KTM 250 EXC TPI 2019 Operating instructions

REPAIR MANUAL 2019
250 EXC TPI
250 EXC Six Days TPI
250 XC‑W TPI
300 EXC TPI
300 EXC Six Days TPI
300 XC-W TPI
300 XC-W Six Days TPI
Art. no. 3206345en

INTRODUCTION
*3206345en*
3206345en
04/2018
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly
and properly.
This repair manual was written to correspond to the latest state of this model series. We reserve the right to make
changes in the interest of technical advancement without updating this repair manual at the same time.
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 repair 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, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2018 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 assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
250 EXC TPI EU (F7303S7)
250 EXC Six Days TPI EU (F7303S2)
250 XC‑W TPI US (F7375S4)
300 EXC TPI EU (F7403S7)
300 EXC Six Days TPI EU (F7403S2)
300 XC‑W TPI US (F7475S3)
300 XC‑W Six Days TPI US (F7475S2)

TABLE OF CONTENTS
2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ...................... 7
1.1 Symbols used .................................... 7
1.2 Formats used..................................... 7
2 SAFETY ADVICE............................................ 8
2.1 Repair Manual ................................... 8
2.2 Safety advice..................................... 8
2.3 Degrees of risk and symbols ................ 8
2.4 Work rules......................................... 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 Figures ............................................. 9
4 SERIAL NUMBERS ..................................... 10
4.1 Chassis number ............................... 10
4.2 Type label ....................................... 10
4.3 Engine number ................................ 10
4.4 Fork part number ............................. 10
4.5 Shock absorber article number .......... 11
5 MOTORCYCLE ............................................ 12
5.1 Raising the motorcycle with a lift
stand .............................................. 12
5.2 Removing the motorcycle from the
lift stand ......................................... 12
5.3 Starting the vehicle.......................... 12
5.4 Starting the motorcycle to check the
function .......................................... 13
6 FORK, TRIPLE CLAMP ................................ 14
6.1 Adjusting the compression damping
of the fork ....................................... 14
6.2 Adjusting the rebound damping of
the fork........................................... 15
6.3 Adjusting the spring preload of the
fork (All Six Days models) ................. 16
6.4 Bleeding the fork legs....................... 16
6.5 Cleaning the dust boots of the fork
legs ................................................ 17
6.6 Removing the fork legs ..................... 17
6.7 Installing the fork legs...................... 18
6.8 Removing the fork protector .............. 19
6.9 Installing the fork protector............... 19
6.10 All standard EXC/XC-W models .......... 20
6.10.1 Servicing the fork......................... 20
6.10.2 Disassembling the fork legs .......... 20
6.10.3 Disassembling the cartridge .......... 23
6.10.4 Disassembling the tap
compression................................ 26
6.10.5 Checking the fork legs.................. 27
6.10.6 Assembling the tap compression ... 28
6.10.7 Assembling the cartridge .............. 29
6.10.8 Assembling the fork legs............... 33
6.10.9 Lubricating the steering head
bearing ....................................... 37
6.10.10 Removing the lower triple clamp ... 37
6.10.11 Installing the lower triple clamp .... 38
6.10.12 Changing the steering head
bearing ....................................... 40
6.10.13 Checking the play of the steering
head bearing ............................... 42
6.10.14 Adjusting the steering head
bearing play ................................ 42
6.11 All Six Days models.......................... 43
6.11.1 Servicing the fork......................... 43
6.11.2 Disassembling the fork legs .......... 43
6.11.3 Disassembling the cartridge .......... 46
6.11.4 Disassembling the tap
compression................................ 49
6.11.5 Checking the fork legs.................. 50
6.11.6 Assembling the tap compression ... 51
6.11.7 Assembling the cartridge .............. 52
6.11.8 Assembling the fork legs............... 56
6.11.9 Lubricating the steering head
bearing ....................................... 61
6.11.10 Removing the lower triple clamp ... 61
6.11.11 Installing the lower triple clamp .... 62
6.11.12 Changing the steering head
bearing ....................................... 64
6.11.13 Checking the play of the steering
head bearing ............................... 65
6.11.14 Adjusting the steering head
bearing play ................................ 66
7 HANDLEBAR, CONTROLS............................ 67
7.1 Handlebar position........................... 67
7.2 Adjusting the handlebar position ....... 67
7.3 Adjusting the basic position of the
clutch lever ..................................... 69
7.4 Checking the rubber grip .................. 70
7.5 Checking throttle cable routing.......... 70
7.6 Checking the play in the throttle
cable .............................................. 71
7.7 Adjusting the play in the throttle
cable .............................................. 71
7.8 Setting the characteristic map of the
throttle response.............................. 72
8 FRAME ...................................................... 74
8.1 Checking the frame.......................... 74
8.2 Removing the engine guard (All
Six Days models) ............................. 74
8.3 Installing the engine guard (All
Six Days models) ............................. 74
8.4 Changing the footrests...................... 74

TABLE OF CONTENTS
3
9 SHOCK ABSORBER, SWINGARM ................. 78
9.1 Adjusting the high-speed
compression damping of the shock
absorber.......................................... 78
9.2 Adjusting the low-speed
compression damping of the shock
absorber.......................................... 78
9.3 Adjusting the rebound damping of
the shock absorber........................... 79
9.4 Measuring the rear wheel dimension
unloaded......................................... 80
9.5 Checking the static sag of the shock
absorber.......................................... 80
9.6 Checking the riding sag of the shock
absorber.......................................... 81
9.7 Adjusting the spring preload of the
shock absorber ................................ 81
9.8 Adjusting the riding sag.................... 82
9.9 Removing the shock absorber............ 83
9.10 Installing the shock absorber............. 83
9.11 Servicing the shock absorber............. 83
9.12 Removing the spring......................... 84
9.13 Disassembling the damper ................ 85
9.14 Disassembling the seal ring
retainer........................................... 86
9.15 Disassembling the piston rod ............ 87
9.16 Replacing the pilot bushing .............. 88
9.17 Checking the damper ....................... 89
9.18 Removing the heim joint................... 90
9.19 Installing the heim joint.................... 91
9.20 Assembling seal ring retainer ............ 91
9.21 Assembling the piston rod................. 92
9.22 Assembling the damper .................... 94
9.23 Bleeding and filling the damper ........ 96
9.24 Filling damper with nitrogen ............. 99
9.25 Installing the spring ....................... 100
9.26 Checking the swingarm................... 101
9.27 Checking the heim joint for play ...... 101
9.28 Changing the heim joint.................. 102
9.29 Changing the heim joint on the
swingarm ...................................... 103
9.30 Checking the swingarm bearing for
play .............................................. 105
9.31 Removing the swingarm.................. 105
9.32 Installing the swingarm................... 106
9.33 Changing the swingarm bearing....... 108
10 EXHAUST................................................. 111
10.1 Removing the manifold................... 111
10.2 Installing the manifold ................... 112
10.3 Removing the main silencer ............ 113
10.4 Installing the main silencer............. 114
10.5 Changing the glass fiber yarn filling
in the main silencer ....................... 114
11 AIR FILTER .............................................. 116
11.1 Removing the air filter box cover ..... 116
11.2 Installing the air filter box cover ...... 116
11.3 Removing the air filter.................... 117
11.4 Installing the air filter..................... 117
11.5 Cleaning the air filter and air filter
box............................................... 118
11.6 Preparing air filter box cover for
securing........................................ 118
11.7 Sealing the air filter box ................. 119
12 FUEL TANK, SEAT, TRIM .......................... 120
12.1 Opening the filler cap..................... 120
12.2 Closing the filler cap ...................... 120
12.3 Removing the seat ......................... 121
12.4 Mounting the seat.......................... 121
12.5 Removing the fuel tank................... 122
12.6 Installing the fuel tank ................... 123
12.7 Changing the fuel screen ................ 125
12.8 Changing the fuel filter................... 126
12.9 Changing the fuel pump ................. 129
12.10 Checking the fuel pressure.............. 132
13 MASK, FENDER........................................ 134
13.1 Removing front fender .................... 134
13.2 Installing front fender..................... 134
13.3 Removing the headlight mask with
the headlight ................................. 135
13.4 Installing the headlight mask with
the headlight ................................. 135
14 WHEELS .................................................. 137
14.1 Checking the tire air pressure.......... 137
14.2 Checking the tire condition ............. 137
14.3 Checking the wheel bearing for
play .............................................. 138
14.4 Checking the brake discs ................ 139
14.5 Checking the rim run-out ................ 139
14.6 Checking spoke tension .................. 140
14.7 Front wheel ................................... 141
14.7.1 Removing the front wheel ........... 141
14.7.2 Installing the front wheel............ 142
14.7.3 Changing the front brake disc ..... 142
14.7.4 Changing front wheel bearing...... 143
14.8 Rear wheel .................................... 144
14.8.1 Removing the rear wheel ............ 144
14.8.2 Installing the rear wheel ............. 145
14.8.3 Changing the rear brake disc....... 146
14.8.4 Changing the rear wheel
bearing ..................................... 147
14.8.5 Checking the chain for dirt ......... 149
14.8.6 Cleaning the chain..................... 149
14.8.7 Checking the chain tension......... 150

TABLE OF CONTENTS
4
14.8.8 Checking the chain, rear
sprocket, engine sprocket, and
chain guide ............................... 151
14.8.9 Adjusting the chain tension ........ 153
14.8.10 Changing the drivetrain kit.......... 154
15 WIRING HARNESS, BATTERY.................... 157
15.1 Ignition curve plug-in connector ...... 157
15.2 Changing the main fuse.................. 157
15.3 Changing the fuses of individual
power consumers ........................... 159
15.4 Disconnecting the negative cable
of the battery................................. 160
15.5 Connecting the negative cable of
the battery .................................... 161
15.6 Removing the battery ..................... 161
15.7 Installing the battery ...................... 162
15.8 Recharging the battery ................... 163
15.9 Checking the charging voltage......... 164
15.10 Checking the open-circuit current.... 165
15.11 Checking the starter relay ............... 165
15.12 Diagnostics connector .................... 166
16 BRAKE SYSTEM ....................................... 167
16.1 Checking the front brake linings ...... 167
16.2 Changing the front brake linings...... 167
16.3 Checking the free travel of the
hand brake lever ............................ 169
16.4 Adjusting free travel of hand brake
lever (All EXC models) .................... 170
16.5 Adjusting the basic position of the
hand brake lever (All XC‑W
models)......................................... 170
16.6 Checking the front brake fluid
level ............................................. 170
16.7 Adding front brake fluid.................. 171
16.8 Changing the front brake fluid......... 172
16.9 Checking the brake linings of the
rear brake...................................... 174
16.10 Changing the rear brake linings ....... 174
16.11 Checking the free travel of foot
brake lever .................................... 176
16.12 Adjusting the basic position of the
foot brake lever.............................. 177
16.13 Checking the rear brake fluid
level ............................................. 178
16.14 Adding rear brake fluid................... 178
16.15 Changing the rear brake fluid .......... 179
17 LIGHTING SYSTEM, INSTRUMENTS .......... 182
17.1 Changing the headlight bulb ........... 182
17.2 Changing the turn signal bulb (All
EXC models).................................. 182
17.3 Checking the headlight setting ........ 183
17.4 Adjusting the headlight range.......... 184
17.5 Changing the combination
instrument .................................... 184
17.6 Combination instrument overview .... 185
17.7 Activation and test ......................... 185
17.8 Setting the kilometers or miles ........ 185
17.9 Adjusting the combination
instrument function........................ 186
17.10 Setting the clock............................ 187
17.11 Activating additional functions ........ 187
17.12 Setting the wheel circumference ..... 188
17.13 Viewing the lap time....................... 188
18 ENGINE ................................................... 190
18.1 Cleaning the pressure sensor hose ... 190
18.2 Removing the engine...................... 190
18.3 Installing the engine....................... 196
18.4 Engine disassembly........................ 203
18.4.1 Clamping the engine into the
engine work stand...................... 203
18.4.2 Removing the shift lever ............. 203
18.4.3 Removing the clutch push rod..... 203
18.4.4 Draining the gear oil................... 203
18.4.5 Removing the spacer.................. 204
18.4.6 Removing the alternator cover ..... 204
18.4.7 Removing the kick starter ........... 205
18.4.8 Removing injection valves........... 205
18.4.9 Removing the cylinder head........ 205
18.4.10 Removing the cylinder................ 206
18.4.11 Removing the piston .................. 208
18.4.12 Removing the water pump
cover ........................................ 209
18.4.13 Removing the clutch cover.......... 209
18.4.14 Removing the clutch discs.......... 210
18.4.15 Removing the clutch basket........ 211
18.4.16 Removing the balancer shaft....... 212
18.4.17 Removing the kick starter shaft ... 213
18.4.18 Removing the intermediate kick
starter gear................................ 213
18.4.19 Removing the shift shaft............. 214
18.4.20 Removing the shift drum
locating unit.............................. 214
18.4.21 Removing the locking lever ......... 214
18.4.22 Removing the rotor..................... 214
18.4.23 Removing the starter motor......... 215
18.4.24 Removing the reed valve
housing..................................... 216
18.4.25 Removing the left engine case
section ..................................... 217
18.4.26 Removing the shift rails.............. 217
18.4.27 Removing the shift drum ............ 217
18.4.28 Removing the shift forks............. 218
18.4.29 Removing the transmission
shafts ....................................... 218
18.4.30 Removing the crankshaft ............ 218

TABLE OF CONTENTS
5
18.5 Working on individual parts............. 219
18.5.1 Working on the right section of
the engine case ......................... 219
18.5.2 Working on the left section of
the engine case ......................... 220
18.5.3 Removing the crankshaft
bearing inner race...................... 222
18.5.4 Installing the crankshaft bearing
inner race ................................. 222
18.5.5 Changing the connecting rod,
conrod bearing, and crank pin..... 223
18.5.6 Checking the crankshaft run-out
at the bearing pin ...................... 224
18.5.7 Checking/measuring the
cylinder .................................... 224
18.5.8 Cleaning the pressure sensor
cylinder connection.................... 225
18.5.9 Removing the exhaust control ..... 225
18.5.10 Checking the exhaust control ...... 227
18.5.11 Installing the exhaust control ...... 229
18.5.12 Cylinder - Nikasil®coating .......... 232
18.5.13 Checking/measuring the piston.... 232
18.5.14 Checking the piston ring end
gap........................................... 233
18.5.15 Measuring the piston/cylinder
mounting clearance.................... 233
18.5.16 Disassemble the reed valve
housing..................................... 234
18.5.17 Checking the reed valve
housing, reed valve and intake
flange ....................................... 235
18.5.18 Assemble the reed valve
housing..................................... 235
18.5.19 Working on the clutch cover........ 237
18.5.20 Checking the clutch ................... 240
18.5.21 Preassembling shift shaft ........... 241
18.5.22 Checking the shift mechanism .... 242
18.5.23 Disassembling the main shaft ..... 243
18.5.24 Disassembling the
countershaft.............................. 244
18.5.25 Checking the transmission .......... 244
18.5.26 Assembling the main shaft.......... 246
18.5.27 Assembling the countershaft....... 246
18.5.28 Checking the kick starter ............ 248
18.5.29 Preassembling the kick starter
shaft......................................... 248
18.5.30 Checking the electric starter
drive......................................... 249
18.6 Engine assembly............................ 250
18.6.1 Installing the crankshaft............. 250
18.6.2 Installing the transmission
shafts ....................................... 251
18.6.3 Installing the shift forks.............. 251
18.6.4 Installing the shift drum............. 252
18.6.5 Installing the shift rails .............. 252
18.6.6 Installing the left engine case
section ..................................... 252
18.6.7 Installing the reed valve
housing..................................... 253
18.6.8 Installing the starter motor.......... 254
18.6.9 Installing the rotor ..................... 255
18.6.10 Installing the locking lever.......... 255
18.6.11 Installing the shift drum
locating unit.............................. 256
18.6.12 Installing the shift shaft ............. 256
18.6.13 Installing the intermediate kick
starter gear................................ 256
18.6.14 Installing the kick starter shaft.... 256
18.6.15 Installing the balancer shaft........ 257
18.6.16 Installing the clutch basket......... 258
18.6.17 Installing the clutch discs........... 259
18.6.18 Installing the clutch cover .......... 261
18.6.19 Installing the water pump
cover ........................................ 263
18.6.20 Installing the piston ................... 264
18.6.21 Installing the cylinder................. 265
18.6.22 Checking the X-distance ............. 267
18.6.23 Adjusting the X-distance............. 267
18.6.24 Adjusting the Z-distance............. 269
18.6.25 Installing the cylinder head......... 271
18.6.26 Installing injection valves ........... 272
18.6.27 Installing the kick starter............ 272
18.6.28 Installing the alternator cover...... 272
18.6.29 Installing the spacer................... 273
18.6.30 Installing the gear oil drain
plug ......................................... 273
18.6.31 Installing the clutch push rod ..... 274
18.6.32 Installing the shift lever.............. 274
18.6.33 Removing the engine from the
engine work stand...................... 274
19 CLUTCH................................................... 275
19.1 Checking/correcting the fluid level
of the hydraulic clutch.................... 275
19.2 Changing the hydraulic clutch
fluid ............................................. 276
19.3 Checking the clutch ....................... 277
20 WATER PUMP, COOLING SYSTEM ............. 286
20.1 Cooling system .............................. 286
20.2 Checking the antifreeze and
coolant level.................................. 286
20.3 Checking the coolant level .............. 287
20.4 Draining the coolant....................... 287
20.5 Refilling with coolant ..................... 288
21 EXHAUST CONTROL ................................. 291
21.1 Checking/adjusting the exhaust
control .......................................... 291

TABLE OF CONTENTS
6
22 LUBRICATION SYSTEM............................. 294
22.1 Changing the gear oil...................... 294
22.2 Checking the gear oil level .............. 295
22.3 Adding gear oil .............................. 295
22.4 Checking 2-stroke oil level .............. 296
22.5 Opening 2-stroke oil tank cap.......... 297
22.6 Adding 2-stroke oil......................... 297
22.7 Closing 2-stroke oil tank cap ........... 297
22.8 Priming the oil pump...................... 298
22.9 Replacing the oil pump .................. 299
23 IGNITION SYSTEM.................................... 302
23.1 Checking the ignition system........... 302
23.2 Ignition coil - checking the primary
winding......................................... 303
23.3 Checking the spark plug
connector...................................... 304
23.4 Alternator –checking the stator
winding......................................... 304
23.5 Checking the crankshaft position
sensor........................................... 305
23.6 Changing the spark plug ................. 306
23.7 Changing the spark plug and spark
plug connector............................... 307
23.8 Removing the stator ....................... 307
23.9 Installing the stator........................ 308
24 ELECTRIC STARTER ................................. 309
24.1 Checking the starter motor.............. 309
25 THROTTLE VALVE BODY ........................... 310
25.1 Adjusting the idle speed ................. 310
25.2 Programming ambient pressure ....... 310
25.3 Cold start button............................ 311
26 TECHNICAL DATA..................................... 312
26.1 Engine .......................................... 312
26.1.1 All 250 models.......................... 312
26.1.2 All 300 models.......................... 312
26.2 Tolerance, engine wear limits.......... 313
26.3 Engine tightening torques ............... 314
26.4 Capacities ..................................... 315
26.4.1 Gear oil..................................... 315
26.4.2 Engine oil ................................. 315
26.4.3 Coolant ..................................... 315
26.4.4 Fuel ......................................... 316
26.5 Chassis ......................................... 316
26.6 Electrical system............................ 317
26.7 Tires............................................. 317
26.8 Fork.............................................. 317
26.8.1 All standard EXC/XC-W models.... 317
26.8.2 All Six Days models.................... 318
26.9 Shock absorber.............................. 318
26.10 Chassis tightening torques .............. 319
27 CLEANING, CARE ..................................... 322
27.1 Cleaning the motorcycle ................. 322
27.2 Checks and maintenance steps for
winter operation............................. 323
28 STORAGE................................................. 324
28.1 Storage ......................................... 324
28.2 Preparing for use after storage......... 325
29 SERVICE SCHEDULE ................................ 326
29.1 Additional information.................... 326
29.2 Required work ............................... 326
29.3 Recommended work ....................... 327
30 WIRING DIAGRAM .................................... 330
30.1 Page 1 of 8 (All EXC models) .......... 330
30.2 Page 2 of 8 (All EXC models) .......... 332
30.3 Page 3 of 8 (All EXC models) .......... 334
30.4 Page 4 of 8 (All EXC models) .......... 336
30.5 Page 5 of 8 (All EXC models) .......... 338
30.6 Page 6 of 8 (All EXC models) .......... 340
30.7 Page 7 of 8 (All EXC models) .......... 342
30.8 Page 8 of 8 (All EXC models) .......... 344
30.9 Page 1 of 6 (All XC‑W models) ........ 346
30.10 Page 2 of 6 (All XC‑W models) ........ 348
30.11 Page 3 of 6 (All XC‑W models) ........ 350
30.12 Page 4 of 6 (All XC‑W models) ........ 352
30.13 Page 5 of 6 (All XC‑W models) ........ 354
30.14 Page 6 of 6 (All XC‑W models) ........ 356
31 SUBSTANCES .......................................... 358
32 AUXILIARY SUBSTANCES ......................... 360
33 SPECIAL TOOLS ....................................... 362
34 STANDARDS ............................................ 377
35 INDEX OF SPECIAL TERMS ....................... 378
36 LIST OF ABBREVIATIONS.......................... 379
INDEX ............................................................. 380

MEANS OF REPRESENTATION 1
7
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.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

2 SAFETY ADVICE
8
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 product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or 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.
Note
Indicates 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 a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals,
sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a thread locker (e.g. Loctite®) is required. Apply according to the manufacturer's
instructions.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.

IMPORTANT NOTES 3
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
Note
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 in accordance with the Owner's Manual and specification.
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 disassemble the component to perform the activity in question. Please follow the instructions
in the text.

4 SERIAL NUMBERS
10
4.1 Chassis number
401945-10
The chassis number 1is stamped on the right side of the steer-
ing head.
4.2 Type label
401946-10
Type label 1is fixed to the front of the steering head.
4.3 Engine number
H01047-10
The engine number 1is located on the left side of the engine
over the engine sprocket.
4.4 Fork part number
401947-10
The fork part number 1is stamped on the inside of the axle
clamp.

SERIAL NUMBERS 4
11
4.5 Shock absorber article number
0
0
11
401948-10
Shock absorber article number 1is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.

5 MOTORCYCLE
12
5.1 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) ( p. 370)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
5.2 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 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 the vehicle
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.
401944-10
–Take the motorcycle off side stand 1and secure the side
stand with rubber band 2.
–Shift gear to neutral.
Condition
Ambient temperature: < 10 °C (< 50 °F)
–Pull the cold start button fully out and turn it by a ¼ turn.

MOTORCYCLE 5
13
Info
If the engine is warm, the cold start button must be
deactivated.
400733-01
–Press the electric starter button or push the kick starter
robustly through its full range.
Info
Do not open the throttle.
Press the electric starter button for a maximum of
5 seconds. Wait for 30 seconds before a further
attempt at starting.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
5.4 Starting the motorcycle to check the function
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.
–Shift gear to neutral.
400733-01
–Press the electric starter button or push the kick starter
robustly through its full range.
Info
Press the electric starter button for a maximum of 5
seconds. Wait for 30 seconds before a further attempt
at starting.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
Do not open the throttle.

6 FORK, TRIPLE CLAMP
14
6.1 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 1clockwise as far as it will
go.
Info
Adjusting screw 1is located at the upper end of
the left fork leg.
The compression damping is located in left fork
leg COMP (white adjusting screw). The rebound
damping is located in right fork leg REB (red adjust-
ing screw).
–Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counter-
clockwise to reduce damping.
E00324-10
(All Six Days models)
–Turn white adjusting screw 1clockwise as far as it will
go.
Info
Adjusting screw 1is located at the upper end of
the left fork leg.
The compression damping is located in left fork
leg COM (white adjusting screw). The rebound
damping is located in right fork leg REB (red
adjusting screw).
–Turn counterclockwise by the number of clicks correspond-
ing to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counter-
clockwise to reduce damping.

FORK, TRIPLE CLAMP 6
15
6.2 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 1clockwise as far as it will go.
Info
Adjusting screw 1is 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 correspond-
ing to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counter-
clockwise to reduce damping.
E00325-10
(All Six Days models)
–Turn red adjusting screw 1clockwise as far as it will go.
Info
Adjusting screw 1is 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 correspond-
ing to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counter-
clockwise to reduce damping.

6 FORK, TRIPLE CLAMP
16
6.3 Adjusting the spring preload of the fork (All Six Days models)
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 12)
E00867-10
Main work
–Turn the adjusting wings 1counterclockwise all the way.
The marking +0 aligns with the adjusting 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.
Basically, however, you should set the rebound damp-
ing higher with a higher spring preload.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 12)
6.4 Bleeding the fork legs
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 12)
H01595-10
Main work
–Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
–Tighten the bleeder screws.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 12)

FORK, TRIPLE CLAMP 6
17
6.5 Cleaning the dust boots of the fork legs
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 12)
–Remove the fork protector. ( p. 19)
K00070-10
Main work
–Push dust boots 1of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles
from the inside fork tubes. Over time, dirt can accumu-
late behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
–Always keep the brake discs free of oil and grease.
–Clean the brake discs with brake cleaner when nec-
essary.
–Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray ( p. 361)
–Press the dust boots back into their installation position.
–Remove excess oil.
Finishing work
–Install the fork protector. ( p. 19)
–Remove the motorcycle from the lift stand. ( p. 12)
6.6 Removing the fork legs
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 12)
–Remove the front wheel. ( p. 141)
–Remove the headlight mask with the headlight. ( p. 135)
E00375-10
Main work
–Remove screws 1and take off the clamp.
–Remove the cable tie.
–Remove screws 2and take off the brake caliper.
–Allow the brake caliper and brake line to hang loosely to the
side.

6 FORK, TRIPLE CLAMP
18
E00914-10
(All standard EXC/XC-W models)
–Loosen screws 3. Remove the left fork leg.
–Loosen screws 4. Remove the right fork leg.
E00919-10
(All Six Days models)
–Loosen screws 3. Remove the left fork leg.
–Loosen screws 4. Remove the right fork leg.
6.7 Installing the fork legs
H01595-10
Main work
–Position the fork legs.
Bleeder screws 1are positioned toward the front.
Info
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).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the top edge of the upper triple clamp.
E00914-11
(All standard EXC/XC-W models)
–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)