Om KTM 2012 125 200 250 300

OWNER'S MANUAL 2012
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
250 EXC EU
250 EXC AUS
250 EXC SIX DAYS EU
250 XC‑W USA
300 EXC EU
300 EXC AUS
300 EXC SIX DAYS EU
300 XC‑W USA
Art. no. 3211718en
DEAR KTM CUSTOMER 1
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
DEAR KTM CUSTOMER
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.

Chassis number ( p. 10) Dealer's stamp
Engine number ( p. 11)
Key number (All EXC models) ( p. 10)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can, however, not be completely excluded.
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 delivery.
© 2011 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
Preparations for riding on wet sand ................................. 27

TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................ 5

IMPORTANT INFORMATION ................................................ 6 Preparations for riding on wet and muddy surfaces ........... 28
VIEW OF VEHICLE............................................................... 8 Preparations for riding at high temperatures and low
View of vehicle, front left (example)................................... 8 speeds.......................................................................... 28
View of vehicle, rear right (example) .................................. 9 Preparing for rides at low temperatures or in snow ............ 29
SERIAL NUMBERS............................................................ 10 RIDING INSTRUCTIONS .................................................... 30
Chassis number............................................................. 10 Checks and maintenance work when preparing for use ...... 30
Type label..................................................................... 10 Starting ........................................................................ 30
Key number (All EXC models) ......................................... 10 Start off........................................................................ 31
Engine number.............................................................. 11 Shifting, riding .............................................................. 31
Fork part number........................................................... 11 Braking ........................................................................ 31
Shock absorber part number........................................... 11 Stopping, parking .......................................................... 32
CONTROLS ....................................................................... 12 Refueling...................................................................... 32
Clutch lever .................................................................. 12 SERVICE SCHEDULE......................................................... 34
Hand brake lever ........................................................... 12 Service schedule ........................................................... 34
Throttle grip.................................................................. 12 Maintenance work (as an additional order) ....................... 35
Kill switch (All EXC models) ........................................... 12 TUNING THE CHASSIS...................................................... 36
Short circuit button (XC-W) ............................................ 13 Checking the basic chassis setting with the rider's
Light switch (All EXC models) ......................................... 13 weight .......................................................................... 36
Turn signal switch (All EXC models) ................................ 13 Compression damping of shock absorber.......................... 36
Horn button (All EXC models) ......................................... 13 Adjusting the high-speed compression damping of the
shock absorber .............................................................. 36
Emergency OFF switch (200 EXC AUS) ........................... 13
Adjusting the low-speed compression damping of the
Emergency OFF switch (250/300 EXC AUS) .................... 14
shock absorber .............................................................. 37
Electric starter button (250/300 EXC EU,
Adjusting the rebound damping of the shock absorber....... 37
EXC SIX DAYS, 250/300 XC‑W) ...................................... 14
Measuring the sag of the unloaded rear wheel .................. 38
Electric starter button (250/300 EXC AUS)...................... 14
Checking the static sag of the shock absorber .................. 38
Light switch (XC-W) ....................................................... 14
Checking the riding sag of the shock absorber .................. 39
Overview of indicator lamps (All EXC models) ................... 14
Adjusting the spring preload of the shock absorber x ...... 39
Speedometer................................................................. 15
Adjusting the riding sag .............................................
x 40
Speedometer activation and test ..................................... 15
Checking the basic setting of the fork.............................. 40
Tripmaster switch .......................................................... 15
Adjusting the compression damping of the fork ................ 41
Setting kilometers or miles ............................................. 15
Adjusting the rebound damping of the fork....................... 41
Setting the clock ........................................................... 16
Adjusting the spring preload of the fork ........................... 42
Adjusting the speedometer functions............................... 16
Handlebar position ........................................................ 42
Querying lap time .......................................................... 17
Adjusting the handlebar position x ................................ 42
Display mode SPEED (speed) ......................................... 17
SERVICE WORK ON THE CHASSIS ..................................... 44
Display mode SPEED/H (operating hours) ........................ 17
Raising the motorcycle with the lift stand ........................ 44
Display mode SPEED/CLK (clock) ................................... 18
Removing the motorcycle from the lift stand .................... 44
Display mode SPEED/LAP (lap time) ............................... 18
Bleeding the fork legs .................................................... 44
Display mode SPEED/ODO (odometer) ............................. 18
Cleaning the dust boots of the fork legs ........................... 45
Display mode SPEED/TR1 (trip master 1) ........................ 18
Loosening the fork protection.......................................... 45
Display mode SPEED/TR2 (trip master 2) ........................ 19
Positioning the fork protection ........................................ 46
Display mode SPEED/A1 (average speed 1)...................... 19
Display mode SPEED/A2 (average speed 2)...................... 19 Removing the fork legs x .............................................. 46
Display mode SPEED/S1 (stop watch 1) .......................... 20 Installing the fork legs ...............................................
x 46
Display mode SPEED/S2 (stop watch 2) .......................... 20 Removing the fork protector x ....................................... 47
Fuel tap........................................................................ 21 Installing the fork protector x ....................................... 48
Opening the filler cap .................................................... 21 Removing the lower triple clamp x (EXC EU/AUS,
Closing the filler cap...................................................... 22 XC‑W)........................................................................... 48
Shift lever..................................................................... 22 Removing the lower triple clamp x (EXC SIX DAYS) ........ 48
Kickstarter .................................................................... 22 Installing the lower triple clamp x (EXC EU/AUS,
XC‑W)........................................................................... 49
Foot brake lever............................................................. 23
Installing the lower triple clamp x (EXC SIX DAYS) ......... 50
Side stand .................................................................... 23
Checking the play of the steering head bearing................. 52
Steering lock (All EXC models)........................................ 23
Locking the steering (All EXC models) ............................. 23 Adjusting the play of the steering head bearing ............ x 52
Unlocking the steering (All EXC models) .......................... 24 Greasing the steering head bearing x ............................. 53
PREPARING FOR USE ....................................................... 25 Removing the start number plate (XC-W).......................... 53
Advice on first use ......................................................... 25 Installing the start number plate (XC-W) .......................... 53
Running in the engine.................................................... 26 Removing the front fender .............................................. 54
Preparing the vehicle for difficult operating conditions ...... 26 Installing the front fender............................................... 54
Preparations for riding on dry sand .................................. 27 Removing the shock absorber .....................................
x 54
Installing the shock absorber x ..................................... 54
TABLE OF CONTENTS 3
Removing the seat ......................................................... 55 Removing the headlight mask with the headlight (All EXC
Mounting the seat ......................................................... 55 models) ........................................................................ 85
Removing the air filter box lid......................................... 56 Refitting the headlight mask with the headlight (All EXC
Installing the air filter box lid.......................................... 56 models) ........................................................................ 86
Removing the air filter ...............................................
x 56 Changing the headlight bulb (All EXC models).................. 86
Installing the air filter x ............................................... 56 Checking the headlight setting (All EXC models)............... 87
Cleaning the air filter and air filter box ........................
x 57 Adjusting the headlight range (All EXC models) ................ 87
Removing the main silencer............................................ 57 Changing the speedometer battery .................................. 87
Installing the main silencer ............................................ 58 COOLING SYSTEM ............................................................ 89
Changing the glass fiber yarn filling of the main Cooling system .............................................................. 89
silencer ...................................................................
x 58 Checking the antifreeze and coolant level ........................ 89
Removing the fuel tank x ............................................. 58 Checking the coolant level.............................................. 90
Installing the fuel tank x .............................................. 59 Draining the coolant .................................................. 90
x
Checking the chain for dirt ............................................. 60 Refilling with coolant x ................................................ 91
Cleaning the chain......................................................... 60 TUNING THE ENGINE ....................................................... 93
Checking the chain tension ............................................ 61 Checking the play in the throttle cable............................. 93
Checking the chain, rear sprocket, engine sprocket and Adjusting the play in the throttle cable x ....................... 93
chain guide................................................................... 61 Carburetor .................................................................... 93
Adjusting the chain tension ............................................ 63 Carburetor - adjusting the idle speed x .......................... 94
Adjusting the chain guide x .......................................... 64 Emptying the carburetor float chamber x ....................... 95
Checking the frame ...................................................
x 65 Checking the basic position of the shift lever.................... 96
Checking the swingarm x ............................................. 65 Adjusting the basic position of the shift lever x .............. 96
Checking the throttle cable routing.................................. 65 Engine characteristic - auxiliary spring
Checking the rubber grip ................................................ 66 (All 250/300 models) .................................................... 96
Additionally securing the rubber grip ............................... 66 Engine characteristic - adjusting the auxiliary spring x
Adjusting the basic position of the clutch lever................. 66 (All 250/300 models) .................................................... 96
Checking the fluid level of the hydraulic clutch ................ 67 SERVICE WORK ON THE ENGINE ...................................... 98
Changing the hydraulic clutch fluid x ............................ 67 Checking the gear oil level.............................................. 98
BRAKES ........................................................................... 69 Changing the gear oil x ................................................ 98
Checking free travel of hand brake lever........................... 69 Draining the gear oil x ................................................. 99
Adjusting the basic position of the hand brake lever Refilling with gear oil x ................................................ 99
(XC-W).......................................................................... 69 Adding gear oil x....................................................... 100
Adjusting free travel of hand brake lever (All EXC CLEANING, CARE ........................................................... 101
models) ........................................................................ 69 Cleaning the motorcycle ............................................... 101
Checking the brake discs................................................ 70 Checks and maintenance steps for winter operation ........ 102
Checking the front brake fluid level ................................. 70 STORAGE ....................................................................... 103
Adding front brake fluid x ............................................ 70 Storage....................................................................... 103
Checking the front brake linings...................................... 71 Preparing for use after storage ...................................... 103
Changing the front brake linings x ................................. 72 TROUBLESHOOTING....................................................... 104
Checking the free travel of foot brake lever....................... 73 TECHNICAL DATA - ENGINE ............................................ 106
Adjusting the basic position of the foot brake lever x ...... 73 125 EXC EU, 125 EXC SIX DAYS EU ............................ 106
Checking the rear brake fluid level .................................. 74 All 200 models ........................................................... 106
Adding brake fluid for the rear brake x .......................... 74 All 250 models ........................................................... 107
Checking the rear brake linings ....................................... 75 All 300 models ........................................................... 107
Removing the rear brake linings x ................................. 75 Capacity - transmission oil............................................ 108
Installing the rear brake linings x .................................. 76 Capacity - coolant........................................................ 108
Changing the rear brake linings x .................................. 76 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 109
WHEELS, TIRES ............................................................... 78 All 125/200 models .................................................... 109
Removing the front wheel x .......................................... 78 All 250/300 models .................................................... 110
Installing the front wheel x ........................................... 78 TECHNICAL DATA - CARBURETOR................................... 111
Removing the rear wheel x ........................................... 79 125 EXC EU, 125 EXC SIX DAYS EU ............................ 111
Installing the rear wheel x ............................................ 79 200 EXC EU ............................................................... 111
Checking the tire condition............................................. 80 200 EXC AUS ............................................................. 111
Checking the tire air pressure ......................................... 81 200 XC‑W USA ........................................................... 111
Checking the spoke tension ............................................ 81 250 EXC EU, 250 EXC SIX DAYS EU ............................ 112
ELECTRICAL SYSTEM ....................................................... 83 250 EXC AUS ............................................................. 112
Removing the battery x (All 250/300 models) ................ 83 250 XC‑W USA ........................................................... 112
Installing the battery x (All 250/300 models)................. 83 300 EXC EU, 300 EXC SIX DAYS EU ............................ 112
Recharging the battery x (All 250/300 models) .............. 83 300 EXC AUS ............................................................. 113
Changing the main fuse (All 250/300 models) ................. 84 300 XC‑W USA ........................................................... 113
Carburetor configuration (125 EXC EU,
125 EXC SIX DAYS EU) x .......................................... 113
TABLE OF CONTENTS 4
Carburetor configuration (All 200 models) ................. x 115

General carburetor configuration x .............................. 118
TECHNICAL DATA - CHASSIS .......................................... 119
Lighting equipment ..................................................... 120
Tires .......................................................................... 120
Capacity - fuel............................................................. 120
TECHNICAL DATA - FORK................................................ 121
All 125/200 models .................................................... 121
All 250/300 models .................................................... 121
TECHNICAL DATA - SHOCK ABSORBER ........................... 123
All 125/200 models .................................................... 123
All 250/300 models .................................................... 123
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................ 125
SUBSTANCES................................................................. 126
AUXILIARY SUBSTANCES................................................ 128
STANDARDS................................................................... 130
INDEX ............................................................................ 131
MEANS OF REPRESENTATION 5
Symbols used
The symbols used are explained below.
Indicates an expected reaction (e.g., to a work step or a function).
Indicates an unexpected reaction (e.g., to a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a specific name.
Name® Identifies a protected name.
Brand™ Identifies a brand available on the open market.

IMPORTANT INFORMATION 6
Use definition (All EXC models)

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for public road traffic in the homologous (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.
Use definition (XC-W)

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only on closed off property remote from public road traffic.
The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.
Service
A prerequisite for perfect operation and prevention of wear is that the engine and chassis service, care and adjustment work described
in the owner's manual is properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage
of components.
Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of compo-
nents such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the
limit specified in the service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parenthe-
ses. E.g.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash-
ers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
IMPORTANT INFORMATION 7
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Switch off the engine.

– Turn handle  of the fuel tap to the OFF position.
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
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.
Owner's manual
– It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and
tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle
to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on ser-
vicing the motorcycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
VIEW OF VEHICLE 8
View of vehicle, front left (example)

3.1
B00784-10
1 Hand brake lever ( p. 12)

2 Kill switch ( p. 12)
3 Clutch lever ( p. 12)
4 Air filter box lid
5 Fuel tap ( p. 21)
6 Chain guide
7 Side stand ( p. 23)
8 Shift lever ( p. 22)
9 Fork rebound adjustment
10 Fork compression adjustment
VIEW OF VEHICLE 9
View of vehicle, rear right (example)

3.2
B00783-10
1 Filler cap
2 Bleeder screw, fork leg
3 Throttle grip ( p. 12)
4 Chassis number ( p. 10)
5 Kickstarter ( p. 22)
6 Foot brake lever ( p. 23)
7 Shock absorber, compression adjustment
8 Level viewer, rear brake fluid
9 Shock absorber, rebound adjustment
SERIAL NUMBERS 10
Chassis number
4.1
(XC-W)
The chassis number  is stamped on the right side of the steering head.
B00015-10
(All EXC models)

The chassis number  is stamped on the right side of the steering head.
303438-10
Type label
4.2
(XC-W)
The type label  is fixed to the front of the steering head.
400284-10
(All EXC models)

The type label  is fixed to the front of the steering head.
303439-10
Key number (All EXC models)

4.3
The key number  for the steering lock is stamped onto the key connector.
500125-10
SERIAL NUMBERS 11
Engine number
4.4
The engine number  is stamped on the left side of the engine under the engine
sprocket.
B00016-10
Fork part number

4.5
The fork part number  is stamped on the inner side of the fork stub.
B00265-01
Shock absorber part number

4.6
The shock absorber part number  is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
B00786-10
CONTROLS 12
Clutch lever
5.1
(All 125/200 models)

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00001-10

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00009-10
Hand brake lever

5.2
Hand brake lever  is located on the right side of the handlebar.

The hand brake lever is used to activate the front brake.
400196-10
Throttle grip
5.3
Throttle grip  is fitted on the right side of the handlebar.
B00060-10
Kill switch (All EXC models)

5.4
The kill switch  is fitted on the left side of the handlebar.

Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
B00078-10
CONTROLS 13
Short circuit button (XC-W)

5.5
Short circuit button  is fitted on the left side of the handlebar.

Possible states
• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
B00002-10
Light switch (All EXC models)

5.6
The light switch  is fitted on the left side of the handlebar.

Possible states
Light off – Light switch is turned to the right. In this position, the light
is switched off.
Low beam on – Light switch is in the central position. In this position,

the low beam and tail light are switched on.
High beam on – Light switch is turned to the left. In this position, the
high beam and the tail light are switched on.
B00082-10
Turn signal switch (All EXC models)

5.7
Turn signal switch  is fitted on the left side of the handlebar.

Possible states
Turn signal off – The turn signal switch is in the central position.
Left turn signal, on – The turn signal switch is turned to the left.
Right turn signal, on – The turn signal switch is turned to the right.
101299-10
Horn button (All EXC models)

5.8
The horn button  is fitted on the left side of the handlebar.

Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
B00083-10
Emergency OFF switch (200 EXC AUS)

5.9
The emergency OFF switch  is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a run-
Ignition on – In this position, the ignition circuit is closed, and the

engine can be started.
B00087-10
CONTROLS 14
Emergency OFF switch (250/300 EXC AUS)

5.10
The emergency OFF switch  is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a run-
Ignition on – In this position, the ignition circuit is closed, and the

engine can be started.
B00079-10
Electric starter button (250/300 EXC EU, EXC SIX DAYS, 250/300 XC‑W)
5.11
The electric starter button  is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
B00080-10
Electric starter button (250/300 EXC AUS)

5.12
The electric starter button  is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
B00081-10
Light switch (XC-W)

5.13
Light switch  is located to the right of the speedometer.

Possible states
• The light switch has no function when the vehicle is delivered – It can be used to
retrofit the vehicle with a lighting system.
500146-10
Overview of indicator lamps (All EXC models)

5.14
Possible states
High beam indicator lamp lights up blue – High beam is switched on.
Turn signal indicator lamp flashes green – Turn signal light is switched
on.
500147-01
CONTROLS 15
Speedometer
5.15
– Press the button to change the display mode or change to one of the Setup
menus.
– Press the button to control different functions.
– Press the button to control different functions.
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
400312-01
Speedometer activation and test

5.16
Activating the speedometer

The speedometer is activated when one of the buttons is pressed or an impulse comes
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.
400313-01
WS (wheel size)
After the display function test, the wheel size WS is displayed briefly.
Info
The number 2205 mm equals the circumference of the 21" front wheel with a
series production tire.
The display then changes to the last selected mode.
400314-01
Tripmaster switch
5.17
(Option: Tripmaster switch)

You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info
The trip master is an optional accessory.
Setting kilometers or miles

5.18
Info
If you change the unit of measure, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The Setup menu is displayed and the active functions are shown.
– Press the button repeatedly until the Km/h/Mph display flashes.
Adjusting Km/h
– Press the button .
Adjusting Mph
400329-01 – Press the button .
CONTROLS 16

The settings are stored and the Setup menu is closed.
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
Setting the clock

5.19
Condition
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
The hour display flashes.
– Set the hour display with the button and/or button .
– Press the button briefly.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the hours by pressing the
400330-01 button and the button .
Info
The seconds can only be set to zero.

Info
If no button is pressed for 20 seconds, or if a pulse arrives from the wheel
speed sensor, the settings are stored automatically and the Setup menu is
closed.
Adjusting the speedometer functions

5.20
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
display.
The Setup menu is displayed and the activated functions are shown.
– Change to the desired function by pressing the button briefly.
The selected function flashes.
Activating a function
400318-01 The symbol remains on the screen and the display changes to the next
function.
Deactivating the function
The symbol on the screen goes out and the display changes to the next
function.
– All desired functions are activated or deactivated accordingly.
CONTROLS 17
Info
If no button is pressed for 20 seconds, or if a pulse arrives from the wheel
speed sensor, the settings are stored automatically and the Setup menu is
closed.
Querying lap time

5.21
Info
This function can be called up only if lap times are measured.
Condition
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
LAP 1 appears on the left side of the display.
– Laps 1-10 can be displayed by pressing the button .
– The button has no function.
Next display mode
400321-01
Info
If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.
Display mode SPEED (speed)

5.22
– Press the button briefly and repeatedly until SPEED appears on the left side of
the display.
The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.
Info
Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.
400317-02
Display mode SPEED/H (operating hours)

5.23
Condition
• The motorcycle is stationary.
display.
In display mode H, the operating hours of the engine are displayed.
The operating hours counter stores the total traveling time.
Info
The operating hours counter is necessary for ensuring that maintenance work is
400316-01 carried out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automati-
cally changes to the ODO display mode.
The H display mode is suppressed during the journey.
Press the button . No function

Press the button The display changes to the Setup menu of the speedometer
for 3 - 5 seconds. functions.
Press the button Next display mode
briefly.
CONTROLS 18
Display mode SPEED/CLK (clock)

5.24
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
The time is displayed in CLK display mode.
Press the button The display changes to the Setup menu of the clock.
for 3 - 5 seconds.
400319-01 briefly.
Display mode SPEED/LAP (lap time)

5.25
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
Info
If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .
400320-01 Press the button . Starts or stops the clock.

Press the button . Stops the current lap time and saves it, and the stop watch
starts the next lap.
Press the button The stop watch and the lap time are reset.
for 3 - 5 seconds.
briefly.
Display mode SPEED/ODO (odometer)

5.26
– Press the button briefly and repeatedly until ODO appears at the bottom right of
the display.
The total distance traveled is displayed in the ODO display mode.
Press the button –
for 3 - 5 seconds.
400317-01 briefly.
Display mode SPEED/TR1 (trip master 1)

5.27
– Press the button briefly and repeatedly until TR1 appears at the top right of the
display.
TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to
0.0.
400323-01
Press the button The TR1, A1 and S1 displays are reset to 0.0.
for 3 - 5 seconds.
briefly.
CONTROLS 19
Display mode SPEED/TR2 (trip master 2)

5.28
– Press the button briefly and repeatedly until TR2 appears at the top right of the
display.
TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . This is a
very practical function when riding using the road book.
Info
The TR2 value can also be corrected manually during the journey with the but-
ton and the button .
400324-01 If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
Press the button . Increases value of TR2.

Press the button . Reduces value of TR2.
Press the button Deletes value of TR2.
for 3 - 5 seconds.
briefly.
Display mode SPEED/A1 (average speed 1)

5.29
– Press the button briefly and repeatedly until A1 appears at the top right of the
display.
A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas-
ter 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.
400325-01 Press the button The TR1, A1 and S1 displays are reset to 0.0.
for 3 - 5 seconds.
briefly.
Display mode SPEED/A2 (average speed 2)

5.30
– Press the button briefly and repeatedly until A2 appears at the top right of the
display.
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.
Info
The displayed value can differ from the actual average speed if S2 was not
timed after the ride.
400326-01 Press the button . No function

Press the button –
for 3 - 5 seconds.
briefly.
CONTROLS 20
Display mode SPEED/S1 (stop watch 1)

5.31
– Press the button briefly and repeatedly until S1 appears at the top right of the
display.
S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.
400327-01 Press the button Displays of TR1, A1 and S1 are reset to 0.0.
for 3 - 5 seconds.
briefly.
Display mode SPEED/S2 (stop watch 2)

5.32
– Press the button briefly and repeatedly until S2 appears at the top right of the
display.
S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.
Press the button . Starts or stops S2.
Press the button Displays of S2 and A2 are reset to 0.0.
for 3 - 5 seconds.
400328-01 Press the button Next display mode
briefly.
Table of functions
Display Press the button . Press the button . Press the button for 3 - Press the button
5 seconds. briefly.
Display mode SPEED/H No function No function The display changes to Next display mode
(operating hours) the Setup menu of the
speedometer functions.
Display mode SPEED/CLK No function No function The display changes to Next display mode
(clock) the Setup menu of the
clock.
Display mode SPEED/LAP Starts or stops the Stops the current lap The stop watch and the Next display mode
(lap time) clock. time and saves it, and lap time are reset.
the stop watch starts
the next lap.
Display mode No function No function – Next display mode
SPEED/ODO (odometer)
Display mode SPEED/TR1 No function No function The TR1, A1 and S1 dis- Next display mode
(trip master 1) plays are reset to 0.0.
Display mode SPEED/TR2 Increases value of TR2. Reduces value of TR2. Deletes value of TR2. Next display mode
(trip master 2)
Display mode SPEED/A1 No function No function The TR1, A1 and S1 dis- Next display mode
(average speed 1) plays are reset to 0.0.
Display mode SPEED/A2 No function No function – Next display mode
(average speed 2)
Display mode SPEED/S1 No function No function Displays of TR1, A1 and Next display mode
(stop watch 1) S1 are reset to 0.0.
Display mode SPEED/S2 Starts or stops S2. No function Displays of S2 and A2 Next display mode
(stop watch 2) are reset to 0.0.
Table of conditions and menu activation

Display The motorcycle is Menu can be acti-
stationary. vated
Display mode SPEED/H (operating hours) •
Display mode SPEED/CLK (clock) •
CONTROLS 21
Table of conditions and menu activation

Display The motorcycle is Menu can be acti-
stationary. vated
Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •
Fuel tap
5.33
The fuel tap is on the left side of the fuel tank.

Tap handle  on the fuel tap is used to open or close the supply of fuel to the carbure-
tor.
Possible states
• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.
• Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The
fuel tank empties completely.
601157-10
Opening the filler cap

5.34
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
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.
CONTROLS 22
– Press release button , turn the filler cap counterclockwise and lift it free.
303520-10
Closing the filler cap

5.35
– Replace the filler cap and turn clockwise until the release button  locks in place.
Info
Run the fuel tank breather hose  without kinks.
303521-10
Shift lever
5.36
Shift lever  is mounted on the left side of the engine.
B00005-10
The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.
B00005-12
Kickstarter
5.37
The kickstarter  is fitted on the right side of the engine. The top part can be
swiveled.
B00787-10
CONTROLS 23
Foot brake lever

5.38
Foot brake lever  is located in front of the right footrest.

The foot brake lever is used to activate the rear brake.
B00788-10
Side stand
5.39
The side stand  is on the left side of the vehicle.
B00789-10
The side stand is used to park the motorcycle.
Info
When you are riding, side stand  must be folded up and secured with rubber
band .
B00790-10
Steering lock (All EXC models)

5.40
Steering lock  is fitted on the left side of the steering head.

The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.
B00791-10
Locking the steering (All EXC models)

5.41
Note
– Park the vehicle.

– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in and turn it to the
right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
400732-01
CONTROLS 24
Unlocking the steering (All EXC models)

5.42
– Insert the key in the steering lock, turn it to the left, pull it out and turn it to the
right. Remove the key.
You can now steer the bike again.
Info
Never leave the key in the steering lock.
400731-01
PREPARING FOR USE 25
Advice on first use

6.1
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take
your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 66)
(XC-W)
– Adjust the basic position of the hand brake lever. ( p. 69)
(All EXC models)
– Adjust the free travel of the hand brake lever. ( p. 69)
– Adjust the basic position of the foot brake lever. x( p. 73)
– Adjust the basic position of the shift lever. x( p. 96)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Offroad, you should be accompanied by another person on another machine so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-
tribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Check the spoke tension. ( p. 81)
Info
The spoke tension must be checked after half an hour of operation.
– Run the engine in.
Running in the engine

6.2
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
– Avoid fully opening the throttle!
Preparing the vehicle for difficult operating conditions

6.3
Info
Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.
– Seal the air filter box. x

Tip
Seal the air filter box at the edges against dirt.
– Clean the air filter and air filter box. x( p. 57)
Info
Check the air filter approx. every 30 minutes.
– Additionally secure the rubber grip. ( p. 66)

– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult operating conditions are:
– Riding on dry sand. ( p. 27)
– Riding on wet sand. ( p. 27)
– Riding on wet and muddy surfaces. ( p. 28)
– Riding at high temperatures and low speeds. ( p. 28)
– Rides at low temperatures or in snow. ( p. 29)
Preparations for riding on dry sand

6.4
– Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)
» If the displayed value does not equal the setpoint value:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling
600872-10 system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
– Change the radiator cap.

– Mount the dust cover for the air filter.
Dust cover for air filter (59006019000)
Info
Read the KTM PowerParts installation instructions.
600869-01
– Mount the dust cover for the air filter for sand.
Sand cover for air filter (59006022000)
Info
– Adjust the carburetor jetting and setting.
Info
600871-01
Recommendations on the carburetor setting are available from your autho-
rized KTM workshop.
– Clean the chain.

Chain cleaner ( p. 128)
– Mount the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.

600868-01 – Carefully align bent radiator fins.
– If used in sand regularly, replace the piston every 10 operating hours.
Preparations for riding on wet sand

6.5

Warning

– Mount the rain cover for the air filter.
Rain cover for air filter (59006021000)
Info
Info
600870-01
Recommendations on the carburetor setting are available from your autho-
rized KTM workshop.

Tip
Do not grease the chain.

600868-01 – Carefully align bent radiator fins.
– If used in sand regularly, replace the piston every 10 operating hours.
Preparations for riding on wet and muddy surfaces

6.6

Info
Follow the KTM PowerParts mounting instructions.
Info
600870-01
The recommended carburetor tuning is available from your authorized KTM
workshop.

– Clean the motorcycle. ( p. 101)
– Carefully align bent radiator fins.
600868-01
Preparations for riding at high temperatures and low speeds

6.7

Warning

– Adjust the secondary ratio to the terrain.
Info
The engine oil heats up rapidly if the clutch needs to be operated too fre-
quently because the secondary ratio is too long.

600868-01
– Carefully align bent radiator fins.
– Check the coolant level. ( p. 90)
Preparing for rides at low temperatures or in snow

6.8

Info
Follow the KTM PowerParts mounting instructions.
Info
600870-01
The recommended carburetor tuning is available from your authorized KTM
workshop.
RIDING INSTRUCTIONS 30
Checks and maintenance work when preparing for use

7.1
Info
Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.
– Check the gear oil level. ( p. 98)

– Check the electrical system.
– Check the front brake fluid level. ( p. 70)
– Check the rear brake fluid level. ( p. 74)
– Check the front brake linings. ( p. 71)
– Check the rear brake linings. ( p. 75)
– Check that the brake system is functioning properly.
– Check the chain for dirt. ( p. 60)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 61)
– Check the chain tension. ( p. 61)
– Check the tire condition. ( p. 80)
– Check the tire air pressure. ( p. 81)
– Check the spoke tension. ( p. 81)
– Clean the dust boots of the fork legs. ( p. 45)
– Bleed the fork legs. ( p. 44)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts and hose clamps regularly for tightness.
– Check the fuel supply.
Starting
7.2
Danger
Danger of poisoning Exhaust gases are poisonous 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 is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Engine has been out of use for more than 1 week

– Empty the carburetor float chamber. ( x p. 95)
– Turn handle  of the fuel tap to the ON position. (Figure 601157-10 p. 21)
Fuel can flow from the fuel tank to the carburetor.
– Remove the motorcycle from the stand.
– Shift gear to neutral.
(200 EXC AUS)
– Turn the emergency OFF switch to the position .
(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 kick starter forcefully through its full range.
Info
Do not open the throttle.
Start off
7.3
Info
Before riding, switch on the lights if your vehicle is equipped with a lighting system. This will make it easier for other road
users to see you.
When you are riding, the side stand must be folded up and secured with the rubber band.
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
Shifting, riding
7.4
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
– If the choke function was activated, deactivate it after the engine has warmed up.
– When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces
vehicle speed but lowers fuel consumption considerably.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, brake and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.
Guideline
≥ 2 min
– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
Braking
7.5
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– On sandy, wet or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
Stopping, parking
7.6
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
Note
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side
stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
– Brake the motorcycle.

(All EXC models)
– Press and hold the kill switch while the engine is idling until the engine stops.
(XC-W)
– Press and hold the short circuit button while the engine is idling until the engine stops.
– Park the motorcycle on firm ground.
Refueling
7.7
Danger
Warning
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
– Switch off the engine.

– Open the filler cap. ( p. 21)
– Fill the fuel tank with fuel up to measurement .

Guideline
Measurement of  35 mm (1.38 in)
A Total fuel tank

capacity, approx.
9.5 l
(2.51 US gal)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 127)
(EXC EU,
EXC SIX DAYS)
Total fuel tank 10 l (2.6 US gal) Super unleaded gasoline, mixed with
400382-10 capacity, approx. 2-stroke engine oil (1:60) ( p. 127)
(EXC AUS, XC‑W)
2-stroke engine oil ( p. 126)

– Close the filler cap. ( p. 22)
SERVICE SCHEDULE 34
Service schedule
8.1
S20A S40A
Check that the electrical equipment is functioning properly. • •
Check and charge the battery. x (All 250/300 models) • •
Change the gear oil. x( p. 98) • •
Check the front brake linings. ( p. 71) • •
Check the rear brake linings. ( p. 75) • •
Check the brake discs. ( p. 70) • •
Check the brake lines for damage and leakage. • •
Check the rear brake fluid level. ( p. 74) • •
Check the free travel of the foot brake lever. ( p. 73) • •
Check the frame and swingarm. x • •
Check the swingarm bearing. x •
Check the heim joints at the top and bottom of the shock absorber. x • •
Check the tire condition. ( p. 80) • •
Check the tire air pressure. ( p. 81) • •
Check the wheel bearing for play. x • •
Check the wheel hubs. x • •
Check the rim run-out. x • •
Check the spoke tension. ( p. 81) • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 61) • •
Check the chain tension. ( p. 61) • •
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. x • •
Check the fluid level of the hydraulic clutch. ( p. 67) • •
Check the front brake fluid level. ( p. 70) • •
Check the free travel of the hand brake lever. ( p. 69) • •
Check the play of the steering head bearing. ( p. 52) • •
Change the spark plug and spark plug connector. x • •
Check the intake diaphragm. x • •
Check the exhaust control for functioning and smooth operation. x •
Check the clutch. x •
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing. x • •
Check the antifreeze and coolant level. ( p. 89) • •
Check the cables for damage and routing without sharp bends. x • •
Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • •
Clean the air filter and air filter box. x( p. 57) • •
Change the glass fiber yarn filling of the main silencer. x( p. 58) • •
Check the screws and nuts for tightness. x • •
Check the headlight setting. (All EXC models) ( p. 87) • •
Check the idle. • •
Final check: Check the vehicle for safe operation and take a test ride. • •
Make the service entry in KTM DEALER.NET and in the service record. x • •
S20A: Every 20 operating hours
S40A: Every 40 operating hours/after every race
SERVICE SCHEDULE 35
Maintenance work (as an additional order)

8.2
S10N S40A S80A J1A

Change the front brake fluid. x •
Change the rear brake fluid. x •
Change the foot brake cylinder seals. x •
Change the hydraulic clutch fluid.x ( p. 67) •
Grease the steering head bearing. x ( p. 53) •
Check/set the carburetor components. x • •
Perform a fork service. x • • •
Service the shock absorber. x • •
Check the starter drive. x (All 250/300 models) • •
Change the piston and check the cylinder. x (125 EXC EU, 125 EXC SIX DAYS EU) • •
Change the piston and check the cylinder. x (All 200/250/300 models) •
Change the connecting rod, conrod bearing and crank pin. x •
Check the transmission and shift mechanism. x •
Change all engine bearings. x •
S10N: Once after 10 operating hours
S40A: Every 40 operating hours
S80A: Every 80 operating hours/every 40 operating hours when used for motorsports
J1A: Annually
TUNING THE CHASSIS 36
Checking the basic chassis setting with the rider's weight

9.1
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for a standard rider weight
(with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
– If the rider's weight is above or below the standard range, the basic setting of the
suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.
401030-01
Compression damping of shock absorber

9.2
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, affects the compression when landing after a jump: the rear wheel suspension compresses more
quickly.
The low-speed setting, for example, affects the compression when riding over long ground swells: the rear wheel suspension com-
presses more slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
Adjusting the high-speed compression damping of the shock absorber

9.3
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw  all the way clockwise using a socket wrench.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
B00793-10 Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Full payload 1.25 turns

Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Adjusting the low-speed compression damping of the shock absorber

9.4
Caution
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw  clockwise with a screwdriver to the last click.
Info
– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
B00794-10 Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Full payload 15 clicks
Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
ing.
Adjusting the rebound damping of the shock absorber

9.5
Caution
– Turn adjusting screw  clockwise with a screwdriver to the last click.
Info
– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
B00792-10 Rebound damping
Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Sport 22 clicks
Rebound damping
Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Info
ing.
Measuring the sag of the unloaded rear wheel

9.6
– Raise the motorcycle with the lift stand. ( p. 44)

– Measure the distance – as vertical as possible – between the rear axle and a fixed
point, for example, a mark on the side cover.
– Note down the value as dimension .
A
0 – Remove the motorcycle from the lift stand. ( p. 44)
400988-10
Checking the static sag of the shock absorber

9.7
– Measure distance  of the unloaded rear wheel. ( p. 38)

– Hold the motorcycle upright with the aid of an assistant.
– Measure the distance between the rear axle and the fixed point again.
A
0 – Note down the value as dimension .
Info
The static sag is the difference between measurements  and .
– Check the static sag.

Static sag 33… 35 mm (1.3… 1.38 in)
Static sag 33… 35 mm (1.3… 1.38 in)
B
0 » If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. x( p. 39)
400989-10
Checking the riding sag of the shock absorber

9.8
– Measure distance  of the unloaded rear wheel. ( p. 38)

– With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
A
0 and down a few times.
The rear wheel suspension levels out.
– Another person now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension .
Info
The riding sag is the difference between measurements  and .
– Check the riding sag.

Guideline
C
0 Riding sag 105… 115 mm (4.13… 4.53 in)
Riding sag 105… 115 mm (4.13… 4.53 in)
» If the riding sag differs from the specified measurement:
400990-10
– Adjust the riding sag. x( p. 40)
Adjusting the spring preload of the shock absorber

9.9 x
Caution
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
– Remove the shock absorber. x( p. 54)

– After removing the shock absorber, clean it thoroughly.
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length when not under tension.
– Tighten the spring by turning adjusting ring  to measurement .
Guideline
Spring preload
Comfort 6 mm (0.24 in)
Standard 6 mm (0.24 in)
Sport 6 mm (0.24 in)
Full payload 7 mm (0.28 in)
Spring preload
401026-10
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
– Tighten screw .
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
– Install the shock absorber. x( p. 54)
Adjusting the riding sag

9.10 x
– Remove the shock absorber. x( p. 54)
– After removing the shock absorber, clean it thoroughly.
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65… 75 kg 63 N/mm (360 lb/in)
(143… 165 lb.)
(165… 187 lb.)
B00292-10 Weight of rider: 85… 95 kg 69 N/mm (394 lb/in)
(187… 209 lb.)
Spring rate
(143… 165 lb.)
(165… 187 lb.)
(187… 209 lb.)
Info
The spring rate is shown on the outside of the spring.
– Install the shock absorber. x( p. 54)

– Check the static sag of the shock absorber. ( p. 38)
– Check the riding sag of the shock absorber. ( p. 39)
– Adjust the rebound damping of the shock absorber. ( p. 37)
Checking the basic setting of the fork

9.11
Info
For various reasons, no exact riding sag can be determined for the forks.
– As with the shock absorber, smaller differences in the rider's weight can be com-
pensated by the spring preload.
– However, if the fork is often overloaded (hard end stop on compression), harder
springs must be fit to avoid damage to the fork and frame.
401000-01
Adjusting the compression damping of the fork

9.12
Info
The hydraulic compression damping determines the fork suspension behavior.
– Remove protection covers .

– Turn adjusting screws  clockwise all the way.
Info
Adjusting screws  are 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
100020-10 (All 125/200 models)
Compression damping
Comfort 24 clicks
Standard 22 clicks
Sport 20 clicks
Compression damping
Comfort 24 clicks
Standard 22 clicks
Sport 20 clicks
Info
ing.
– Mount protection covers .
Adjusting the rebound damping of the fork

9.13
Info
The hydraulic rebound damping determines the fork suspension behavior.
– Turn adjusting screws  clockwise all the way.
Info
Adjusting screws  are located at the top end of the fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
800017-10 Rebound damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Rebound damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Info
ing.
Adjusting the spring preload of the fork

9.14
– Turn the adjusting screws counterclockwise all the way.
Info
– Turn back clockwise by the number of turns corresponding to the fork type.
Guideline
Spring preload - Preload Adjuster
B00795-01
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Full payload 4 turns
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.
Handlebar position
9.15
On the upper triple clamp, there are two holes a distance of  apart.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of  from the center.
0
A B
0 A
0 B
0
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. In this way, the handlebar
can be mounted in the position that is most comfortable for the rider.
400223-11
Adjusting the handlebar position

9.16 x
Warning
Danger of accidents Handlebar breakage.
– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-
bar.
– Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it
0
1 1
0 to one side.
2
0 0
2 Info
Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.
– Remove screws . Remove the handlebar support.
400223-10
– Place the handlebar support in the required position. Mount and tighten screws .
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
– Position the handlebar clamp. Mount and tighten screws .

Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
SERVICE WORK ON THE CHASSIS 44
Raising the motorcycle with the lift stand

10.1
Note
– Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)
The wheels must no longer touch the ground.
B00796-01
– Secure the motorcycle against falling over.
Note
– Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)
The wheels must no longer touch the ground.
B00803-10
– Secure the motorcycle against falling over.
Removing the motorcycle from the lift stand

10.2
Note

– 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.
B00789-10

– 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.
B00802-10
Bleeding the fork legs

10.3

(All EXC models)

– Remove bleeder screws  briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
303391-10
(XC-W)
– Remove bleeder screws  briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
– Remove the motorcycle from the lift stand. ( p. 44)
303637-10
Cleaning the dust boots of the fork legs

10.4

– Loosen the fork protection. ( p. 45)
– Push dust boots  of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the 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
B00797-10 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. 129)
– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 46)
Loosening the fork protection

10.5
– Remove screws  and take off the clamp.

– Remove screws  on the left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.
B00800-10
Positioning the fork protection

10.6
– Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line. Position the clamp and mount and tighten screws .
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
B00800-11
Removing the fork legs

10.7 x
(All EXC models)
– Remove the headlight mask with the headlight. ( p. 85)
(XC-W)
– Remove the start number plate. ( p. 53)
– Remove the front wheel. x( p. 78)
– Remove screws  and take off the clamp.
– Remove cable binder .
– Remove screws  and take off the brake caliper.
– Hang the brake caliper and the brake line loosely to the side.
B00798-10
(EXC EU/AUS, XC‑W)

– Loosen screws . Remove the fork leg on the left.
– Loosen screws . Remove the fork leg on the right.
B00799-10
(EXC SIX DAYS)

– Loosen screws . Remove the fork leg on the left.
– Loosen screws . Remove the fork leg on the right.
B00804-10
Installing the fork legs

10.8 x
(All EXC models)
– Position the fork legs.
Info
The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws  toward the front.
303637-10
(XC-W)
Info
The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws  toward the front.
303391-10

– Tighten screws .
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
– Tighten screws .
Guideline
Screw, bottom triple clamp M8 15 Nm
B00799-11 (11.1 lbf ft)
(EXC SIX DAYS)
– Tighten screws .
Guideline
(12.5 lbf ft)
Guideline
B00804-11 (8.9 lbf ft)
– Position the brake caliper and mount and tighten screws .
Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Mount cable binder .
– Position the brake line and wiring harness. Put the clamp on and mount and
tighten screws .
– Install the front wheel. x( p. 78)
B00798-11
(All EXC models)
– Refit the headlight mask with the headlight. ( p. 86)
(XC-W)
– Install the start number plate. ( p. 53)
Removing the fork protector

10.9 x
– Remove the fork legs. x( p. 46)
– Remove screws  on the left fork leg. Lift off the fork protector.
– Remove the screws on the right fork leg. Lift off the fork protector.
B00801-10
Installing the fork protector

10.10 x
– Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
– Install the fork legs. x( p. 46)
B00801-10
Removing the lower triple clamp

10.11 x (EXC EU/AUS, XC‑W)
– Remove the front fender. ( p. 54)
– Remove the handlebar cushion.
– Remove screw . Loosen screw . Take off the upper triple clamp with the han-
dlebar and set it aside.
Info
them.
B00805-10
– Remove O-ring . Remove protective ring .

– Take out the lower triple clamp with the steering stem.
– Take out the upper steering head bearing.
B00806-10
Removing the lower triple clamp

10.12 x (EXC SIX DAYS)
– Remove the front fender. ( p. 54)
– Remove the handlebar cushion.
– Remove screw . Release screw , take off the top triple clamp with the handle-
bar, and place it on one side.
Info
them.
B00807-10
– Remove O-ring . Remove protective ring .

– Take out the lower triple clamp with the steering stem.
– Take out the upper steering head bearing.
B00808-10
Installing the lower triple clamp

10.13 x (EXC EU/AUS, XC‑W)
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 128)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
2
0 – Check whether the top steering head seal  is correctly positioned.
1
0 – Push on protective ring .
500151-10
– Position the upper triple clamp with the steering.

– Position the clutch line and wiring harness.
– Mount screw  but do not tighten yet.
B00805-11
Info
The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws  toward the front.
B00809-10
– Tighten screws .
Guideline
(11.1 lbf ft)
B00799-12
– Tighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
B00810-10
– Tighten screw .
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
B00810-11
– Tighten screws .
Guideline
(14.8 lbf ft)
B00799-13
– Position the brake caliper. Mount and tighten screws .

Guideline
(18.4 lbf ft)
– Mount cable binder .
– Position the brake line, wiring harness and clamp. Mount and tighten screws .
– Install the front fender. ( p. 54)
– Mount the handlebar cushion.
B00798-12
(EXC EU/AUS)
(XC-W)
– Install the start number plate. ( p. 53)
– Check that the wiring harness, throttle cables and brake and clutch lines can move
freely and are routed correctly.
– Check the play of the steering head bearing. ( p. 52)
Installing the lower triple clamp

10.14 x (EXC SIX DAYS)
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 128)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
3
0 bearing.
2
0 – Check whether the top steering head seal  is correctly positioned.
1
0 – Slide on protective ring  and O-ring .
303408-01
– Position the upper triple clamp with the steering.

– Mount screw  but do not tighten yet.
– Position the clutch line and wiring harness.
B00807-11
Info
The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws  toward the front.
B00811-10
– Tighten screws .
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
B00804-12
– Tighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
B00811-11
– Tighten screw .
Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 lbf ft)
B00811-12
– Tighten screws .
Guideline
(12.5 lbf ft)
B00804-13
– Position the brake caliper. Mount and tighten screws .

Guideline
(18.4 lbf ft)
– Mount cable binder .
– Position the brake line, wiring harness and clamp. Mount and tighten screws .
– Install the front fender. ( p. 54)
– Mount the handlebar cushion.
B00798-13
– Check that the wiring harness, throttle cables and brake and clutch lines can move
freely and are routed correctly.
Checking the play of the steering head bearing

10.15
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
– Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-
aged over time.

– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
– Adjust the play of the steering head bearing. x( p. 52)
– Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. There
400738-11 should be no perceptible detent positions.
» If detent positions are noticeable:
– Adjust the play of the steering head bearing. x( p. 52)
– Check the steering head bearing and replace if required.
Adjusting the play of the steering head bearing

10.16 x
– Loosen screws  and .
– Loosen and retighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm
(8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Tighten screws .
B00812-10
Guideline
(14.8 lbf ft)
– Tighten screw .
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
(EXC SIX DAYS)

– Loosen screws . Remove screw .
– Loosen and retighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm
(8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Tighten screws .
B00813-10
Guideline
(12.5 lbf ft)
– Mount and tighten screw .
Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 lbf ft)
Greasing the steering head bearing

10.17 x
– Remove the lower triple clamp. x ( p. 48)
– Install the lower triple clamp.
x ( p. 49)
(EXC SIX DAYS)
– Remove the lower triple clamp. x ( p. 48)
– Install the lower triple clamp. x ( p. 50)
800010-10
Removing the start number plate (XC-W)

10.18
– Remove screw  and take off the clamp.

– Remove screw . Remove the start number plate.
500123-10
Installing the start number plate (XC-W)

10.19
– Position the start number plate. Mount and tighten screw .

Guideline
Info
Ensure that the holding lugs engage in the fender.
– Position the brake line. Put on the clamp and mount and tighten screw .
500123-11
Removing the front fender

10.20
– Remove screws . Remove the front fender.

– Make sure the spacers remain in place.
B00814-10
Installing the front fender

10.21
– Ensure that the spacers are mounted in the fender.

– Position the front fender. Mount and tighten screws .
Guideline
Info
Make sure the holding lugs engage in the start number plate.
B00814-10
Removing the shock absorber

10.22 x
– Remove screw  and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
– Remove screw , push splash protector  to the side, and remove the shock
absorber.
B00815-10

– Remove screw  and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
– Remove screw , push splash protector  to the side, and remove the shock
absorber.
B00816-10
Installing the shock absorber

10.23 x
– Push splash protector  to the side and position the shock absorber. Mount
and tighten screw .
Guideline
Screw, top shock M12 80 Nm Loctite® 2701
absorber (59 lbf ft)
– Mount and tighten screw .
Guideline
B00815-11 Screw, bottom shock M12 80 Nm Loctite® 2701
Info
The heim joint for the shock absorber at the swing arm is Teflon
coated. It must not be lubricated with grease or with other lubricants.
Lubricants dissolve the Teflon coating, thereby drastically reducing the
service life.

– Push splash protector  to the side and position the shock absorber. Mount
and tighten screw .
Guideline
Screw, top shock M12 80 Nm Loctite® 2701
– Mount and tighten screw .
Guideline
B00816-11 Screw, bottom shock M12 80 Nm Loctite® 2701
Info
The heim joint for the shock absorber at the swing arm is Teflon
coated. It must not be lubricated with grease or with other lubricants.
Lubricants dissolve the Teflon coating, thereby drastically reducing the
service life.
Removing the seat

10.24
– Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
B00817-10
Mounting the seat

10.25
– Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear
and simultaneously push forward.
– Make sure that the seat is correctly locked in.
B00818-01
– Mount and tighten screw  of the seat fixation.

Guideline
B00817-10
Removing the air filter box lid

10.26
– Pull off the air filter box lid in area  sideways and remove it toward the front.
B00819-10
Installing the air filter box lid

10.27
– Insert the air filter box lid into the rear area  and clip it into the front area .
B00819-11
Removing the air filter

10.28 x
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
– Remove the air filter box lid. ( p. 56)

– Detach air filter holder  at the bottom and swing it to one side. Remove the air
filter with the air filter support.
– Remove the air filter from the air filter support.
B00820-10
Installing the air filter

10.29 x
– Mount the clean air filter onto the air filter support.
– Grease the air filter in area .
Long-life grease ( p. 128)
301262-10
– Put in both parts together, position them, and fix them with air filter holder .
Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
– Install the air filter box lid. ( p. 56)
B00820-10
Cleaning the air filter and air filter box

10.30 x
Warning
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
– Remove the air filter. x( p. 56)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner ( p. 128)
Info
Only press the air filter to dry it; never wring it out.
– Oil the dry air filter with a high quality filter oil.
Oil for foam air filter ( p. 128)
B00325-01
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
– Install the air filter. x( p. 56)
Removing the main silencer

10.31
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down. Do not touch hot components.
– Remove screws .
– Pull the main silencer off of the manifold at the rubber sleeve .
B00821-10
Installing the main silencer

10.32
– Mount the main silencer with rubber sleeve .

– Mount and tighten screws .
Guideline
B00821-11
Changing the glass fiber yarn filling of the main silencer

10.33 x
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down. Do not touch hot components.
Info
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.
– Remove the main silencer. ( p. 57)

– Remove screws . Pull out inner tube .
– Pull the glass fiber yarn filling  from the inner tube.
– Clean the parts that are to be reinstalled.
– Mount the new glass fiber yarn filling  on the inner tube.
0
4 – Slide outer tube  over the inner tube with the new glass fiber yarn filling.
– Mount and tighten all screws .
1
0 – Install the main silencer. ( p. 58)
2
0
3
0
401045-10
Removing the fuel tank

10.34 x
Danger
Warning
– Remove the seat. ( p. 55)

– Turn handle  of the fuel tap to the OFF position. (Figure 601157-10 p. 21)
– Pull off the fuel hose.
Info
Remaining fuel may run out of the fuel hose.
– Remove screws  with the collar sleeve.

(All EXC models)
– Hang the horn and horn bracket to one side.
B00090-10
– Remove screw  with the rubber bushing.

– Remove the tube from the fuel tank vent line.
B00822-10
– Pull both spoilers off of the sides of the radiator bracket  and lift off the fuel
tank.
B00032-10
Installing the fuel tank

10.35 x
Danger
Warning
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
– Check the throttle cable routing. ( p. 65)

– Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
– Make sure that no cables are trapped or damaged.
B00032-01
– Mount the fuel tank vent hose.

– Mount and tighten screw  with the rubber bushing.
Guideline
(All EXC models)
– Position the horn with the horn bracket.
B00822-11
– Mount and tighten screws  with the collar sleeve.

Guideline
– Connect the fuel hose.
– Mount the seat. ( p. 55)
B00090-11
Checking the chain for dirt

10.36
– Check the chain for heavy soiling.

» If the chain is very dirty:
– Clean the chain. ( p. 60)
400678-01
Cleaning the chain

10.37
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
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.
Warning
Info
The service life of the chain depends largely on its maintenance.
– Clean the chain regularly and then treat with chain spray.
Off-road chain spray ( p. 128)
400725-01
Checking the chain tension

10.38
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

– Push the chain at the end of the chain sliding component upwards to measure
chain tension .
Info
The bottom chain section  must be taut.
When the chain guard is mounted, it must be possible to pull up the chain
at least to the point where it makes contact with chain guard .
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension 55… 58 mm (2.17… 2.28 in)

» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 63)
101430-10
Checking the chain, rear sprocket, engine sprocket and chain guide
10.39

– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the rear sprocket or engine sprocket. x
Info
The engine sprocket, rear sprocket, and chain should always be
changed together.
400227-01
– Pull on the upper part of the chain with the specified weight .
Guideline
Weight, chain wear measurement 10… 15 kg (22… 33 lb.)
0
A – Measure the distance  of 18 chain links in the lower chain section.
Info
Chain wear is not always even; repeat this measurement at different chain
positions.
Maximum distance  at the longest 272 mm (10.71 in)

chain section
» If the distance  is greater than the specified measurement:
– Change the chain. x
B
0 Info
When you replace the chain, you should also change the rear
sprocket and engine sprocket.
New chains wear out faster on old, worn sprockets.
1 2 3 16 17 18
400987-10
– Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
guard:
– Change the chain sliding guard. x
– Check the chain sliding guard for tightness.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
Guideline
Screw, chain sliding M6 6 Nm Loctite® 243™
guard (4.4 lbf ft)
B00823-01
– Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
piece:
– Change the chain sliding piece. x
– Check the chain sliding piece for tightness.
» If the chain sliding piece is loose:
– Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)
B00824-01
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:

– Change the chain guide. x
400985-01
– Check the chain guide for tightness.

» If the chain guide is loose:
– Tighten the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
100865-10
Adjusting the chain tension

10.40
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

– Push the chain at the end of the chain sliding component upwards to measure
chain tension .
Info
The bottom chain section  must be taut.
When the chain guard is mounted, it must be possible to pull up the chain
at least to the point where it makes contact with chain guard .
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
101430-10
– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning adjusting screws  to the left and right.
Guideline
Chain tension 55… 58 mm (2.17… 2.28 in)
Turn adjusting screws  on the left and right so that the markings on the left
and right chain adjusters are in the same position relative to reference marks .
The rear wheel is then correctly aligned.
– Tighten nuts .
– Make sure that chain adjusters  are fitted correctly on adjusting screws .
– Tighten nut .
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary ratios with the same chain length.
Chain adjusters  can be turned by 180°.
B00825-10
Adjusting the chain guide

10.41 x
– Remove the nut of screw .
– Remove screws  and . Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .
Guideline
(7.4 lbf ft)
– Mount the nut on screw  and tighten.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)
Condition
Number of teeth: ≥ 45 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .
400252-10 Guideline
(7.4 lbf ft)
– Mount the nut on screw  and tighten.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)
Checking the frame

10.42 x
– Check the frame for cracking and deformation.
» If the frame exhibits cracking or deformation due to a mechanical impact:
– Change the frame. x
Info
A frame that has been damaged due to a mechanical impact must
always be changed. Repair of the frame is not authorized by KTM.
401347-01
Checking the swingarm

10.43 x
– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
– Change the swingarm. x
Info
A damaged swingarm must always be changed. Repair of the
swingarm is not authorized by KTM.
401341-01
Checking the throttle cable routing

10.44
– Remove the fuel tank. x( p. 58)

– Check the throttle cable routing.
The throttle cable must be routed to the carburetor on the left side of the
upper frame tube behind the handlebars.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
B00826-01

– Check the throttle cable routing.
The throttle cable must be routed to the carburetor on the left side of the
upper frame tube behind the handlebars.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
B00827-01
Checking the rubber grip

10.45
– Check the rubber grips on the handlebar for damage and wear and to ensure they
are firmly seated.
» If a rubber grip is damaged, worn, or loose:
– Change and secure the rubber grip.
Rubber grip adhesive (00062030051) ( p. 129)
401197-01
Additionally securing the rubber grip

10.46
– Check the rubber grip. ( p. 66)

– Secure the rubber grip at two points using the securing wire.
Securing wire (54812016000)
Wire twister forceps (U6907854)
The twisted wire ends face away from the hands and are bent toward the rub-
ber grip.
401198-01
Adjusting the basic position of the clutch lever

10.47

– Adjust the basic setting of the clutch lever to your hand size by turning adjust-
ing screw .
Info
Turn the adjusting screw counterclockwise to increase the distance
between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
B00001-11
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

– Adjust the basic setting of the clutch lever to your hand size by turning adjust-
ing screw .
Info
Turn the adjusting screw counterclockwise to decrease the distance
between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
B00009-11
Checking the fluid level of the hydraulic clutch

10.48
Info
The fluid level rises with increasing wear of the clutch lining discs.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-
tion.
– Remove cover  with membrane .
– Check the fluid level.
Fluid level under top edge of con- 4 mm (0.16 in)
tainer
400245-10
» If the level of the fluid does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 127)
– Position the cover with the membrane. Mount and tighten the screws.
tion.
– Check the fluid level.
tainer
B00040-10
» If the level of the fluid does not meet specifications:
Brake fluid DOT 4 / DOT 5.1 ( p. 126)
Changing the hydraulic clutch fluid

10.49 x
Warning

tion.
400245-10
– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Hydraulic fluid (15) ( p. 127)
– On the slave cylinder, remove bleeder screw  and mount bleeding syringe .
B00041-10
– Inject the liquid into the system until it escapes from hole  of the master
cylinder without bubbles.
– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
Guideline
tainer
400247-10
tion.
B00040-10
– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
– On the slave cylinder, remove bleeder screw  and mount bleeding syringe .
303440-10
– Inject the liquid into the system until it escapes from hole  of the master
cylinder without bubbles.
– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
Guideline
tainer
B00042-10
BRAKES 69
Checking free travel of hand brake lever

11.1
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due
to overheating. Adjust free travel on hand brake lever according to specifications.
(XC-W)
– Push the hand brake lever forwards and check free travel .
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the basic position of the hand brake lever. ( p. 69)
400196-11
(All EXC models)

– Push the hand brake to the handlebar and check free travel .
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
– Adjust the free travel of the hand brake lever. ( p. 69)
400196-13
Adjusting the basic position of the hand brake lever (XC-W)

11.2
– Check the free travel of the hand brake lever. ( p. 69)

– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing screw .
Info
Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.
400196-12 The range of adjustment is limited.
Adjusting free travel of hand brake lever (All EXC models)

11.3
– Check the free travel of the hand brake lever. ( p. 69)

– Adjust the free travel of the hand brake lever with the adjustment screw .
Info
Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
400196-12 Turn the adjusting screw by hand only, and do not apply any force.
BRAKES 70
Checking the brake discs

11.4
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
– Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement .
Info
A Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit

Front 2.5 mm (0.098 in)
400257-10 Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the brake disc.
– Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc exhibits damage, cracking or deformation:
– Change the brake disc.
Checking the front brake fluid level

11.5
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking effect caused by old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .
» If the brake fluid is below the MIN marking:
– Add front brake fluid. x( p. 70)
B00070-10
Adding front brake fluid

11.6 x
Warning
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
BRAKES 71
Warning
be glad to help.)
Warning
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
– Add brake fluid to level .
Guideline
Dimension  (brake fluid level below 5 mm (0.2 in)
top edge of container)

Info
Clean up overflowed or spilt brake fluid immediately with water.
600706-10
Checking the front brake linings

11.7
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings. x( p. 72)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the front brake linings. x( p. 72)
100394-10
BRAKES 72
Changing the front brake linings

11.8 x
Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Warning
be glad to help.)
Warning
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
brake fluid.
– Press the brake caliper onto the brake disc by hand in order to push back the brake
pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir,
using suction to remove it if it does.
Info
Make sure when pushing back the brake pistons that you do not press the
100395-10 brake caliper against the spokes.
– Remove locking split pins , withdraw bolt , and take out the brake linings.
– Clean the brake caliper and brake caliper support.
100396-10
BRAKES 73
– Check that leaf spring  in the brake caliper and sliding plate  in the brake
7
0 caliper support are seated correctly.
06 100397-01
– Fit the brake linings, insert the bolt, and mount the locking split pins.
– Operate the hand brake lever several times until the brake linings are lying correctly
against on the brake disc and there is a pressure point.
100398-10
– Correct the brake fluid quantity to level .

Guideline
Dimension  (brake fluid level below 5 mm (0.2 in)
top edge of container)

Info
100399-10
Checking the free travel of foot brake lever

11.9
Warning
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
– Disconnect spring .
– Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel .
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
– Adjust the basic position of the foot brake lever. x( p. 73)
– Reconnect spring .
B00028-10
Adjusting the basic position of the foot brake lever

11.10 x
Warning
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
BRAKES 74
– Disconnect spring .
– Loosen nut  and, with push rod , turn it back until you have maximum free
travel.
– To adjust the basic position of the foot brake lever individually, loosen nut  and
turn screw  accordingly.
Info
B00828-10 – Turn push rod  accordingly until you have free travel . If necessary, adjust the
basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
– Hold screw  and tighten nut .
Guideline
Nut, foot brake lever stop M8 30 Nm
(22.1 lbf ft)
– Hold push rod  and tighten nut .
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
– Reconnect spring .
Checking the rear brake fluid level

11.11
Warning
Warning
be glad to help.)
– Stand the vehicle upright.

– Check the brake fluid level in the viewer .
» If an air bubble is visible in viewer :
– Add brake fluid for the rear brake. x( p. 74)
B00829-10
Adding brake fluid for the rear brake

11.12 x
Warning
Warning
BRAKES 75
Warning
be glad to help.)
Warning
Info
brake fluid.

– Remove screw cap  with membrane  and the O-ring.
– Mount the screw cap with the membrane and the O-ring.
Info
400233-10
Checking the rear brake linings

11.13
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings. x( p. 76)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the rear brake linings. x( p. 76)
400238-10
Removing the rear brake linings

11.14 x
Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
– Remove locking split pins , withdraw bolt , and take out the brake linings.
– Clean the brake caliper and brake caliper support.
400236-10
BRAKES 76
Installing the rear brake linings

11.15 x
Warning
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
– Check the brake discs. ( p. 70)

– Check that leaf spring  in the brake caliper and sliding plate  in the brake
caliper support are seated correctly.
Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.
500122-10
– Insert the brake linings, insert bolt , and mount locking split pins .
Info
Make sure that the decoupling plate  is mounted on the piston side of the
brake lining.
– Operate the foot brake lever several times until the brake linings are lying correctly
against the brake disc and there is a pressure point.
400237-10
Changing the rear brake linings

11.16 x
Warning
Warning
be glad to help.)
Warning
Info
brake fluid.
BRAKES 77
– Remove the rear brake linings. x( p. 75)

– Remove screw cap  with membrane  and the O-ring.
– Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
– Install the rear brake linings. x( p. 76)
400233-10
– Mount the screw cap with the membrane and the O-ring.
Info
WHEELS, TIRES 78
Removing the front wheel

12.1 x
pistons.
Info
Make sure when pushing back the brake pistons that you do not press the
B00055-10
– Remove screw .
– Loosen screws .
500084-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
500085-10
– Remove spacers .
500086-10
Installing the front wheel

12.2 x
Warning
– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change the wheel bearing. x
– Clean and grease shaft seal rings  and bearing surface  of the spacers.
– Insert the spacers.
500086-11
WHEELS, TIRES 79
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
– Operate the hand brake lever several times until the brake linings are lying correctly
against on the brake disc.
500084-11
– Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
Removing the rear wheel

12.3 x
piston.
Info
Make sure when pushing back the brake piston that you do not press the
– Remove nut .
– Remove chain adjuster . Withdraw wheel spindle  only enough to allow the rear
wheel to be pushed forward.
– Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
B00830-10
– Remove spacers .
400260-11
Installing the rear wheel

12.4 x
Warning
WHEELS, TIRES 80
– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change the wheel bearing. x
– Clean and grease shaft seal rings  and bearing surface  of the spacers.
– Insert the spacers.
400260-10
– Lift the rear wheel into the swing arm, position it, and insert wheel spindle .
– Apply the chain.
B00831-10
– Position chain adjuster . Mount nut , but do not tighten it yet.

– Make sure that chain adjusters  are fitted correctly on adjusting screws .
– Check the chain tension. ( p. 61)
– Tighten nut .
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.18 in))
enables different secondary ratios with the same chain length.
Chain adjusters  can be turned by 180°.
– Operate the foot brake lever several times until the brake linings are lying correctly
against the brake disc and there is a pressure point.
B00825-11
Checking the tire condition

12.5
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tire exhibits cuts, run-in objects or other damage:
– Change the tire.
– Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum permissible depth:
WHEELS, TIRES 81

– Check the tire age.
Info
The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits indi-
cate the week of manufacture and the last two digits the year of manufac-
ture.
KTM recommends that the tires are changed at the latest after 5 years,
regardless of the actual state of wear.
» If the tire is older than five years:

Checking the tire air pressure

12.6
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
– Remove the dust cap.

– Check the tire air pressure when the tires are cold.
Tire air pressure off road
Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)
Tire air pressure, road (All EXC models)

400695-01
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.
Checking the spoke tension

12.7
Warning
Danger of accidents Instable handling due to incorrect spoke tension.
– Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
Info
A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
– Briefly strike each spoke with the tip of a screwdriver.
Info
The tone frequency depends on the length of the spoke and the spoke diam-
eter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.
You should hear a high note.

400694-01 » If the spoke tension varies:
– Correct the spoke tension. x
– Check the spoke torque.
WHEELS, TIRES 82
Guideline
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7…
4.4 lbf ft)
Spoke nipple, rear wheel M5 5… 6 Nm (3.7…
4.4 lbf ft)
Torque wrench with various accessories in set (58429094000)

ELECTRICAL SYSTEM 83
Removing the battery

13.1 x (All 250/300 models)
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
– Switch off all power consumers and switch off the engine.
– Disconnect the negative (minus) cable  of the battery.
– Pull back the plus pole cover  and disconnect the positive (plus) cable of the bat-
tery.
– Detach rubber band  at the bottom.
– Lift the battery out.
500069-10
Installing the battery

13.2 x (All 250/300 models)
– Insert the battery into the battery compartment with the terminals facing to the
front.
Battery (YTX4L-BS) ( p. 119)
– Attach rubber band .
– Connect the positive cable  and negative cable .
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
Info
Contact disks  must be mounted between battery terminals  and cable
sockets  with the claws facing up.
– Slide positive terminal cover  over the positive terminal.

101394-10
Recharging the battery

13.3 x (All 250/300 models)
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
– Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid .
400240-10
Charge the battery with at most 10% of the capacity specified on the bat-
tery .
– Switch off the charger after charging. Disconnect the battery.

Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the 3 months
motorcycle is not in use
Changing the main fuse (All 250/300 models)

13.4
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the filter box cover.
– Remove the air filter box lid. ( p. 56)
– Remove screw .
101395-10
– Lift rear fairing  slightly and pull starter relay  out of the bracket.
101396-10
– Remove the protection caps.

– Remove the faulty main fuse .
Info
A defective fuse is indicated by a burned-out fuse wire .
A reserve fuse  is located in the starter relay.
– Fit a new main fuse.

Fuse (58011109110)
B00832-10
– Check the functioning of the electrical equipment.
Tip
Insert the spare fuse so that it is available if needed.
– Fit the protection caps.

– Mount the starter relay onto the bracket and lay the cable.
– Position the rear fairing. Mount and tighten the screw.
Guideline
– Install the air filter box lid. ( p. 56)
Removing the headlight mask with the headlight (All EXC models)
13.5
– Switch off all power consumers.

– Remove screw  and take off the clamp.
– Release rubber band . Slide the headlight mask up and swing it forward.
B00833-10
– Disconnect the electrical plug-in connection  and take off the headlight mask
with the headlight.
303402-10
Refitting the headlight mask with the headlight (All EXC models)
13.6
– Connect the electric plug connector .
303402-11
– Position the headlight mask and fix it with the rubber band .
Info
Ensure that the holding lugs engage in the fender.
– Position the brake line and wiring harness. Put on the clamp and mount and
tighten screw .
– Check the headlight setting. ( p. 87)
B00833-11
Changing the headlight bulb (All EXC models)

13.7
Note
Damage to reflector Reduced luminance.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease
before mounting.

– Turn rubber cap  together with the underlying lamp socket counterclockwise all
the way and remove it.
– Pull lamp socket  of the parking light out of the reflector.
100861-10
– Press headlight bulb  lightly into the lamp socket, turn it counterclockwise and
pull it out.
– Insert the new headlight bulb.
Headlight (S2 / socket BA20d) ( p. 120)
– Insert the rubber cap with the lamp socket into the reflector and turn it clockwise
all the way.
Info
100862-10 Ensure that the O-ring  is seated properly.
– Insert the lamp socket of the parking light into the reflector.
Checking the headlight setting (All EXC models)

13.8
– Position the vehicle upright on a horizontal surface in front of a light wall and make
a mark at the height of the center of the low beam headlight.
A
0 – Make another mark a distance  under the first mark.
Guideline
Distance  5 cm (2 in)
0
B – Position the vehicle vertically a distance  away from the wall.
Guideline
Distance  5 m (16 ft)
400726-10
– The rider now sits down on the motorcycle.
– Switch on the low beam.
– Check the headlight setting.
The boundary between light and dark must be exactly on the lower mark for an
operational motorcycle with a rider.
» If the light-dark border does not meet specifications:
– Adjust the headlight range. ( p. 87)
Adjusting the headlight range (All EXC models)

13.9
– Check the headlight setting. ( p. 87)

– Loosen screw .
– Adjust the headlight range by moving the headlight.
Guideline
The boundary between light and dark must be exactly on the lower mark for an
operational motorcycle with a rider (to prepare the mark, see: Checking the head-
light setting).
Info
301251-10
The headlight range may need to be corrected if luggage is carried on the
vehicle.
– Tighten screw .
Changing the speedometer battery

13.10
(All EXC models)

(XC-W)
– Remove the start number plate. ( p. 53)
– Pull the speedometer up and out of the holder.
100859-10
– Turn locking cap  counterclockwise all the way using a coin and remove it.
– Remove speedometer battery .
– Insert the new battery with the lettering facing up.
Speedometer battery (CR 2430)
– Check that the O-Ring of the locking cap is seated properly.
100860-10
– Position locking cap  and turn it clockwise all the way using a coin.
– Press any button on the speedometer.
The speedometer is activated.
– Position the speedometer in the holder.
– Mount and tighten the screws with the washers.
(All EXC models)
(XC-W)
100864-10 – Install the start number plate. ( p. 53)
– Set kilometers or miles. ( p. 15)
– Adjust the speedometer functions. ( p. 16)
– Set the clock. ( p. 16)
COOLING SYSTEM 89
Cooling system
14.1

Water pump  in the engine circulates the coolant.
The pressure resulting from the warming of the cooling system is regulated by a
valve in radiator cap . This ensures that operating the vehicle at the specified
coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the
cooling effect.
B00834-10

Water pump  in the engine circulates the coolant.
The pressure resulting from the warming of the cooling system is regulated by a
valve in radiator cap . This ensures that operating the vehicle at the specified
coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the
cooling effect.
B00835-10
Checking the antifreeze and coolant level

14.2
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant antifreeze.
−25… −45 °C (−13… −49 °F)
» If the coolant antifreeze does not meet specifications:
– Correct the coolant antifreeze.
– Check the coolant level in the radiator.
400243-10 Coolant level  above the radiator fins. 10 mm (0.39 in)
» If the level of the coolant does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 126)
Alternative 2
Coolant (mixed ready to use) ( p. 126)
– Mount the radiator cap.
COOLING SYSTEM 90
Checking the coolant level

14.3
Warning
Warning
Condition
The engine is cold.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level  above the radiator fins. 10 mm (0.39 in)
» If the level of the coolant does not meet specifications:
– Correct the coolant level.
Alternative 1
400243-10 Coolant ( p. 126)
Alternative 2
– Mount the radiator cap.
Draining the coolant

14.4 x
Warning
Warning
Condition
The engine is cold.
– Position the motorcycle upright.
– Place a suitable container under the water pump cover.
– Remove screw . Remove radiator cap .
– Completely drain the coolant.
– Mount screw  with a new seal ring and tighten it.
Guideline
Drain plug, water pump cover M10x1 15 Nm
(11.1 lbf ft)
B00834-11
COOLING SYSTEM 91

– Remove screw . Remove radiator cap .
– Completely drain the coolant.
– Mount screw  with a new seal ring and tighten it.
Guideline
Drain plug, water pump cover M10x1 15 Nm
(11.1 lbf ft)
B00835-11
Refilling with coolant

14.5 x
Warning

– Make sure that screw  is tightened.
– Stand the motorcycle upright.
– Fill the radiator completely with coolant.
Coolant 1.2 l (1.3 qt.) Coolant ( p. 126)
Coolant (mixed ready to use)
( p. 126)
B00071-10
– Loosen screw  until coolant that does not contain any bubbles escapes.
Replace and retighten screw .
Guideline
Bleeder screw, cylinder head M6 10 Nm
(7.4 lbf ft)
B00091-10

– Make sure that screw  is tightened.
– Stand the motorcycle upright.
( p. 126)
B00072-10
– Position the vehicle as shown and secure it against rolling away. A height differ-
ence of  must be reached.
Guideline
Height difference  75 cm (29.5 in)
Info
To ensure that all of the air can escape from the cooling system, the
A
0 front of the vehicle must be jacked up. A poorly bled cooling system is
less effective at cooling and may result in overheating of the engine.
400677-10
– Place the vehicle back on a level surface.
COOLING SYSTEM 92

– Mount radiator cap .
– Run the engine until it is warm.
B00836-10
TUNING THE ENGINE 93
Checking the play in the throttle cable

15.1
– Check the throttle grip for smooth operation.

– Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable. x( p. 93)
Danger
400192-10 Danger of poisoning Exhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
– Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. x( p. 93)
Adjusting the play in the throttle cable

15.2 x
– Remove the fuel tank. x( p. 58)
– Expose the throttle cable.
– Move the handlebar to the straight-ahead position.
– Push back sleeve .
– Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster .
– Push back sleeve .
– Loosen nut .
– Turn barrel adjuster  until throttle cable play  exists at the bottom throttle
cable sleeve.
Guideline
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
– Tighten nut .
– Slide on sleeves  and .
– Route the throttle cable and fasten it.
– Install the fuel tank. x( p. 59)
– Check the throttle grip for smooth operation.
800216-10
Carburetor
15.3
The idle setting of the carburetor has a big influence on the starting behavior, stable
idling and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.
Info
The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.
The factory setting for the carburetor is set for the following values.
B00048-11 Elevation above sea level 500 m (1,640 ft)

Ambient temperature 20 °C (68 °F)
Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 127)
The idle speed is adjusted with adjusting screw .
The idle mixture is adjusted with the idle air adjusting screw .
Idle air range A

D
0 Operation with the throttle slide closed. This range is influenced by adjusting screw 
and the idle air adjusting screw .
Transition range B
0
C Behavior of the engine when the throttle slide is being opened. This range is influenced
by the idling jet and by the form of the throttle slide.
If the engine sputters and smokes heavily when it starts despite a good idle and part-
0
B load setting, and if it abruptly reaches full power at a high rpm, the carburetor setting
A
0 is too rich, or the float level is too high or the float needle valve is leaky.
500282-01 Part-load range C
Operation with the throttle slide partially open. This range is influenced by the jet
needle (form and position). The idle setting influences the engine tuning in the lower
range, and the main jet influences the engine tuning in the upper range.
If the engine stutters when accelerating with a partially open throttle slide, the jet nee-
dle must be lowered by one notch. If the engine knocks when accelerating at the full
power rpm range, the jet needle must be raised. If the above events occur on idle or
just above it, the idle system must be set to a leaner setting if the engine is stuttering
or to a richer setting if the engine is knocking.
Full-load range D
Operation with the throttle slide open (full throttle). This range is influenced by the
main jet and jet needle.
If the insulator of a new spark plug is very light or white after a brief ride at full throt-
tle, or if the engine knocks, a larger main jet needs to be used. If the insulator is dark
brown or sooty, a smaller main jet needs to be used.
Carburetor - adjusting the idle speed

15.4 x
– Screw in idle air adjusting screw  all the way and turn it to the specified basic
position.
Guideline
Idle air adjusting screw (125 EXC EU, 125 EXC SIX DAYS EU)
Open 2.75 turns
Idle air adjusting screw (XC-W)
Open 2.0 turns
Idle air adjusting screw (200 EXC EU)
B00048-11
Open 1.5 turns
Idle air adjusting screw (200 EXC AUS)
Open 1.0 turn
Idle air adjusting screw (250/300 EXC AUS)
Open 3.5 turns
Open 1.5 turns
Open 1.75 turns
– Run the engine until warm.
Guideline
Warm-up time ≥ 5 min
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may
– Adjust the idle speed with adjusting screw .

Guideline
Idle speed 1,400… 1,500 rpm
– Turn idle air adjusting screw  slowly in a clockwise direction until the idle speed
begins to fall.
– Note the position and turn the idle air adjusting screw slowly counterclockwise until
the idle speed falls again.
– Adjust to the point between these two positions with the highest idle speed.
Info
If there is a large engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of
engine speed, you need to install a smaller idling jet.
After changing the idling jet, repeat the adjusting steps from the beginning.
Following extreme air temperature or altitude changes, adjust the idle speed
again.
Emptying the carburetor float chamber

15.5 x
Danger
Warning
Warning
Info
Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.

No more fuel flows from the tank to the carburetor.
– Place a cloth beneath the carburetor to soak up emerging fuel.
– Remove plug .
– Completely drain the fuel.
– Mount and tighten the plug.
B00047-10
Checking the basic position of the shift lever

15.6
– Sit on the vehicle in the riding position and determine the distance  between the
upper edge of your boot and the shift lever.
Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in)
edge of boot
» If the distance does not meet specifications:
A
0 – Adjust the basic position of the shift lever. x( p. 96)
400692-10
Adjusting the basic position of the shift lever

15.7 x
– Remove screw  and remove shift lever .
B00065-10
– Clean gear teeth  of the shift lever and shift shaft.

– Mount the shift lever on the shift shaft in the required position and engage the
gearing.
Info
The shift lever must not come into contact with any other vehicle compo-
nents during the shift procedure.
B00066-10
– Mount and tighten the screw.
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 lbf ft)
Engine characteristic - auxiliary spring (All 250/300 models)

15.8
The auxiliary spring is located on the right side of the engine below the water pump
cover.
Possible states
• Auxiliary spring with yellow marking – Auxiliary spring mounted at the factory with
medium tuning (standard) for good rideability.
1
0 • Auxiliary spring with green marking – Auxiliary spring contained in the separate
enclosure for softer performance.
• Auxiliary spring with red marking – Auxiliary spring contained in the separate
enclosure for more aggressive performance.
B00056-10 The engine characteristic can be influenced by different spring strengths of the auxil-
iary spring .
Engine characteristic - adjusting the auxiliary spring

15.9 x (All 250/300 models)
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
– Tilt the motorcycle approx. 45º to the left and secure it in this position to prevent it
from falling over.
B00057-10
– Take locking cap , adjusting spring , auxiliary spring  and spring insert  out
0
2 of the clutch cover.
– Pull both springs off of the spring insert.
3
0
4
0
0
5
B00056-11
– Mount the desired auxiliary spring  and adjusting spring  and slide them into
the clutch cover together.
Auxiliary spring with yellow marking (54637072300)
Auxiliary spring with green marking (54837072100)
Auxiliary spring with red marking (54837072000)
The cut-out of spring insert  engages in the angle lever.
Info
B00058-10 Under no circumstances should screw  be turned as this would have a
negative effect on the engine characteristic.
– Check the O-ring in the locking cap.

– Position the locking cap.
– Mount and tighten the screws.
Guideline
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft)
SERVICE WORK ON THE ENGINE 98
Checking the gear oil level

16.1
Info
The gear oil level must be checked when the engine is cold.

– Remove gear oil level check screw .
– Check the gear oil level.
A small amount of gear oil should flow out of the hole.
» If no gear oil flows out:
– Add gear oil. x( p. 100)
– Mount and tighten the gear oil level check screw.
B00049-10 Guideline
Screw, gear oil level check M6 10 Nm
(7.4 lbf ft)
– Check the gear oil level.
A small amount of gear oil should flow out of the hole.
» If no gear oil flows out:
– Add gear oil. x( p. 100)
B00050-10 Guideline
(7.4 lbf ft)
Changing the gear oil

16.2 x
– Drain the gear oil. x( p. 99)
400721-01
– Refill with gear oil. x( p. 99)
400722-01
Draining the gear oil

16.3 x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Info
Drain the gear oil only when the engine is warm.
– Place the motorcycle on a level surface.

– Place a suitable container under the engine.
– Remove the gear oil drain plug with magnet .
– Remove the gear oil drain plug .
– Completely drain the gear oil.
– Clean the gear oil drain plug thoroughly.
– Clean the sealing area on the engine.
– Mount the gear oil drain plug with magnet  and the seal ring and tighten it.
Guideline
B00051-10
Gear oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
– Mount gear oil drain plug  with the seal ring and tighten it.
Guideline
Gear oil drain plug M10x1 15 Nm
(11.1 lbf ft)
– Remove the gear oil drain plug with magnet .
– Completely drain the gear oil.
– Thoroughly clean the gear oil drain plug with a magnet.
– Clean the sealing area on the engine.
– Mount the gear oil drain plug with magnet  and the seal ring and tighten it.
Guideline
Gear oil drain plug with magnet M12x1.5 20 Nm
B00052-10 (14.8 lbf ft)
Refilling with gear oil

16.4 x
Info
Too little gear oil or poor-quality oil results in premature wear of the transmission.
– Remove screw cap  and fill up gear oil.

Gear oil 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 126)
(All 125/200
models)
Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 126)
(All 250/300 mod-
els)
– Mount and tighten the screw cap.
B00053-10
Danger
– Start the engine and check that it is oil-tight.

– Check the gear oil level. ( p. 98)
Adding gear oil

16.5 x
Info
Too little gear oil or poor-quality oil results in premature wear of the transmission.
The gear oil must be added when the engine is cold.
– Place the motorcycle on a level surface.

B00049-10

B00050-10
– Remove screw cap .

– Add gear oil until it flows out of the hole of the gear oil level check screw.
Engine oil (15W/50) ( p. 126)
Guideline
(7.4 lbf ft)
B00053-11
(7.4 lbf ft)
– Mount and tighten screw cap .
Danger
– Start the engine and check that it is oil-tight.

CLEANING, CARE 101
Cleaning the motorcycle

17.1
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-
cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunlight on the motorcycle during cleaning.
– Close off the exhaust system to prevent water from entering.

– Remove coarse dirt particles by spraying gently with water.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft
brush.
Motorcycle cleaner ( p. 128)
Info
Clean the vehicle with warm water containing normal motorcycle cleaner
401061-01 and a soft sponge.
– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
– Empty the carburetor float chamber. x( p. 95)
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– After cleaning, take a short ride until the engine reaches operating temperature.
Info
The heat produced causes water at inaccessible positions in the engine and
the brakes to evaporate.
– Push back the protection caps on the handlebar controls to allow water that may
have penetrated there to evaporate.
– After the motorcycle has cooled down, lubricate all moving parts and bearings.
– Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 128)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care prod-
uct.
Cleaning and preserving materials for metal, rubber and plastic ( p. 128)
(All EXC models)
– Lubricate the steering lock.
Universal oil spray ( p. 129)
CLEANING, CARE 102
Checks and maintenance steps for winter operation

17.2
Info
If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against the aggressive
road salt.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of
salt.

– Clean the brakes.
Info
After EVERY trip on salted roads, thoroughly wash the brake calipers and
brake linings with cold water and dry carefully. This should be done after
the parts are cooled down and while they are installed.
After riding on salted roads, thoroughly wash the motorcycle with cold water
and dry it well.
401060-01
– Treat the engine, swingarm and all other bright and zinc-plated parts (except for
the brake discs) with a wax-based corrosion inhibitor.
Info
Corrosion inhibitor is not permitted to come in contact with the brake discs
as this would greatly reduce the braking force.

STORAGE 103
Storage
18.1
Warning
Info
If you want to put the motorcycle into storage for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– Change the gear oil. x( p. 98)
– Check the antifreeze and coolant level. ( p. 89)
– Drain the fuel from the tank into a suitable container.
– Empty the carburetor float chamber. x( p. 95)
– Check the tire air pressure. ( p. 81)
– Remove the battery. x( p. 83)
401058-01
– Recharge the battery. x ( p. 83)
Guideline
Storage temperature of battery with- 0… 35 °C (32… 95 °F)
out direct sunlight
– Store the vehicle in a dry location that is not subject to large fluctuations in tem-
perature.
Info
KTM recommends raising the motorcycle.

– Cover the vehicle with a tarp or cover that is permeable to air.
Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Because the engine will not
warm up sufficiently, the water vapor produced during combustion will con-
dense, causing engine parts and the exhaust system to rust.
Preparing for use after storage

18.2

– Recharge the battery. x( p. 83)
– Install the battery. x( p. 83)
– Refuel. ( p. 32)
– Perform checks and maintenance work when preparing the vehicle for use.
( p. 30)
401059-01 – Make a test ride.
TROUBLESHOOTING 104
Faults Possible cause Action

The engine cannot be cranked (elec- Operating error – Go through the steps of starting the engine.
tric starter) ( p. 30)
(All 250/300 models) Battery discharged – Recharge the battery. x( p. 83)
– Check the charging voltage.x
– Check the closed current. x
– Check the alternator. x
Main fuse is blown – Remove the main fuse.
– Install the main fuse.
Starter relay faulty – Check the starter relay.x
Starter motor faulty – Check the starter motor. x
Engine turns but does not start Operating error – Go through the steps of starting the engine.
( p. 30)
Motorcycle was out of use for a long – Empty the carburetor float chamber. x
time and there is old fuel in the float ( p. 95)
chamber
Fuel feed interrupted – Check the fuel tank breather.
– Clean the fuel tap.
– Check/set the carburetor components.
Spark plug oily or wet – Clean and dry the spark plug, or change it if
necessary.
Electrode distance (plug gap) of spark – Adjust the plug gap.
plug too wide Guideline
Spark plug electrode gap
0.60 mm (0.0236 in)
Spark plug electrode gap
0.60 mm (0.0236 in)
Fault in ignition system – Check the ignition system. x
Short circuit cable in wiring harness – Check the kill switch. x
frayed, kill switch defective
Socket connector or ignition coil is – Clean the plug-in connector and treat it with
loose or oxidized contact spray.
Water in carburetor or jets blocked – Check/set the carburetor components.
Engine has no idle Idling jet blocked – Check/set the carburetor components.
Adjusting screws on carburetor dis- – Carburetor - adjust the idle speed. x
torted ( p. 94)
Spark plug defective – Change the spark plug.
Ignition system defective – Check the ignition coil. x
– Check the spark plug connector. x
Engine does not speed up Carburetor running over because float – Check/set the carburetor components.
needle dirty or worn
Loose carburetor jets – Check/set the carburetor components.
Engine has too little power Fuel feed interrupted – Check the fuel tank breather.
– Clean the fuel tap.
– Check/set the carburetor components.
Air filter very dirty – Clean the air filter and air filter box. x
( p. 57)
Exhaust system leaky, deformed or – Check exhaust system for damage.
too little glass fiber yarn filling in – Change the glass fiber yarn filling of the main
main silencer silencer. x( p. 58)
Diaphragm or reed valve housing – Check the diaphragm and reed valve housing.
damaged
TROUBLESHOOTING 105
Faults Possible cause Action

Engine stalls or is popping into the Lack of fuel – Turn handle  of the fuel tap to the ON posi-
carburetor tion.
– Refuel. ( p. 32)
Engine takes in bad air – Check the intake flange and carburetor for
tightness.
Socket connector or ignition coil is – Clean the plug-in connector and treat it with
loose or oxidized contact spray.
Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.
Too little air stream – Switch off engine when stationary.
Radiator fins very dirty – Clean the radiator fins.
Foam formation in cooling system – Drain the coolant. x( p. 90)
– Refill with coolant. x ( p. 91)
Damaged cylinder head or cylinder – Check the cylinder head or cylinder head gas-
head gasket ket.
Bent radiator hose – Change the radiator hose. x
Incorrect ignition point due to loose (All 125/200 models)
stator – Adjust the ignition. x
White smoke emission (steam in Damaged cylinder head or cylinder – Check the cylinder head or cylinder head gas-
exhaust gas) head gasket ket.
Gear oil exits at the vent hose Too much gear oil added – Check the gear oil level. ( p. 98)
Water in the gear oil Damaged shaft seal ring or water – Check the shaft seal ring and water pump.
pump
TECHNICAL DATA - ENGINE 106
125 EXC EU, 125 EXC SIX DAYS EU

20.1
Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and

exhaust control
Displacement 124.8 cm³ (7.616 cu in)
Stroke 54.5 mm (2.146 in)
Bore 54 mm (2.13 in)
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in)
Z (height of control flap) 43.7 mm (1.72 in)
Primary transmission 23:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear, claw shifted
Transmission ratio
1st gear 12:33
2nd gear 15:31
3rd gear 17:28
4th gear 19:26
5th gear 21:25
6th gear 20:20
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Ignition point (BTDC) 1.4 mm (0.055 in)
Spark plug NGK BR9 ECMVX
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter
All 200 models

20.2

exhaust control
Displacement 193 cm³ (11.78 cu in)
Stroke 60 mm (2.36 in)
Piston rings 2 rectangular rings
Z (height of control flap) 47 mm (1.85 in)
Transmission ratio
1st gear 12:33
2nd gear 15:31
3rd gear 17:28
4th gear 19:26
5th gear 17:19
6th gear 22:20

Spark plug NGK BR 8 EG
Starting aid Kick starter
All 250 models

20.3

exhaust control
Bore 66.4 mm (2.614 in)
Exhaust valve - Beginning of adjustment 5,600 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,200 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,900 rpm
Exhaust valve - end of adjustment with green auxiliary spring 8,400 rpm
Piston rings 2 half keystone rings
Z (height of control flap) 48 mm (1.89 in)
Transmission ratio
1st gear 14:32
2nd gear 16:26
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Spark plug NGK BR 7 ES
Starting aid Kick starter and electric starter
All 300 models

20.4

exhaust control
Exhaust valve - Beginning of adjustment 5,600 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,200 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,900 rpm
Exhaust valve - end of adjustment with green auxiliary spring 8,400 rpm

Piston rings 2 rectangular rings
Z (height of control flap) 48.5 mm (1.909 in)
Transmission ratio
1st gear 14:32
2nd gear 16:26
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Spark plug NGK BR 7 ES
Starting aid Kick starter and electric starter
Capacity - transmission oil

20.5
Gear oil (All 125/200 models) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 126)
Gear oil (All 250/300 models) 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 126)
Capacity - coolant
20.6

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 109
All 125/200 models

21.1
Screw, membrane M4 2 Nm (1.5 lbf ft) Loctite® 243™

Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, alternator cover M5 5 Nm (3.7 lbf ft) –
Screw, centrifugal timer M5 8 Nm (5.9 lbf ft) Loctite® 243™
Screw, exhaust control cover M5 5 Nm (3.7 lbf ft) –
Screw, exhaust flange M5 6 Nm (4.4 lbf ft) –
Screw, ignition system/stator M5 6 Nm (4.4 lbf ft) Loctite® 222
Screw, lock washer, axle for control M5 6 Nm (4.4 lbf ft) Loctite® 243™
flap
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, water pump wheel M5 6 Nm (4.4 lbf ft) Loctite® 243™
Adjustment cable, exhaust control M6 10 Nm (7.4 lbf ft) Loctite® 243™
Bleeder screw, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, exhaust control M6 10 Nm (7.4 lbf ft) –
Screw, gear oil level check M6 10 Nm (7.4 lbf ft) –
Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) –
Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, shifting gate M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, water pump cover M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, cylinder head M7 18 Nm (13.3 lbf ft) –
Axle for control flap, exhaust control M8 Step 1 –
3 Nm (2.2 lbf ft)
Step 2 (loosen, counter-
clockwise)
1/4 turn
Nut, cylinder base M8 30 Nm (22.1 lbf ft) –
Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, shift drum locating M8 25 Nm (18.4 lbf ft) Loctite® 243™
Stud, cylinder base M8 35 Nm (25.8 lbf ft) –
Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) –
Gear oil drain plug M10x1 15 Nm (11.1 lbf ft) –
Nut, rotor M12x1 60 Nm (44.3 lbf ft) –
Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Spark plug M14x1.25 25 Nm (18.4 lbf ft) –
Nut, primary gear M16LHx1.5 130 Nm (95.9 lbf ft) Loctite® 243™
Nut, inner clutch hub M18x1.5 130 Nm (95.9 lbf ft) Loctite® 243™
Cap nut, exhaust control M26x1 35 Nm (25.8 lbf ft) –
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 110
All 250/300 models

21.2
Screw, angle lever, exhaust control M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft) –
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, retaining bracket of exhaust M5 7 Nm (5.2 lbf ft) Loctite® 243™
control
Screw, water pump wheel M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, alternator cover M6 8 Nm (5.9 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, control flap, exhaust control M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 8 Nm (5.9 lbf ft) –
Screw, gear oil level check M6 10 Nm (7.4 lbf ft) –
Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) –
Screw, intermediate wheel bolt M6 8 Nm (5.9 lbf ft) Loctite® 648™
Screw, kick starter spring M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift drum bearing retainer M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, starter motor M6 8 Nm (5.9 lbf ft) –
Screw, stator M6 8 Nm (5.9 lbf ft) Loctite® 243™
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, cylinder head M8 27 Nm (19.9 lbf ft) –
Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite® 243™
Nut, cylinder base M10 35 Nm (25.8 lbf ft) –
Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) –
Nut, rotor M12x1 60 Nm (44.3 lbf ft) –
Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Spark plug M14x1.25 25 Nm (18.4 lbf ft) –
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite® 648™
Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite® 648™
TECHNICAL DATA - CARBURETOR 111

22.1
Carburetor type KEIHIN PWK 36S AG

Carburetor identification number FK125
Needle position 4th position from top
Jet needle N84I (NOZF / NOZG / NOZH)
Main jet 100 (168/170/172)
Idling jet 38X38 (45)
Starting jet 50 (85)
Idle air adjusting screw
Open 2.75 turns
Throttle slide 7 with cut-out
Slide stop -
200 EXC EU
22.2

Needle position 3rd position from top
Jet needle NPRH (NOZH / NOZI / NOZJ)
Main jet 100 (160 / 162)
Idling jet 35x35 (42)
Open 1.5 turns
Slide stop Present
200 EXC AUS

22.3

Needle position 3rd position from top
Jet needle R1475J (NOZH / NOZI / NOZJ)
Main jet 162 (160)
Idling jet 35 (42)
Starting jet 85
Open 1.0 turn
Slide stop Present
200 XC‑W USA

22.4

Carburetor identification number BC2 0
Jet needle NOZI (NOZH / NOZJ)
Main jet 160 (162)
Idling jet 42
Starting jet 85
Open 2.0 turns
Slide stop -

22.5

Needle position 2nd position from top
Jet needle N84K (N8RW / N8RJ / N8RK)
Main jet 110 (162/165)
Open 1.5 turns
Slide stop Present
250 EXC AUS

22.6

Carburetor identification number 3600C
Needle position 1st position from top
Jet needle N3CJ (N8RW / N8RJ / N8RK / N2ZK / N2ZJ / N2ZL)
Main jet 160 (162/165)
Idling jet 35
Starting jet 85
Open 3.5 turns
Slide stop Present
250 XC‑W USA

22.7

Jet needle N8RJ (N8RW / N8RK)
Main jet 165 (162)
Idling jet 35
Starting jet 85
Open 2.0 turns
Slide stop -

22.8

Needle position 2nd position from top
Jet needle N84K (N2ZJ / N2ZK / N2ZL)
Main jet 115 (162/165)
Open 1.75 turns
Slide stop Present
300 EXC AUS

22.9

Carburetor identification number 3600C
Needle position 1st position from top
Jet needle N3CJ (N8RW / N8RJ / N8RK / N2ZK / N2ZJ / N2ZL)
Main jet 160 (162/165)
Idling jet 35
Starting jet 85
Open 3.5 turns
Slide stop Present
300 XC‑W USA

22.10

Jet needle N2ZK (N2ZJ / N2ZL)
Main jet 165 (162)
Idling jet 35
Starting jet 85
Open 2.0 turns
Slide stop -
Carburetor configuration (125 EXC EU, 125 EXC SIX DAYS EU)
22.11 x
Danger
Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous
(reduced) version only.
– In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
401348-01
M/FT ASL Sea level

TEMP Temperature
ASO Idle air adjusting screw is open
IJ Idling jet
NDL Needle
POS Needle position from above
MJ Main jet
Does not apply to sand surfaces!
Carburetor configuration (All 200 models)

22.12 x
Danger
401042-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet

22.13 x
Danger
401043-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet

22.14 x
Danger
401044-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
General carburetor configuration

22.15 x
1... 5 Needle position from above
The five needle positions are shown here.
0
1 The carburetor configuration depends on the defined ambient and operating conditions.
0
2
30
4
0
5
0
B00075-10
TECHNICAL DATA - CHASSIS 119
Frame Central tube frame made of chrome molybdenum steel tubing

Fork WP Suspension Up Side Down 4860 MXMA PA
Suspension travel
Front 300 mm (11.81 in)
Rear 335 mm (13.19 in)
Fork offset 22 mm (0.87 in)
Shock absorber WP Suspension PDS 5018 DCC
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter
Front 260 mm (10.24 in)
Rear 220 mm (8.66 in)
Brake discs - wear limit
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
Tire air pressure, road (All EXC models)
Tire air pressure off road
Secondary ratio (125 EXC EU, 125 EXC SIX DAYS EU) 14:50 (13:50)
Secondary ratio (200 EXC EU, 200 EXC AUS) 14:45
Secondary ratio (All 250/300 EXC models) 14:50 (13:50)
Secondary ratio (250/300 XC‑W) 13:50
Secondary ratio (200 XC‑W USA) 14:48
Chain 5/8 x 1/4"
Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase (All 125/200 models) 1,471±10 mm (57.91±0.39 in)
Wheelbase (All 250/300 models) 1,482±10 mm (58.35±0.39 in)
Seat height unloaded 960 mm (37.8 in)
Ground clearance unloaded 355 mm (13.98 in)
Weight without fuel, approx. (200 EXC EU, 200 EXC AUS) 97 kg (214 lb.)
Weight without fuel, approx. (125 EXC EU, 95 kg (209 lb.)
125 EXC SIX DAYS EU, 200 XC‑W USA)
Weight without fuel, approx. (All 250/300 EXC models) 104 kg (229 lb.)
Weight without fuel, approx. (250/300 XC‑W) 102 kg (225 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)
Battery (All 250/300 models) YTX4L-BS Battery voltage: 12 V

Nominal capacity: 3 Ah
maintenance-free
TECHNICAL DATA - CHASSIS 120
Lighting equipment
23.1
Headlight (All EXC models) S2 / socket BA20d 12 V

35/35 W
Parking light (All EXC models) W5W / socket W2.1x9.5d 12 V
5W
Indicator lamps (All EXC models) W2.3W / socket W2x4.6d 12 V
2.3 W
Turn signal (All EXC models) R10W / socket BA15s 12 V
10 W
Brake/tail light (All EXC models) LED
License plate lamp (All EXC models) W2.3W / socket W2.1x4.6d 12 V
2.3 W
Tires
23.2
Validity Front tire Rear tire

(All 125/200 EXC models) 90/90 - 21 M/C 54M M+S TT 120/90 - 18 M/C 65M M+S TT
Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME
(All 250/300 EXC models) 90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT
Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME
(200 XC‑W USA) 80/100 - 21 51M TT 100/100 - 18 59M TT
Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51
(250/300 XC‑W) 80/100 - 21 51M TT 110/100 - 18 64M TT
Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51
Additional information is available in the Service section under:
http://www.ktm.com
Capacity - fuel
23.3
Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)
approx. (EXC EU, ( p. 127)
EXC SIX DAYS)
Total fuel tank capacity, 10 l (2.6 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)
approx. (EXC AUS, XC‑W) ( p. 127)
Fuel reserve, approx. (EXC EU, EXC SIX DAYS) 2 l (2 qt.)

Fuel reserve, approx. (EXC AUS, XC‑W) 2.5 l (2.6 qt.)
TECHNICAL DATA - FORK 121
All 125/200 models

24.1
Fork part number 14.18.7L.61

Compression damping
Comfort 24 clicks
Standard 22 clicks
Sport 20 clicks
Rebound damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Spring length with preload spacer(s)
Weight of rider: 65… 75 kg (143… 165 lb.) 513 mm (20.2 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 3.8 N/mm (21.7 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 4.2 N/mm (24 lb/in)
Fork length 940 mm (37.01 in)
Air chamber length 110+10 +0.39
−20 mm (4.33−0.79 in)
Fork oil per fork leg 620 ml (20.96 fl. oz.) Fork oil (SAE 5) ( p. 126)
All 250/300 models

24.2
Fork part number 14.18.7L.63

Compression damping
Comfort 24 clicks
Standard 22 clicks
Sport 20 clicks
Rebound damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Spring length with preload spacer(s)
TECHNICAL DATA - FORK 122

Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.) 4.2 N/mm (24 lb/in)
Fork length 940 mm (37.01 in)
Air chamber length 110+10 +0.39
−20 mm (4.33−0.79 in)
Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 5) ( p. 126)
TECHNICAL DATA - SHOCK ABSORBER 123
All 125/200 models

25.1
Shock absorber part number 12.18.7L.61

Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Rebound damping
Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Sport 22 clicks
Spring preload
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 63 N/mm (360 lb/in)
Spring length 250 mm (9.84 in)
Gas pressure 10 bar (145 psi)
Static sag 33… 35 mm (1.3… 1.38 in)
Riding sag 105… 115 mm (4.13… 4.53 in)
Fitted length 417 mm (16.42 in)
Shock absorber oil ( p. 127) SAE 2.5
All 250/300 models

25.2
Shock absorber part number 12.18.7L.63

Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Rebound damping
Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
TECHNICAL DATA - SHOCK ABSORBER 124
Spring preload
Spring rate
Spring length 250 mm (9.84 in)
Gas pressure 10 bar (145 psi)
Static sag 33… 35 mm (1.3… 1.38 in)
Riding sag 105… 115 mm (4.13… 4.53 in)
Fitted length 417 mm (16.42 in)
Shock absorber oil ( p. 127) SAE 2.5
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 125
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –

Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot M6 10 Nm (7.4 lbf ft) Loctite® 243™
brake cylinder
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Nut, foot brake lever stop M8 30 Nm (22.1 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 2701
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
(EXC SIX DAYS)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, side stand attachment M8 40 Nm (29.5 lbf ft) Loctite® 2701
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite® 2701
Screw, top steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243™
(EXC SIX DAYS)
Screw, top triple clamp (EXC EU/AUS, M8 20 Nm (14.8 lbf ft) –
XC‑W)
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
(EXC SIX DAYS)
Engine bracket screw M10 60 Nm (44.3 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™
Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite® 2701
Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite® 2701
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite® 243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
SUBSTANCES 126
2-stroke engine oil

According to
– JASO FC ( p. 130)
Guideline
– Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex® products.
Fully synthetic
Supplier
Motorex®
– Cross Power 2T
Brake fluid DOT 4 / DOT 5.1

According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
−49 °F) 50 % distilled water

Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
– Anti Freeze
Engine oil (15W/50)

According to
– JASO T903 MA ( p. 130)
– SAE ( p. 130) (15W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Top Speed 4T
Fork oil (SAE 5)

According to
– SAE ( p. 130) (SAE 5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Racing Fork Oil
SUBSTANCES 127
Hydraulic fluid (15)

According to
– ISO VG (15)
Guideline
– Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 130) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.
Super unleaded (ROZ 95/RON 95/PON 91)

According to
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)

According to
– DIN EN 228
– JASO FC ( p. 130) (1:60)
Mixture ratio
1:60 2-stroke engine oil ( p. 126)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 127)
Supplier
Motorex®
– Cross Power 2T
AUXILIARY SUBSTANCES 128
Air filter cleaner

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Twin Air Dirt Bio Remover
Chain cleaner
Guideline
Supplier
Motorex®
– Chain Clean
Cleaning and preserving materials for metal, rubber and plastic

Guideline
Supplier
Motorex®
– Protect & Shine
High viscosity grease

Guideline
– KTM recommends SKF® products.
Supplier
SKF®
– LGHB 2
Long-life grease
Guideline
Supplier
Motorex®
– Bike Grease 2000
Motorcycle cleaner
Guideline
Supplier
Motorex®
– Moto Clean 900
Off-road chain spray

Guideline
Supplier
Motorex®
– Chainlube Offroad
Oil for foam air filter

Guideline
Supplier
Motorex®
– Twin Air Liquid Bio Power
AUXILIARY SUBSTANCES 129
Rubber grip adhesive (00062030051)

Supplier
– GRIP GLUE
Universal oil spray

Guideline
Supplier
Motorex®
– Joker 440 Synthetic
STANDARDS 130
JASO FC
JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX 131
Compression damping
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air filter Compression damping, high-speed

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 36
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Compression damping, low-speed
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 37
Air filter box Coolant
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air filter box lid refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Coolant level
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-90
Antifreeze Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 D
B Difficult operating conditions . . . . . . . . . . . . . . . . . . . . . . . 26
Basic chassis setting dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
checking with rider's weight . . . . . . . . . . . . . . . . . . . . 36 high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery low temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 riding at low speeds . . . . . . . . . . . . . . . . . . . . . . . . . 28
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Brake discs
wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
E
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Brake fluid level Engine

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 70 running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 74 Engine characteristic
Brake linings auxiliary spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 72 auxiliary spring, setting . . . . . . . . . . . . . . . . . . . . . . . 96
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 71 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 76 Engine sprocket
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 75 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . . . 76
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . . . 75
F
C
Filler cap
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
float chamber, emptying . . . . . . . . . . . . . . . . . . . . . . 95
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
idle speed, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 94
Filling up
Chain
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 73
Chain guide
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 73
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fork
basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 40
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fork legs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleaning, care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101-102
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Clutch spring preload, setting . . . . . . . . . . . . . . . . . . . . . . . . 42
fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fork protector
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INDEX 132
Frame installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Front fender Motorcycle
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 44
Front wheel removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 44
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 O
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel tank Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 P
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Preparing for use
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuse checks and maintenance work when preparing for use . . 30
main fuse, changing . . . . . . . . . . . . . . . . . . . . . . . . . 84
R
G
Rear sprocket
Gear oil checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Rear wheel
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Rebound damping
Gear oil level
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 37
H Riding sag
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 69 Rubber grip
free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 69 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 69 securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 S
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Seat
Headlight
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
range, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Headlight bulb
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35
Headlight mask with headlight
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
basic position, checking . . . . . . . . . . . . . . . . . . . . . . 96
Headlight setting
Shock absorber
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
compression damping, general information . . . . . . . . . . 36
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
K removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 39
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 spring preload, setting . . . . . . . . . . . . . . . . . . . . . . . . 39
Kill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 38
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . 11
L
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lower triple clamp Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-50
Speedometer
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
M battery, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Main fuse clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 function description . . . . . . . . . . . . . . . . . . . . . . . . . 15
kilometers or miles, setting . . . . . . . . . . . . . . . . . . . . 15
Main silencer
glass fiber yarn filling, changing . . . . . . . . . . . . . . . . . 58 Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INDEX 133
Start number plate

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Steering
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Steering head bearing
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Swingarm
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
T
Technical data
carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111-118
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-120
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 125
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-108
engine tightening torques . . . . . . . . . . . . . . . . . 109-110
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-122
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . 123-124
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 104-105
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
U
Use definition ................................. 6
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . 102
Work rules ................................... 6
*3211718en*
3211718en
05/2011
Photo: Mitterbauer
5230 Mattighofen/Austria
http://www.ktm.com

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OWNER'S MANUAL 2012

give you enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

Engine number ( p. 11)

Key number (All EXC models) ( p. 10)

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria

ISO 9001(12 100 6061)

Preparations for riding on wet sand ................................. 27

MEANS OF REPRESENTATION ............................................ 5

Carburetor configuration (All 200 models) ................. x 115

Indicates an unexpected reaction (e.g., to a work step or a function).

Identifies a page reference (more information is provided on the specified page).

Name® Identifies a protected name.

Brand™ Identifies a brand available on the open market.

Use definition (All EXC models)

Use definition (XC-W)

Fuel, oils, etc.

Spare parts, accessories

– Switch off the engine.

View of vehicle, front left (example)

1 Hand brake lever ( p. 12)

View of vehicle, rear right (example)

(All EXC models)

(All EXC models)

Key number (All EXC models)

Fork part number

Shock absorber part number

(All 125/200 models)

(All 250/300 models)

Hand brake lever

Hand brake lever  is located on the right side of the handlebar.

Throttle grip  is fitted on the right side of the handlebar.

Kill switch (All EXC models)

The kill switch  is fitted on the left side of the handlebar.

Short circuit button (XC-W)

Short circuit button  is fitted on the left side of the handlebar.

Light switch (All EXC models)

The light switch  is fitted on the left side of the handlebar.

Low beam on – Light switch is in the central position. In this position,

Turn signal switch (All EXC models)

Turn signal switch  is fitted on the left side of the handlebar.

Horn button (All EXC models)

The horn button  is fitted on the left side of the handlebar.

Emergency OFF switch (200 EXC AUS)

Ignition on – In this position, the ignition circuit is closed, and the

Emergency OFF switch (250/300 EXC AUS)

Ignition on – In this position, the ignition circuit is closed, and the

Electric starter button (250/300 EXC AUS)

Light switch (XC-W)

Light switch  is located to the right of the speedometer.

Overview of indicator lamps (All EXC models)

Speedometer activation and test

Activating the speedometer

The display then changes to the last selected mode.

(Option: Tripmaster switch)

Setting kilometers or miles

– Press the button for 3 - 5 seconds.

Setting the clock