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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 (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
-
Advertisement
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 (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
-
Advertisement
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 (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 (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 (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 (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 (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 (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 (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 (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 (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 (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
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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 (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 (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 (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.