KTM 125 XC-W EU 2017 Manual

SETUP INSTRUCTIONS 2017
125 XC‑W
150 XC‑W
250 EXC
250 XC‑W
250 EXC Six Days
300 EXC
300 EXC Six Days
300 XC‑W Six Days
Art. no. 3213579en

INTRODUCTION 1
*3213579en*
3213579en
08/2016
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest
of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It
is assumed that the work will be performed by a fully trained mechanic.
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 XC‑W US (F7375Q3)
250 EXC Six Days EU (F7303Q2)
300 EXC EU (F7403Q6)
300 EXC AU (F7460Q6)
300 EXC BR (F7440Q6)
300 XC‑W US (F7475Q3)
300 EXC Six Days EU (F7403Q2)
300 XC‑W Six Days US (F7475Q2)

1 MEANS OF REPRESENTATION 2
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).
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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
B02176-10
Condition
Packaging V2
–Remove the box and the plastic film.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that everything is
included and complete using the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
402050-01
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
H01768-10
(All EXC/EXC Six Days models)
–Position the turn signal indicator lamp in the speedometer bracket.
–Remove the headlight mask with the headlight. ( p. 24)
B02008-10
Condition
Packaging V12
–Remove the box and the plastic film.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove and unpack the separate enclosure and attachments. Check that every-
thing is included and complete using the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Remove the two cable ties on the triple clamp.
402051-01
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle and attachments for transport damage.
–Install the shock absorber. ( p. 19)

2 SETUP 4
H01768-10
(All EXC/EXC Six Days models)
–Position the turn signal indicator lamp in the speedometer bracket.
402736-10
(all EXC/EXC Six Days models, 125 XC‑W)
–Position the connector retainer and speedometer on the upper triple clamp.
–Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
402737-10
(XC‑W US, XC‑W Six Days US)
–Position the speedometer on the upper triple clamp.
–Mount and tighten screws with the collar bushings.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
–Install the fork legs. ( p. 20)
S01414-10
(All standard EXC/XC-W models)
–Remove screws and take off handlebar supports.
–Move the handlebar supports to the desired position and 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.
E00483-01
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)

2 SETUP 5
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
S01415-10
(All Six Days models)
–Remove screws and take off handlebar supports.
–Move the handlebar supports to the desired position and 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.
S01413-01
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
S01450-01
(125 XC‑W EU)
–Position the controls on the right half of the handlebar.
S01451-01
(All XC‑W/XC‑W Six Days models, EXC EU, EXC Six Days EU, 300 EXC BR)
–Position the controls on the right half of the handlebar.

2 SETUP 6
S01452-01
(EXC AU)
–Position the controls on the right half of the handlebar.
S01453-01
(all EXC/EXC Six Days models, 125 XC‑W)
–Position the controls on the left half of the handlebar.
S01454-01
(XC‑W US, XC‑W Six Days US)
–Position the controls on the left half of the handlebar.
402148-01
(All EXC/EXC Six Days models)
–Mount the turn signal switch.
S01455-10
Condition
Packaging V12
(all EXC/EXC Six Days models, 125 XC‑W)
–Connect all plug-in connectors to the plug-in holder.
–Route the cable without tension and secure with cable tie.

2 SETUP 7
S01456-10
(XC‑W US, XC‑W Six Days US)
–Connect all plug-in connectors.
–Connect light pull switch with the yellow and white cables.
–Route the cable without tension and secure with cable tie.
S01457-10
–Route the cable without tension and secure with cable ties and cable holder.
H01060-01
(All EXC/EXC Six Days models)
–Mount the mirror clamps on both sides.
S01458-01
–Mount both rear mirrors with the adapter.

2 SETUP 8
E00475-01
–Preassemble the hand guards on the left and right.
S01461-10
–Mount the left hand guard.
–Mount the right hand guard.
S01459-01
–Secure the handlebar cushion with two cable ties.
–Install the front fender. ( p. 24)
–Install the front wheel. ( p. 20)
(XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models)
–Remove the battery. ( p. 21)
–Recharge the battery. ( p. 22)
(All XC‑W/XC‑W Six Days models)
–Install the headlight mask with the headlight. ( p. 25)
(All EXC/EXC Six Days models)
–Remove the fuel tank. ( p. 17)
S01393-11
–Position turn signal cable harness.
–Insert the indicator lamp with the black and violet cable colors into socket .

2 SETUP 9
S01460-10
–Position turn signal on the headlight mask on both sides, mount nuts with
washers and tighten.
–Connect the plug-in connector of the left turn signal using the violet and
brown cable colors of the turn signal cable harness.
–Connect the plug-in connector of the right turn signal using the black and
brown cable colors of the turn signal cable harness.
Info
Pay attention to where the brake line is routed when doing so.
–Connect plug-in connector of the headlight.
–Connect plug-in connector of the turn signal switch.
–Secure turn signal relay  with a cable tie and plug in the connector.
–Install the headlight mask with the headlight. ( p. 25)
S01462-10
–Remove the cable tie(s).
–Remove screws  with washers and hang the CDI unit to the side.
S01463-01
–Route the turn signal cable harness from the front to the back as far as the bat-
tery compartment.
–Position and secure turn signal cable harness using cable ties to the main
wiring harness under the rubber bands of fuel tank support.
S01464-10
–Remove screw .
–Remove screw .
–Pull off the side cover in area and area and remove it toward the rear.
S01465-10
–Remove screws  with the washers.
–Pull off the main silencer from the manifold at rubber sleeve .

2 SETUP 10
S01466-10
–Disconnect plug-in connector  on main wiring harness and take off.
–Connect turn signal cable harness plug-in connector to the main wiring harness
plug-in connector.
E00489-11
–Remove screw  with the collar bushing.
–Remove screw .
–Remove screw  with negative cable and contact disk.
S01416-11
–Remove screws .
–Carefully pull the tail light cable out of the frame, paying attention to the plug
as you do so.
–Take off license plate holder with tail light toward the rear.
E00491-11
–Remove screws  and hang the tail light to the side.
–Drill a hole at the marking to the size of the marking.

2 SETUP 11
E00492-11
–Route the turn signal cable harness toward the rear and pass through the frame
paying attention to the plugs as you do so.
–Route turn signal cable harness on the license plate holder and pass turn signal
cable harness through the drill hole.
–Position tail light on license plate holder, and mount and tighten screws .
E00495-11
–Carefully pass the tail light cable through the frame, paying attention to the
plug as you do so.
–Position license plate holder on the rear.
–Mount and tighten screws .
E00489-11
–Mount and tighten screw  with the collar bushing.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Mount and tighten screw  with negative cable and contact disk.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

2 SETUP 12
S01467-01
–Connect the tail light plug-in connector to the main wiring harness plug-in con-
nector.
S01462-10
–Position the CDI unit, and mount and tighten screws  with the washers.
Info
The wiring harness runs under the CDI unit.
–Position the turn signal cable harness and main wiring harness and secure with
cable ties.
S01465-10
–Mount the main silencer with rubber sleeve .
–Mount and tighten screws  with the washers.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
S01464-10
–Attach the side cover in area and engage it in area .
–Mount and tighten screw .
Guideline
Screw, subframe M8 35 Nm
(25.8 lbf ft)
Loctite®2701™
–Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Install the battery. ( p. 23)
–Install the fuel tank. ( p. 18)
E00496-11
–Position turn signal on both sides, mount nuts with washers and tighten.
–Position license plate lamp on the license plate holder, and mount and tighten
screws .
–Mount reflector  on license plate holder .
–Pass cable through the license plate holder.
E00497-11
–Position license plate holder on the license plate holder.
–Connect the plug-in connector of the license plate lamp.
–Connect the plug-in connector of the left turn signal which is marked red.
–Connect the plug-in connector of the right turn signal which is marked green.
–Mount and tighten screws .

2 SETUP 13
R01229-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still be mounted.
S01395-11
–Position spring as shown.
Spring engages in area .
S01396-11
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
S01397-11
–Mount the washer and split pin .
S01398-10
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can still be mounted.

2 SETUP 14
S01399-10
–Position spring as shown.
Spring engages in area .
S01400-11
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
S01401-11
–Mount the washer and split pin .
S01468-10
–Position the frame protectors on both sides.
–Mount and tighten screws .
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws  with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount the cable tie(s).
(All Six Days models, EXC AU)
–Install the engine guard. ( p. 26)
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
–Apply the sticker included in the delivery (optional).
–Set kilometers or miles. ( p. 28)
–Set the speedometer functions. ( p. 28)
–Set the clock. ( p. 29)
–Refuel. ( p. 27)

2 SETUP 15
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 WORK 16
3.1 Raising the motorcycle with a lift stand
401942-01
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401943-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand to the ground with your foot and lean
the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with the
rubber band.
3.3 Removing the seat
V00342-10
–Remove screws .
–Raise the rear of the seat, pull the seat back, and lift it off.
3.4 Mounting the seat
V00343-10
–Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the
rear and push it forward.
–Make sure that the seat is correctly locked in.

3 WORK 17
V00342-10
–Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.5 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–Remove the seat. ( p. 16)
V00350-10
Main work
–Turn handle of the fuel tap to the OFF position.
–Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
–Remove screws with the collar bushings.
(All EXC/EXC Six Days models)
–Hang the horn and horn bracket to one side.
V00351-10
–Remove screw with the rubber bushing.
–Remove the tube from the fuel tank breather.

3 WORK 18
V00352-10
–Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank.
3.6 Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
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.
V00352-11
Main work
–Check throttle cable routing. ( p. 19)
–Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
–Make sure that no cables or throttle cables are trapped or damaged.
V00351-11
–Attach the fuel tank breather hose.
–Mount and tighten screw with the rubber bushing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
(All EXC/EXC Six Days models)
–Position the horn with the horn bracket.
V00350-11
–Mount and tighten screws with the collar bushings.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Connect the fuel hose.