KTM 250 EXC EU Operating instructions

REPAIR MANUAL 2014
250 EXC EU
250 EXC SIX DAYS EU
250 EXC AUS
250 XC‑W USA
300 EXC EU
300 EXC SIX DAYS EU
300 EXC AUS
300 XC‑W USA
300 XC‑W SIX DAYS USA
Art. no. 3206179en

INTRODUCTION 1
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair 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 repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, 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 AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 6
1.1 Symbols used ................................................... 6
1.2 Formats used.................................................... 6
2 SAFETY ADVICE........................................................... 7
2.1 Repair Manual .................................................. 7
2.2 Safety advice.................................................... 7
2.3 Degrees of risk and symbols ............................... 7
2.4 Work rules........................................................ 7
3 IMPORTANT INFORMATION ......................................... 8
3.1 Guarantee, warranty .......................................... 8
3.2 Operating and auxiliary substances ..................... 8
3.3 Spare parts, accessories .................................... 8
3.4 Figures ............................................................ 8
4 SERIAL NUMBERS ...................................................... 9
4.1 Chassis number ................................................ 9
4.2 Type label ........................................................ 9
4.3 Engine number ................................................. 9
4.4 Fork part number .............................................. 9
4.5 Shock absorber part number .............................. 9
5 MOTORCYCLE ........................................................... 10
5.1 Raising the motorcycle with the lift stand.......... 10
5.2 Removing the motorcycle from the lift stand...... 10
5.3 Starting.......................................................... 10
5.4 Starting the motorcycle for checking................. 11
6 FORK, TRIPLE CLAMP ............................................... 12
6.1 EXC EU/AUS, XC‑W......................................... 12
6.1.1 Adjusting the compression damping of the
fork ........................................................... 12
6.1.2 Adjusting the rebound damping of the fork.... 12
6.1.3 Adjusting the spring preload of the fork......... 12
6.1.4 Bleeding the fork legs ................................. 13
6.1.5 Cleaning the dust boots of the fork legs......... 13
6.1.6 Loosening the fork protection....................... 14
6.1.7 Positioning the fork protection ..................... 14
6.1.8 Removing the fork legs................................ 14
6.1.9 Installing the fork legs................................. 14
6.1.10 Removing the fork protector......................... 15
6.1.11 Installing the fork protector.......................... 15
6.1.12 Performing a fork service ............................. 16
6.1.13 Disassembling the fork legs ......................... 16
6.1.14 Cartridge disassembly ................................. 19
6.1.15 Disassembling the compression damping
fitting ........................................................ 21
6.1.16 Checking the fork legs................................. 21
6.1.17 Assembling the compression damping
fitting ........................................................ 22
6.1.18 Assembling the cartridge ............................. 23
6.1.19 Assembling the fork legs.............................. 24
6.1.20 Greasing the steering head bearing............... 29
6.1.21 Removing the lower triple clamp .................. 29
6.1.22 Installing the lower triple clamp ................... 30
6.1.23 Checking the play of the steering head
bearing ...................................................... 31
6.1.24 Adjusting the play of the steering head
bearing ...................................................... 32
6.2 250/300 SIX DAYS......................................... 32
6.2.1 Adjusting the compression damping of the
fork ........................................................... 32
6.2.2 Adjusting the rebound damping of the fork.... 33
6.2.3 Bleeding the fork legs ................................. 33
6.2.4 Cleaning the dust boots of the fork legs......... 33
6.2.5 Loosening the fork protection....................... 34
6.2.6 Positioning the fork protection ..................... 34
6.2.7 Removing the fork legs................................ 34
6.2.8 Installing the fork legs................................. 35
6.2.9 Removing the fork protector......................... 35
6.2.10 Installing the fork protector.......................... 36
6.2.11 Performing a fork service ............................. 36
6.2.12 Disassembling the fork legs ......................... 36
6.2.13 Removing the spring ................................... 38
6.2.14 Disassembling the cartridge ......................... 39
6.2.15 Disassembling the piston rod ....................... 40
6.2.16 Disassembling the hydrostop unit ................. 41
6.2.17 Disassembling the seal ring retainer.............. 42
6.2.18 Checking the fork legs................................. 42
6.2.19 Assembling the seal ring retainer.................. 43
6.2.20 Assembling the hydrostop unit ..................... 44
6.2.21 Assembling the piston rod ........................... 44
6.2.22 Assembling the cartridge ............................. 46
6.2.23 Assembling the fork legs.............................. 47
6.2.24 Greasing the steering head bearing............... 50
6.2.25 Removing the lower triple clamp .................. 51
6.2.26 Installing the lower triple clamp ................... 51
6.2.27 Checking the play of the steering head
bearing ...................................................... 53
6.2.28 Adjusting the play of the steering head
bearing ...................................................... 53
7 HANDLEBAR, CONTROLS........................................... 54
7.1 Handlebar position.......................................... 54
7.2 Adjusting the handlebar position ...................... 54
7.3 Adjusting the basic position of the clutch
lever .............................................................. 54
7.4 Checking the routing of the throttle cable.......... 55
7.5 Checking the play in the throttle cable .............. 55
7.6 Adjusting the play in the throttle cable.............. 56
8 FRAME ..................................................................... 57
8.1 Removing the engine guard
(250/300 SIX DAYS)....................................... 57
8.2 Installing the engine guard
(250/300 SIX DAYS)....................................... 57
9 SHOCK ABSORBER, SWINGARM ................................ 58
9.1 Adjusting the high-speed compression
damping of the shock absorber......................... 58
9.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 58
9.3 Adjusting the rebound damping of the shock
absorber......................................................... 59
9.4 Measuring the sag of the unloaded rear wheel.... 59
9.5 Checking the static sag of the shock absorber.... 59
9.6 Checking the riding sag of the shock absorber.... 60
9.7 Adjusting the spring preload of the shock
absorber......................................................... 60
9.8 Adjusting the riding sag................................... 61
9.9 Removing the shock absorber........................... 61
9.10 Installing the shock absorber............................ 61
9.11 Servicing the shock absorber............................ 62
9.12 Removing the spring........................................ 62
9.13 Disassembling the damper ............................... 63
9.14 Disassembling the piston rod ........................... 64
9.15 Disassembling the seal ring retainer.................. 65
9.16 Replacing the pilot bushing ............................. 66
9.17 Checking the damper ...................................... 67
9.18 Disassembling the rebound adjuster.................. 67
9.19 Removing the heim joint.................................. 68
9.20 Installing the heim joint................................... 69

TABLE OF CONTENTS 3
9.21 Assembling the rebound adjuster...................... 70
9.22 Assembling the seal ring retainer...................... 70
9.23 Assembling the piston rod................................ 71
9.24 Assembling the damper ................................... 72
9.25 Bleeding and filling the damper ....................... 75
9.26 Filling the damper with nitrogen....................... 77
9.27 Installing the spring ........................................ 78
9.28 Changing the heim joint................................... 79
10 EXHAUST.................................................................. 81
10.1 Removing the main silencer ............................. 81
10.2 Installing the main silencer.............................. 81
10.3 Changing the glass fiber yarn filling of the
main silencer.................................................. 81
11 AIR FILTER ............................................................... 83
11.1 Removing the air filter box lid .......................... 83
11.2 Installing the air filter box lid ........................... 83
11.3 Removing the air filter..................................... 83
11.4 Installing the air filter...................................... 83
11.5 Cleaning the air filter and air filter box.............. 84
11.6 Sealing the air filter box .................................. 84
12 FUEL TANK, SEAT, TRIM ........................................... 85
12.1 Opening the filler cap...................................... 85
12.2 Closing the filler cap ....................................... 85
12.3 Removing the seat .......................................... 85
12.4 Mounting the seat........................................... 86
12.5 Removing the fuel tank.................................... 86
12.6 Installing the fuel tank .................................... 87
12.7 Fuel tap ......................................................... 88
13 MASK, FENDER......................................................... 89
13.1 Removing the front fender ............................... 89
13.2 Installing the front fender ................................ 89
13.3 Removing the headlight mask with the
headlight........................................................ 89
13.4 Refitting the headlight mask with the
headlight........................................................ 90
14 WHEELS ................................................................... 91
14.1 Checking the tire air pressure........................... 91
14.2 Checking the tire condition .............................. 91
14.3 Checking the brake discs ................................. 92
14.4 Checking the spoke tension.............................. 92
14.5 Front wheel .................................................... 93
14.5.1 Removing the front wheel ............................ 93
14.5.2 Installing the front wheel............................. 93
14.5.3 Removing the brake disc of the front brake.... 94
14.5.4 Installing the brake disc of the front brake .... 94
14.6 Rear wheel ..................................................... 94
14.6.1 Removing the rear wheel ............................. 94
14.6.2 Installing the rear wheel .............................. 95
14.6.3 Removing the brake disc of the rear brake..... 96
14.6.4 Installing the brake disc of the rear brake...... 96
14.6.5 Checking the chain for dirt .......................... 96
14.6.6 Cleaning the chain...................................... 97
14.6.7 Checking the chain tension.......................... 97
14.6.8 Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 98
14.6.9 Adjusting the chain tension ......................... 99
15 WIRING HARNESS, BATTERY................................... 101
15.1 Plug-in connection, ignition timing map.......... 101
15.2 Removing the main fuse ................................ 101
15.3 Installing the main fuse................................. 101
15.4 Recharging the battery .................................. 101
15.5 Disconnecting the negative cable of the
battery ......................................................... 102
15.6 Connecting the negative cable of the battery.... 103
15.7 Removing the battery .................................... 103
15.8 Installing the battery ..................................... 104
15.9 Checking the charging voltage........................ 104
15.10 Checking the closed current........................... 104
15.11 Checking the starter relay .............................. 105
16 BRAKE SYSTEM ...................................................... 106
16.1 Checking the front brake linings ..................... 106
16.2 Changing the front brake linings..................... 106
16.3 Checking the free travel of the hand brake
lever ............................................................ 108
16.4 Adjusting free travel of hand brake lever (All
250/300 EXC models)................................... 108
16.5 Adjusting the basic position of the hand
brake lever (all 250/300 XC‑W) ...................... 108
16.6 Checking the front brake fluid level ................ 109
16.7 Adding front brake fluid................................. 109
16.8 Changing the front brake fluid........................ 110
16.9 Checking the rear brake linings ...................... 111
16.10 Changing the brake linings of the rear brake .... 112
16.11 Checking the free travel of foot brake lever ...... 113
16.12 Adjusting the basic position of the foot brake
lever ............................................................ 113
16.13 Checking the rear brake fluid level.................. 114
16.14 Adding brake fluid for the rear brake............... 114
16.15 Changing the rear brake fluid ......................... 115
17 LIGHTING SYSTEM, INSTRUMENTS ......................... 117
17.1 Checking the headlight setting ....................... 117
17.2 Adjusting the headlight range......................... 117
17.3 EXC EU/AUS, XC‑W....................................... 117
17.3.1 Speedometer overview............................... 117
17.3.2 Activation and test.................................... 118
17.3.3 Setting kilometers or miles ........................ 118
17.3.4 Adjusting the speedometer functions .......... 118
17.3.5 Setting the clock ...................................... 119
17.3.6 Activating the additional functions ............. 119
17.3.7 Setting the wheel circumference ................ 120
17.3.8 Querying lap time ..................................... 120
17.4 250/300 SIX DAYS....................................... 121
17.4.1 Speedometer overview............................... 121
17.4.2 Activation and test.................................... 121
17.4.3 Setting kilometers or miles ........................ 121
17.4.4 Setting the speedometer functions ............. 122
17.4.5 Setting the clock ...................................... 122
17.4.6 Setting the wheel circumference ................ 123
17.4.7 Viewing the lap time ................................. 123
18 ENGINE .................................................................. 124
18.1 Removing the engine..................................... 124
18.2 Installing the engine...................................... 128
18.3 Engine disassembly....................................... 133
18.3.1 Clamping the engine into the engine work
stand....................................................... 133
18.3.2 Draining the gear oil.................................. 133
18.3.3 Removing the clutch push rod.................... 133
18.3.4 Removing the shift lever ............................ 133
18.3.5 Removing the engine sprocket.................... 133
18.3.6 Removing the spacer................................. 134
18.3.7 Removing the starter motor........................ 134
18.3.8 Removing the kick starter .......................... 135
18.3.9 Removing the cylinder head....................... 136

TABLE OF CONTENTS 4
18.3.10 Removing the cylinder............................... 136
18.3.11 Removing the piston ................................. 137
18.3.12 Removing the water pump cover................. 138
18.3.13 Removing the clutch cover......................... 138
18.3.14 Removing the clutch discs......................... 138
18.3.15 Removing the clutch basket....................... 139
18.3.16 Removing the kick starter shaft .................. 140
18.3.17 Removing the intermediate kick starter
gear......................................................... 140
18.3.18 Removing the shift shaft............................ 141
18.3.19 Removing the shift drum locating unit ........ 141
18.3.20 Removing the locking lever ........................ 141
18.3.21 Removing the rotor.................................... 141
18.3.22 Removing the reed valve housing................ 142
18.3.23 Removing the left engine case section ........ 142
18.3.24 Removing the shift rails............................. 142
18.3.25 Removing the shift drum ........................... 143
18.3.26 Removing the shift forks............................ 143
18.3.27 Removing the transmission shafts............... 143
18.3.28 Removing the crankshaft ........................... 143
18.4 Work on individual parts ................................ 144
18.4.1 Work on the right section of the engine
case ........................................................ 144
18.4.2 Work on the left section of the engine
case ........................................................ 145
18.4.3 Removing the crankshaft bearing inner
race......................................................... 145
18.4.4 Installing the crankshaft bearing inner
race......................................................... 146
18.4.5 Changing the connecting rod, conrod
bearing, and crank pin .............................. 146
18.4.6 Checking the crankshaft run-out at the
bearing pin............................................... 147
18.4.7 Checking/measuring the cylinder ................ 147
18.4.8 Removing the exhaust control .................... 148
18.4.9 Checking the exhaust control ..................... 150
18.4.10 Installing the exhaust control ..................... 150
18.4.11 Cylinder - Nikasil®coating ......................... 152
18.4.12 Checking/measuring the piston................... 153
18.4.13 Checking the piston ring end gap ............... 154
18.4.14 Piston/cylinder - measuring the mounting
clearance ................................................. 154
18.4.15 Checking the reed valve housing, reed
valve, and intake flange............................. 155
18.4.16 Work on the clutch cover ........................... 155
18.4.17 Checking the clutch .................................. 159
18.4.18 Preassembling the shift shaft..................... 160
18.4.19 Checking the shift mechanism ................... 161
18.4.20 Disassembling the main shaft .................... 162
18.4.21 Disassembling the countershaft.................. 163
18.4.22 Checking the transmission ......................... 163
18.4.23 Assembling the main shaft......................... 164
18.4.24 Assembling the countershaft...................... 165
18.4.25 Checking the kick starter ........................... 167
18.4.26 Preassembling the kick starter shaft ........... 167
18.4.27 Checking the electric starter drive .............. 169
18.5 Engine assembly........................................... 170
18.5.1 Installing the crankshaft............................ 170
18.5.2 Installing the transmission shafts ............... 170
18.5.3 Installing the shift forks............................. 171
18.5.4 Installing the shift drum............................ 171
18.5.5 Installing the shift rails ............................. 171
18.5.6 Installing the left engine case section ......... 171
18.5.7 Installing the reed valve housing ................ 172
18.5.8 Installing the rotor .................................... 172
18.5.9 Installing the locking lever......................... 173
18.5.10 Installing the shift drum locating unit ......... 173
18.5.11 Installing the shift shaft ............................ 173
18.5.12 Installing the intermediate kick starter
gear......................................................... 173
18.5.13 Installing the kick starter shaft................... 173
18.5.14 Installing the clutch basket........................ 174
18.5.15 Installing the clutch discs.......................... 175
18.5.16 Installing the clutch cover ......................... 176
18.5.17 Installing the water pump cover.................. 177
18.5.18 Installing the piston .................................. 177
18.5.19 Installing the cylinder................................ 178
18.5.20 Checking the X-distance ............................ 179
18.5.21 Adjusting the X-distance............................ 180
18.5.22 Adjusting the Z-distance............................ 180
18.5.23 Installing the cylinder head........................ 182
18.5.24 Installing the kick starter........................... 182
18.5.25 Installing the starter motor......................... 182
18.5.26 Installing the spacer.................................. 184
18.5.27 Installing the engine sprocket .................... 184
18.5.28 Installing the shift lever............................. 184
18.5.29 Installing the clutch push rod .................... 185
18.5.30 Installing the gear oil drain plug................. 185
18.5.31 Removing the engine from the work stand ... 185
19 CARBURETOR ......................................................... 186
19.1 Choke .......................................................... 186
19.2 Carburetor - adjusting the idle speed .............. 186
19.3 Emptying the carburetor float chamber ........... 187
19.4 Removing the carburetor................................ 187
19.5 Installing the carburetor ................................ 188
19.6 Checking/adjusting the carburetor
components.................................................. 189
19.7 Disassembling the carburetor ......................... 190
19.8 Checking the choke slide ............................... 191
19.9 Checking the jet needle ................................. 191
19.10 Checking the throttle slide ............................. 191
19.11 Checking the float needle valve ...................... 192
19.12 Assembling the carburetor ............................. 192
19.13 Checking/adjusting the float level ................... 193
20 CLUTCH.................................................................. 194
20.1 Checking/correcting the fluid level of the
hydraulic clutch............................................ 194
20.2 Changing the hydraulic clutch fluid ................ 194
21 WATER PUMP, COOLING SYSTEM ............................ 195
21.1 Cooling system ............................................. 195
21.2 Checking the antifreeze and coolant level........ 195
21.3 Checking the coolant level ............................. 195
21.4 Draining the coolant...................................... 196
21.5 Refilling with coolant .................................... 196
22 EXHAUST CONTROL ................................................ 198
22.1 Engine characteristic - setting the auxiliary
spring .......................................................... 198
23 LUBRICATION SYSTEM............................................ 199
23.1 Changing the gear oil..................................... 199
23.2 Draining the gear oil...................................... 199
23.3 Refilling with gear oil .................................... 200
23.4 Checking the gear oil level ............................. 200
23.5 Adding gear oil ............................................. 200
24 IGNITION SYSTEM................................................... 202
24.1 Checking the ignition system.......................... 202

TABLE OF CONTENTS 5
24.2 Ignition coil - checking the primary winding..... 202
24.3 Ignition coil - checking the secondary
winding........................................................ 203
24.4 Checking the spark plug connector ................. 203
24.5 Alternator - checking the charging coil of the
ignition ........................................................ 204
24.6 Alternator - checking the battery winding ........ 204
24.7 Alternator - checking the light winding............ 205
24.8 Checking the ignition pulse generator ............. 205
24.9 Removing the stator and crankshaft position
sensor.......................................................... 206
24.10 Installing the stator and crankshaft position
sensor.......................................................... 206
25 ELECTRIC STARTER ................................................ 207
25.1 Checking the starter motor............................. 207
26 TECHNICAL DATA.................................................... 208
26.1 Engine ......................................................... 208
26.1.1 All 250 models......................................... 208
26.1.2 All 300 models......................................... 208
26.2 Engine tolerance, wear limits ......................... 209
26.3 Engine tightening torques .............................. 210
26.4 Capacities .................................................... 210
26.4.1 Gear oil.................................................... 210
26.4.2 Coolant .................................................... 210
26.4.3 Fuel ........................................................ 211
26.5 Chassis ........................................................ 211
26.6 Electrical system........................................... 212
26.7 Tires............................................................ 212
26.8 Fork............................................................. 212
26.8.1 EXC EU/AUS, XC‑W................................... 212
26.8.2 250/300 SIX DAYS................................... 213
26.9 Shock absorber............................................. 213
26.10 Chassis tightening torques ............................. 214
26.11 Carburetor.................................................... 215
26.11.1 250 EXC EU, 250 EXC SIX DAYS EU ......... 215
26.11.2 250 EXC AUS .......................................... 215
26.11.3 250 XC‑W USA......................................... 215
26.11.4 300 EXC EU, 300 EXC SIX DAYS EU ......... 215
26.11.5 300 EXC AUS .......................................... 216
26.11.6 300 XC‑W USA,
300 XC‑W SIX DAYS USA.......................... 216
26.12 Carburetor tuning.......................................... 217
26.12.1 Carburetor tuning (All 250 models) ............ 217
26.12.2 Carburetor tuning (All 300 models) ............ 218
26.12.3 General carburetor tuning .......................... 219
27 CLEANING, CARE .................................................... 220
27.1 Cleaning the motorcycle ................................ 220
27.2 Checks and maintenance steps for winter
operation...................................................... 221
28 STORAGE................................................................ 222
28.1 Storage ........................................................ 222
28.2 Preparing for use after storage........................ 222
29 SERVICE SCHEDULE ............................................... 223
29.1 Service schedule........................................... 223
29.2 Service work (as additional order) ................... 224
30 WIRING DIAGRAM ................................................... 226
30.1 Page 1 of 5 (250 EXC EU, 300 EXC EU)......... 226
30.2 Page 2 of 5 (250 EXC EU, 300 EXC EU)......... 228
30.3 Page 3 of 5 (250 EXC EU, 300 EXC EU)......... 230
30.4 Page 4 of 5 (250 EXC EU, 300 EXC EU)......... 232
30.5 Page 5 of 5 (250 EXC EU, 300 EXC EU)......... 234
30.6 Page 1 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 236
30.7 Page 2 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 238
30.8 Page 3 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 240
30.9 Page 4 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 242
30.10 Page 5 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)................................. 244
30.11 Page 1 of 5 (250/300 EXC AUS).................... 246
30.12 Page 2 of 5 (250/300 EXC AUS).................... 248
30.13 Page 3 of 5 (250/300 EXC AUS).................... 250
30.14 Page 4 of 5 (250/300 EXC AUS).................... 252
30.15 Page 5 of 5 (250/300 EXC AUS).................... 254
30.16 Page 1 of 3 (250 XC‑W USA,
300 XC‑W USA)............................................ 256
30.17 Page 2 of 3 (250 XC‑W USA,
300 XC‑W USA)............................................ 258
30.18 Page 3 of 3 (250 XC‑W USA,
300 XC‑W USA)............................................ 260
30.19 Page 1 of 3 (300 XC‑W SIX DAYS USA) .......... 262
30.20 Page 2 of 3 (300 XC‑W SIX DAYS USA) .......... 264
30.21 Page 3 of 3 (300 XC‑W SIX DAYS USA) .......... 266
31 SUBSTANCES ......................................................... 268
32 AUXILIARY SUBSTANCES ........................................ 270
33 SPECIAL TOOLS ...................................................... 272
34 STANDARDS ........................................................... 282
INDEX ............................................................................ 283

1 MEANS OF REPRESENTATION 6
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.

2 SAFETY ADVICE 7
2.1 Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
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
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 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.

3 IMPORTANT INFORMATION 8
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or 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 get into the ground water, the ground, 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
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 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.

4 SERIAL NUMBERS 9
4.1 Chassis number
602696-10
The chassis number 1is stamped on the right side of the steering head.
4.2 Type label
602696-11
The type label 1is fixed to the front of the steering head.
4.3 Engine number
B01139-10
The engine number 1is stamped on the left side of the engine under the engine
sprocket.
4.4 Fork part number
B01494-10
The fork part number 1is stamped on the inner side of the fork stub.
4.5 Shock absorber part number
B00786-10
The shock absorber part number 1is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

5 MOTORCYCLE 10
5.1 Raising the motorcycle with the lift stand
602709-01
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (54829055000) ( p. 273)
The wheels must no longer touch the ground.
–Secure the motorcycle against falling over.
5.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
602704-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to 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.
5.3 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
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.
Motorcycle standstill of more than 1 week
–Empty the carburetor float chamber. ( p. 187)
–Turn handle 1of the fuel tap to the ON position. (Figure 602702-10 p. 88)
Fuel can flow from the fuel tank to the carburetor.
–Take the motorcycle off of the stand.
–Shift gear to neutral.
(250/300 EXC AUS)
–Turn the emergency OFF switch to the position .
The engine is cold
–Pull out the choke lever all the way.
–Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not turn the throttle.

5 MOTORCYCLE 11
5.4 Starting the motorcycle for checking
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
–Shift gear to neutral.
(250/300 EXC AUS)
–Turn the emergency OFF switch to the position .
–Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not open the throttle.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.

6 FORK, TRIPLE CLAMP 12
6.1 EXC EU/AUS, XC‑W
6.1.1 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
B01510-10
–Remove protection caps 1.
–Turn adjusting screws 2clockwise all the way.
Info
Adjusting screws 2are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
–Mount protection caps 1.
6.1.2 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
602708-10
–Turn adjusting screws 1clockwise all the way.
Info
Adjusting screws 1are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 18 clicks
Sport 16 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
6.1.3 Adjusting the spring preload of the fork
602708-11
–Turn the adjusting screws counterclockwise all the way.
Info
Make the same adjustment on both fork legs.
–Turn back clockwise by the number of turns corresponding to the fork type.

6 FORK, TRIPLE CLAMP 13
Guideline
Spring preload - Preload Adjuster
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Info
Turn clockwise to increase spring preload; turn counterclockwise to reduce
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.
6.1.4 Bleeding the fork legs
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 10)
602710-10
Main work
–Remove bleeder screws 1briefly.
Any excess pressure escapes from the interior of the fork.
–Mount and tighten bleeder screws.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 10)
6.1.5 Cleaning the dust boots of the fork legs
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 10)
–Loosen the fork protection. ( p. 14)
B00797-10
Main work
–Push dust boots 1of both fork legs downwards.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 271)
–Press the dust boots back into their normal position.
–Remove excess oil.
Finishing work
–Position the fork protection. ( p. 14)
–Remove the motorcycle from the lift stand. ( p. 10)

6 FORK, TRIPLE CLAMP 14
6.1.6 Loosening the fork protection
B01515-10
–Remove screws 1and take off the clamp.
–Remove screws 2on the left fork leg. Push the fork protection downwards.
–Remove the screws on the right fork leg. Push the fork protection downwards.
6.1.7 Positioning the fork protection
B01515-11
–Position the fork protection on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the brake line. Position the clamp and mount and tighten screws 2.
–Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
6.1.8 Removing the fork legs
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 10)
–Remove the front wheel. ( p. 93)
–Remove the headlight mask with the headlight. ( p. 89)
B00798-10
Main work
–Remove screws 1and take off the clamp.
–Remove cable binder 2.
–Remove screws 3and take off the brake caliper.
–Hang the brake caliper and the brake line loosely to the side.
602711-11
–Loosen screws 4. Remove the fork leg on the left.
–Loosen screws 5. Remove the fork leg on the right.
6.1.9 Installing the fork legs
602753-10
Main work
–Position the fork legs.
Info
Grooves are milled into the side of the upper end of the fork legs. The sec-
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
Position bleeder screws 1toward the front.

6 FORK, TRIPLE CLAMP 15
602711-10
–Tighten screws 2.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
–Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
B00798-11
–Position the brake caliper and mount and tighten screws 4.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite®243™
–Mount cable binder 5.
–Position the brake line and wiring harness. Put the clamp on and mount and
tighten screws 6.
Finishing work
–Install the front wheel. ( p. 93)
–Refit the headlight mask with the headlight. ( p. 90)
–Check the headlight setting. ( p. 117)
6.1.10 Removing the fork protector
Preparatory work
–Raise the motorcycle with the lift stand. ( p. 10)
–Remove the front wheel. ( p. 93)
–Remove the headlight mask with the headlight. ( p. 89)
–Remove the fork legs. ( p. 14)
101327-10
Main work
–Remove screws 1on the left fork leg. Lift off the fork protector.
–Remove the screws on the right fork leg. Lift off the fork protector.
6.1.11 Installing the fork protector
101327-10
Main work
–Position the fork protection on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Finishing work
–Install the fork legs. ( p. 14)
–Install the front wheel. ( p. 93)
–Refit the headlight mask with the headlight. ( p. 90)
–Check the headlight setting. ( p. 117)

6 FORK, TRIPLE CLAMP 16
6.1.12 Performing a fork service
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.
200979-01
–Disassemble the fork legs. ( p. 16)
–Disassemble the cartridge. ( p. 19)
–Check the fork legs. ( p. 21)
–Assemble the cartridge. ( p. 23)
–Assemble the fork legs. ( p. 24)
6.1.13 Disassembling the fork legs
Info
The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
200736-10
–Remove protective cover A.
–Note down the present state of rebound damping 1and compression damping 2.
–Note down of the present state of the spring preload.
–Completely open the adjusters of the rebound damping and compression damping.
201347-10
–Clamp the fork leg in the area of lower triple clamp.
Clamping stand (T1403S) ( p. 279)

6 FORK, TRIPLE CLAMP 17
200737-10
–Loosen Preload Adjuster 3.
Pin wrench (T103) ( p. 276)
Info
The Preload Adjuster cannot be taken off yet.
200690-10
–Take out the fork leg and clamp with the axle clamp.
Info
Use soft jaws.
200738-10
–Push the outer tube downward.
–Pull the spring downward. Place the special tool on the hexagonal part.
Open-end wrench (T14032) ( p. 279)
Info
The preload spacers 4should be above the special tool.
200739-10
–Clamp the special tool in the bench vise. Loosen Preload Adjuster 3.
200740-10
–Remove Preload Adjuster 3with preload spacers 4.
–Remove adjustment tube 5.
201348-10
–Pull the spring downward. Remove the special tool.
–Remove the spring.

6 FORK, TRIPLE CLAMP 18
201349-10
–Drain the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.
200691-10
–Clamp the fork leg with the axle clamp.
Guideline
Use soft jaws.
–Unscrew and remove the compression damping fitting 6.
Info
Place a fluid collector beneath it, as usually some oil will drain out.
201350-10
–Remove the cartridge.
200741-10
–Remove dust boot 7.
–Remove fork protector ring B.
Info
The fork protector ring does not necessarily need to be disassembled for the
further repair.
200742-10
–Remove lock ring 8.
Info
The lock ring has a coarsely finished end against which the screwdriver can
be placed.
201351-10
–Warm up the outer tube in area Bof the lower sliding bushing.
Guideline
50 °C (122 °F)
–Jerk the outer tube out of the inner tube.
Info
The lower sliding bushing 9must be pulled out of its bearing seat when
doing this.