20

    • Display Mode SPEED/TR2 (Trip Master 2)

      21

    • Display Mode SPEED/A1 (Average Speed 1)

      21

    • Display Mode SPEED/A2 (Average Speed 2)

      21

    • Display Mode SPEED/S1 (Stop Watch 1)

      22

    • Display Mode SPEED/S2 (Stop Watch 2)

      22

    • Fuel Tap

      23

    • Opening the Filler Cap

      23

    • Closing the Filler Cap

      24

    • Shift Lever

      24

    • Kickstarter

      24

    • Foot Brake Lever

      25

    • Side Stand

      25

    • Steering Lock (All EXC Models)

      25

    • Locking the Steering (All EXC Models)

      25

    • Unlocking the Steering (All EXC Models)

      26

  • Preparing for Use

    27

    • Advice on First Use

      27

    • Running in the Engine

      28

    • Preparing the Vehicle for Difficult Operating Conditions

      28

    • Preparations for Riding on Dry Sand

      29

    • Preparations for Riding on Wet Sand

      29

    • Preparations for Riding on Wet and Muddy Surfaces

      30

    • Preparations for Riding at High Temperatures and Low Speeds

      30

    • Preparing for Rides at Low Temperatures or in Snow

      31

  • Riding Instructions

    32

    • Checks and Maintenance Work When Preparing for Use

      32

    • Starting

      32

    • Start off

      33

    • Shifting, Riding

      33

    • Braking

      33

    • Stopping, Parking

      34

    • Refueling

      34

  • Service Schedule

    36

    • Maintenance Work (as an Additional Order)

      37

  • Tuning the Chassis

    38

    • Checking the Basic Chassis Setting with the Rider’s Weight

      38

    • Compression Damping of Shock Absorber

      38

    • Adjusting the High-Speed Compression Damping of the Shock Absorber

      38

    • Adjusting the Low-Speed Compression Damping of the Shock Absorber

      39

    • Adjusting the Rebound Damping of the Shock Absorber

      39

    • Measuring the Sag of the Unloaded Rear Wheel

      40

    • Checking the Static Sag of the Shock Absorber

      40

    • Checking the Riding Sag of the Shock Absorber

      41

    • Adjusting the Spring Preload of the Shock Absorber

      41

    • Adjusting the Riding Sag

      42

    • Checking the Basic Setting of the Fork

      42

    • Adjusting the Compression Damping of the Fork

      43

    • Adjusting the Rebound Damping of the Fork

      43

    • Adjusting the Spring Preload of the Fork

      44

    • Handlebar Position

      44

    • Adjusting the Handlebar Position

      44

  • Service Work on the Chassis

    46

    • Raising the Motorcycle with the Lift Stand

      46

    • Removing the Motorcycle from the Lift Stand

      46

    • Bleeding the Fork Legs

      46

    • Cleaning the Dust Boots of the Fork Legs

      47

    • Loosening the Fork Protection

      47

    • Positioning the Fork Protection

      48

    • Removing the Fork Legs

      48

    • Installing the Fork Legs

      48

    • Removing the Fork Protector

      49

    • Installing the Fork Protector

      50

    • Removing the Lower Triple Clamp (EXC EU/AUS, XC-W)

      50

    • Removing the Lower Triple Clamp X (EXC SIX DAYS)

      50

    • Installing the Lower Triple Clamp (EXC EU/AUS, XC-W)

      51

    • Installing the Lower Triple Clamp (EXC SIX DAYS)

      52

    • Checking the Play of the Steering Head Bearing

      54

    • Adjusting the Play of the Steering Head Bearing

      54

    • Greasing the Steering Head Bearing

      55

    • Removing the Start Number Plate (XC-W)

      55

    • Installing the Start Number Plate (XC-W)

      55

    • Removing the Front Fender

      56

    • Installing the Front Fender

      56

    • Removing the Shock Absorber

      56

    • Installing the Shock Absorber

      56

    • Removing the Seat

      57

    • Mounting the Seat

      57

    • Removing the Air Filter Box Lid

      58

    • Installing the Air Filter Box Lid

      58

    • Removing the Air Filter

      58

    • Installing the Air Filter

      58

    • Cleaning the Air Filter and Air Filter Box

      59

    • Removing the Main Silencer

      59

    • Installing the Main Silencer

      60

    • Changing the Glass Fiber Yarn Filling of the Main Silencer

      60

    • Removing the Fuel Tank

      60

    • Installing the Fuel Tank

      61

    • Checking the Chain for Dirt

      62

    • Cleaning the Chain

      62

    • Checking the Chain Tension

      63

    • Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide

      63

    • Adjusting the Chain Tension

      65

    • Adjusting the Chain Guide

      66

    • Checking the Frame

      67

    • Checking the Swingarm

      67

    • Checking the Throttle Cable Routing

      67

    • Checking the Rubber Grip

      68

    • Additionally Securing the Rubber Grip

      68

    • Adjusting the Basic Position of the Clutch Lever

      68

    • Checking the Fluid Level of the Hydraulic Clutch

      69

    • Changing the Hydraulic Clutch Fluid

      69

  • Brakes

    71

    • Checking Free Travel of Hand Brake Lever

      71

    • Adjusting the Basic Position of the Hand Brake Lever (XC-W)

      71

    • Adjusting Free Travel of Hand Brake Lever (All EXC Models)

      71

    • Checking the Brake Discs

      72

    • Checking the Front Brake Fluid Level

      72

    • Adding Front Brake Fluid

      72

    • Checking the Front Brake Linings

      73

    • Changing the Front Brake Linings

      74

    • Checking the Free Travel of Foot Brake Lever

      75

    • Adjusting the Basic Position of the Foot Brake Lever

      75

    • Checking the Rear Brake Fluid Level

      76

    • Adding Brake Fluid for the Rear Brake

      76

    • Checking the Rear Brake Linings

      77

    • Removing the Rear Brake Linings

      77

    • Installing the Rear Brake Linings

      78

    • Changing the Rear Brake Linings

      78

  • Wheels, Tires

    80

    • Removing the Front Wheel

      80

    • Installing the Front Wheel

      80

    • Removing the Rear Wheel

      81

    • Installing the Rear Wheel

      81

    • Checking the Tire Condition

      82

    • Checking the Tire Air Pressure

      83

    • Checking the Spoke Tension

      83

  • Electrical System

    85

    • Removing the Battery (All 250/300 Models)

      85

    • Installing the Battery (All 250/300 Models)

      85

    • Recharging the Battery (All 250/300 Models)

      85

    • Changing the Main Fuse (All 250/300 Models)

      86

    • Removing the Headlight Mask with the Headlight (All EXC Models)

      87

    • Refitting the Headlight Mask with the Headlight (All EXC Models)

      88

    • Changing the Headlight Bulb (All EXC Models)

      88

    • Checking the Headlight Setting (All EXC Models)

      89

    • Adjusting the Headlight Range (All EXC Models)

      89

    • Changing the Speedometer Battery

      89

  • Cooling System

    91

    • Checking the Antifreeze and Coolant Level

      91

    • Checking the Coolant Level

      92

    • Draining the Coolant

      92

    • Refilling with Coolant

      93

  • Tuning the Engine

    95

    • Checking the Play in the Throttle Cable

      95

    • Adjusting the Play in the Throttle Cable

      95

    • Carburetor

      95

    • Carburetor — Adjusting the Idle Speed

      96

    • Emptying the Carburetor Float Chamber

      97

    • Checking the Basic Position of the Shift Lever

      98

    • Adjusting the Basic Position of the Shift Lever

      98

    • Engine Characteristic — Auxiliary Spring (All 250/300 Models)

      98

    • Engine Characteristic — Adjusting the Auxiliary Spring (All 250/300 Models)

      98

  • Service Work on the Engine

    100

    • Checking the Gear Oil Level

      100

    • Changing the Gear Oil

      100

    • Draining the Gear Oil

      101

    • Refilling with Gear Oil

      101

    • Adding Gear Oil

      102

  • Cleaning, Care

    103

    • Cleaning the Motorcycle

      103

    • Checks and Maintenance Steps for Winter Operation

      104

  • Storage

    105

    • Preparing for Use after Storage

      105

  • Troubleshooting

    106

  • Technical Data — Engine

    108

    • 125 Exc Eu, 125 Exc Six Days Eu

      108

    • All 200 Models

      108

    • All 250 Models

      109

    • All 300 Models

      109

    • Capacity — Transmission Oil

      110

    • Capacity — Coolant

      110

  • Technical Data — Engine Tightening Torques

    111

    • All 125/200 Models

      111

    • All 250/300 Models

      112

  • Technical Data — Carburetor

    113

    • 125 Exc Eu, 125 Exc Six Days Eu

      113

    • 200 Exc Eu

      113

    • 200 Exc aus

      113

    • 200 XC-W Usa

      113

    • 250 Exc Eu, 250 Exc Six Days Eu

      114

    • 250 Exc aus

      114

    • 250 XC-W Usa

      114

    • 300 Exc Eu, 300 Exc Six Days Eu

      114

    • 300 Exc aus

      115

    • 300 XC-W Usa

      115

    • Carburetor Configuration (125 EXC EU, 125 EXC SIX DAYS EU)

      115

    • Carburetor Configuration (All 200 Models)

      117

    • Carburetor Configuration (All 250 Models)

      118

    • Carburetor Configuration (All 300 Models)

      119

    • General Carburetor Configuration

      120

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More KTM Manuals

View a manual of the KTM 300 EXC (2017) below. All manuals on ManualsCat.com can be viewed completely free of charge. By using the ‘Select a language’ button, you can choose the language of the manual you want to view.

Page: 1

DEAR KTM CUSTOMER 1
*3213477en*
3213477en
07/2016
DEAR KTM 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. 12) Dealer’s stamp
Engine number ( p. 12)
Key number (All EXC/EXC Six Days models, 125 XC‑W EU)
( p. 12)
The Owner’s Manual contained the latest information for this model series at the time of going to print. However, minor differences due to
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 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
5230 Mattighofen, Austria
This document is valid for the following models:
125 XC‑W EU (F7103Q3)
150 XC‑W US (F7175Q3)
250 EXC EU (F7303Q6)
250 EXC AU (F7360Q6)
250 EXC Six Days EU (F7303Q2)
250 XC‑W US (F7375Q3)
300 EXC EU (F7403Q6)
300 EXC AU (F7460Q6)
300 EXC BR (F7440Q6)
300 EXC Six Days EU (F7403Q2)
300 XC‑W US (F7475Q3)
300 XC‑W Six Days US (F7475Q2)

Page: 2

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ………………………………. 5
1.1 Symbols used …………………………………………… 5
1.2 Formats used……………………………………………. 5
2 SAFETY ADVICE………………………………………………….. 6
2.1 Use definition – intended use……………………….. 6
2.2 Safety advice……………………………………………. 6
2.3 Degrees of risk and symbols…………………………. 6
2.4 Tampering warning…………………………………….. 6
2.5 Safe operation ………………………………………….. 7
2.6 Protective clothing …………………………………….. 7
2.7 Work rules……………………………………………….. 7
2.8 Environment…………………………………………….. 7
2.9 Owner’s Manual ………………………………………… 8
3 IMPORTANT NOTES…………………………………………….. 9
3.1 Manufacturer and implied warranty………………… 9
3.2 Operating and auxiliary substances ………………… 9
3.3 Spare parts, accessories ……………………………… 9
3.4 Service …………………………………………………… 9
3.5 Figures …………………………………………………… 9
3.6 Customer service……………………………………….. 9
4 VIEW OF VEHICLE …………………………………………….. 10
4.1 View of vehicle, front left (example) ……………… 10
4.2 View of vehicle, rear right (example) …………….. 11
5 SERIAL NUMBERS ……………………………………………. 12
5.1 Chassis number ………………………………………. 12
5.2 Type label ……………………………………………… 12
5.3 Key number (All EXC/EXC Six Days models,
125 XC‑W EU)………………………………………… 12
5.4 Engine number ……………………………………….. 12
5.5 Fork part number …………………………………….. 13
5.6 Shock absorber article number ……………………. 13
6 CONTROLS………………………………………………………. 14
6.1 Clutch lever……………………………………………. 14
6.2 Hand brake lever……………………………………… 14
6.3 Throttle grip …………………………………………… 14
6.4 Kill switch (All EXC/EXC Six Days models,
125 XC‑W EU)………………………………………… 14
6.5 Kill switch (XC‑W US, XC‑W Six Days US) ……… 14
6.6 Horn button (All EXC/EXC Six Days models,
125 XC‑W EU)………………………………………… 15
6.7 Light switch (All EXC/EXC Six Days models,
125 XC‑W EU)………………………………………… 15
6.8 Light switch (XC‑W US, XC‑W Six Days US) ……. 15
6.9 Turn signal switch (All EXC/EXC Six Days
models)…………………………………………………. 15
6.10 Emergency OFF switch (EXC AU)…………………. 15
6.11 Electric starter button (All 250/300 models,
XC‑W US, XC‑W Six Days US)……………………… 16
6.12 Indicator lamps overview (All
EXC/EXC Six Days models)…………………………. 16
6.13 Indicator lamps overview (All
XC‑W/XC‑W Six Days models) ……………………… 16
6.14 Opening the filler cap……………………………….. 16
6.15 Closing the filler cap ………………………………… 17
6.16 Fuel tap ………………………………………………… 17
6.17 Choke …………………………………………………… 17
6.18 Shift lever ……………………………………………… 18
6.19 Kick starter ……………………………………………. 18
6.20 Foot brake lever ………………………………………. 18
6.21 Side stand……………………………………………… 18
6.22 Steering lock (All EXC/EXC Six Days models,
125 XC‑W EU)………………………………………… 19
6.23 Locking the steering (All EXC/EXC Six Days
models, 125 XC‑W EU)……………………………… 19
6.24 Unlocking the steering (All EXC/EXC Six Days
models, 125 XC‑W EU)……………………………… 19
7 SPEEDOMETER ………………………………………………… 20
7.1 Speedometer overview ………………………………. 20
7.2 Activation and test …………………………………… 20
7.3 Setting kilometers or miles…………………………. 20
7.4 Setting the speedometer functions……………….. 21
7.5 Setting the clock……………………………………… 21
7.6 Viewing the lap time…………………………………. 21
7.7 Display mode SPEED (speed)……………………… 22
7.8 Display mode SPEED/H (service hours) …………. 22
7.9 Setup menu …………………………………………… 23
7.10 Setting the unit of measurement …………………. 23
7.11 Display mode SPEED/CLK (time)…………………. 24
7.12 Setting the clock……………………………………… 24
7.13 Display mode SPEED/LAP (lap time)…………….. 24
7.14 Viewing the lap time…………………………………. 25
7.15 Display mode SPEED/ODO (odometer) ………….. 25
7.16 Display mode SPEED/TR1 (trip master 1)………. 25
7.17 Display mode SPEED/TR2 (trip master 2)………. 26
7.18 Setting TR2 (trip master 2)………………………… 26
7.19 Display mode SPEED/A1 (average speed 1) ……. 26
7.20 Display mode SPEED/A2 (average speed 2) ……. 27
7.21 Display mode SPEED/S1 (stop watch 1)………… 27
7.22 Display mode SPEED/S2 (stop watch 2)………… 27
7.23 Table of functions……………………………………. 28
7.24 Table of conditions and menu activation ……….. 29
8 PREPARING FOR USE………………………………………… 30
8.1 Advice on first use …………………………………… 30
8.2 Running in the engine ………………………………. 31
8.3 Preparing the vehicle for difficult riding
conditions ……………………………………………… 31
8.4 Preparing for rides on dry sand……………………. 32
8.5 Preparing for rides on wet sand …………………… 33
8.6 Preparations for riding on wet and muddy
surfaces ………………………………………………… 33
8.7 Preparing for rides at high temperature and
slow speed …………………………………………….. 34
8.8 Preparing for riding at low temperatures or in
snow…………………………………………………….. 34
9 RIDING INSTRUCTIONS……………………………………… 35
9.1 Checks and maintenance measures when
preparing for use……………………………………… 35
9.2 Starting…………………………………………………. 35
9.3 Start off ………………………………………………… 36
9.4 Shifting, riding ……………………………………….. 36
9.5 Braking…………………………………………………. 36
9.6 Stopping, parking…………………………………….. 37
9.7 Transport ………………………………………………. 37
9.8 Refueling ………………………………………………. 38
10 SERVICE SCHEDULE …………………………………………. 39
10.1 Additional information………………………………. 39
10.2 Required work ………………………………………… 39
10.3 Recommended work…………………………………. 40
11 TUNING THE CHASSIS ………………………………………. 41
11.1 Checking the basic chassis setting with the
rider’s weight………………………………………….. 41
11.2 Compression damping of the shock absorber…… 41
11.3 Adjusting the low-speed compression damping
of the shock absorber ……………………………….. 41

Page: 3

TABLE OF CONTENTS 3
11.4 Adjusting the high-speed compression
damping of the shock absorber……………………. 42
11.5 Adjusting the rebound damping of the shock
absorber………………………………………………… 42
11.6 Measuring the rear wheel dimension
unloaded……………………………………………….. 43
11.7 Checking the static sag of the shock absorber…. 44
11.8 Checking the riding sag of the shock absorber…. 44
11.9 Adjusting the spring preload of the shock
absorber …………………………………………….. 44
11.10 Adjusting the riding sag …………………………. 45
11.11 Checking the basic setting of the fork …………… 46
11.12 Adjusting the compression damping of the
fork ……………………………………………………… 46
11.13 Adjusting the rebound damping of the fork …….. 47
11.14 Adjusting the spring preload of the fork (All
Six Days models) …………………………………….. 48
11.15 Handlebar position…………………………………… 48
11.16 Adjusting the handlebar position ………………. 49
12 SERVICE WORK ON THE CHASSIS………………………… 51
12.1 Raising the motorcycle with a lift stand…………. 51
12.2 Removing the motorcycle from the lift stand…… 51
12.3 Bleeding the fork legs……………………………….. 51
12.4 Cleaning the dust boots of the fork legs…………. 51
12.5 Removing the fork protector ……………………….. 52
12.6 Installing the fork protector………………………… 52
12.7 Removing the fork legs …………………………… 52
12.8 Installing the fork legs …………………………… 53
12.9 Removing the lower triple clamp (All
standard EXC/XC-W models)……………………….. 54
12.10 Removing the lower triple clamp (All
Six Days models) …………………………………….. 54
12.11 Installing the lower triple clamp (All
standard EXC/XC-W models)……………………….. 55
12.12 Installing the lower triple clamp (All
Six Days models) …………………………………….. 57
12.13 Checking the play of the steering head
bearing …………………………………………………. 58
12.14 Adjusting the steering head bearing play …….. 59
12.15 Lubricating the steering head bearing ………… 59
12.16 Removing the front fender …………………………. 60
12.17 Installing the front fender ………………………….. 60
12.18 Removing the shock absorber ………………….. 60
12.19 Installing the shock absorber …………………… 61
12.20 Removing the seat …………………………………… 61
12.21 Mounting the seat……………………………………. 61
12.22 Removing the air filter box cover …………………. 62
12.23 Installing the air filter box cover ………………….. 62
12.24 Removing the air filter …………………………… 63
12.25 Installing the air filter ……………………………. 63
12.26 Cleaning the air filter and air filter box ………. 63
12.27 Securing the air filter box cover ……………….. 64
12.28 Sealing the air filter box …………………………. 64
12.29 Removing the main silencer ……………………….. 65
12.30 Installing the main silencer………………………… 65
12.31 Changing the glass fiber yarn filling in the
main silencer ………………………………………. 65
12.32 Removing the fuel tank ………………………….. 66
12.33 Installing the fuel tank …………………………… 67
12.34 Checking the chain for dirt…………………………. 68
12.35 Cleaning the chain …………………………………… 68
12.36 Checking the chain tension………………………… 69
12.37 Adjusting the chain tension………………………… 69
12.38 Checking the chain, rear sprocket, motor
sprocket, and chain guide………………………….. 70
12.39 Checking the frame ………………………………. 72
12.40 Checking the swingarm ………………………….. 72
12.41 Checking throttle cable routing……………………. 72
12.42 Checking the rubber grip …………………………… 73
12.43 Adjusting the basic position of the clutch
lever …………………………………………………….. 73
12.44 Checking/correcting the fluid level of the
hydraulic clutch………………………………………. 73
12.45 Changing the hydraulic clutch fluid …………… 74
12.46 Removing the engine guard (All Six Days
models, EXC AU) …………………………………….. 75
12.47 Installing the engine guard (All Six Days
models, EXC AU) …………………………………….. 75
13 BRAKE SYSTEM ……………………………………………….. 76
13.1 Checking the free travel of the hand brake
lever …………………………………………………….. 76
13.2 Adjusting free travel of hand brake lever (All
EXC/EXC Six Days models, 125 XC‑W EU)……… 76
13.3 Adjusting the basic position of the hand brake
lever (XC‑W US, XC‑W Six Days US)……………… 76
13.4 Checking the brake discs …………………………… 77
13.5 Checking the front brake fluid level ……………… 77
13.6 Adding front brake fluid …………………………. 78
13.7 Checking the front brake linings ………………….. 79
13.8 Changing the front brake linings ………………. 79
13.9 Checking the free travel of foot brake lever …….. 81
13.10 Adjusting the basic position of the foot brake
lever ………………………………………………….. 81
13.11 Checking the rear brake fluid level……………….. 82
13.12 Adding rear brake fluid ………………………….. 82
13.13 Checking the rear brake linings …………………… 83
13.14 Changing the rear brake linings ………………… 83
14 WHEELS, TIRES ……………………………………………….. 85
14.1 Removing the front wheel ……………………….. 85
14.2 Installing the front wheel ……………………….. 85
14.3 Removing the rear wheel ………………………… 86
14.4 Installing the rear wheel …………………………. 87
14.5 Checking the tire condition ………………………… 88
14.6 Checking the tire air pressure……………………… 88
14.7 Checking spoke tension …………………………….. 89
15 ELECTRICAL SYSTEM ………………………………………… 90
15.1 Removing the battery (All 250/300 models,
XC‑W US, XC‑W Six Days US)……………………… 90
15.2 Installing the battery (All 250/300 models,
XC‑W US, XC‑W Six Days US)……………………… 91
15.3 Recharging the battery (All 250/300
models, XC‑W US, XC‑W Six Days US) ………….. 91
15.4 Changing the main fuse (All 250/300 models,
XC‑W US, XC‑W Six Days US)……………………… 93
15.5 Removing the headlight mask with the
headlight……………………………………………….. 94
15.6 Installing the headlight mask with the
headlight……………………………………………….. 95
15.7 Changing the headlight bulb ………………………. 95
15.8 Changing the turn signal bulb (All
EXC/EXC Six Days models)…………………………. 96
15.9 Checking the headlight setting ……………………. 97
15.10 Adjusting the headlight range……………………… 97
15.11 Changing the speedometer battery……………….. 97
16 COOLING SYSTEM …………………………………………….. 99
16.1 Cooling system ……………………………………….. 99

Page: 4

TABLE OF CONTENTS 4
16.2 Checking the antifreeze and coolant level………. 99
16.3 Checking the coolant level ……………………….. 100
16.4 Draining the coolant ……………………………. 100
16.5 Refilling with coolant …………………………… 101
17 TUNING THE ENGINE………………………………………. 103
17.1 Checking the play in the throttle cable ………… 103
17.2 Adjusting the play in the throttle cable …….. 103
17.3 Carburetor setting ………………………………….. 104
17.4 Carburetor — idle…………………………………….. 106
17.5 Carburetor – adjusting the idle speed ………. 106
17.6 Ignition curve plug-in connector ………………… 107
17.7 Changing the ignition curve………………………. 107
17.8 Checking the basic position of the shift lever … 107
17.9 Adjusting the basic position of the shift
lever ………………………………………………… 107
17.10 Engine characteristic – auxiliary spring ……….. 108
17.11 Engine characteristic – setting the auxiliary
spring ………………………………………………. 108
18 SERVICE WORK ON THE ENGINE ……………………….. 111
18.1 Emptying the carburetor float chamber …….. 111
18.2 Checking the gear oil level ……………………….. 111
18.3 Changing the gear oil …………………………… 112
18.4 Adding gear oil …………………………………… 114
19 CLEANING, CARE ……………………………………………. 115
19.1 Cleaning the motorcycle ………………………….. 115
19.2 Checks and maintenance steps for winter
operation……………………………………………… 116
20 STORAGE………………………………………………………. 117
20.1 Storage ……………………………………………….. 117
20.2 Preparing for use after storage…………………… 118
21 TROUBLESHOOTING ……………………………………….. 119
22 TECHNICAL DATA……………………………………………. 121
22.1 Engine ………………………………………………… 121
22.1.1 125 XC‑W EU……………………………………. 121
22.1.2 150 XC‑W US……………………………………. 121
22.1.3 All 250 models………………………………….. 122
22.1.4 All 300 models………………………………….. 122
22.2 Engine tightening torques ………………………… 123
22.2.1 125 XC‑W EU……………………………………. 123
22.2.2 150 XC‑W US……………………………………. 124
22.2.3 All 250/300 models……………………………. 125
22.3 Capacities ……………………………………………. 126
22.3.1 Gear oil……………………………………………. 126
22.3.2 Coolant……………………………………………. 126
22.3.3 Fuel ……………………………………………….. 126
22.4 Chassis ……………………………………………….. 126
22.5 Electrical system……………………………………. 127
22.6 Tires…………………………………………………… 127
22.7 Fork……………………………………………………. 128
22.7.1 All 125/150 models……………………………. 128
22.7.2 All standard 250/300 EXC/XC-W models….. 128
22.7.3 All Six Days models…………………………….. 128
22.8 Shock absorber……………………………………… 129
22.8.1 All 125/150 models……………………………. 129
22.8.2 All 250/300 models……………………………. 129
22.9 Chassis tightening torques ……………………….. 130
22.10 Carburetor……………………………………………. 132
22.10.1 125 XC‑W EU……………………………………. 132
22.10.2 150 XC‑W US……………………………………. 132
22.10.3 250 EXC EU, 250 EXC AU,
250 EXC Six Days EU …………………………. 132
22.10.4 250 XC‑W US……………………………………. 132
22.10.5 300 EXC EU, 300 EXC AU,
300 EXC Six Days EU …………………………. 133
22.10.6 300 XC‑W US, 300 XC‑W Six Days US…….. 133
22.10.7 300 EXC BR …………………………………….. 133
23 CARBURETOR TUNING…………………………………….. 134
23.1 Carburetor tuning (125 XC‑W EU) …………… 134
23.2 Carburetor tuning (150 XC‑W US) …………… 135
23.3 Carburetor tuning (250 EXC EU,
250 EXC AU, 250 EXC Six Days EU) ……….. 136
23.4 Carburetor tuning (250 XC‑W US) …………… 137
23.5 Carburetor tuning (300 EXC EU,
300 EXC AU, 300 EXC Six Days EU) ……….. 138
23.6 Carburetor tuning (300 XC‑W US,
300 XC‑W Six Days US) ……………………….. 139
23.7 Carburetor tuning (300 EXC BR) …………….. 140
24 SUBSTANCES ………………………………………………… 141
25 AUXILIARY SUBSTANCES …………………………………. 143
26 STANDARDS ………………………………………………….. 144
27 LIST OF ABBREVIATIONS………………………………….. 145
28 LIST OF SYMBOLS…………………………………………… 146
28.1 Yellow and orange symbols……………………….. 146
28.2 Green and blue symbols…………………………… 146
INDEX …………………………………………………………………. 147

Page: 5

1 MEANS OF REPRESENTATION 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
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti-
mally cared for by specially trained experts using the specialist 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.
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name® Identifies a protected name.
Brand™ Identifies a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in
the glossary.

Page: 6

2 SAFETY ADVICE 6
2.1 Use definition – intended use
(All EXC/EXC Six Days models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for public road traffic in the homologated (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off properties remote from public road traffic.
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
(All XC‑W/XC‑W Six Days models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
Your motorcycle is not approved for use on public roads.
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
2.2 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.
2.3 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.
2.4 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 replacement, 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:

Page: 7

2 SAFETY ADVICE 7
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 manu-
facturer.
2.5 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.
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 environmen-
tally 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.
2.6 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.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle 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.

Page: 8

2 SAFETY ADVICE 8
2.9 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 cus-
tomize 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.

Page: 9

3 IMPORTANT NOTES 9
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 dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
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

Page: 10

4 VIEW OF VEHICLE 10
4.1 View of vehicle, front left (example)
E00320-10
1 Hand brake lever ( p. 14)
2 Light switch ( p. 15)
2 Kill switch ( p. 14)
2 Turn signal switch ( p. 15)
2 Horn button ( p. 15)
3 Clutch lever ( p. 14)
4 Chain guide
5 Air filter box cover
6 Side stand ( p. 18)
7 Shift lever ( p. 18)
8 Fuel tap ( p. 17)

Page: 11

4 VIEW OF VEHICLE 11
4.2 View of vehicle, rear right (example)
E00319-10
1 Filler cap
2 Throttle grip ( p. 14)
3 Chassis number ( p. 12)
4 Kick starter ( p. 18)
5 Foot brake lever ( p. 18)
6 Level viewer for brake fluid, rear

Page: 12

5 SERIAL NUMBERS 12
5.1 Chassis number
401945-10
The chassis number  is stamped on the right side of the steering head.
5.2 Type label
401945-10
Type label  is fixed to the front of the steering head.
5.3 Key number (All EXC/EXC Six Days models, 125 XC‑W EU)
402247-10
The key number  for the steering lock is stamped onto the key connector.
5.4 Engine number
401949-10
(All 125/150 models)
The engine number  is located on the left side of the engine under the engine
sprocket.
H01047-10
(All 250/300 models)
The engine number  is located on the left side of the engine over the engine
sprocket.

Page: 13

5 SERIAL NUMBERS 13
5.5 Fork part number
401947-10
The fork part number  is stamped on the inside of the axle clamp.
5.6 Shock absorber article number
0
0
1
1
401948-10
Shock absorber article number  is stamped on the top of the shock absorber above
the adjusting ring towards the engine side.

Page: 14

6 CONTROLS 14
6.1 Clutch lever
V00322-10
Clutch lever  is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
6.2 Hand brake lever
E00311-10
Hand brake lever  is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3 Throttle grip
E00312-10
Throttle grip  is fitted on the right side of the handlebar.
6.4 Kill switch (All EXC/EXC Six Days models, 125 XC‑W EU)
E00318-10
The kill switch  is 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 run-
ning engine stops, and a non-running engine will not start.
6.5 Kill switch (XC‑W US, XC‑W Six Days US)
E00316-10
The kill switch  is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.

Page: 15

6 CONTROLS 15
6.6 Horn button (All EXC/EXC Six Days models, 125 XC‑W EU)
E00318-11
(125 XC‑W EU)
The horn button  is fitted on the left side of the handlebar.
Info
The horn button has no function when the vehicle is delivered.
(All EXC/EXC Six Days models)
The horn button  is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
6.7 Light switch (All EXC/EXC Six Days models, 125 XC‑W EU)
E00321-10
Light switch  is 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.
6.8 Light switch (XC‑W US, XC‑W Six Days US)
E00317-10
Light switch  is located to the left of the speedometer.
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.
6.9 Turn signal switch (All EXC/EXC Six Days models)
V00323-12
Turn signal switch  is fitted on the left side of the handlebar.
Possible states
Turn signal off – The turn signal switch is in the central position.
Left turn signal, on – The turn signal switch is turned to the left.
Right turn signal, on – The turn signal switch is turned to the right.
6.10 Emergency OFF switch (EXC AU)
E00322-10
The emergency OFF switch  is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.

Page: 16

6 CONTROLS 16
6.11 Electric starter button (All 250/300 models, XC‑W US, XC‑W Six Days US)
E00313-10
The electric starter button  is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
6.12 Indicator lamps overview (All EXC/EXC Six Days models)
E00314-01
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
Turn signal indicator lamp flashes green – The turn signal is switched
on.
6.13 Indicator lamps overview (All XC‑W/XC‑W Six Days models)
E00371-01
Possible states
High beam indicator lamp – inoperative
Malfunction indicator lamp – inoperative
Fuel level warning lamp – inoperative
6.14 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.

Page: 17

6 CONTROLS 17
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.
V00325-10
– Press release button , turn the filler cap counterclockwise and lift it free.
6.15 Closing the filler cap
V00325-11
– Replace the filler cap and turn clockwise until the release button  locks in
place.
Info
Run the fuel tank breather hose  without kinks.
6.16 Fuel tap
V00326-10
The fuel tap is on the left side of the fuel tank.
Open or close the supply of fuel to the carburetor using tap handle  on 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.
6.17 Choke
V00327-10
Choke  is 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.
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.

Page: 18

6 CONTROLS 18
6.18 Shift lever
401950-10
Shift lever  is mounted on the left side of the engine.
401950-11
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
6.19 Kick starter
0
0
1
1
401954-10
Kick starter  is 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.
6.20 Foot brake lever
401956-10
Foot brake lever  is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
6.21 Side stand
401943-10
The side stand  is on the left side of the vehicle.

Page: 19

6 CONTROLS 19
401944-10
The side stand is used to park the motorcycle.
Info
When you are riding, side stand  must be folded up and secured with rubber
band .
6.22 Steering lock (All EXC/EXC Six Days models, 125 XC‑W EU)
V00328-10
Steering lock  is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.
6.23 Locking the steering (All EXC/EXC Six Days models, 125 XC‑W EU)
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level 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 and turn it to the
right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
6.24 Unlocking the steering (All EXC/EXC Six Days models, 125 XC‑W EU)
400731-01
– 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.
Info
Never leave the key in the steering lock.

Page: 20

7 SPEEDOMETER 20
7.1 Speedometer overview
401761-01
– Press the button to control different functions.
– Press the button to control different functions.
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
7.2 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 display function check, the wheel size WS is displayed briefly.
Info
The number 2205 equals the circumference of the 21″ front wheel with stan-
dard tires.
The display then changes to the last selected mode.
7.3 Setting 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.
400329-01
– 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 .
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.

Page: 21

7 SPEEDOMETER 21
7.4 Setting the speedometer functions
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
400318-01
– 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.
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 function 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.
7.5 Setting the clock
Condition
The motorcycle is stationary.
400330-01
– 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.

Page: 22

7 SPEEDOMETER 22
400321-01
– 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.
– 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.
7.7 Display mode SPEED (speed)
400317-02
– 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
Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.
7.8 Display mode SPEED/H (service hours)
400316-01
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.
Info
The service hour counter is necessary for ensuring that service work is carried
out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automati-
cally changes to the ODO display mode.
The H display mode is suppressed during the journey.
Press the button
for 2–3 seconds.
The display changes to the Setup menu of the speedometer
functions.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function

Page: 23

7 SPEEDOMETER 23
7.9 Setup menu
400344-01
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.
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.
Briefly press the
button .
Activates the flashing display and changes to the next display
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
Deactivates the flashing display and changes to the next dis-
play
Press the button
for 2–3 seconds.
No function
Wait 3–5 seconds Changes to the next display without changes
Wait 10–12 sec-
onds
Setup menu starts, stores the settings, and changes to H or
ODO.
7.10 Setting the unit of measurement
400329-01
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.
Info
If no button is pressed for 5 seconds, the settings are automatically saved.
Briefly press the
button .
Starts selection, activates Km/h display
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
Activates Mph display
Press the button
for 2–3 seconds.
No function
Wait 3–5 seconds Changes to the next display, changes from selection to the
Setup menu
Wait 10–12 sec-
onds
Saves and closes the Setup menu

Page: 24

7 SPEEDOMETER 24
7.11 Display mode SPEED/CLK (time)
400319-01
– Repeatedly press the button briefly until CLK appears at the bottom right of the
display.
The time is shown in display mode CLK.
Press the button
for 2–3 seconds.
The display changes to the Setup menu of the clock.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function
7.12 Setting the clock
400319-01
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.
Increases the value
Briefly press the
button .
Increases the value
Press the button
for 2–3 seconds.
Reduces the value
Briefly press the
button .
Reduces the value
Wait 3–5 seconds Changes to the next value
Wait 10–12 sec-
onds
Closes the SETUP menu
7.13 Display mode SPEED/LAP (lap time)
400320-01
– Repeatedly press the button briefly 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 running after the button is pressed, 9 memory loca-
tions are occupied.
Lap 10 must be timed using the button .
Press the button
for 2–3 seconds.
The stop watch and the lap time are reset.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
Stops the clock.
Briefly press the
button .
Starts the stop watch or stop the current lap time measure-
ment, stores it and the stop watch starts the next lap.

Page: 25

7 SPEEDOMETER 25
7.14 Viewing the lap time
400321-01
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.
The stop watch and the lap time are reset.
Briefly press the
button .
Select a lap from 1–10
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
View the next lap time.
7.15 Display mode SPEED/ODO (odometer)
400317-01
– 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.
No function
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function
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 dis-
play.
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.
Displays of TR1, A1 and S1 are reset to 0,0.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function

Page: 26

7 SPEEDOMETER 26
7.17 Display mode SPEED/TR2 (trip master 2)
400324-01
– Repeatedly press the button briefly until TR2 appears at the top right of the dis-
play.
TR2 (trip master 2) runs constantly and counts up to 999.9.
Press the button
for 2–3 seconds.
Clears the values TR2 and A2.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
Reduces value of TR2.
Briefly press the
button .
Reduces value of TR2.
7.18 Setting TR2 (trip master 2)
400324-01
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until TR2 appears at the top right of the dis-
play.
– 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.
Info
The TR2 value can also be corrected manually during the journey with the but-
ton 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.
Increases value of TR2.
Briefly press the
button .
Increases value of TR2.
Press the button
for 2–3 seconds.
Reduces value of TR2.
Briefly press the
button .
Reduces value of TR2.
Wait 10–12 sec-
onds
Saves and closes the Setup menu
7.19 Display mode SPEED/A1 (average speed 1)
400325-01
– Repeatedly press the button briefly until A1 appears at the top right of the dis-
play.
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 seconds.
Displays of TR1, A1 and S1 are reset to 0,0.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function

Page: 27

7 SPEEDOMETER 27
7.20 Display mode SPEED/A2 (average speed 2)
400326-01
– Repeatedly press the button briefly until A2 appears at the top right of the dis-
play.
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.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function
7.21 Display mode SPEED/S1 (stop watch 1)
400327-01
– Repeatedly press the button briefly until S1 appears at the top right of the dis-
play.
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 button
for 2–3 seconds.
Displays of TR1, A1 and S1 are reset to 0,0.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
No function
7.22 Display mode SPEED/S2 (stop watch 2)
400328-01
– Repeatedly press the button briefly until S2 appears at the top right of the dis-
play.
S2 (Stop watch 2) is a manual stop watch.
If S2 is running in the background, the display S2 flashes on the speedometer.
Press the button
for 2–3 seconds.
The displays of S2 and A2 are set to 0,0.
Briefly press the
button .
Next display mode
Press the button
for 2–3 seconds.
No function
Briefly press the
button .
Starts or stops S2.

Page: 28

7 SPEEDOMETER 28
7.23 Table of functions
Display Press the but-
ton for 2–3
seconds.
Briefly press the
button .
Press the but-
ton for 2–3
seconds.
Briefly press the
button .
Wait 3–5 sec-
onds
Wait 10–12 sec-
onds
Display mode
SPEED/H (service
hours)
The display
changes to the
Setup menu of
the speedome-
ter functions.
Next display
mode
No function No function
Setup menu No function Activates the
flashing display
and changes to
the next display
No function Deactivates the
flashing display
and changes to
the next display
Changes to the
next display
without changes
Setup menu
starts, stores
the settings,
and changes to
H or ODO.
Setting the unit of
measurement
No function Starts selection,
activates Km/h
display
No function Activates Mph
display
Changes to the
next display,
changes from
selection to the
Setup menu
Saves and
closes the Setup
menu
Display mode
SPEED/CLK (time)
The display
changes to the
Setup menu of
the clock.
Next display
mode
No function No function
Setting the clock Increases the
value
Increases the
value
Reduces the
value
Reduces the
value
Changes to the
next value
Closes the
SETUP menu
Display mode
SPEED/LAP (lap
time)
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 measure-
ment, stores it
and the stop
watch starts the
next lap.
Viewing the lap
time
The stop watch
and the lap time
are reset.
Select a lap
from 1–10
No function View the next
lap time.
Display mode
SPEED/ODO
(odometer)
No function Next display
mode
No function No function
Display mode
SPEED/TR1 (trip
master 1)
Displays of TR1,
A1 and S1 are
reset to 0,0.
Next display
mode
No function No function
Display mode
SPEED/TR2 (trip
master 2)
Clears the val-
ues TR2 and A2.
Next display
mode
Reduces value
of TR2.
Reduces value
of TR2.
Setting TR2 (trip
master 2)
Increases value
of TR2.
Increases value
of TR2.
Reduces value
of TR2.
Reduces value
of TR2.
Saves and
closes the Setup
menu
Display mode
SPEED/A1 (average
speed 1)
Displays of TR1,
A1 and S1 are
reset to 0,0.
Next display
mode
No function No function
Display mode
SPEED/A2 (average
speed 2)
No function Next display
mode
No function No function
Display mode
SPEED/S1 (stop
watch 1)
Displays of TR1,
A1 and S1 are
reset to 0,0.
Next display
mode
No function No function
Display mode
SPEED/S2 (stop
watch 2)
The displays of
S2 and A2 are
set to 0,0.
Next display
mode
No function Starts or stops
S2.

Page: 29

7 SPEEDOMETER 29
7.24 Table of conditions and menu activation
Display The motorcycle is
stationary.
Menu can be acti-
vated
Display mode SPEED/H (service 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) •

Page: 30

8 PREPARING FOR USE 30
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 characteristic.
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. 73)
(All EXC/EXC Six Days models, 125 XC‑W EU)
– Adjust the free travel of the hand brake lever. ( p. 76)
(XC‑W US, XC‑W Six Days US)
– Adjust the basic position of the hand brake lever. ( p. 76)
– Adjust the basic position of the foot brake lever. ( p. 81)
– Adjust the basic position of the shift lever. ( p. 107)
– Get used to handling the motorcycle on a suitable piece of land 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.

Page: 31

8 PREPARING FOR USE 31
– 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 distri-
bution 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. 89)
Info
The spoke tension must be checked after half an hour of operation.
– Run in the engine. ( p. 31)
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!
8.3 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 neces-
sary to inspect or replace parts before the next scheduled service.
– Seal the air filter box. ( p. 64)
– Clean the air filter and air filter box. ( p. 63)
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. 32)
– Rides on wet sand. ( p. 33)
– Riding on wet and muddy surfaces. ( p. 33)
– Rides at high temperature and slow speed. ( p. 34)
– Riding at low temperatures or in snow. ( p. 34)

Page: 32

8 PREPARING FOR USE 32
8.4 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 operation, the coolant gets
very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling sys-
tem components if the engine or the cooling system are at oper-
ating 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.
M01104-01
– Fit a dust cover on the air filter.
Dust cover for air filter (79006920000)
Info
See the KTM PowerParts fitting instructions.
M01105-01
– 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.
600868-01
– Clean the chain.
Chain cleaner ( p. 143)
– 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.

Page: 33

8 PREPARING FOR USE 33
8.5 Preparing for rides on wet 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 operation, the coolant gets
very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling sys-
tem components if the engine or the cooling system are at oper-
ating 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.
M01106-01
– 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.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
600868-01
– Clean the chain.
Chain cleaner ( p. 143)
– 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.
8.6 Preparations for riding on wet and muddy surfaces
M01106-01
– 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.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.

Page: 34

8 PREPARING FOR USE 34
600868-01
– Mount the steel sprocket.
– Clean the motorcycle. ( p. 115)
– Carefully align bent radiator fins.
8.7 Preparing for rides at high temperature and slow speed
M01129-01
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to the setpoint value:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling sys-
tem components if the engine or the cooling system are at oper-
ating 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.
600868-01
– 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.
Chain cleaner ( p. 143)
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 100)
8.8 Preparing for riding at low temperatures or in snow
M01106-01
– 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.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.

Page: 35

9 RIDING INSTRUCTIONS 35
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.
– Check the gear oil level. ( p. 111)
– Check the electrical system.
– Check the front brake fluid level. ( p. 77)
– Check the rear brake fluid level. ( p. 82)
– Check the front brake linings. ( p. 79)
– Check the rear brake linings. ( p. 83)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 100)
– Check the chain for dirt. ( p. 68)
– Check the chain, rear sprocket, motor sprocket, and chain guide. ( p. 70)
– Check the chain tension. ( p. 69)
– Check the tire condition. ( p. 88)
– Check the tire air pressure. ( p. 88)
– Check the spoke tension. ( p. 89)
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. 51)
– Bleed the fork legs. ( p. 51)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts, and hose clamps regularly for tightness.
– Check the fuel level.
9.2 Starting
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.
Info
If the motorcycle does not start easily, there may be old fuel in the float chamber. The easily ignitable components of the fuel
evaporate during lengthy periods of disuse.
When the float chamber is filled with fresh, ignitable fuel, the engine will start immediately.
Condition
The motorcycle was stationary for more than 1 week.
– Empty the carburetor float chamber. ( p. 111)
– Turn handle  of the fuel tap to the ON position. (Figure V00326-10 p. 17)
Fuel can flow from the fuel tank to the carburetor.
– Take the motorcycle off of the stand.
– Shift gear to neutral.
Condition
The engine is cold.

Page: 36

9 RIDING INSTRUCTIONS 36
– Pull the choke lever out as far as possible.
(All 250/300 models, XC‑W US, XC‑W Six Days US)
– Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not turn the throttle.
(125 XC‑W EU)
– Press the kick starter robustly through its full range.
Info
Do not turn 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.
– 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 consumption.
– 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.)

Page: 37

9 RIDING INSTRUCTIONS 37
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.
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/EXC Six Days models, 125 XC‑W EU)
– Press and hold the kill switch while the engine is idling until the engine stops.
(XC‑W US, XC‑W Six Days US)
– Press and hold the kill switch while the engine is idling until the engine stops.
– Turn handle  of the fuel tap to the OFF position. (Figure V00326-10 p. 17)
– Park the motorcycle on firm ground.
9.7 Transport
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.

Page: 38

9 RIDING INSTRUCTIONS 38
401475-01
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.
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. 16)
400382-10
– Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of  35 mm (1.38 in)
Total fuel tank
capacity, approx.
9.5 l
(2.51 US gal)
Super unleaded (95 octane)
mixed with 2-stroke engine
oil (1:60) ( p. 142) (All
XC‑W/XC‑W Six Days models,
All 250/300 EU/AU/US models)
Super unleaded, type C (ROZ 95/RON
95/PON 91 mixed with 2-stroke engine
oil, 1:60) ( p. 142) (300 EXC BR)
Engine oil, 2-stroke ( p. 141)
– Close the filler cap. ( p. 17)

Page: 39

10 SERVICE SCHEDULE 39
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.
10.2 Required work
Every 40 operating hours/after every race
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. (All 250/300 models, XC‑W US, XC‑W Six Days US) ● ●
Check the front brake linings. ( p. 79) ● ●
Check the rear brake linings. ( p. 83) ● ●
Check the brake discs. ( p. 77) ● ●
Check the brake lines for damage and leakage. ● ●
Check the rear brake fluid level. ( p. 82) ● ●
Check the free travel of the foot brake lever. ( p. 81) ● ●
Check the frame and swingarm. ● ●
Check the swingarm bearing for play. ● ●
Check the heim joints at the top and bottom of the shock absorber. ● ●
Check the tire condition. ( p. 88) ○ ● ●
Check the tire air pressure. ( p. 88) ○ ● ●
Check the wheel bearing for play. ● ●
Check the wheel hubs. ● ●
Check the rim run-out. ○ ● ●
Check the spoke tension. ( p. 89) ○ ● ●
Check the chain, rear sprocket, motor sprocket, and chain guide. ( p. 70) ● ●
Check the chain tension. ( p. 69) ○ ● ●
Grease all moving parts (e.g. side stand, hand lever, chain, …) and check for smooth operation. ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 73) ● ●
Check the front brake fluid level. ( p. 77) ● ●
Check the free travel of the hand brake lever. ( p. 76) ● ●
Check the play of the steering head bearing. ( p. 58) ○ ● ●
Change the spark plug and spark plug connector. ●
Check the inlet membrane. ● ●
Change the gear oil. ( p. 112) ○ ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect rout-
ing.
○ ● ●
Check the antifreeze and coolant level. ( p. 99) ○ ● ●
Check the cables for damage and routing without sharp bends. ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly. ○ ● ●
Clean the air filter and air filter box. ( p. 63) ● ●
Change glass fiber yarn filling in the main silencer. ( p. 65) ● ●
Check the screws and nuts for tightness. ○ ● ●
Check the headlight setting. ( p. 97) ○ ● ●
Check idle. ● ●
Final check: Check the vehicle for safe operation 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

Page: 40

10 SERVICE SCHEDULE 40
10.3 Recommended work
Annually
Every 80 operating hours/every 40 operating hours when used for motorsports
Every 40 operating hours/every 10 operating hours when used for motorsports
Once after 10 operating hours
Change the front brake fluid. ●
Change the rear brake fluid. ●
Change the hydraulic clutch fluid. ( p. 74) ●
Lubricate the steering head bearing. ( p. 59) ●
Check/adjust the carburetor components. ● ●
Service the fork. ○ ● ●
Service the shock absorber. ● ●
Check the starter drive. (All 250/300 models, XC‑W US, XC‑W Six Days US) ● ●
Change the piston and check the cylinder. (125 XC‑W EU) ● ●
Change the piston and check the cylinder. (All 250/300 models, XC‑W US, XC‑W Six Days US) ●
Perform minor engine service. (Check the exhaust control for functioning and smooth operation. Check the
clutch.)
● ●
Perform major engine service including removing and installing the engine. (Change the connecting rod, con-
rod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)

○ One-time interval
● Periodic interval

Page: 41

11 TUNING THE CHASSIS 41
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.
401030-01
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider’s weight.
– As delivered, KTM offroad motorcycles are adjusted for a standard rider weight
(with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
– If the rider’s weight is above or below the standard range, the basic setting of the
suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.
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.
V00329-10
– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible
click.
Info
Do not loosen fitting !
– Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.

Page: 42

11 TUNING THE CHASSIS 42
Guideline
Compression damping, low-speed (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping, low-speed (All 250/300 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
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.
V00330-10
– Using an open end wrench, turn adjusting screw  clockwise all the way.
Info
Do not loosen fitting !
– Turn counterclockwise by the number of turns corresponding to the shock absorber
type.
Guideline
Compression damping, high-speed (All 125/150 models)
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Compression damping, high-speed (All 250/300 models)
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
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.)

Page: 43

11 TUNING THE CHASSIS 43
V00331-10
– Turn adjusting screw  clockwise up to the last perceptible click.
– Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
Guideline
Rebound damping (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping (All 250/300 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
11.6 Measuring the rear wheel dimension unloaded
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 51)
402415-10
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 dimension .
Finishing work
– Remove the motorcycle from the lift stand. ( p. 51)

Page: 44

11 TUNING THE CHASSIS 44
11.7 Checking the static sag of the shock absorber
402416-10
– Measure dimension  of rear wheel unloaded. ( p. 43)
– Hold the motorcycle upright with the aid of an assistant.
– Again measure the distance between the rear axle and marking SAG on the rear
fender using the sag gauge.
– Note down the value as dimension .
Info
The static sag is the difference between measurements  and .
– Check the static sag.
Static sag (All 125/150 models) 35 mm (1.38 in)
Static sag (All 250/300 models) 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( p. 44)
11.8 Checking the riding sag of the shock absorber
402417-10
– Measure dimension  of rear wheel unloaded. ( p. 43)
– With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear axle and
marking SAG on the rear fender using the sag gauge.
– Note down the value as dimension .
Info
The riding sag is the difference between measurements  and .
– Check the riding sag.
Riding sag (All 125/150 models) 110 mm (4.33 in)
Riding sag (All 250/300 models) 110 mm (4.33 in)
» If the riding sag differs from the specified measurement:
– Adjust the riding sag. ( p. 45)
11.9 Adjusting the spring preload 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 preload, 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. 51)
– Remove the shock absorber. ( p. 60)

Page: 45

11 TUNING THE CHASSIS 45
– After removing the shock absorber, clean it thoroughly.
402405-10
Main work
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.
Hook wrench (90129051000)
– Measure the overall spring length while the spring is not under tension.
– Tighten the spring by turning adjusting ring  to measurement .
Guideline
Spring preload (All 125/150 models)
Comfort 6 mm (0.24 in)
Standard 6 mm (0.24 in)
Sport 6 mm (0.24 in)
Spring preload (All 250/300 models)
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 preload.
– Tighten screw .
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
Finishing work
– Install the shock absorber. ( p. 61)
– Remove the motorcycle from the lift stand. ( p. 51)
11.10 Adjusting the riding sag
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 51)
– Remove the shock absorber. ( p. 60)
– After removing the shock absorber, clean it thoroughly.
B00292-10
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (All 125/150 models)
Weight of rider: 65… 75 kg (143…
165 lb.)
57 N/mm (325 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
60 N/mm (343 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
63 N/mm (360 lb/in)
Spring rate (All 250/300 models)
Weight of rider: 65… 75 kg (143…
165 lb.)
60 N/mm (343 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
63 N/mm (360 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
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. 61)
– Remove the motorcycle from the lift stand. ( p. 51)

Page: 46

11 TUNING THE CHASSIS 46
– Check the static sag of the shock absorber. ( p. 44)
– Check the riding sag of the shock absorber. ( p. 44)
– Adjust the rebound damping of the shock absorber. ( p. 42)
11.11 Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
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 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 operation, the fork legs
need to be bled.
11.12 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
E00323-10
(All standard EXC/XC-W models)
– Turn white adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is located at the upper end of the left fork leg.
The compression damping is located in left fork leg COMP (white adjust-
ing screw). The rebound damping is located in right fork leg REB (red
adjusting screw).
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping (All standard 250/300 EXC/XC-W models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
E00324-10
(All Six Days models)
– Turn white adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is located at the upper end of the left fork leg.
The compression damping is located in left fork leg COM (white adjust-
ing screw). The rebound damping is located in right fork leg REB (red
adjusting screw).
– Turn counterclockwise by the number of clicks corresponding to the fork type.

Page: 47

11 TUNING THE CHASSIS 47
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
11.13 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
E00326-10
(All standard EXC/XC-W models)
– Turn red adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is 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 corresponding to the fork type.
Guideline
Rebound damping (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping (All standard 250/300 EXC/XC-W models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
E00325-10
(All Six Days models)
– Turn red adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is 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 corresponding 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.

Page: 48

11 TUNING THE CHASSIS 48
11.14 Adjusting the spring preload of the fork (All Six Days models)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 51)
E00327-10
Main work
– Turn the adjusting wings  counterclockwise 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.
– 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.
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 preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 51)
11.15 Handlebar position
M00993-10
(All standard EXC/XC-W models)
On the upper triple clamp, there are 2 holes at a distance of  to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of  from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This allows the handle-
bar to be mounted in the most comfortable position for the rider.

Page: 49

11 TUNING THE CHASSIS 49
M00987-10
(All Six Days models)
On the upper triple clamp, there are 2 holes at a distance of  to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of  from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This allows the handle-
bar 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.
M00993-11
(All standard EXC/XC-W models)
– Remove screws . 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 screws . Take off the handlebar supports.
– Place the handlebar supports in the required position. Mount and tighten
screws .
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 screws  and tighten evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.

Page: 50

11 TUNING THE CHASSIS 50
M00987-11
(All Six Days models)
– Remove screws . 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 screws . Take off the handlebar supports.
– Place the handlebar supports in the required position. Mount and tighten
screws .
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 screws  and tighten evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.

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The Austrian company KTM is one of the largest and most famous manufacturers of sports motorcycles in Europe. The official date of foundation of the enterprise is 1934. It was
then that a young but very ambitious engineer named Hans Trunkenpolz, who lived in the city of Mattinghofen, opened a metal processing workshop, which received the name Kraftfahrzeuge Trunkenpolz
Mattighofen (KTM).

This series consists of two machines: the dual-use 125EXE and the urban enduro 125 Supermoto. They differ from each other mainly in wheels, dressed in universal
tires (125ЕХЕ) and highway «rubber» (125 Supermoto). Both motorcycles are equipped with a new two-stroke engine, unified in design with sports power units. The frame is tubular, welded, made of
chrome-molybdenum steel. Telescopic front fork — inverted type. The rear suspension of the PDS (Progressive Damping System) system, as on all “adult” KTMs, provides a progressive characteristic
without an intermediate linkage only due to the design of the shock absorber itself.

Motorcycles for enduro competitions in their design are as close as possible to cross-country motorcycles. They install a wide range of two-stroke engines (models 125EXC, 200EXC,
250EXC, 300EXC and 380EXC), including the new 250 cc engine. The new generation four-stroke engines are used on 400EXC Racing and 520EXC Racing motorcycles.

The company is also developing a two-cylinder V-shaped four-stroke 1000 cc LC8 engine. This power unit is designed for a powerful motorcycle for a rally and for the future road version of Super
Duke. The debut of the novelty will take place in the fall of 2000.

Parade Horse of the company — the famous model 640 Duke II. This is an urban enduro-style motorcycle with 17-inch alloy wheels. The futuristic half fairing with two headlights located one above
the other looks peculiar. The 640 cc engine is equipped with an electric starter.

Dual-use motorcycles 400LC4-E Hard Enduro and 640LC4-E Hard Enduro, unlike many of their classmates, really have excellent off-road qualities. Both cars are equipped with a four-stroke engine
with an electric starter, two-seat saddles and steps for the passenger. The 640 cc modification is also available as the urban enduro 640LC4-E Supermoto.

Option 620LC4 SC (Supercompetition) closer to purely sports models. It is made single, the engine is deprived of an electric starter. Tires are distinguished by off-road tread patterns.
Nevertheless, the presence of a complete set of lighting equipment allowed to certify this car for driving on ordinary roads. It is also available in the 620LC4 SC Super-moto variant.

For serious off-road raids, the 640LC4 Adventure-R is designed, which is equipped with a 640-cc engine with an electric starter, a Paris-Dakar-style fairing with two headlights, a 30-liter gas
tank and a strong rear trunk.

In collaboration with the Italian company Lem, KTM produces a wide range of children’s cross-country motorcycles. The 50 Mini Adventure is designed for the youngest athletes, ages 4 to 6 years.
It is equipped with a single-cylinder, two-stroke air-cooled engine with automatic centrifugal clutch and without gearbox. Modification 50SX Junior features a forced engine and increased
suspension travels. The engine of the 50SX Senior motorcycle, designed for athletes aged 7 to 9 years, is even stronger.

At a higher level of technical excellence is a motorcycle with an index of 60 / 65SX. It is equipped with a two-stroke liquid-cooled motor (60 or 65 cc) installed in a frame made of
chrome-molybdenum steel. The machine has a six-speed gearbox, disc brakes on both wheels and is designed for 9-11 year old athletes.

Motorcycles 125SX, 250SX and 380SX are equipped with single-cylinder two-stroke power units. The 250 cc version of the engine received a new cylinder, cylinder head and crank group by the 2000
season. Compared with last year’s version, the dimension of the motor has changed (66.4×72 mm instead of 67.5×69.5 mm).

A new four-stroke engine is also installed on the 400SX Racing and 520SX Racing motorcycles. This is an exceptionally lightweight and compact unit — it is narrower than a 250 cc two-stroke
engine. In the cross version, the motor is aggregated with a four-speed gearbox.

KTM Duke 390 Service Repair Manual
KTM Duke 390

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