KTM Exc 2017

OWNER'S MANUAL 2017
125 XC‑W
150 XC‑W
250 EXC
250 XC‑W
300 EXC
300 XC‑W
Art. no. 3213477en
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 properly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.

Chassis number ( p. 12) Dealer's stamp
Engine number ( p. 12)
Key number (All EXC/EXC Six Days models, 125 XC‑W EU)
( p. 12)
The Owner's Manual contained the latest information for this model series at the time of going to print. However, minor differences due to
developments in design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria

All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH

5230 Mattighofen, Austria
This document is valid for the following models:

125 XC‑W EU (F7103Q3)
150 XC‑W US (F7175Q3)
250 EXC EU (F7303Q6)
250 EXC AU (F7360Q6)
250 EXC Six Days EU (F7303Q2)
250 XC‑W US (F7375Q3)
300 EXC EU (F7403Q6)
300 EXC AU (F7460Q6)
300 EXC BR (F7440Q6)
300 EXC Six Days EU (F7403Q2)
300 XC‑W US (F7475Q3)
300 XC‑W Six Days US (F7475Q2)
*3213477en*
3213477en
07/2016
TABLE OF CONTENTS 2
6.23
Locking the steering (All EXC/EXC Six Days
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5

1.1 Symbols used ................................................... 5 models, 125 XC‑W EU).................................... 19
1.2 Formats used.................................................... 5 6.24 Unlocking the steering (All EXC/EXC Six Days
2 SAFETY ADVICE........................................................... 6 models, 125 XC‑W EU).................................... 19
2.1 Use definition – intended use............................. 6 7 SPEEDOMETER ......................................................... 20
2.2 Safety advice.................................................... 6 7.1 Speedometer overview ..................................... 20
2.3 Degrees of risk and symbols ............................... 6 7.2 Activation and test .......................................... 20
2.4 Tampering warning............................................ 6 7.3 Setting kilometers or miles............................... 20
2.5 Safe operation .................................................. 7 7.4 Setting the speedometer functions.................... 21
2.6 Protective clothing ............................................ 7 7.5 Setting the clock............................................. 21
2.7 Work rules........................................................ 7 7.6 Viewing the lap time........................................ 21
2.8 Environment..................................................... 7 7.7 Display mode SPEED (speed) ........................... 22
2.9 Owner's Manual ................................................ 8 7.8 Display mode SPEED/H (service hours) ............. 22
3 IMPORTANT NOTES..................................................... 9 7.9 Setup menu ................................................... 23
3.1 Manufacturer and implied warranty..................... 9 7.10 Setting the unit of measurement ...................... 23
3.2 Operating and auxiliary substances ..................... 9 7.11 Display mode SPEED/CLK (time) ...................... 24
3.3 Spare parts, accessories .................................... 9 7.12 Setting the clock............................................. 24
3.4 Service ............................................................ 9 7.13 Display mode SPEED/LAP (lap time)................. 24
3.5 Figures ............................................................ 9 7.14 Viewing the lap time........................................ 25
3.6 Customer service............................................... 9 7.15 Display mode SPEED/ODO (odometer) .............. 25
4 VIEW OF VEHICLE ..................................................... 10 7.16 Display mode SPEED/TR1 (trip master 1).......... 25
4.1 View of vehicle, front left (example) .................. 10 7.17 Display mode SPEED/TR2 (trip master 2).......... 26
4.2 View of vehicle, rear right (example) ................. 11 7.18 Setting TR2 (trip master 2) .............................. 26
5 SERIAL NUMBERS .................................................... 12 7.19 Display mode SPEED/A1 (average speed 1) ....... 26
5.1 Chassis number .............................................. 12 7.20 Display mode SPEED/A2 (average speed 2) ....... 27
5.2 Type label ...................................................... 12 7.21 Display mode SPEED/S1 (stop watch 1) ............ 27
5.3 Key number (All EXC/EXC Six Days models, 7.22 Display mode SPEED/S2 (stop watch 2) ............ 27
125 XC‑W EU)................................................ 12 7.23 Table of functions ........................................... 28
5.4 Engine number ............................................... 12 7.24 Table of conditions and menu activation ........... 29
5.5 Fork part number ............................................ 13 8 PREPARING FOR USE................................................ 30
5.6 Shock absorber article number ......................... 13 8.1 Advice on first use .......................................... 30
6 CONTROLS................................................................ 14 8.2 Running in the engine ..................................... 31
6.1 Clutch lever.................................................... 14 8.3 Preparing the vehicle for difficult riding
6.2 Hand brake lever............................................. 14 conditions ...................................................... 31
6.3 Throttle grip ................................................... 14 8.4 Preparing for rides on dry sand ......................... 32
6.4 Kill switch (All EXC/EXC Six Days models, 8.5 Preparing for rides on wet sand ........................ 33
125 XC‑W EU)................................................ 14 8.6 Preparations for riding on wet and muddy
6.5 Kill switch (XC‑W US, XC‑W Six Days US) ......... 14 surfaces ......................................................... 33
6.6 Horn button (All EXC/EXC Six Days models, 8.7 Preparing for rides at high temperature and
125 XC‑W EU)................................................ 15 slow speed ..................................................... 34
6.7 Light switch (All EXC/EXC Six Days models, 8.8 Preparing for riding at low temperatures or in
125 XC‑W EU)................................................ 15 snow.............................................................. 34
6.8 Light switch (XC‑W US, XC‑W Six Days US) ....... 15 9 RIDING INSTRUCTIONS............................................. 35
6.9 Turn signal switch (All EXC/EXC Six Days 9.1 Checks and maintenance measures when
models).......................................................... 15 preparing for use............................................. 35
6.10 Emergency OFF switch (EXC AU) ...................... 15 9.2 Starting.......................................................... 35
6.11 Electric starter button (All 250/300 models, 9.3 Start off ......................................................... 36
XC‑W US, XC‑W Six Days US)........................... 16 9.4 Shifting, riding ............................................... 36
6.12 Indicator lamps overview (All 9.5 Braking .......................................................... 36
EXC/EXC Six Days models) ............................... 16 9.6 Stopping, parking............................................ 37
6.13 Indicator lamps overview (All 9.7 Transport ....................................................... 37
XC‑W/XC‑W Six Days models) ........................... 16 9.8 Refueling ....................................................... 38
6.14 Opening the filler cap...................................... 16 10 SERVICE SCHEDULE ................................................. 39
6.15 Closing the filler cap ....................................... 17 10.1 Additional information ..................................... 39
6.16 Fuel tap ......................................................... 17 10.2 Required work ................................................ 39
6.17 Choke ............................................................ 17 10.3 Recommended work ........................................ 40
6.18 Shift lever ...................................................... 18 11 TUNING THE CHASSIS .............................................. 41
6.19 Kick starter .................................................... 18 11.1 Checking the basic chassis setting with the
6.20 Foot brake lever .............................................. 18 rider's weight.................................................. 41
6.21 Side stand...................................................... 18 11.2 Compression damping of the shock absorber...... 41
6.22 Steering lock (All EXC/EXC Six Days models, 11.3 Adjusting the low-speed compression damping
125 XC‑W EU)................................................ 19 of the shock absorber ...................................... 41
TABLE OF CONTENTS 3
11.4
Adjusting the high-speed compression 12.38 Checking the chain, rear sprocket, motor
damping of the shock absorber......................... 42 sprocket, and chain guide ................................ 70
11.5 Adjusting the rebound damping of the shock 12.39 Checking the frame ..................................... 72
absorber......................................................... 42 12.40 Checking the swingarm ................................ 72
11.6 Measuring the rear wheel dimension 12.41 Checking throttle cable routing......................... 72
unloaded........................................................ 43 12.42 Checking the rubber grip ................................. 73
11.7 Checking the static sag of the shock absorber .... 44 12.43 Adjusting the basic position of the clutch
11.8 Checking the riding sag of the shock absorber.... 44 lever .............................................................. 73
11.9 Adjusting the spring preload of the shock 12.44 Checking/correcting the fluid level of the
absorber ..................................................... 44 hydraulic clutch.............................................. 73
11.10 Adjusting the riding sag ............................... 45 12.45 Changing the hydraulic clutch fluid ............... 74
11.11 Checking the basic setting of the fork ............... 46 12.46 Removing the engine guard (All Six Days
11.12 Adjusting the compression damping of the models, EXC AU) ............................................ 75
fork ............................................................... 46 12.47 Installing the engine guard (All Six Days
11.13 Adjusting the rebound damping of the fork ........ 47 models, EXC AU) ............................................ 75
11.14 Adjusting the spring preload of the fork (All 13 BRAKE SYSTEM ........................................................ 76
Six Days models) ............................................ 48 13.1 Checking the free travel of the hand brake
11.15 Handlebar position.......................................... 48 lever .............................................................. 76
11.16 Adjusting the handlebar position ................... 49 13.2 Adjusting free travel of hand brake lever (All
12 SERVICE WORK ON THE CHASSIS.............................. 51 EXC/EXC Six Days models, 125 XC‑W EU) ......... 76
12.1 Raising the motorcycle with a lift stand............. 51 13.3 Adjusting the basic position of the hand brake
12.2 Removing the motorcycle from the lift stand...... 51 lever (XC‑W US, XC‑W Six Days US).................. 76
12.3 Bleeding the fork legs...................................... 51 13.4 Checking the brake discs ................................. 77
12.4 Cleaning the dust boots of the fork legs............. 51 13.5 Checking the front brake fluid level .................. 77
12.5 Removing the fork protector ............................. 52 13.6 Adding front brake fluid ............................... 78
12.6 Installing the fork protector.............................. 52 13.7 Checking the front brake linings ....................... 79
12.7 Removing the fork legs ................................. 52 13.8 Changing the front brake linings ................... 79
12.8 Installing the fork legs ................................. 53 13.9 Checking the free travel of foot brake lever ........ 81
12.9 Removing the lower triple clamp (All 13.10 Adjusting the basic position of the foot brake
standard EXC/XC-W models)............................. 54 lever ........................................................... 81
12.10 Removing the lower triple clamp (All 13.11 Checking the rear brake fluid level.................... 82
Six Days models) ............................................ 54 13.12 Adding rear brake fluid ................................ 82
12.11 Installing the lower triple clamp (All 13.13 Checking the rear brake linings ........................ 83
standard EXC/XC-W models)............................. 55 13.14 Changing the rear brake linings ..................... 83
12.12 Installing the lower triple clamp (All 14 WHEELS, TIRES ........................................................ 85
Six Days models) ............................................ 57 14.1 Removing the front wheel ............................. 85
12.13 Checking the play of the steering head 14.2 Installing the front wheel ............................. 85
bearing .......................................................... 58 14.3 Removing the rear wheel .............................. 86
12.14 Adjusting the steering head bearing play ........ 59 14.4 Installing the rear wheel ............................... 87
12.15 Lubricating the steering head bearing ............ 59 14.5 Checking the tire condition .............................. 88
12.16 Removing the front fender ............................... 60 14.6 Checking the tire air pressure........................... 88
12.17 Installing the front fender ................................ 60 14.7 Checking spoke tension ................................... 89
12.18 Removing the shock absorber ....................... 60 15 ELECTRICAL SYSTEM ................................................ 90
12.19 Installing the shock absorber ........................ 61 15.1 Removing the battery (All 250/300 models,
12.20 Removing the seat .......................................... 61 XC‑W US, XC‑W Six Days US)........................... 90
12.21 Mounting the seat ........................................... 61 15.2 Installing the battery (All 250/300 models,
12.22 Removing the air filter box cover ...................... 62 XC‑W US, XC‑W Six Days US)........................... 91
12.23 Installing the air filter box cover ....................... 62 15.3 Recharging the battery (All 250/300
12.24 Removing the air filter ................................. 63 models, XC‑W US, XC‑W Six Days US) .............. 91
12.25 Installing the air filter .................................. 63 15.4 Changing the main fuse (All 250/300 models,
12.26 Cleaning the air filter and air filter box .......... 63 XC‑W US, XC‑W Six Days US)........................... 93
12.27 Securing the air filter box cover .................... 64 15.5 Removing the headlight mask with the
headlight........................................................ 94
12.28 Sealing the air filter box ............................... 64
15.6 Installing the headlight mask with the
12.29 Removing the main silencer ............................. 65
headlight........................................................ 95
12.30 Installing the main silencer.............................. 65
15.7 Changing the headlight bulb ............................ 95
12.31 Changing the glass fiber yarn filling in the
15.8 Changing the turn signal bulb (All
main silencer .............................................. 65
EXC/EXC Six Days models) ............................... 96
12.32 Removing the fuel tank ................................ 66
15.9 Checking the headlight setting ......................... 97
12.33 Installing the fuel tank ................................. 67
15.10 Adjusting the headlight range........................... 97
12.34 Checking the chain for dirt............................... 68
15.11 Changing the speedometer battery .................... 97
12.35 Cleaning the chain .......................................... 68
16 COOLING SYSTEM ..................................................... 99
12.36 Checking the chain tension .............................. 69
16.1 Cooling system ............................................... 99
12.37 Adjusting the chain tension.............................. 69
TABLE OF CONTENTS 4
16.2 Checking the antifreeze and coolant level .......... 99 22.10.5 300 EXC EU, 300 EXC AU,
16.3 Checking the coolant level ............................. 100 300 EXC Six Days EU ............................... 133
16.4 Draining the coolant .................................. 100 22.10.6 300 XC‑W US, 300 XC‑W Six Days US........ 133
16.5 Refilling with coolant ................................. 101 22.10.7 300 EXC BR ............................................ 133
17 TUNING THE ENGINE.............................................. 103 23 CARBURETOR TUNING ............................................ 134
17.1 Checking the play in the throttle cable ............ 103 23.1 Carburetor tuning (125 XC‑W EU) ............... 134
17.2 Adjusting the play in the throttle cable ........ 103 23.2 Carburetor tuning (150 XC‑W US) ............... 135
17.3 Carburetor setting ......................................... 104 23.3 Carburetor tuning (250 EXC EU,
17.4 Carburetor - idle............................................ 106 250 EXC AU, 250 EXC Six Days EU) ........... 136
17.5 Carburetor – adjusting the idle speed .......... 106 23.4 Carburetor tuning (250 XC‑W US) ............... 137
17.6 Ignition curve plug-in connector ..................... 107 23.5 Carburetor tuning (300 EXC EU,
300 EXC AU, 300 EXC Six Days EU) ........... 138
17.7 Changing the ignition curve............................ 107
23.6 Carburetor tuning (300 XC‑W US,
17.8 Checking the basic position of the shift lever ... 107
300 XC‑W Six Days US) ............................. 139
17.9 Adjusting the basic position of the shift
23.7 Carburetor tuning (300 EXC BR) ................. 140
lever ......................................................... 107
24 SUBSTANCES ......................................................... 141
17.10 Engine characteristic – auxiliary spring ........... 108
25 AUXILIARY SUBSTANCES ........................................ 143
17.11 Engine characteristic – setting the auxiliary
spring ....................................................... 108 26 STANDARDS ........................................................... 144
18 SERVICE WORK ON THE ENGINE ............................. 111 27 LIST OF ABBREVIATIONS......................................... 145
18.1 Emptying the carburetor float chamber ........ 111 28 LIST OF SYMBOLS................................................... 146
18.2 Checking the gear oil level ............................. 111 28.1 Yellow and orange symbols............................. 146
18.3 Changing the gear oil ................................. 112 28.2 Green and blue symbols................................. 146
18.4 Adding gear oil .......................................... 114 INDEX ............................................................................ 147
19 CLEANING, CARE .................................................... 115
19.1 Cleaning the motorcycle ................................ 115
19.2 Checks and maintenance steps for winter
operation...................................................... 116
20 STORAGE ................................................................ 117
20.1 Storage ........................................................ 117
20.2 Preparing for use after storage........................ 118
21 TROUBLESHOOTING ............................................... 119
22 TECHNICAL DATA.................................................... 121
22.1 Engine ......................................................... 121
22.1.1 125 XC‑W EU........................................... 121
22.1.2 150 XC‑W US........................................... 121
22.1.3 All 250 models......................................... 122
22.1.4 All 300 models......................................... 122
22.2 Engine tightening torques .............................. 123
22.2.1 125 XC‑W EU........................................... 123
22.2.2 150 XC‑W US........................................... 124
22.2.3 All 250/300 models.................................. 125
22.3 Capacities .................................................... 126
22.3.1 Gear oil.................................................... 126
22.3.2 Coolant .................................................... 126
22.3.3 Fuel ........................................................ 126
22.4 Chassis ........................................................ 126
22.5 Electrical system........................................... 127
22.6 Tires ............................................................ 127
22.7 Fork............................................................. 128
22.7.1 All 125/150 models.................................. 128
22.7.2 All standard 250/300 EXC/XC-W models ..... 128
22.7.3 All Six Days models................................... 128
22.8 Shock absorber ............................................. 129
22.8.1 All 125/150 models.................................. 129
22.8.2 All 250/300 models.................................. 129
22.9 Chassis tightening torques ............................. 130
22.10 Carburetor .................................................... 132
22.10.1 125 XC‑W EU........................................... 132
22.10.2 150 XC‑W US........................................... 132
22.10.3 250 EXC EU, 250 EXC AU,
250 EXC Six Days EU ............................... 132
22.10.4 250 XC‑W US........................................... 132
1 MEANS OF REPRESENTATION 5
1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti-
mally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
1.2 Formats used

The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name® Identifies a protected name.
Brand™ Identifies a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in
the glossary.
2 SAFETY ADVICE 6
2.1 Use definition – intended use

(All EXC/EXC Six Days models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for public road traffic in the homologated (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off properties remote from public road traffic.
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
(All XC‑W/XC‑W Six Days models)

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
Your motorcycle is not approved for use on public roads.
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are
not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
2 SAFETY ADVICE 7
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
2.5 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle
parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmen-
tally compatible manner.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all
rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE 8
2.9 Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-
tomize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 9
3.1 Manufacturer and implied warranty

The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the
Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage
caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty
Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad
to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and
chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service

Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.

International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 10
4.1 View of vehicle, front left (example)
E00320-10
1 Hand brake lever ( p. 14)

2 Light switch ( p. 15)
2 Kill switch ( p. 14)
2 Turn signal switch ( p. 15)
2 Horn button ( p. 15)
3 Clutch lever ( p. 14)
4 Chain guide
5 Air filter box cover
6 Side stand ( p. 18)
7 Shift lever ( p. 18)
8 Fuel tap ( p. 17)
4 VIEW OF VEHICLE 11
4.2 View of vehicle, rear right (example)
E00319-10
1 Filler cap
2 Throttle grip ( p. 14)
3 Chassis number ( p. 12)
4 Kick starter ( p. 18)
5 Foot brake lever ( p. 18)
6 Level viewer for brake fluid, rear
5 SERIAL NUMBERS 12
5.1 Chassis number

The chassis number  is stamped on the right side of the steering head.
401945-10
5.2 Type label

Type label  is fixed to the front of the steering head.
401945-10
5.3 Key number (All EXC/EXC Six Days models, 125 XC‑W EU)
The key number  for the steering lock is stamped onto the key connector.
402247-10
5.4 Engine number

(All 125/150 models)
The engine number  is located on the left side of the engine under the engine
sprocket.
401949-10

The engine number  is located on the left side of the engine over the engine
sprocket.
H01047-10
5 SERIAL NUMBERS 13
5.5 Fork part number

The fork part number  is stamped on the inside of the axle clamp.
401947-10
5.6 Shock absorber article number

Shock absorber article number  is stamped on the top of the shock absorber above
the adjusting ring towards the engine side.
1
0
401948-10
6 CONTROLS 14
6.1 Clutch lever

Clutch lever is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
V00322-10
6.2 Hand brake lever

Hand brake lever  is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
E00311-10
6.3 Throttle grip

Throttle grip  is fitted on the right side of the handlebar.
E00312-10
6.4 Kill switch (All EXC/EXC Six Days models, 125 XC‑W EU)
The kill switch  is fitted on the left side of the handlebar.
Possible states
• Kill switch in the basic position – In this position, the ignition circuit is closed
and the engine can be started.
• Kill switch is pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
E00318-10
6.5 Kill switch (XC‑W US, XC‑W Six Days US)

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-
E00316-10
6 CONTROLS 15
6.6 Horn button (All EXC/EXC Six Days models, 125 XC‑W EU)
(125 XC‑W EU)
The horn button  is fitted on the left side of the handlebar.
Info
The horn button has no function when the vehicle is delivered.

The horn button 
is fitted on the left side of the handlebar.
Possible states
E00318-11 • Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
6.7 Light switch (All EXC/EXC Six Days models, 125 XC‑W EU)
Light switch  is fitted on the left side of the handlebar.
Possible states
Low beam on – Light switch is in the central position. In this position,
the low beam and tail light are switched on.
High beam on – Light switch is turned to the left. In this position, the
high beam and the tail light are switched on.
E00321-10
6.8 Light switch (XC‑W US, XC‑W Six Days US)

Light switch  is located to the left of the speedometer.
Possible states
• Light off – Light switch is pressed in up to the stop. In this position, the light is
switched off.
• Light on – Light switch is pulled out to the stop. In this position, the low beam
and tail light are switched on.
E00317-10
6.9 Turn signal switch (All EXC/EXC Six Days models)

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.
V00323-12
6.10 Emergency OFF switch (EXC AU)

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.
E00322-10
6 CONTROLS 16
6.11 Electric starter button (All 250/300 models, XC‑W US, XC‑W Six Days US)
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.
E00313-10
6.12 Indicator lamps overview (All EXC/EXC Six Days models)

Possible states
The high beam indicator lamp lights up blue – The high beam is
switched on.
Malfunction indicator lamp – inoperative
Fuel level warning lamp – inoperative
Turn signal indicator lamp flashes green – The turn signal is switched
E00314-01 on.
6.13 Indicator lamps overview (All XC‑W/XC‑W Six Days models)

Possible states
High beam indicator lamp – inoperative
E00371-01
6.14 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
6 CONTROLS 17
Warning
– Press release button , turn the filler cap counterclockwise and lift it free.
V00325-10
6.15 Closing the filler cap

– Replace the filler cap and turn clockwise until the release button  locks in
place.
Info
Run the fuel tank breather hose  without kinks.
V00325-11
6.16 Fuel tap

The fuel tap is on the left side of the fuel tank.
Open or close the supply of fuel to the carburetor using tap handle  on the fuel tap.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel
tank empties down to the reserve level.
• Fuel reserve supply open RES – Fuel can flow from the fuel tank to the carburetor.
The fuel tank empties completely.
V00326-10
6.17 Choke
Choke  is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through which the
engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed
for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated – The choke lever is pulled out to the stop.
V00327-10
• Choke function deactivated – The choke lever is pushed in to the stop.
6 CONTROLS 18
6.18 Shift lever

Shift lever  is mounted on the left side of the engine.
401950-10
The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.
401950-11
6.19 Kick starter

Kick starter  is fitted on the right side of the engine.
The top part of the kick starter pivots.
Info
1
0 Before riding, swing the top part of the kick starter inward toward the engine.
401954-10
6.20 Foot brake lever

Foot brake lever  is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
401956-10
6.21 Side stand

The side stand  is on the left side of the vehicle.
401943-10
6 CONTROLS 19
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 
.
401944-10
6.22 Steering lock (All EXC/EXC Six Days models, 125 XC‑W EU)
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.
V00328-10
6.23 Locking the steering (All EXC/EXC Six Days models, 125 XC‑W EU)
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– 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
6.24 Unlocking the steering (All EXC/EXC Six Days models, 125 XC‑W EU)
– 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
7 SPEEDOMETER 20
7.1 Speedometer overview

– 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.
401761-01
7.2 Activation and test

Activating the speedometer
The speedometer is activated when one of the buttons is pressed or an impulse comes
from the wheel speed sensor.
Display test
To enable you to check that the display is functioning properly, all display segments
light up briefly.
400313-01
WS (wheel size)
After the display function check, the wheel size WS is displayed briefly.
Info
The number 2205 equals the circumference of the 21" front wheel with stan-
dard tires.
The display then changes to the last selected mode.
400314-01
7.3 Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1 , TR2 , A1 , A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the bottom right of the
display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are shown.
– Repeatedly press the button briefly until Km/h/Mph flashes.
Setting the Km/h
– Press the button .
Setting the Mph
400329-01 – Press the button .
– Wait 3–5 seconds
The settings are stored.
Info
If no button is pressed for 10 -12 seconds, or if an impulse comes from
the wheel speed sensor, the settings are automatically saved and the setup
menu is closed.
7 SPEEDOMETER 21
7.4 Setting the speedometer functions
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
display.
The Setup menu is displayed and the active functions are shown.
Info
If no button is pressed for 10–12 seconds, the settings are automatically
saved.
If no button is pressed for 20 seconds, or if an impulse comes from the
400318-01 wheel speed sensor, the settings are automatically saved and the setup
menu is closed.
– Repeatedly press the button briefly until the desired function flashes.
The selected function flashes.
Activating the function
The symbol continues to appear in the display and the next function
appears.
Deactivating a function
The symbol disappears in the display and the next function appears.
7.5 Setting the clock

Condition
– Repeatedly press the button briefly until CLK appears at the bottom right of the
display.
The hour display flashes.
– Set the hour display with the button and/or button .
– Wait 3–5 seconds
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the hours by pressing
400330-01 the button and the button .
Info
The seconds can only be set to zero.
If no button is pressed for 15 -20 seconds, or if an impulse comes from
the wheel speed sensor, the settings are automatically saved and the setup
menu is closed.
7.6 Viewing the lap time
Info
This function can only be opened if lap times have actually been timed.
Condition
7 SPEEDOMETER 22
– Repeatedly press the button briefly until LAP appears at the bottom right of the
display.
– Briefly press the button .
LAP 1 appears on the left side of the display.
– The laps 1–10 can be viewed with the button .
– Press and hold the button for 3-5 seconds.
The lap times are deleted.
400321-01
Next display mode
Info
When an impulse is received from the wheel speed sensor, the left side of
the display changes back to the SPEED mode.
7.7 Display mode SPEED (speed)

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

Condition
• The motorcycle is stationary.
display.
In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.
Info
The service hour counter is necessary for ensuring that service work is carried
400316-01 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 The display changes to the Setup menu of the speedometer
for 2–3 seconds. functions.
Briefly press the Next display mode
button .
Press the button No function
for 2–3 seconds.
Briefly press the No function
button .
7 SPEEDOMETER 23
7.9 Setup menu

Condition
display.
The Setup menu displays the active functions.
Info
Repeatedly press the button briefly until the desired function is reached.
400344-01
If no button is pressed for 20 seconds, the settings are automatically saved.
Briefly press the Activates the flashing display and changes to the next display
button .
for 2–3 seconds.
Briefly press the Deactivates the flashing display and changes to the next dis-
button . play
for 2–3 seconds.
Wait 3–5 seconds Changes to the next display without changes
Wait 10–12 sec- Setup menu starts, stores the settings, and changes to H or
onds ODO.
7.10 Setting the unit of measurement

Condition
display.
– Repeatedly press the button briefly until Km/h/Mph flashes.
In measurement unit mode, you can change the unit of measurement.
Info
400329-01
If no button is pressed for 5 seconds, the settings are automatically saved.
Briefly press the Starts selection, activates Km/h display

button .
for 2–3 seconds.
Briefly press the Activates Mph display
button .
for 2–3 seconds.
Wait 3–5 seconds Changes to the next display, changes from selection to the
Setup menu
Wait 10–12 sec- Saves and closes the Setup menu
onds
7 SPEEDOMETER 24
7.11 Display mode SPEED/CLK (time)

display.
The time is shown in display mode CLK.
Press the button The display changes to the Setup menu of the clock.
for 2–3 seconds.
button .
400319-01 for 2–3 seconds.
button .
7.12 Setting the clock

Condition
display.
Press the button Increases the value
for 2–3 seconds.
Briefly press the Increases the value
400319-01 button .
Press the button Reduces the value
for 2–3 seconds.
Briefly press the Reduces the value
button .
Wait 3–5 seconds Changes to the next value
Wait 10–12 sec- Closes the SETUP menu
onds
7.13 Display mode SPEED/LAP (lap time)

display.
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
Info
If the lap time continues running after the button is pressed, 9 memory loca-
tions are occupied.
Lap 10 must be timed using the button .
400320-01 Press the button The stop watch and the lap time are reset.
for 2–3 seconds.
button .
Press the button Stops the clock.
for 2–3 seconds.
Briefly press the Starts the stop watch or stop the current lap time measure-
button . ment, stores it and the stop watch starts the next lap.
7 SPEEDOMETER 25
7.14 Viewing the lap time

Condition
display.
Press the button The stop watch and the lap time are reset.
for 2–3 seconds.
Briefly press the Select a lap from 1–10
400321-01 button .
for 2–3 seconds.
Briefly press the View the next lap time.
button .
7.15 Display mode SPEED/ODO (odometer)

– Repeatedly press the button briefly until ODO appears at the bottom right of the
display.
The total traveled distance is shown in display mode ODO.
for 2–3 seconds.
button .
400317-01 for 2–3 seconds.
button .
7.16 Display mode SPEED/TR1 (trip master 1)

– Repeatedly press the button briefly until TR1 appears at the top right of the dis-
play.
TR1 (trip master 1) runs constantly and counts up to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to
0.0.
400323-01
Press the button Displays of TR1, A1 and S1 are reset to 0,0.
for 2–3 seconds.
button .
for 2–3 seconds.
button .
7 SPEEDOMETER 26
7.17 Display mode SPEED/TR2 (trip master 2)

play.
TR2 (trip master 2) runs constantly and counts up to 999.9.
Press the button Clears the values TR2 and A2.
for 2–3 seconds.
button .
Press the button Reduces value of TR2.
400324-01 for 2–3 seconds.
Briefly press the Reduces value of TR2.
button .
7.18 Setting TR2 (trip master 2)

Condition
play.
– Press the button for 2–3 seconds until TR2 flashes.
The displayed value can be set manually with the button and the button . This is a
very practical function when riding using the road book.
Info
400324-01 The TR2 value can also be corrected manually during the journey with the but-
ton and the button .
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
Press the button Increases value of TR2.

for 2–3 seconds.
Briefly press the Increases value of TR2.
button .
Press the button Reduces value of TR2.
for 2–3 seconds.
Briefly press the Reduces value of TR2.
button .
Wait 10–12 sec- Saves and closes the Setup menu
onds
7.19 Display mode SPEED/A1 (average speed 1)

– Repeatedly press the button briefly until A1 appears at the top right of the dis-
play.
A1 (average speed 1) shows the average speed calculated using TR1 (trip master 1) and
S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.
for 2–3 seconds.
400325-01
button .
for 2–3 seconds.
button .
7 SPEEDOMETER 27
7.20 Display mode SPEED/A2 (average speed 2)

– Repeatedly press the button briefly until A2 appears at the top right of the dis-
play.
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.
Info
The displayed value can differ from the actual average speed if S2 was not
stopped after the ride.
400326-01 Briefly press the Next display mode

button .
for 2–3 seconds.
for 2–3 seconds.
button .
7.21 Display mode SPEED/S1 (stop watch 1)

– Repeatedly press the button briefly until S1 appears at the top right of the dis-
play.
S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon
as an impulse arrives from the wheel speed sensor.
The calculation of this value starts with the first impulse from the wheel speed sensor
and ends 3 seconds after the last impulse.
for 2–3 seconds.
400327-01
button .
for 2–3 seconds.
button .
7.22 Display mode SPEED/S2 (stop watch 2)

– Repeatedly press the button briefly until S2 appears at the top right of the dis-
play.
S2 (Stop watch 2) is a manual stop watch.
If S2 is running in the background, the display S2 flashes on the speedometer.
Press the button The displays of S2 and A2 are set to 0,0.
for 2–3 seconds.
button .
400328-01 Press the button No function
for 2–3 seconds.
Briefly press the Starts or stops S2.
button .
7 SPEEDOMETER 28
7.23 Table of functions

Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec-
ton for 2–3 button . ton for 2–3 button . onds onds
seconds. seconds.
Display mode The display Next display No function No function
SPEED/H (service changes to the mode
hours) Setup menu of
the speedome-
ter functions.
Setup menu No function Activates the No function Deactivates the Changes to the Setup menu
flashing display flashing display next display starts, stores
and changes to and changes to without changes the settings,
the next display the next display and changes to
H or ODO.
Setting the unit of No function Starts selection, No function Activates Mph Changes to the Saves and
measurement activates Km/h display next display, closes the Setup
display changes from menu
selection to the
Setup menu
Display mode The display Next display No function No function
SPEED/CLK (time) changes to the mode
Setup menu of
the clock.
Setting the clock Increases the Increases the Reduces the Reduces the Changes to the Closes the
value value value value next value SETUP menu
Display mode The stop watch Next display Stops the clock. Starts the stop
SPEED/LAP (lap and the lap time mode watch or stop
time) are reset. the current lap
time measure-
ment, stores it
and the stop
watch starts the
next lap.
Viewing the lap The stop watch Select a lap No function View the next
time and the lap time from 1–10 lap time.
are reset.
Display mode No function Next display No function No function
SPEED/ODO mode
(odometer)
Display mode Displays of TR1, Next display No function No function
SPEED/TR1 (trip A1 and S1 are mode
master 1) reset to 0,0.
Display mode Clears the val- Next display Reduces value Reduces value
SPEED/TR2 (trip ues TR2 and A2. mode of TR2. of TR2.
master 2)
Setting TR2 (trip Increases value Increases value Reduces value Reduces value Saves and
master 2) of TR2. of TR2. of TR2. of TR2. closes the Setup
menu
SPEED/A1 (average A1 and S1 are mode
speed 1) reset to 0,0.
Display mode No function Next display No function No function
SPEED/A2 (average mode
speed 2)
SPEED/S1 (stop A1 and S1 are mode
watch 1) reset to 0,0.
Display mode The displays of Next display No function Starts or stops
SPEED/S2 (stop S2 and A2 are mode S2.
watch 2) set to 0,0.
7 SPEEDOMETER 29
7.24 Table of conditions and menu activation

Display The motorcycle is Menu can be acti-
stationary. vated
Display mode SPEED/H (service hours) •
Setup menu •
Setting the unit of measurement •
Setting the clock •
Display mode SPEED/LAP (lap time) •
Viewing the lap time •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Setting TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •
8 PREPARING FOR USE 30
8.1 Advice on first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all
rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
– Before your first trip, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 73)
(All EXC/EXC Six Days models, 125 XC‑W EU)
– Adjust the free travel of the hand brake lever. ( p. 76)
(XC‑W US, XC‑W Six Days US)
– Adjust the basic position of the hand brake lever. ( p. 76)
– Adjust the basic position of the foot brake lever. ( p. 81)
– Adjust the basic position of the shift lever. ( p. 107)
– Get used to handling the motorcycle on a suitable piece of land before undertaking a more challenging trip.
Info
When off road, it is recommended that you are accompanied by another person on another vehicle so that you can help
each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distri-
bution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Check the spoke tension. ( p. 89)
Info
The spoke tension must be checked after half an hour of operation.
– Run in the engine. ( p. 31)
8.2 Running in the engine

– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
– Avoid fully opening the throttle!
8.3 Preparing the vehicle for difficult riding conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more
rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be neces-
sary to inspect or replace parts before the next scheduled service.
– Seal the air filter box. ( p. 64)

– Clean the air filter and air filter box. ( p. 63)
Info
Check the air filter approx. every 30 minutes.
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult riding conditions are:
– Rides on dry sand. ( p. 32)
– Rides on wet sand. ( p. 33)
– Riding on wet and muddy surfaces. ( p. 33)
– Rides at high temperature and slow speed. ( p. 34)
– Riding at low temperatures or in snow. ( p. 34)
8.4 Preparing for rides on dry sand

– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the required value:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling sys-
M01129-01 tem components if the engine or the cooling system are at oper-
ating temperature.
– Allow the cooling system and the engine to cool down before you
open the radiator, the radiator hoses or other components of the
cooling system.
– In the event of scalding, rinse the area affected immediately
with lukewarm water.
– Change the radiator cap.

– Fit a dust cover on the air filter.
Dust cover for air filter (79006920000)
Info
See the KTM PowerParts fitting instructions.
M01104-01
– Fit a sand cover on the air filter.

Sand cover for air filter (79006922000)
Info
– Adjust the carburetor jetting and setting.
Info
M01105-01
Your authorized KTM workshop can recommend the right carburetor tuning.
– Clean the chain.

Chain cleaner ( p. 143)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.

600868-01 – Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
8.5 Preparing for rides on wet sand

» If the indicated value does not correspond to the required value:
Warning
ating temperature.
cooling system.

– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
Info
M01106-01

– Fit the steel sprocket.
Tip
Do not grease the chain.

600868-01 – Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
8.6 Preparations for riding on wet and muddy surfaces

– Mount the rain cover for the air filter.
Info
Follow the KTM PowerParts mounting instructions.
Info
M01106-01
– Mount the steel sprocket.

– Clean the motorcycle. ( p. 115)
– Carefully align bent radiator fins.
600868-01
8.7 Preparing for rides at high temperature and slow speed

» If the displayed value does not correspond to the setpoint value:
Warning
ating temperature.
cooling system.

– Adjust the secondary drive to the road conditions.
Info
The transmission oil heats up quickly when the clutch is operated frequently
due to an excessively high secondary drive.

600868-01
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 100)
8.8 Preparing for riding at low temperatures or in snow

– Mount the rain cover for the air filter.
Info
Follow the KTM PowerParts mounting instructions.
Info
M01106-01
9 RIDING INSTRUCTIONS 35
9.1 Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
– Check the gear oil level. ( p. 111)

– Check the electrical system.
– Check the front brake fluid level. ( p. 77)
– Check the rear brake fluid level. ( p. 82)
– Check the front brake linings. ( p. 79)
– Check the rear brake linings. ( p. 83)
– Check that the brake system is functioning properly.
– Check the chain for dirt. ( p. 68)
– Check the chain, rear sprocket, motor sprocket, and chain guide. ( p. 70)
– Check the chain tension. ( p. 69)
– Check the tire condition. ( p. 88)
– Check the tire air pressure. ( p. 88)
– Check the spoke tension. ( p. 89)
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
– Clean the dust boots of the fork legs. ( p. 51)

– Bleed the fork legs. ( p. 51)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts, and hose clamps regularly for tightness.
– Check the fuel level.
9.2 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
Info
If the motorcycle does not start easily, there may be old fuel in the float chamber. The easily ignitable components of the fuel
evaporate during lengthy periods of disuse.
When the float chamber is filled with fresh, ignitable fuel, the engine will start immediately.
Condition
The motorcycle was stationary for more than 1 week.
– Empty the carburetor float chamber. ( p. 111)
– Turn handle  of the fuel tap to the ON position. (Figure V00326-10 p. 17)
Fuel can flow from the fuel tank to the carburetor.
– Take the motorcycle off of the stand.
– Shift gear to neutral.
Condition
The engine is cold.
– Pull the choke lever out as far as possible.

(All 250/300 models, XC‑W US, XC‑W Six Days US)
– Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not turn the throttle.
(125 XC‑W EU)

– Press the kick starter robustly through its full range.
Info
Do not turn the throttle.
9.3 Start off
Info
Before riding, switch on the lights if your vehicle is equipped with a lighting system. This will make it easier for other road
users to see you.
When you are riding, the side stand must be folded up and secured with the rubber band.
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
9.4 Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Do not change into a low gear at high engine speed.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop.
First gear is used for starting off and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simultaneously
pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the choke function was activated, deactivate the choke function after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the
speed but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, apply the brakes and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.
– Switch off the engine if running at idle or standing for a long time.
Guideline
≥ 2 min
– Avoid frequent and longer slipping of the clutch. As a result the gear oil, engine and cooling system heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
9.5 Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be
glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– On sandy, wet or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
9.6 Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.

– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Apply the brakes on the motorcycle.

– Shift gear to neutral.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Turn handle  of the fuel tap to the OFF position. (Figure V00326-10 p. 17)
– Park the motorcycle on firm ground.
9.7 Transport
Note
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.
401475-01
9.8 Refueling
Danger
Warning
Warning
– Switch off the engine.

– Open the filler cap. ( p. 16)
– Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of  35 mm (1.38 in)
Total fuel tank 9.5 l Super unleaded (95 octane)

capacity, approx. (2.51 US gal) mixed with 2-stroke engine
oil (1:60) ( p. 142) (All
XC‑W/XC‑W Six Days models,
All 250/300 EU/AU/US models)
400382-10
Super unleaded, type C (ROZ 95/RON
95/PON 91 mixed with 2-stroke engine
oil, 1:60) ( p. 142) (300 EXC BR)
Engine oil, 2-stroke ( p. 141)

– Close the filler cap. ( p. 17)
10 SERVICE SCHEDULE 39
10.1 Additional information

Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced
separately.
10.2 Required work

Every 40 operating hours/after every race
Every 20 operating hours
Once after 5 operating hours
Once after 1 operating hour
Check that the electrical system is functioning properly. ○ ● ●
Check and charge the battery. (All 250/300 models, XC‑W US, XC‑W Six Days US) ● ●
Check the front brake linings. ( p. 79) ● ●
Check the rear brake linings. ( p. 83) ● ●
Check the brake discs. ( p. 77) ● ●
Check the brake lines for damage and leakage. ● ●
Check the rear brake fluid level. ( p. 82) ● ●
Check the free travel of the foot brake lever. ( p. 81) ● ●
Check the frame and swingarm. ● ●
Check the swingarm bearing for play. ● ●
Check the heim joints at the top and bottom of the shock absorber. ● ●
Check the tire condition. ( p. 88) ○ ● ●
Check the tire air pressure. ( p. 88) ○ ● ●
Check the wheel bearing for play. ● ●
Check the wheel hubs. ● ●
Check the rim run-out. ○ ● ●
Check the spoke tension. ( p. 89) ○ ● ●
Check the chain, rear sprocket, motor sprocket, and chain guide. ( p. 70) ● ●
Check the chain tension. ( p. 69) ○ ● ●
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 73) ● ●
Check the front brake fluid level. ( p. 77) ● ●
Check the free travel of the hand brake lever. ( p. 76) ● ●
Check the play of the steering head bearing. ( p. 58) ○ ● ●
Change the spark plug and spark plug connector. ●
Check the inlet membrane. ● ●
Change the gear oil. ( p. 112) ○ ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect rout- ○ ● ●
ing.
Check the antifreeze and coolant level. ( p. 99) ○ ● ●
Check the cables for damage and routing without sharp bends. ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly. ○ ● ●
Clean the air filter and air filter box. ( p. 63) ● ●
Change glass fiber yarn filling in the main silencer. ( p. 65) ● ●
Check the screws and nuts for tightness. ○ ● ●
Check the headlight setting. ( p. 97) ○ ● ●
Check idle. ● ●
Final check: Check the vehicle for safe operation and take a test ride. ○ ○ ● ●
Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ ○ ● ●
○ One-time interval
● Periodic interval
10 SERVICE SCHEDULE 40
10.3 Recommended work

Annually
Every 80 operating hours/every 40 operating hours when used for motorsports
Every 40 operating hours/every 10 operating hours when used for motorsports
Once after 10 operating hours
Change the front brake fluid. ●
Change the rear brake fluid. ●
Change the hydraulic clutch fluid. ( p. 74) ●
Lubricate the steering head bearing. ( p. 59) ●
Check/adjust the carburetor components. ● ●
Service the fork. ○ ● ●
Service the shock absorber. ● ●
Check the starter drive. (All 250/300 models, XC‑W US, XC‑W Six Days US) ● ●
Change the piston and check the cylinder. (125 XC‑W EU) ● ●
Change the piston and check the cylinder. (All 250/300 models, XC‑W US, XC‑W Six Days US) ●
Perform minor engine service. (Check the exhaust control for functioning and smooth operation. Check the ● ●
clutch.)
Perform major engine service including removing and installing the engine. (Change the connecting rod, con- ●
rod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)
○ One-time interval
● Periodic interval
11 TUNING THE CHASSIS 41
11.1 Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– 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
11.2 Compression damping of the shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
11.3 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.
– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible

click.
Info
Do not loosen fitting !
– Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
V00329-10
Guideline
Compression damping, low-speed (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping, low-speed (All 250/300 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
11.4 Adjusting the high-speed compression damping of the shock absorber
Caution
Info
The effect of the high-speed setting can be seen in fast compression of the shock absorber.
– Using an open end wrench, turn adjusting screw  clockwise all the way.
Info
Do not loosen fitting !
– Turn counterclockwise by the number of turns corresponding to the shock absorber
type.
Guideline
Compression damping, high-speed (All 125/150 models)
V00330-10
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Compression damping, high-speed (All 250/300 models)
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Info
ing.
11.5 Adjusting the rebound damping of the shock absorber
Caution
– Turn adjusting screw  clockwise up to the last perceptible click.

– Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
Guideline
Rebound damping (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
V00331-10
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
ing.
11.6 Measuring the rear wheel dimension unloaded

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 51)
Main work
– Position the sag gauge in the rear axle and measure the distance to marking SAG on
the rear fender.
Sag gauge (00029090100)
Pin for sag gauge (00029990010)
– Note down the value as dimension .
402415-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 51)
11.7 Checking the static sag of the shock absorber

– Measure dimension  of rear wheel unloaded. ( p. 43)
– Hold the motorcycle upright with the aid of an assistant.
– Again measure the distance between the rear axle and marking SAG on the rear
fender using the sag gauge.
– Note down the value as dimension .
Info
The static sag is the difference between measurements  and .
– Check the static sag.
Static sag (All 125/150 models) 35 mm (1.38 in)
Static sag (All 250/300 models) 35 mm (1.38 in)

» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( p. 44)
402416-10
11.8 Checking the riding sag of the shock absorber

– Measure dimension  of rear wheel unloaded. ( p. 43)
– With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear axle and
marking SAG on the rear fender using the sag gauge.
– Note down the value as dimension .
Info
The riding sag is the difference between measurements  and .
– Check the riding sag.
Riding sag (All 125/150 models) 110 mm (4.33 in)
Riding sag (All 250/300 models) 110 mm (4.33 in)

» If the riding sag differs from the specified measurement:
– Adjust the riding sag. ( p. 45)
402417-10
11.9 Adjusting the spring preload of the shock absorber
Caution
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Preparatory work
– Remove the shock absorber. ( p. 60)
– After removing the shock absorber, clean it thoroughly.

Main work
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.
Hook wrench (90129051000)
– Measure the overall spring length while the spring is not under tension.
– Tighten the spring by turning adjusting ring  to measurement .
Guideline
Spring preload (All 125/150 models)
Comfort 6 mm (0.24 in)
Standard 6 mm (0.24 in)
Sport 6 mm (0.24 in)
Spring preload (All 250/300 models)
402405-10 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)
Finishing work
– Install the shock absorber. ( p. 61)
11.10 Adjusting the riding sag

Preparatory work
– Remove the shock absorber. ( p. 60)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (All 125/150 models)
Weight of rider: 65… 75 kg (143… 57 N/mm (325 lb/in)
165 lb.)
187 lb.)
B00292-10 Weight of rider: 85… 95 kg (187… 63 N/mm (360 lb/in)
209 lb.)
Spring rate (All 250/300 models)
165 lb.)
187 lb.)
209 lb.)
Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber. ( p. 61)
– Check the static sag of the shock absorber. ( p. 44)

– Check the riding sag of the shock absorber. ( p. 44)
– Adjust the rebound damping of the shock absorber. ( p. 42)
11.11 Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
– As with the shock absorber, smaller differences in the rider's weight can be com-
pensated by the spring preload.
– However, if the fork frequently bottoms out (hard end stop on compression), harder
springs must be fitted to avoid damage to the fork and frame.
– If the fork feels unusually hard after extended periods of operation, the fork legs
need to be bled.
401000-01
11.12 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
(All standard EXC/XC-W models)

– Turn white adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is located at the upper end of the left fork leg.
The compression damping is located in left fork leg COMP (white adjust-
ing screw). The rebound damping is located in right fork leg REB (red
adjusting screw).
E00323-10
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping (All 125/150 models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping (All standard 250/300 EXC/XC-W models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
(All Six Days models)

– Turn white adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is located at the upper end of the left fork leg.
The compression damping is located in left fork leg COM (white adjust-
ing screw). The rebound damping is located in right fork leg REB (red
adjusting screw).
E00324-10
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
damping.
11.13 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.

– Turn red adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is located at the upper end of the right fork leg.
The rebound damping is located in right fork leg REB (red adjusting
screw). The compression damping is located in left fork leg COMP (white
adjusting screw).
E00326-10
Guideline
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping (All standard 250/300 EXC/XC-W models)
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
damping.

– Turn red adjusting screw  clockwise as far as it will go.
Info
Adjusting screw  is located at the upper end of the right fork leg.
The rebound damping is located in right fork leg REB (red adjusting
screw). The compression damping is located in left fork leg COM (white
adjusting screw).
E00325-10
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
damping.
11.14 Adjusting the spring preload of the fork (All Six Days models)
Preparatory work
Main work
– Turn the adjusting wings  counterclockwise all the way.
The marking +0 aligns with the right wing on both fork legs.
Info
Make the adjustment by hand only. Do not use a tool.
Make the same adjustment on both fork legs.
– Turn the adjusting wings clockwise.

E00327-10 Guideline
Spring preload - Preload Adjuster
Comfort +0
Standard +0
Sport +3
The adjusting wings engage noticeably at the numerical values.
Info
Adjust the spring preload to the numerical values only as the preload will
not engage between the numerical values.
Turn clockwise to increase the spring preload; turn counterclockwise to
reduce the spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.
Finishing work
11.15 Handlebar position

On the upper triple clamp, there are 2 holes at a distance of  to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of  from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This allows the handle-
bar to be mounted in the most comfortable position for the rider.
M00993-10

On the upper triple clamp, there are 2 holes at a distance of  to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of  from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This allows the handle-
bar to be mounted in the most comfortable position for the rider.
M00987-10
11.16 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.

– Remove screws  . Take off the handlebar clamps. Remove the handlebar and
lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
– Remove screws . Take off the handlebar supports.

– Place the handlebar supports in the required position. Mount and tighten
screws  .
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.

M00993-11 Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamps. Mount screws  and tighten evenly.

Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.

– Remove screws  . Take off the handlebar clamps. Remove the handlebar and
lay it to one side.
Info
Do not kink the cables and lines.
– Remove screws . Take off the handlebar supports.

– Place the handlebar supports in the required position. Mount and tighten
screws  .
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.

M00987-11 Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamps. Mount screws  and tighten evenly.

Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.
12 SERVICE WORK ON THE CHASSIS 51
12.1 Raising the motorcycle with a lift stand
Note
– Raise the motorcycle at the frame underneath the engine.

Lift stand (78129955100)
Neither wheel is in contact with the ground.
401942-01 – Secure the motorcycle against falling over.
12.2 Removing the motorcycle from the lift stand
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.
401943-10
12.3 Bleeding the fork legs

Preparatory work
Main work
– Release bleeder screws .
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
H01595-10
Finishing work
12.4 Cleaning the dust boots of the fork legs

Preparatory work
– Remove the fork protector. ( p. 52)
Main work
– Push dust boots  of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is
not removed, the oil seals behind can start to leak.
K00070-10
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking
effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
– Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 143)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 52)
12.5 Removing the fork protector

– Remove screws  and take off the clamp.
– Remove screws  and take off the left fork protector.
– Remove screws  and take off the right fork protector.
V00332-10
12.6 Installing the fork protector

– Position the fork protector on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line, wiring harness, and clamp. Mount and tighten screws .
– Position the fork protector on the right fork leg. Mount and tighten screws .
Guideline
V00332-11
12.7 Removing the fork legs

Preparatory work
– Remove the front wheel. ( p. 85)
– Remove the headlight mask with the headlight. ( p. 94)
Main work
– Remove screws  and take off the clamp.
– Remove the cable tie(s).
– Remove screws  and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the side.
E00375-10

– Loosen screws . Take out the left fork leg.
– Loosen screws . Take out the right fork leg.
E00376-10

– Loosen screws . Take out the left fork leg.
– Loosen screws . Take out the right fork leg.
E00377-10
12.8 Installing the fork legs

Main work
– Position the fork legs.
Bleeder screws  are positioned toward the front.
Info
The rebound damping is located in right fork leg REB (red adjusting screw).
The compression damping is located in left fork leg COM (white adjusting
screw).
Grooves are milled into the side of the upper end of the fork legs. The sec-
H01595-10 ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.

– Tighten screws  .
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
– Tighten screws .
Guideline
Screw, bottom triple clamp M8 15 Nm
V00334-11
(11.1 lbf ft)
– Tighten screws .
Guideline
(12.5 lbf ft)
Guideline
V00355-11
(11.1 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 the cable tie(s).
– Position the brake line, wiring harness, and clamp. Mount and tighten screws .
E00375-11
Finishing work
– Install the front wheel. ( p. 85)
– Install the headlight mask with the headlight. ( p. 95)
– Check the headlight setting. ( p. 97)
12.9 Removing the lower triple clamp (All standard EXC/XC-W models)
Preparatory work
– Remove the fork legs. ( p. 52)
– Remove the front fender. ( p. 60)
– Remove the handlebar cushion.
Main work
– Remove screw . Loosen screw . Pull off the upper triple clamp with the han-
dlebar and hang it to one side.
Info
Protect the components against damage by covering them.
Do not bend the cables and lines.
V00336-10
– Remove O-ring . Remove protective ring .

– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
V00335-10
12.10 Removing the lower triple clamp (All Six Days models)
Preparatory work
– Remove the fork legs. ( p. 52)
– Remove the front fender. ( p. 60)
– Remove the handlebar cushion.
Main work
– Remove screw 
. Remove screw . Pull off the upper triple clamp with the han-
dlebar and hang it to one side.
Info
Protect the components against damage by covering them.
Do not bend the cables and lines.
V00357-10
– Remove O-ring . Remove protective ring .

– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
V00358-10
12.11 Installing the lower triple clamp (All standard EXC/XC-W models)
Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 143)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
–  is correctly positioned.
Check whether upper steering head seal
– Mount protective ring  and O-ring .
V00359-10
– Position the upper triple clamp with the handlebar.

– Position the clutch line and wiring harness.
– Mount screw  but do not tighten yet.
V00336-11

Bleeder screws  are positioned toward the front.
Info
The compression damping is located in left fork leg COMP (white adjusting
screw).
ond milled groove (from the top) must be flush with the top edge of the
H01637-10 upper triple clamp.
– Tighten screws .
Guideline
(14.8 lbf ft)
– Tighten screws .
Guideline
(11.1 lbf ft)
V00338-10
– Tighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
V00337-10
– Tighten screw .
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
V00337-11
– Position the brake caliper, and mount and tighten screws .

Guideline
(18.4 lbf ft)
– Position the brake line, wiring harness, and clamp. Mount and tighten screws .
E00375-12
Finishing work
– Mount the handlebar cushion.
– Install the front fender. ( p. 60)
– 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. 58)
12.12 Installing the lower triple clamp (All Six Days models)
Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 143)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
–  is correctly positioned.
Check whether upper steering head seal
– Mount protective ring  and O-ring .
B01218-10
– Position the upper triple clamp with the handlebar.

– Mount screw  but do not tighten yet.
– Position the clutch line and wiring harness.
V00356-10

Bleeder screws  are positioned toward the front.
Info
The compression damping is located in left fork leg COMP (white adjusting
screw).
ond milled groove (from the top) must be flush with the top edge of the
H01637-10 upper triple clamp.
– Tighten screws .
Guideline
(12.5 lbf ft)
– Tighten screws .
Guideline
(11.1 lbf ft)
V00353-10
– Tighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
V00360-10
– Mount and tighten screw .

Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 lbf ft)
V00361-10
– Position the brake caliper, and mount and tighten screws .

Guideline
(18.4 lbf ft)
– Position the brake line, wiring harness, and clamp. Mount and tighten screws .
E00375-12
Finishing work
– Install the front fender. ( p. 60)
– Mount the handlebar cushion.
– Check that the wiring harness, throttle cables, and brake and clutch lines can move
freely and are routed correctly.
12.13 Checking the play of the steering head bearing
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the
frame can become damaged over time.
Preparatory work
Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play. ( p. 59)
– Move the handlebar to and fro over the entire steering range.
H01167-01 It must be possible to move the handlebar easily over the entire steering range.
There should be no detectable detent positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 59)
– Check the steering head bearing and change if necessary.
Finishing work
12.14 Adjusting the steering head bearing play

Preparatory work
Main work
– 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 stresses.
V00339-10
– Tighten screws .
Guideline
(14.8 lbf ft)
– Tighten screw .
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
– 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 stresses.
– Tighten screws .
V00362-10
Guideline
(12.5 lbf ft)
– Mount and tighten screw .
Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 lbf ft)
Finishing work
12.15 Lubricating the steering head bearing

– Remove the lower triple clamp. ( p. 54)
– Install the lower triple clamp. ( p. 55)
800010-10
12.16 Removing the front fender

Preparatory work
Main work
– Remove screws .
V00340-10
– Remove screws . Remove the front fender.
V00341-10
12.17 Installing the front fender

Main work
– Position the front fender. Mount and tighten screws .
Guideline
V00341-11
– Mount and tighten screws .

Guideline
V00340-11
Finishing work
12.18 Removing the shock absorber

Preparatory work
Main work
– Remove screw  and lower the rear wheel with the swingarm as far as possible
without blocking the rear wheel. Secure the rear wheel in this position.
– Remove screw , push splash protector  to the side, and remove the shock
absorber.
V00344-10
12.19 Installing the shock absorber

Main work
– Push splash protector  to the side and position the shock absorber. Mount and
tighten screw 
.
Guideline
Screw, top shock absorber M12 80 Nm Loctite® 2701™
(59 lbf ft)
– Mount and tighten screw .
Guideline
V00344-11
Screw, bottom shock M12 80 Nm Loctite® 2701™
absorber (59 lbf ft)
Info
The heim joint for the shock absorber at the swingarm is Teflon-coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.
Finishing work
12.20 Removing the seat

– Raise the rear of the seat, pull the seat back, and lift it off.
V00342-10
12.21 Mounting the seat

– Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the
rear and push it forward.
– Make sure that the seat is correctly locked in.
V00343-10
– Mount and tighten screws .

Guideline
V00342-10
12.22 Removing the air filter box cover

Condition
The air filter box cover is secured.
– Remove screw .
V00346-10
– Pull off the air filter box cover in area  sideways and remove it toward the front.
V00346-11
12.23 Installing the air filter box cover

– Insert the air filter box cover in area  and clip it into area .
V00346-12
Condition
The air filter box cover is secured.
– Mount and tighten screw .
Guideline
Screw, air filter box cover EJOT PT® 3 Nm (2.2 lbf ft)
K60x20-Z
V00346-10
12.24 Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.
Preparatory work
– Remove the air filter box cover. ( p. 62)
Main work
– Detach retaining tab . Remove air filter with air filter support.
– Remove air filter from air filter support.
V00345-10
12.25 Installing the air filter

Main work
– Mount the clean air filter on the air filter support.
– Grease the air filter in area .
Long-life grease ( p. 143)
102178-10
– Insert air filter and position retaining pin  in bushing .

The air filter is correctly positioned.
– Insert retaining tab .
Retaining pin  is secured by retaining tab .
Info
If the air filter is not mounted correctly, dust and dirt may enter the engine
and result in damage.
V00347-10
Finishing work
– Install the air filter box cover. ( p. 62)
12.26 Cleaning the air filter and air filter box
Warning
lations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
– Remove the air filter. ( p. 63)
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner ( p. 143)
Info
Only squeeze the air filter to dry it; never wring it out.
– Oil the dry air filter with a high quality filter oil.
102191-01 Oil for foam air filter ( p. 143)

– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Finishing work
– Install the air filter. ( p. 63)
12.27 Securing the air filter box cover

Preparatory work
Main work
– Drill a hole at marking .
Guideline
Diameter 6 mm (0.24 in)
S00846-10
Finishing work
12.28 Sealing the air filter box

Preparatory work
Main work
– Seal the air filter box in the marked area .
S00847-10
Finishing work
12.29 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
– Pull the main silencer off of the manifold at the rubber sleeve .
V00348-10
12.30 Installing the main silencer

– Mount the main silencer with rubber sleeve .
– Mount and tighten screws .
Guideline
V00349-10
12.31 Changing the glass fiber yarn filling in the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
– Remove the main silencer. ( p. 65)
Main work
– Pull out inner tube .
– Remove the glass fiber yarn filling  from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
– Fit the new glass fiber yarn filling  into the inner tube.
–  over the inner tube with the new glass fiber yarn filling.
Position outer tube
Guideline
Screws on the main silencer M5 7 Nm (5.2 lbf ft)
H01759-10
Finishing work
– Install the main silencer. ( p. 65)
12.32 Removing the fuel tank
Danger
Warning
Preparatory work
– Remove the seat. ( p. 61)
Main work
– Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
– Remove screws  with the collar bushings.

V00350-10 – Hang the horn and horn bracket to one side.
– Remove screw  with the rubber bushing.

– Remove the tube from the fuel tank breather.
V00351-10
– Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank.
V00352-10
12.33 Installing the fuel tank
Danger
Warning
Main work
– Check throttle cable routing. ( p. 72)
– Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or damaged.
V00352-11
– Attach the fuel tank breather hose.

– Mount and tighten screw  with the rubber bushing.
Guideline
– Position the horn with the horn bracket.
V00351-11
– Mount and tighten screws  with the collar bushings.

Guideline
– Connect the fuel hose.
V00350-11
Finishing work
– Mount the seat. ( p. 61)
12.34 Checking the chain for dirt

– Check the chain for heavy soiling.
» If the chain is very dirty:
– Clean the chain. ( p. 68)
400678-01
12.35 Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
– Remove the lubricant from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
Warning
lations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
Main work
– Clean the chain regularly and then treat with chain spray.
Off-road chain spray ( p. 143)
400725-01
Finishing work
12.36 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more
quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or
the engine will be damaged.
– Check the chain tension regularly.

– Set the chain tension in accordance with the specification.
Preparatory work
Main work
– Pull the chain at the end of the chain sliding piece upward to measure chain ten-
sion .
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. 69)
V00354-10
Finishing work
12.37 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more
quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or
the engine will be damaged.
– Check the chain tension regularly.

– Set the chain tension in accordance with the specification.
Preparatory work
Main work
– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning adjusting screws  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 (1.18 in))
E00330-10
enables different secondary ratios with the same chain length.
Chain adjusters can be turned by 180°.
Finishing work
12.38 Checking the chain, rear sprocket, motor sprocket, and chain guide
Preparatory work
Main work
– Shift the transmission to idle.
– Check the rear sprocket and motor sprocket for wear.
» If the rear sprocket and motor sprocket are worn:
– Change the drivetrain kit.
Info
The motor sprocket, rear sprocket, and chain should always be
replaced together.
400227-01
– Pull at the top part of the chain with the specified weight .
Guideline
Weight, chain wear measurement 10… 15 kg (22… 33 lb.)
– Measure the distance  of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance  at the longest 272 mm (10.71 in)

chain section
» If distance  is greater than the specified measurement:
– Change the drivetrain kit.
Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
400987-10
– Check the chain sliding guard for wear.

» If the lower edge of the chain pin is at the level of or below the chain sliding
guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screws on the chain sliding guard.
Guideline
Screw, chain sliding M6 6 Nm Loctite® 243™
guard (4.4 lbf ft)
E00331-10
– 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.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten the screw on the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)
E00332-10
– 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.
400985-01
– Check that the chain guide is firmly seated.

» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
E00333-01
Finishing work
12.39 Checking the frame

– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a mechanical impact:
– Change the frame.
Info
Always replace a frame that has been damaged due to a mechanical
impact. Repair of the frame is not authorized by KTM.
S01316-10
12.40 Checking the swingarm

– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
– Change the swingarm.
Info
Always change a damaged swingarm. Repair of the swingarm is not
authorized by KTM.
S01317-10
12.41 Checking throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specification.
Preparatory work
– Remove the fuel tank. ( p. 66)
Main work
– Check throttle cable routing.
The throttle cable must be routed behind the handlebar, on the right of the
frame, and to the carburetor. The throttle cable must be secured behind the fuel
tank contact area rubber band.
» If the throttle cable routing is not as specified:
– Correct throttle cable routing.
E00336-01
Finishing work
– Install the fuel tank. ( p. 67)
12.42 Checking the rubber grip

– Check the rubber grips on the handlebar for damage, wear, and looseness.
Info
The rubber grips are vulcanized onto a sleeve on the left and onto the han-
dle tube of the throttle grip on the right. The left sleeve is clamped onto the
handlebar.
The rubber grip can only be replaced with the sleeve or the throttle tube.
» If a rubber grip is damaged or worn:
401197-01
– Change the rubber grip.
– Check that screw  is firmly seated.

Guideline
Screw, fixed grip M4 5 Nm Loctite® 243™
(3.7 lbf ft)
Diamond  must be located at the top.
K00547-10
12.43 Adjusting the basic position of the clutch lever

– Adjust the basic position of the clutch lever to your hand size by turning adjusting
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.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
V00322-11
Do not make any adjustments while riding.
12.44 Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
lations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws.
– Remove cover  with membrane .
– Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the level of the fluid does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
E00337-10
Brake fluid DOT 4 / DOT 5.1 ( p. 141)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
12.45 Changing the hydraulic clutch fluid
Warning
Warning
lations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5
brake fluid.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
E00337-10
– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
– On the clutch slave cylinder, remove bleeder screw  and mount bleeding
syringe .
E00338-10
– Now inject the fluid into the system until it emerges from drill hole  of the mas-
ter cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir to prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim 4 mm (0.16 in)
E00339-10
Info
12.46 Removing the engine guard (All Six Days models, EXC AU)
– Remove screws  and engine guard.
H01638-10
12.47 Installing the engine guard (All Six Days models, EXC AU)
– Attach the engine guard on the frame at the rear and swing up at the front.
Guideline
H01638-10
13 BRAKE SYSTEM 76
13.1 Checking the free travel of the hand brake lever
Warning
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.

– Press the hand brake lever toward the handlebar and check free travel .
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not equal the specification:
– Adjust the free travel of the hand brake lever. ( p. 76)
E00311-11

– Press the hand brake lever forward and check free travel .
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not equal the specification:
– Adjust the basic position of the hand brake lever. ( p. 76)
E00311-13
13.2 Adjusting free travel of hand brake lever (All EXC/EXC Six Days models, 125 XC‑W EU)
– Check the free travel of the hand brake lever. ( p. 76)
– Adjust the free travel of the hand brake lever with the adjustment screw .
Info
Turn the adjusting screw clockwise to reduce free travel. The pressure point
moves away from the handlebar.
Turn the adjusting screw counterclockwise to increase free travel. The pres-
sure point moves towards the handlebar.
E00311-12 Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
13.3 Adjusting the basic position of the hand brake lever (XC‑W US, XC‑W Six Days US)
– Check the free travel of the hand brake lever. ( p. 76)
– 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.
E00311-12 The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
13 BRAKE SYSTEM 77
13.4 Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
– Check the thickness of the front and rear brake discs at multiple points on each
brake disc to ensure it is at least thickness . 
Info
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit (All standard EXC/XC-W models)

Front 2.5 mm (0.098 in)
400257-10 Rear 3.5 mm (0.138 in)
Brake discs - wear limit (All Six Days models)
Front 2.5 mm (0.098 in)
Rear 3.7 mm (0.146 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc.
– Change the rear 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 front brake disc.
– Change the rear brake disc.
13.5 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin-
ings are worn down.
glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your autho-
rized 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 has dropped below marking :
– Add front brake fluid. ( p. 78)
E00340-10
13 BRAKE SYSTEM 78
13.6 Adding front brake fluid
Warning
ings are worn down.
glad to help.)
Warning
Warning
Warning
lations.
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.
– Add brake fluid to level .
Guideline
Level  (brake fluid level below reser- 5 mm (0.2 in)
voir rim)

Info
E00341-10
13 BRAKE SYSTEM 79
13.7 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced 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. ( p. 79)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the front brake linings. ( p. 79)
E00342-10
13.8 Changing the front brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Warning
Warning
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings,
and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed.
In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Warning
lations.
13 BRAKE SYSTEM 80
Info
brake fluid.
– Remove screws.
– Manually press the brake caliper toward the brake disc to push back the brake pis-
tons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if neces-
sary extract excess.
Info
Make sure that you do not press the brake caliper against the spokes when
E00343-10
pushing back the brake pistons.
– Remove cotter pins , pull out pin , and remove the brake linings.
– Clean the brake caliper and brake caliper support.
E00344-10
– Check that leaf spring  in the brake caliper and sliding plate  in the brake
caliper support are seated correctly.
100397-01
– Insert the new brake linings, insert the pin, and mount the cotter pins.
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
E00345-10
– Correct the brake fluid quantity to level .

Guideline
Level  (brake fluid level below reser- 5 mm (0.2 in)
voir rim)

E00343-11
Info
13 BRAKE SYSTEM 81
13.9 Checking the free travel of foot brake lever
Warning
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– 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)
» If the free travel does not meet specifications:
– Adjust the basic position of the foot brake lever. ( p. 81)
– Reconnect spring .
402026-10
13.10 Adjusting the basic position of the foot brake lever
Warning
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Disconnect spring .
402026-10
– 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 to individual requirements,
loosen nut and turn screw 
accordingly.
Info
– Turn push rod 

accordingly until you have free travel . If necessary, adjust
E00346-10 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 20 Nm
(14.8 lbf ft)
– Hold push rod  and tighten nut .
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
– Reconnect spring .
13 BRAKE SYSTEM 82
13.11 Checking the rear brake fluid level
Warning
ings are worn down.
glad to help.)
Warning
– Stand the vehicle upright.

– Check the brake fluid level in the viewer .
» If the fluid has dropped below marking  in the level viewer:
– Add rear brake fluid. ( p. 82)
E00347-10
13.12 Adding rear brake fluid
Warning
ings are worn down.
glad to help.)
Warning
Warning
Warning
lations.
Info
brake fluid.
13 BRAKE SYSTEM 83
Preparatory work
– Check the rear brake linings. ( p. 83)
Main work
– Remove screw cap  with membrane  and the O-ring.
– Mount the screw cap with the membrane and the O-ring.
Info
E00348-10
13.13 Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced 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. ( p. 83)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the rear brake linings. ( p. 83)
E00349-10
13.14 Changing the rear brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Warning
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings,
and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed.
In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.
– Only use brake linings approved and recommended by KTM.

13 BRAKE SYSTEM 84
Warning
lations.
Info
brake fluid.

– Remove screw cap  with membrane  and the O-ring.
– Press the brake piston back into the basic position and ensure that brake fluid does
not flow out of the brake fluid reservoir, if necessary extract excess.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
E00350-10
– Remove cotter pins , pull out pin , and remove the brake linings.
– Clean the brake caliper and brake caliper support.
E00351-10
– Check that leaf spring  in the brake caliper and sliding plate  in the brake
caliper support are seated correctly.
E00352-10
– Insert the new brake linings, insert the pin, and mount the cotter pins.
Info
Always change the brake linings in pairs.
– Operate the foot brake lever repeatedly until the brake linings are in contact with
E00353-01

– Mount screw cap  with membrane  and O-ring.
Info
E00348-10
14 WHEELS, TIRES 85
14.1 Removing the front wheel

Preparatory work
Main work
– Press the brake caliper onto the brake disc by hand in order to push back the brake
pistons.
Info
Make sure that you do not press the brake caliper against the spokes when
pushing back the brake pistons.
V00363-10
– Loosen screw  by several rotations.

– Loosen screws .
– Press on screw  to push the wheel spindle out of the axle clamp.
– Remove screw .
V00364-10
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
– Always lay the wheel down in such a way that the brake disc is not dam-
aged.
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
V00365-10
Do not pull the hand brake lever when the front wheel is removed.
– Remove spacers .
H00934-10
14.2 Installing the front wheel
Warning
– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change the front wheel bearing.
– Clean and grease shaft seal rings  and contact surface  of the spacers.
– Insert the spacers.
H00935-10
14 WHEELS, TIRES 86
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
The brake linings are correctly positioned.
Guideline
Screw, front wheel spindle M20x1.5 35 Nm
(25.8 lbf ft)
– Operate the hand brake lever several times until the brake linings are seated cor-
rectly against the brake disc.
– Operate the front brake and compress the fork a few times firmly.
V00364-11
The fork legs straighten.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
14.3 Removing the rear wheel

Preparatory work
Main work
– Press the brake caliper onto the brake disc by hand in order to push back the brake
piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
– 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.
Info
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
V00366-10 – Always lay the wheel down in such a way that the brake disc is not dam-
aged.
– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
Info
Do not operate the foot brake lever when the rear wheel is removed.
– Remove spacers .
H00936-10
14 WHEELS, TIRES 87
14.4 Installing the rear wheel
Warning
Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease shaft seal rings  and contact surface  of the spacers.
– Insert the spacers.
H00937-10
– Lift the rear wheel into the swingarm, position it, and insert wheel spindle .
– Mount the chain.
The brake linings are correctly positioned.
V00367-10
– Position chain adjuster. Mount nut , but do not tighten it yet.

– 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 (1.26 in))
enables different secondary ratios with the same chain length.
Chain adjusters  can be turned by 180°.
– Operate the foot brake lever repeatedly until the brake linings are in contact with
V00368-10
Finishing work
14 WHEELS, TIRES 88
14.5 Checking the tire condition
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 a major impact on the handling of the motorcycle.
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 tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check the tread depth.
Info
Adhere to the legally required minimum tread depth.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum tread depth:
– Check the tire age.
Info
The tire date of manufacture is usually contained in the tire label and is
indicated by the last four digits of the DOT number. 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 be changed after 5 years at the latest,
regardless of the actual state of wear.
H01144-01 » If the tires are more than 5 years old:
14.6 Checking the tire air pressure
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, road (All EXC/EXC Six Days models)
Front 1.5 bar (22 psi)
Rear 1.5 bar (22 psi)
Tire air pressure off road

400695-01
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.
14 WHEELS, TIRES 89
14.7 Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral
and radial run-out will form in the wheel. Other spokes will become looser as a result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length and spoke diame-
ter.
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 differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)
Torque wrench with various accessories in set (58429094000)

15 ELECTRICAL SYSTEM 90
15.1 Removing the battery (All 250/300 models, XC‑W US, XC‑W Six Days US)
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
– Do not dispose of batteries as household waste.
– Dispose of batteries at a collection point for used batteries.
Warning
lations.
Preparatory work
– Switch off all power consumers and switch off the engine.
Main work
(XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models)
Warning
Risk of injury Batteries contain harmful substances.
– Keep batteries out of the reach of children.
– Keep sparks and open flames away from the batteries.
– Only charge batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when
F00138-10
charging batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged batteries if charge is already below
the minimum voltage.
Minimum voltage before the start 9 V
of the charge
– Dispose of batteries with less than the minimum voltage correctly.
– Disconnect negative cable  from the battery.

– Pull back positive terminal cover  and disconnect the positive cable from the
battery.
– Remove screw .
– Pull holding bracket  forward and remove battery toward the top.
(300 EXC BR)
Warning
Risk of injury Battery acid and battery gases cause serious chemical
burns.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in
well-ventilated rooms.
– 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.
– Disconnect negative cable  from the battery.

– Pull back positive terminal cover  and disconnect the positive cable from the
battery.
– Remove screw .
– Pull holding bracket  forward and remove battery toward the top.
15.2 Installing the battery (All 250/300 models, XC‑W US, XC‑W Six Days US)
Main work
– Insert the battery into the battery compartment with the terminals facing forward
and secure with holding bracket . 
Battery (HJTZ5S-FP) ( p. 127)
(300 EXC BR)
Battery (YTX5L-BS) ( p. 127)
Guideline
– Connect positive cable  to the battery.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
– Slide positive terminal cover  over the positive terminal.
– Connect negative cable  to the battery.
H00386-10
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
Contact disks  must be mounted under screws  and cable sockets  with
the claws toward the battery terminal.
Finishing work
15.3 Recharging the battery (All 250/300 models, XC‑W US, XC‑W Six Days US)
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
– Do not dispose of batteries as household waste.
– Dispose of batteries at a collection point for used batteries.
Warning
lations.
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the battery is depleted by repeated starting, the battery must be charged immediately.
Preparatory work
– Remove the battery. ( p. 90)
Main work
Warning
Risk of injury Batteries contain harmful substances.
– Keep sparks and open flames away from the batteries.
– Only charge batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when
S00863-10
charging batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged batteries if charge is already below
the minimum voltage.
Minimum voltage before the start 9 V
of the charge
– Dispose of batteries with less than the minimum voltage correctly.
– Check the battery voltage.

» Battery voltage: < 9 V
– Do not charge the battery.
– Replace the battery and dispose of the old battery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
– Recharge the battery.
Guideline
Maximum charging voltage 14.4 V
Maximum charging current 3.0 A
Maximum charging time 12 h
Charge the battery regularly when 6 months
the motorcycle is not in use
Ideal charging and storage tem- 10… 20 °C (50… 68 °F)
perature of the lithium-ion bat-
tery
Info
If the charging current, charging voltage, or charging time are
exceeded, the battery will be destroyed.
If the battery is left in a discharged state for an extended period,
it will become over-discharged and sulfated, destroying the bat-
tery.
The battery is maintenance-free.
Never remove cover  .
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
The charging time may be longer at low temperatures.
This battery charger is not suitable for the trickle charging of lithium-ion batter-
ies.
– Switch off the battery charger after charging and disconnect from the battery.
(300 EXC BR)

Warning
Risk of injury Battery acid and battery gases cause serious chemical
burns.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in
400240-10 well-ventilated rooms.
– 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.
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and start
potential of the battery, and to test the alternator. With this device, you cannot
overcharge the battery.
Info
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 left in a discharged state for an extended period, over-
discharge and sulfating occurs, destroying the battery.
The battery is maintenance-free. The acid level does not have to be
checked.
Never remove cover  .
Charge the battery to a maximum of 10% of the capacity specified on
battery housing  .
– Switch off the battery charger after charging and disconnect from the battery.
Guideline
The charging current, charging voltage, and charging time must not be
exceeded.
Charge the battery regularly when the 3 months
motorcycle is not in use
Finishing work
– Install the battery. ( p. 91)
15.4 Changing the main fuse (All 250/300 models, XC‑W US, XC‑W Six Days US)
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle.
Preparatory work
Main work
– Pull starter relay  from the holder.
E00361-10
– .
Take off protection caps
– Remove faulty main fuse .
Info
You can recognize a defective fuse by a burned-out fuse wire .
A spare fuse  is located in the starter relay.
– Install a new main fuse.

Fuse (58011109110) ( p. 127)
– Check that the electrical equipment is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
– Mount the protection caps.

– Mount the starter relay onto the holder and route the cable.
E00362-10
Finishing work
15.5 Removing the headlight mask with the headlight

– Detach the brake line and wiring harness from the headlight mask.
– Release rubber bands . Slide the headlight mask up and swing it forward.
E00355-10

– Detach plug-in connectors  and take off the headlight mask with the head-
light.
E00356-10

– Detach plug-in connector  and take off the headlight mask with the head-
light.
E00357-10
15.6 Installing the headlight mask with the headlight

Main work
– Connect plug-in connectors .
E00356-11

– Connect plug-in connector .
E00357-11
– Position the headlight mask and fix it with rubber bands .

The holding lugs engage in the fender.
– Position the brake line and wiring harness in the brake line guide.
E00355-11
Finishing work
15.7 Changing the headlight bulb
Note
Damage to reflector Reduced brightness.
– 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.
Preparatory work
Main work
– Turn protection cap together with the underlying bulb socket counterclockwise
all the way and remove it.
– Pull bulb socket  of the parking light out of the reflector.
E00358-10
– Pull out headlight bulb .

– Insert the new headlight bulb.
Headlight (HS1/socket BX43t) ( p. 127)
– Insert the protection cap with the bulb socket into the reflector and turn it clock-
wise all the way.
Info
E00359-10
Ensure that O-ring  is seated properly.
– Insert the bulb socket of the parking light into the reflector.
Finishing work
15.8 Changing the turn signal bulb (All EXC/EXC Six Days models)
Note
Damage to reflector Reduced brightness.
– 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.
Main work
– Remove the screw on the rear of the turn signal housing.
– Carefully remove turn signal glass .
– Lightly squeeze orange cap  in the area of the holding lugs and take it off.
– Press the turn signal bulb lightly into the socket, turn it counterclockwise by about
30°, and take it out of the socket.
Info
Do not touch the reflector with your fingers and keep it free from grease.
– Press the new turn signal bulb carefully into the socket and turn it clockwise until
it stops.
Turn signal (R10W / socket BA15s) ( p. 127)
– Mount the orange cap.
– Position the turn signal glass.
– Insert the screw and first turn counterclockwise until it engages in the thread with
a small jerk. Tighten the screw lightly.
E00360-10
Finishing work
– Check that the turn signal system is functioning properly.
15.9 Checking the headlight setting

– 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.
– Make another mark at a distance  under the first mark.
Guideline
Distance  5 cm (2 in)
– Position the vehicle vertically a distance  away from the wall.

Guideline
400726-10 Distance  5 m (16 ft)
– 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 a
motorcycle with rider.
» If the light-dark border does not meet specifications:
– Adjust the headlight range. ( p. 97)
15.10 Adjusting the headlight range

Preparatory work
Main work
– Loosen screw .
– Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on the lower marking for
a motorcycle with rider (instructions on how to apply the marking: Checking the
headlight setting).
V00369-10
Info
If you have a payload, you may have to correct the headlight range.
– Tighten screw .
15.11 Changing the speedometer battery
Preparatory work
Main work
– Pull the speedometer upward out of the holder.
V00370-10
– Using a coin, turn protection cap  all the way counterclockwise and remove it.
– Remove speedometer battery .
– Insert the new battery with the label facing upward.
Speedometer battery (CR 2430) ( p. 127)
– Check the O-ring of the protection cap for correct seating.
V00371-10
– Position protection cap  and turn all the way clockwise 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 washers.
V00372-10
Finishing work
– Set kilometers or miles. ( p. 20)
– Set the speedometer functions. ( p. 21)
– Set the clock. ( p. 21)
16 COOLING SYSTEM 99
16.1 Cooling system

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
V00373-10 cooling effect.

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
V00374-10 cooling effect.
16.2 Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at
operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components
of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
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 antifreeze in the coolant does not match the specified value:
– Correct the coolant antifreeze.
– Check the coolant level in the radiator.
400243-10 10 mm (0.39 in)
Coolant level  above the radiator
fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 141)
– Mount the radiator cap.
16.3 Checking the coolant level
Warning
Warning
Condition
The engine is cold.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level  above the radiator 10 mm (0.39 in)

fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
400243-10 Coolant ( p. 141)
– Mount the radiator cap.
16.4 Draining the coolant
Warning
Warning
Condition
The engine is cold.
– Position the motorcycle upright.
– Place a suitable container under the water pump cover.

– Remove screw . Take off radiator cap .
– Completely drain the coolant.
– Mount and tighten screw  with a new seal ring.
Guideline
Drain plug, water pump cover M6 8 Nm (5.9 lbf ft)
(125 XC‑W EU)
Drain plug, water pump cover M6 8 Nm (5.9 lbf ft)
V00373-11 (150 XC‑W US)
– Remove screw . Take off radiator cap .
– Completely drain the coolant.
– Mount and tighten screw  with a new seal ring.
Guideline
Screw, water pump cover M6 10 Nm
(7.4 lbf ft)
V00374-11
16.5 Refilling with coolant
Warning

– Make sure that screw  is tightened.
– Completely fill the radiator with coolant.
Coolant ( p. 141)
V00375-10
– Loosen screw  and wait until coolant escapes without bubbles.

Guideline
Bleeder screw, cylinder head M6 8 Nm (5.9 lbf ft)
(125 XC‑W EU)
Bleeder screw, cylinder head M6 8 Nm (5.9 lbf ft)
(150 XC‑W US)
V00377-10

– Make sure that screw  is tightened.
Coolant ( p. 141)
V00376-10
– Loosen screw  and wait until coolant escapes without bubbles.

Guideline
Bleeder screw, cylinder head M6 10 Nm
(7.4 lbf ft)
V00380-10

Coolant ( p. 141)
– Mount radiator cap .
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the
V00379-10 engine.
– Use an effective exhaust extraction system when starting or running the
engine in an enclosed space.
– Allow the engine to warm up and cool down again.

Finishing work
17 TUNING THE ENGINE 103
17.1 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Turn the handlebar as far as possible to the right. Move the throttle grip backwards
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 the specified value:
– Adjust the play in the throttle cable. ( p. 103)
Danger
400192-10 Danger of poisoning Exhaust gases are toxic and inhaling them may result
engine.
– 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. ( p. 103)
17.2 Adjusting the play in the throttle cable
Info
If the correct routing of the throttle cable has already been secured, the fuel tank does not need to be removed.
Preparatory work
– Remove the fuel tank. ( p. 66)
– Check throttle cable routing. ( p. 72)
Main work
– Turn the handlebar as far as possible to the right.
– Push back sleeve .
– Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster .
– Loosen nut  .
– Turn barrel adjuster  so that there is play  in the throttle cable at the throttle
grip.
Guideline
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
– Tighten nut .
– Slide on sleeve .
E00363-10
Finishing work
– Check the throttle grip for smooth operation.
– Install the fuel tank. ( p. 67)
– Check the play in the throttle cable. ( p. 103)
17.3 Carburetor setting

Effects of the carburetor setting
H01400-01
The different carburetor components must be tuned both to one another and for the use intended.
Main jet MJ
The main jet MJ has the greatest influence with the throttle slide open (full throttle).
If the insulator of a new spark plug is very light or white after a brief ride at full throttle, 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.
Needle position POS
The needle position has the greatest influence in the mid throttle slide range.
If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine knocks when
accelerating at the full power rpm range, the jet needle must be raised.
Cylindrical part of the needle CYL
The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.
Idling jet IJ
The idling jet has the greatest influence in the low to mid throttle slide range.
If the engine stutters when idling or accelerating with a partially open throttle slide, a smaller idling jet must be used. If the engine
knocks in this power range, then a larger idling jet must be used.
Idle air adjusting screw open ASO
The idle air adjusting screw has the greatest influence during idling.
Influence of throttle slide adjustment
1 1
3
/4 3
/4
1
/2 1
/2
1
/4 1
/4
1
/8 1
/8
0 0 K00495-01
The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position
have only minimal influence.
When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influ-
ence.
1 1
3
/4 3
/4
1
/2 1
/2
1
/4 1
/4
1
/8 1
/8
0 0 K00496-01
When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindri-
cal part of the needle is less.
When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling
jet is only minimal.
1 1
3
/4 3
/4
1
/2 1
/2
1
/4 1
/4
1
/8 1
/8
0 0 K00497-01
When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal
influence.
When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal
influence.
Needle overview
The jet needles available are shown in the following table.
402674-01
Column 2 corresponds to a needle in the standard position.

Column 1 corresponds to a needle which is half a clip leaner.
Column 3 corresponds to a needle which is half a clip richer.
Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the
needle, the richer the carburation. The larger the diameter of the first cylindrical part of the needle, the leaner the carburation. The
first cylindrical part of the needle has the greatest influence in the lowest load adjustment.
Info
The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1 corresponds
to the leanest. The optimal carburetor tuning is shown under the respective model.
Clip position
1... 5 Clip position from above
0
1 The five possible clip positions are shown here.
0
2 The carburetor tuning depends on the defined ambient and operating conditions.
30
4
0
5
0
B00075-10
17.4 Carburetor - idle

The idle setting of the carburetor has a big influence on the starting behavior, stable
idling, and the response to throttle opening. This means that an engine with a correctly
set idle speed is easier to start than if the idle speed 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.
(EXC EU/AU, EXC EU, EXC Six Days EU)
E00370-10
Height above sea level 301… 750 m (988… 2,461 ft)
Ambient temperature 16… 24 °C (61… 75 °F)
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 142)
(300 EXC BR)
Height above sea level 751… 1,500 m (2,464… 4,921 ft)
Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine
oil, 1:60) ( p. 142)
Height above sea level 0… 300 m (0… 984 ft)
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 142)
The idle speed is adjusted with adjusting screw  .

The idle mixture is adjusted using the idle air adjusting screw .
17.5 Carburetor – adjusting the idle speed
– Screw idle air adjusting screw  all the way in.
– Turn the idle air adjusting screw to the specified basic setting.
Info
The basic adjustment is shown under the respective model.
– Run the engine until warm.

Guideline
Warm-up time ≥ 5 min
E00370-11
Danger
engine.
– Adjust the idle speed with adjusting screw .

Guideline
Choke function deactivated – The choke lever is pushed in to the stop. ( p. 17)
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 again begins to fall.
– Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big 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, mount a smaller idling jet.
After changing the jet, start from the beginning with the adjusting steps.
Following extreme air temperature or altitude changes, adjust the idle speed
again.
17.6 Ignition curve plug-in connector

Plug-in connector  of the ignition timing map adjustment is located on the frame
under the fuel tank.
Possible states
• Soft – The plug-in connector of the ignition timing map adjustment is discon-
nected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing map adjustment is
joined to achieve higher performance.
E00374-10
17.7 Changing the ignition curve

Change the ignition curve from Performance to Soft.
– Disconnect plug-in connector 
of the ignition timing map adjustment. (Figure E00374-10 p. 107)
Soft – better rideability
Change the ignition curve from Soft to Performance.
– Join plug-in connector  of the ignition timing map adjustment. (Figure E00374-10 p. 107)
Performance – better performance
17.8 Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
– Sit on the vehicle in the riding position and determine 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:
– Adjust the basic position of the shift lever. ( p. 107)
400692-10
17.9 Adjusting the basic position of the shift lever

– Remove screw  with washers and take off shift lever .
401950-12
– 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.
401951-10 – Mount and tighten screw  with the washers.

Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(125 XC‑W EU) (10.3 lbf ft)
Screw, shift lever M6 14 Nm Loctite® 243™
(150 XC‑W US) (10.3 lbf ft)
Screw, shift lever (All M6 14 Nm Loctite® 243™
250/300 models) (10.3 lbf ft)
17.10 Engine characteristic – auxiliary spring

The auxiliary spring is located on the right side of the engine below the water pump
cover.
Possible states
• Auxiliary spring with green color coding – Auxiliary spring for soft performance.
• Auxiliary spring with yellow color coding – Auxiliary spring for more aggressive per-
formance than with a green spring.
• Auxiliary spring with blue color coding – Auxiliary spring for more aggressive per-
formance than with a yellow spring.
• Auxiliary spring with red color coding – Auxiliary spring for more aggressive perfor-
B00056-10 mance than with a blue spring.
• Auxiliary spring without color coding – Auxiliary spring for progressive performance
(at first more aggressive than with the red spring, then softer than with the red
spring).
The engine characteristic can be influenced by different spring strengths of auxiliary
spring  .
Info
The auxiliary spring mounted in the as-delivered state as well as the additionally
available auxiliary springs can differ depending on model.
17.11 Engine characteristic – setting the auxiliary spring
Warning
Preparatory work
– Tilt the motorcycle to the left and secure against falling in this position.
Guideline
Angle of title approx. 45°
Main work
E00372-10
– Remove cap , adjusting spring , auxiliary spring , and spring

insert from the clutch cover.
– Pull both springs off of the spring insert.
B00056-11
– Mount the required auxiliary spring ( p. 108)  and adjusting spring 

and position them together in the clutch cover.
(125 XC‑W EU)
Auxiliary spring with yellow marking (54637072300)
Auxiliary spring with green marking (54837072100)
Auxiliary spring with blue color coding (54637072500)
(150 XC‑W US)
E00373-10
Auxiliary spring without color coding (50437069050)
The recess in spring insert  engages in the angle lever.

Info
Screw  must not be turned as this would worsen the engine charac-
teristic.
– Check the O-ring in the cap.

– Position the cap.
– Mount and tighten the screws.
Guideline
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft)
(125 XC‑W EU)
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft)
(150 XC‑W US)
E00364-10
– Remove cap , adjusting spring , auxiliary spring , and spring

insert from the clutch cover.
– Pull both springs off of the spring insert.
B00056-11
– Mount the required auxiliary spring ( p. 108)  and adjusting spring 

and position them together in the clutch cover.
Auxiliary spring with green marking (54837072100)
Auxiliary spring with red marking (54837072000)
The recess in spring insert  engages in the angle lever.

Info
E00365-10
Screw  must not be turned as this would worsen the engine charac-
teristic.
– Check the O-ring in the cap.

– Position the cap.
– Mount and tighten the screws.
Guideline
Screw, exhaust control M5 4 Nm Loctite® 222™
cover (3 lbf ft)
18 SERVICE WORK ON THE ENGINE 111
18.1 Emptying the carburetor float chamber
Danger
Warning
Warning
Info
Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.
Preparatory work
Fuel no longer flows from the fuel tank to the carburetor.
Main work
– Place a cloth beneath the carburetor to soak up emerging fuel.
– Remove plug .
– Completely drain the fuel.
– Mount and tighten the plug.
V00378-10
18.2 Checking the gear oil level
Info
The gear oil level must be checked when the engine is cold.
Preparatory work
Main work
– Remove gear oil monitoring screw .
– Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add gear oil. ( p. 114)
– Mount and tighten the gear oil monitoring screw.
E00367-10
Guideline
Screw, gear oil level check M6 8 Nm (5.9 lbf ft)
(125 XC‑W EU)
(150 XC‑W US)
– Detach the foot brake lever spring.
– Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add gear oil. ( p. 114)
E00366-10 – Mount and tighten the gear oil monitoring screw.
Guideline
Screw, gear oil level check M6 10 Nm
(7.4 lbf ft)
– Attach the foot brake lever spring.
18.3 Changing the gear oil
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
Warning
lations.
Info
Drain the gear oil while the engine is at operating temperature.
Preparatory work
(All Six Days models, EXC AU)
– Remove the engine guard. ( p. 75)
– Park the motorcycle on a level surface.
– Place a suitable container under the engine.
Main work
– Remove gear oil drain plug  with magnet.
– Remove gear oil drain plug .
– Let the gear oil drain fully.
– Thoroughly clean the gear oil drain plug.
– Clean the sealing surface on the engine.
– Mount and tighten gear oil drain plug  with the magnet and a new seal ring.
Guideline
Gear oil drain plug with magnet M12x1.5 20 Nm
(125 XC‑W EU) (14.8 lbf ft)
(150 XC‑W US) (14.8 lbf ft)
– Mount and tighten gear oil drain plug  with a new seal ring.
Guideline
Gear oil drain plug (125 XC‑W EU) M10x1 15 Nm
(11.1 lbf ft)
E00368-10 Gear oil drain plug (150 XC‑W US) M10x1 15 Nm
(11.1 lbf ft)
– Remove filler plug  and fill up with gear oil.
Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 141)
– Mount and tighten the oil filler plug.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may
result in unconsciousness and death.
K00530-10 engine.
– Use an effective exhaust extraction system when starting or running
the engine in an enclosed space.
– Start the engine and check that it is oil-tight.

– Remove gear oil drain plug  with magnet.
– Let the gear oil drain fully.
– Thoroughly clean the gear oil drain plug with magnet.
– Clean the sealing surface on the engine.
– Mount and tighten gear oil drain plug  with the magnet and a new seal ring.
Guideline
E00369-10
(14.8 lbf ft)
– Remove filler plug  and fill up with gear oil.
– Mount and tighten the oil filler plug.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may
result in unconsciousness and death.
401955-11 engine.
– Use an effective exhaust extraction system when starting or running
the engine in an enclosed space.

Finishing work
(All Six Days models, EXC AU)

– Install the engine guard. ( p. 75)
18.4 Adding gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Gear oil must only be topped up when the engine is cold.
Preparatory work
– Park the motorcycle on a level surface.
Main work
E00367-10

E00366-10
– Remove filler plug .

– Add gear oil until it emerges from the drill hole of the gear oil monitoring screw.
Engine oil (15W/50) ( p. 141)
– Mount and tighten the gear oil monitoring screw.
Guideline
(125 XC‑W EU)
401955-11 Screw, gear oil level check M6 8 Nm (5.9 lbf ft)
(150 XC‑W US)
Screw, gear oil level check (All M6 10 Nm (7.4 lbf ft)
250/300 models)
– Mount and tighten filler plug .
Danger
engine.

Finishing work
19 CLEANING, CARE 115
19.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Warning
lations.
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. 143)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
401061-01 Never apply motorcycle cleaner to the dry vehicle; always rinse with water
first.
– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
– Remove the plug from the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake
linings and the brake discs.
– After cleaning, take a short ride until the engine reaches operating temperature.
Info
The heat produced causes water at inaccessible locations in the engine and
brake system to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Preserving materials for paints, metal and rubber ( p. 143)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care prod-
uct.
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
( p. 143)
– Oil the steering lock.
Universal oil spray ( p. 143)
19 CLEANING, CARE 116
19.2 Checks and maintenance steps for winter operation
Info
If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precautions against aggres-
sive road salt.
If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water enhances the corrosive
effects of salt.

– Clean the brakes.
Info
After EVERY trip on salted roads, thoroughly wash the cool and installed
brake calipers and brake linings with cold water and dry carefully.
After riding on salted roads, thoroughly wash the vehicle with cold water and
dry it well.
401060-01
– Treat the engine, the swingarm, and all other bare or galvanized parts (except 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.

20 STORAGE 117
20.1 Storage
Warning
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
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. ( p. 112)
– Check the antifreeze and coolant level. ( p. 99)
– When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive ( p. 143)
– Refuel. ( p. 38)
401058-01
– Check the tire air pressure. ( p. 88)
– Remove the battery. ( p. 90)
– Recharge the battery. ( p. 91)
Guideline
Storage temperature of battery with- 0… 35 °C (32… 95 °F)
out direct sunshine
– Store the vehicle in a dry location that is not subject to large fluctuations in tem-
perature.
Info
KTM recommends jacking up the motorcycle.

– Cover the vehicle with a tarp or similar 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.
20 STORAGE 118
20.2 Preparing for use after storage

– Install the battery. ( p. 91)
– Perform checks and maintenance measures when preparing for use. ( p. 35)
– Make a test ride.
401059-01
21 TROUBLESHOOTING 119
Faults Possible cause Action

The engine cannot be cranked (elec- Operating error – Carry out the start procedure. ( p. 35)
tric starter) Battery discharged – Recharge the battery. ( p. 91)
(All 250/300 models, XC‑W US,
XC‑W Six Days US) – Check the charging voltage.
– Check the closed current.
– Check the alternator.
Main fuse is blown – Change the main fuse. ( p. 93)
Starter relay faulty – Check the starter relay.
Starter motor faulty – Check the starter motor.
Engine turns but does not start Operating error – Carry out the start procedure. ( p. 35)
Motorcycle was out of use for a long – Empty the carburetor float chamber.
time and there is old fuel in the float ( p. 111)
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 (125 XC‑W EU)
0.60 mm (0.0236 in)
Spark plug electrode gap (150 XC‑W US)
0.60 mm (0.0236 in)
Spark plug electrode gap
0.60 mm (0.0236 in)
Fault in ignition system – Check the ignition system.
Kill switch cable in wiring harness – Check the kill switch.
frayed, kill switch defective
The connector or ignition coil is loose – Clean the connector and treat it with contact
or oxidized 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.
torted ( p. 106)
Spark plug defective – Change the spark plug.
Ignition system defective – Check the ignition coil.
– Check the spark plug connector.
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.
( p. 63)
Exhaust system leaky, deformed or – Check exhaust system for damage.
too little glass fiber yarn filling in – Change glass fiber yarn filling in the main
main silencer silencer. ( p. 65)
Diaphragm or reed valve housing – Check the diaphragm and reed valve housing.
damaged
21 TROUBLESHOOTING 120
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. (Figure V00326-10 p. 17)
– Refuel. ( p. 38)
Engine takes in bad air – Check the intake flange and carburetor for
tightness.
The connector or ignition coil is loose – Clean the connector and treat it with contact
or oxidized 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. ( p. 100)
– Refill with coolant. ( p. 101)
Damaged cylinder head or cylinder – Check the cylinder head and cylinder head gas-
head gasket ket.
Bent radiator hose – Change the radiator hose.
Incorrect ignition point due to loose (All 125/150 models)
stator – Adjust the ignition.
White smoke emission (steam in Damaged cylinder head or cylinder – Check the cylinder head and 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. 111)
Water in the gear oil Damaged shaft seal ring or water – Check the shaft seal ring and water pump.
pump
22 TECHNICAL DATA 121
22.1 Engine
22.1.1 125 XC‑W EU
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 Cast aluminum
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) 36.5 mm (1.437 in)
Primary transmission 23:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear, claw shifted
Transmission ratio
First gear 12:33
Second gear 15:31
Third gear 17:28
Fourth gear 19:26
Fifth gear 21:25
Sixth gear 20:20
Alternator 12 V, 75 W
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Spark plug NGK BR9 ECMVX
Spark plug electrode gap 0.60 mm (0.0236 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Kick starter
22.1.2 150 XC‑W US

exhaust control
Displacement 144 cm³ (8.79 cu in)
Stroke 54.5 mm (2.146 in)
Bore 58 mm (2.28 in)
Pistons Forged aluminum
Piston rings 1 rectangular ring, 1 half keystone ring
X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in)
Z (height of control flap) 36.5 mm (1.437 in)
Gearbox 6-gear, claw shifted
Transmission ratio
First gear 12:33
Second gear 15:31

Third gear 17:28
Fourth gear 19:26
Fifth gear 21:25
Sixth gear 20:20
Ignition Contactless controlled fully electronic ignition with digital igni-
Spark plug NGK BR9 ECMVX
Starting aid Electric starter and kick starter
22.1.3 All 250 models

exhaust control
Displacement 249 cm³ (15.19 cu in)
Stroke 72 mm (2.83 in)
Hole 66.4 mm (2.614 in)
Exhaust valve, beginning of adjustment 5,250 rpm
Piston Cast aluminum
Piston rings 2 half keystone rings
X distance (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in)
Z distance (height of control flap) 49 mm (1.93 in)
Transmission 6-gear, claw shifted
Transmission ratio
First gear 14:32
Second gear 16:26
Third gear 20:25
Fourth gear 22:23
Fifth gear 25:22
Sixth gear 26:20
Ignition system Contactless controlled, fully electronic ignition with digital igni-
Spark plug NGK BR 7 ES
Starting aid Kick starter and electric starter
22.1.4 All 300 models

exhaust control
Displacement 293.2 cm³ (17.892 cu in)
Stroke 72 mm (2.83 in)
Hole 72 mm (2.83 in)
Exhaust valve, beginning of adjustment

Piston Cast aluminum
Piston rings 2 rectangular rings
X distance (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in)
Z distance (height of control flap) 49.5 mm (1.949 in)
Transmission 6-gear, claw shifted
Transmission ratio
First gear 14:32
Second gear 16:26
Third gear 20:25
Fourth gear 22:23
Fifth gear 25:22
Sixth gear 26:20
Ignition system Contactless controlled, fully electronic ignition with digital igni-
Spark plug NGK BR 7 ES
Starting aid Kick starter and electric starter
22.2 Engine tightening torques

22.2.1 125 XC‑W EU
Screw, inner membrane sheets EJOT DELTA PT® 35x25 1 Nm (0.7 lbf ft) –
Screw, membrane core plate EJOT DELTA PT® 30x12 1 Nm (0.7 lbf ft) –
Screw, outer membrane sheets EJOT DELTA PT® 30x6 1 Nm (0.7 lbf ft) –
Screw, control lever, exhaust control M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, crankshaft position sensor M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft) –
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, retaining bracket, rotary valve M5 6 Nm (4.4 lbf ft) –
Screw, water pump wheel M5 6 Nm (4.4 lbf ft) Loctite® 243™
Bleeder screw, cylinder head M6 8 Nm (5.9 lbf ft) –
Drain plug, water pump cover M6 8 Nm (5.9 lbf ft) –
Nut, adjusting screw, power valve M6 8 Nm (5.9 lbf ft) –
Screw plug, starter motor mounting M6 8 Nm (5.9 lbf ft) –
Screw, alternator cover M6 8 Nm (5.9 lbf ft) –
Screw, bearing retainer M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Screw, clutch spring retainer M6 10 Nm (7.4 lbf ft) –
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 10 Nm (7.4 lbf ft) –
Screw, gear oil level check M6 8 Nm (5.9 lbf ft) –
Screw, intake flange/reed valve housing M6 6 Nm (4.4 lbf ft) –
Screw, intermediate clutch cover M6x20 10 Nm (7.4 lbf ft) –

Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, outer clutch cover M6x20 8 Nm (5.9 lbf ft) –
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, stator M6 8 Nm (5.9 lbf ft) Loctite® 243™
Screw, stop plate of exhaust control M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, cylinder head M7 18 Nm (13.3 lbf ft) –
Nut, cylinder base M8 23 Nm (17 lbf ft) –
Screw, cylinder base M8 20 Nm (14.8 lbf ft) –
Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite® 243™
Gear oil drain plug M10x1 15 Nm (11.1 lbf ft) –
Nut, rotor M12x1 50 Nm (36.9 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 M18x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
22.2.2 150 XC‑W US

Screw, membrane core plate EJOT DELTA PT® 30x12 1 Nm (0.7 lbf ft) –
Screw, exhaust control cover M5 6 Nm (4.4 lbf ft) –
Screw, retaining bracket, rotary valve M5 6 Nm (4.4 lbf ft) –
Screw, water pump wheel M5 6 Nm (4.4 lbf ft) Loctite® 243™
Drain plug, water pump cover M6 8 Nm (5.9 lbf ft) –
Nut, adjusting screw, power valve M6 8 Nm (5.9 lbf ft) –
Screw, starter motor M6 8 Nm (5.9 lbf ft) –
Screw, starter motor guard M6 8 Nm (5.9 lbf ft) –

Screw, stop plate of exhaust control M6 10 Nm (7.4 lbf ft) Loctite® 243™
Nut, cylinder base M8 23 Nm (17 lbf ft) –
Screw, cylinder base M8 20 Nm (14.8 lbf ft) –
Gear oil drain plug M10x1 15 Nm (11.1 lbf ft) –
22.2.3 All 250/300 models

Screw, membrane support plate EJOT DELTA PT® 30x12 1 Nm (0.7 lbf ft) –
Screw, angle lever, exhaust control M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, exhaust control bearing support M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, exhaust control cap M5 5 Nm (3.7 lbf ft) –
Screw, exhaust control cover M5 4 Nm (3 lbf ft) Loctite® 222™
Screw, retaining bracket of exhaust M5 7 Nm (5.2 lbf ft) Loctite® 2701™
control
Screw, water pump impeller M5 6 Nm (4.4 lbf ft) Loctite® 243™
Outer clutch cover M6 8 Nm (5.9 lbf ft) –
Screw, control flap, exhaust control M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, intermediate clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, starter motor M6 10 Nm (7.4 lbf ft) –
Screw, starter motor bearing bush M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, starter motor protection cap M6 8 Nm (5.9 lbf ft) –
Screw, balancer shaft M8 30 Nm (22.1 lbf ft) Loctite® 243™
Nut, cylinder base M10 35 Nm (25.8 lbf ft) –
Screw, drive chain engine sprocket M10 60 Nm (44.3 lbf ft) Loctite® 2701™

22.3 Capacities
22.3.1 Gear oil
22.3.2 Coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 141)
22.3.3 Fuel
Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded (95 octane) mixed with 2-stroke engine
approx. oil (1:60) ( p. 142) (All XC‑W/XC‑W Six Days models,
All 250/300 EU/AU/US models)
Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with
2-stroke engine oil, 1:60) ( p. 142) (300 EXC BR)
Fuel reserve, approx. 1.5 l (1.6 qt.)
22.4 Chassis
Frame Central tube frame made of chrome molybdenum steel tubing
Fork (All standard EXC/XC-W models) WP Performance Systems MXMA 4860 upside down
Fork (All Six Days models) WP Performance SystemsXplor 48
Suspension travel (All standard EXC/XC-W models)
Front 300 mm (11.81 in)
Suspension travel
Rear 310 mm (12.2 in)
Fork offset 22 mm (0.87 in)
Shock absorber (All 125/150 models) WP Performance Systems 4618 PDS DCC
Shock absorber (All 250/300 models) WP Performance Systems 4618 PDS 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 (All standard EXC/XC-W models)
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
Brake discs - wear limit (All Six Days models)
Front 2.5 mm (0.098 in)
Rear 3.7 mm (0.146 in)
Tire air pressure, road (All EXC/EXC Six Days models)
Tire air pressure off road
Secondary ratio (All 125/150 models) 13:50
Secondary ratio (All 250/300 EU/AU/US models) 14:50 (13:50)
Secondary ratio (300 EXC BR) 13:52
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 125/150 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 370 mm (14.57 in)
Weight without fuel, approx. (125 XC‑W EU) 91 kg (201 lb.)
Weight without fuel, approx. (150 XC‑W US) 91.5 kg (201.7 lb.)
Weight without fuel, approx. (All standard 250/300 EXC/XC- 100 kg (220 lb.)
W models)
Weight without fuel, approx. (All Six Days models) 100.5 kg (221.6 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.)
22.5 Electrical system

Battery (XC‑W US, XC‑W Six Days US, HJTZ5S-FP Lithium-ion battery
All 250/300 EU/AU/US models) Battery voltage: 12 V
Nominal capacity: 2.0 Ah
maintenance-free
Battery (300 EXC BR) YTX5L-BS Battery voltage: 12 V
Nominal capacity: 4 Ah
maintenance-free
Speedometer battery CR 2430 Battery voltage: 3 V
Fuse (All 250/300 models, XC‑W US, 58011109110 10 A
XC‑W Six Days US)
Headlight HS1/socket BX43t 12 V
35/35 W
Turn signal (All EXC/EXC Six Days mod- R10W / socket BA15s 12 V
els) 10 W
License plate lamp (All EXC/EXC Six Days LED
models)
22.6 Tires
Validity Front tires Rear tires
(125 XC‑W EU) 80/100 - 21 M/C 51M TT 120/90 - 18 M/C 65R TT
MAXXIS Maxx EnduPro MAXXIS Maxx EnduPro
(EXC EU/AU, 300 EXC BR) 80/100 - 21 M/C 51M TT 140/80 - 18 M/C 70R M+S TT
MAXXIS Maxx EnduPro MAXXIS Maxx EnduPro
(EXC Six Days EU, 300 EXC BR) 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
(XC‑W US, XC‑W Six Days US) 90/90 - 21 54M TT 110/100 - 18 64M TT
Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81
The tires specified represent one of the possible series production tires. Additional information is available in the Service section
under:
http://www.ktm.com
22.7 Fork
22.7.1 All 125/150 models
Fork part number 14.18.8Q.61
Fork WP Performance Systems MXMA 4860 upside down
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring length with preload spacer(s) 474 mm (18.66 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 928 mm (36.54 in)
Air chamber length 110+10
−20 mm (4.33−0.79 in)
+0.39
Fork oil per fork leg 600 ml (20.29 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 141)
22.7.2 All standard 250/300 EXC/XC-W models

Fork WP Performance Systems MXMA 4860 upside down
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring rate
−20 mm (4.33−0.79 in)
+0.39
22.7.3 All Six Days models

Fork WP Performance SystemsXplor 48
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring preload - Preload Adjuster
Comfort +0
Standard +0
Sport +3
Spring rate
−20 mm (4.33−0.79 in)
+0.39
22.8 Shock absorber

22.8.1 All 125/150 models
Shock absorber article number 12.18.7Q.61
Shock absorber WP Performance Systems 4618 PDS DCC
Compression damping, low-speed
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring preload
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 57 N/mm (325 lb/in)
Spring length 225 mm (8.86 in)
Gas pressure 10 bar (145 psi)
Static sag 35 mm (1.38 in)
Riding sag 110 mm (4.33 in)
Fitted length 415 mm (16.34 in)
Shock absorber fluid ( p. 142) SAE 2.5
22.8.2 All 250/300 models

Shock absorber article number 12.18.7Q.63
Shock absorber WP Performance Systems 4618 PDS DCC
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring preload
Spring rate
Spring length 225 mm (8.86 in)
Gas pressure 10 bar (145 psi)
Static sag 35 mm (1.38 in)
Riding sag 110 mm (4.33 in)
Fitted length 415 mm (16.34 in)
Shock absorber fluid ( p. 142) SAE 2.5
22.9 Chassis tightening torques

Screw, fixed grip M4 5 Nm (3.7 lbf ft) Loctite® 243™
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) –
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M5 5 Nm (3.7 lbf ft) –
Screw, battery terminal (All 250/300 M5 2.5 Nm (1.84 lbf ft) –
models, XC‑W US, XC‑W Six Days US)
Screw, light switch (All M5 1 Nm (0.7 lbf ft) –
EXC/EXC Six Days models,
125 XC‑W EU)
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Nut, cable on starter motor (All M6 4 Nm (3 lbf ft) –
250/300 models, XC‑W US,
XC‑W Six Days US)
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™
Screw, throttle grip M6 5 Nm (3.7 lbf ft) –
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft) –
Screw, bottom triple clamp (All stan- M8 15 Nm (11.1 lbf ft) –

dard EXC/XC-W models)
Screw, bottom triple clamp (All M8 15 Nm (11.1 lbf ft) –
Six Days models)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 25 Nm (18.4 lbf ft) Loctite® 2701™
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 35 Nm (25.8 lbf ft) Loctite® 2701™
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite® 2701™
Screw, top steering stem (All stan- M8 20 Nm (14.8 lbf ft) –
dard EXC/XC-W models)
Screw, top steering stem (All Six Days M8 17 Nm (12.5 lbf ft) Loctite® 243™
models)
Screw, top triple clamp (All M8 20 Nm (14.8 lbf ft) –
standard EXC/XC-W models)
Screw, top triple clamp (All Six Days M8 17 Nm (12.5 lbf ft) –
models)
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, front wheel spindle M20x1.5 35 Nm (25.8 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™
22.10 Carburetor
22.10.1 125 XC‑W EU
Carburetor type MIKUNI TMX 38
Carburetor identification number TMX 38 77
Needle position 3rd position from top
Jet needle 6BFY44‑73 (6BFY43‑73)
Main jet 480 (470, 490, 500, 520)
Idling jet 45 (42.5)
Starting jet 80
Needle jet R‑8
Idle air adjusting screw
Open 2 turns
Throttle slide 4
22.10.2 150 XC‑W US

Jet needle 6BFY43‑74 (6BFY44-74, 6BFY42‑74)
Main jet 480 (470, 490, 500)
Idling jet 40 (37.5/42.5)
Starting jet 80
Needle jet S‑1
Open 1.5 turns
Throttle slide 4
22.10.3 250 EXC EU, 250 EXC AU, 250 EXC Six Days EU
Needle position 1st position from top
Jet needle 6BFY43‑74 (6BFY43‑73, 6BFY43‑72, 6BFY44‑72,
6BFY44‑73)
Main jet 100 (430, 440, 450, 460)
Idling jet 17.5 (35/37.5/40)
Starting jet 50 (80)
Needle jet R‑8
Open 2 turns
Throttle slide 4
Slide stop Present
22.10.4 250 XC‑W US

Jet needle 6BFY43‑72 (6BFY44-72, 6BFY44-73, 6BFY43‑73)
Main jet 440 (430, 450, 460)
Idling jet 40 (35/37.5)
Starting jet 80
Needle jet R‑8

Open 1.5 turns
Throttle slide 4
22.10.5 300 EXC EU, 300 EXC AU, 300 EXC Six Days EU
Needle position 1st position from top
Jet needle 6BFY43‑74 (6BFY44‑73, 6BFY43‑73)
Main jet 100 (420, 430, 440, 450, 460)
Idling jet 17.5 (35/37.5/40)
Starting jet 50 (80)
Needle jet R‑8
Open 2 turns
Throttle slide 4
Slide stop Present
22.10.6 300 XC‑W US, 300 XC‑W Six Days US

Jet needle 6BFY44-73 (6BFY43-73)
Main jet 430 (420, 440, 450, 460)
Idling jet 37.5 (35/40)
Starting jet 80
Needle jet R‑8
Open 1.5 turns
Throttle slide 4
22.10.7 300 EXC BR

Jet needle 6BFY43-73 (6BFY42-73, 6BFY42-74, 6BFY43-74)
Main jet 470 (460, 480, 490)
Idling jet 35 (32.5/37.5/40)
Starting jet 80
Needle jet S-4
Open 2 turns
Throttle slide 4
23 CARBURETOR TUNING 134
23.1 Carburetor tuning (125 XC‑W EU)
402698-01
M/FT ASL Sea level

TEMP Temperature
ASO Idle air adjusting screw open
IJ Idling jet
NDL Needle
POS Needle position from top
MJ Main jet
Info
Do not use on sandy terrain.
23.2 Carburetor tuning (150 XC‑W US)
402699-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
Info
23.3 Carburetor tuning (250 EXC EU, 250 EXC AU, 250 EXC Six Days EU)
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.
402700-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
Info
23.4 Carburetor tuning (250 XC‑W US)
402701-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
Info
23.5 Carburetor tuning (300 EXC EU, 300 EXC AU, 300 EXC Six Days EU)
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.
402702-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
Info
23.6 Carburetor tuning (300 XC‑W US, 300 XC‑W Six Days US)
402703-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
Info
23.7 Carburetor tuning (300 EXC BR)
402729-01
M/FT ASL Sea level

TEMP Temperature
IJ Idling jet
NDL Needle
MJ Main jet
Does not apply on sandy terrain.
24 SUBSTANCES 141
Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre-
sponding properties.
Recommended supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using infe-
rior antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… anti-corrosion/antifreeze
−49 °F) distilled water
Motorex®
– COOLANT M3.0
Engine oil (15W/50)

– JASO T903 MA ( p. 144)
– SAE ( p. 144) (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.
Motorex®
– Top Speed 4T
Engine oil, 2-stroke

– JASO FD ( p. 144)
Guideline
– Only use high grade 2-stroke engine oil of a reputable brand.
Fully synthetic
Motorex®
– Cross Power 2T
Fork oil (SAE 4) (48601166S1)

– SAE ( p. 144) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding
properties.
24 SUBSTANCES 142
Shock absorber fluid (SAE 2.5) (50180751S1)

– SAE ( p. 144) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding
properties.
Super unleaded (ROZ 95/RON 95/PON 91)

– 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 (95 octane) mixed with 2-stroke engine oil (1:60)
– DIN EN 228
– JASO FD ( p. 144) (1:60)
Mixture ratio
1:60 Engine oil, 2-stroke ( p. 141)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 142)
Motorex®
– Cross Power 2T
Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil, 1:60)
– Beschluss Nr. 57 der ANP (Agência Nacional do Petróleo) (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil)
– JASO FD ( p. 144) (1:60)
Mixture ratio
1:60 Engine oil, 2-stroke ( p. 141)
Super unleaded, type C (ROZ 95/RON 95/PON 91) ( p. 142)
Motorex®
– Cross Power 2T
Super unleaded, type C (ROZ 95/RON 95/PON 91)

– Beschluss Nr. 57 der ANP (Agência Nacional do Petróleo) (ROZ 95/RON 95/PON 91)
Guideline
– Only use super unleaded fuel that matches or is equivalent to the following specifications.
– Super unleaded fuel with an ethanol content of 19 to 27 % is permissible.
Info
Do not use fuel made of methanol (e. g. M15, M85, M100).
Do not use fuel with less than 19 % ethanol (e. g. E10).
Do not use fuel with more than 27 % ethanol (e. g. E30, E85, E100).
25 AUXILIARY SUBSTANCES 143
Air filter cleaner

Motorex®
– Racing Bio Dirt Remover
Chain cleaner
Motorex®
– Chain Clean
Fuel additive
Motorex®
– Fuel Stabilizer
High viscosity grease

SKF®
– LGHB 2
Long-life grease
Motorex®
– Bike Grease 2000
Motorcycle cleaner
Motorex®
– Moto Clean
Off-road chain spray

Motorex®
– Chainlube Offroad
Oil for foam air filter

Motorex®
– Racing Bio Liquid Power
Preserving materials for paints, metal and rubber

Motorex®
– Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Motorex®
– Quick Cleaner
Universal oil spray

Motorex®
– Joker 440 Synthetic
26 STANDARDS 144
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. In 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.
JASO FD
JASO FD 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.
27 LIST OF ABBREVIATIONS 145
Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly
28 LIST OF SYMBOLS 146
28.1 Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by
yellow or orange symbols.
28.2 Green and blue symbols

Green and blue symbols reflect information.
The high beam indicator lamp lights up blue – The high beam is switched on.
Turn signal indicator lamp flashes green – The turn signal is switched on.
INDEX 147
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INDEX
A Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cleaning, care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-116
Air filter Clutch
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 fluid level, checking/correcting . . . . . . . . . . . . . . . . . . 73
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air filter box basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 73
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Compression damping
sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Air filter box cover Compression damping, high-speed
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 41
Antifreeze
Coolant
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B Coolant level
Basic chassis setting checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99-100
checking with rider's weight . . . . . . . . . . . . . . . . . . . . 41 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Battery Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 D
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Difficult operating conditions
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
low temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake discs muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake fluid wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
of front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . 78 Difficult riding conditions . . . . . . . . . . . . . . . . . . . . . . . . . 31
of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . 82 dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Brake fluid level high temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 77 slow speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 82 wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Brake linings E
front brake, checking . .. . . . . . . . . . . . . . . . . . . . . . 79 Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
of front brake, changing . . . . . . . . . . . . . . . . . . . . . . 79 Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
of rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . 83
Engine
rear brake, checking . . .. . . . . . . . . . . . . . . . . . . . . . 83
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
C
Engine characteristic
Capacity auxiliary spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 auxiliary spring, setting . . . . . . . . . . . . . . . . . . . . . . 108
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 126 Engine guard
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113, 126 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Carburetor removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
float chamber, emptying . . . . . . . . . . . . . . . . . . . . . 111 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
idle speed, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 106
tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-140 F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Carburetor setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Filler cap
Chain
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Filling up
Chain guide
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chain tension
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 81
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 81
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INDEX 148
Fork Indicator lamps overview . . . . . . . . . . . . . . . . . . . . . . . . . 16

article number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 46
K
Fork legs Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Kick starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 51 Kill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 L
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 48 Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fork protector Lower triple clamp
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 57
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Frame M
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Main fuse
Front fender changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Main silencer
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 changing the glass fiber yarn filling . . . . . . . . . . . . . . . 65
Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Motor sprocket
Fuel tank checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Motorcycle
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuse removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 51
main fuse, changing . . . . . . . . . . . . . . . . . . . . . . . . . 93 O
G Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 P
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Play in throttle cable
Gear oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Preparing for use
H advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 30
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
checks and maintenance measures when preparing for use 35
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 76
free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 76 Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 76 R
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Rear sprocket
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Headlight Rear wheel
light range, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 97 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Headlight bulb removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Rebound damping
Headlight mask with headlight fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Riding sag
Headlight setting adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Rubber grip
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
I S
Ignition curve Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Seat
Ignition timing map mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
plug-in connector . . . . . . . . . . . . . . . . . . . . . . . . . . 107 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INDEX 149
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-40 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-120

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Turn signal bulb
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . 107 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
basic position, checking . . . . . . . . . . . . . . . . . . . . . 107 Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Shock absorber Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
article number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
U
compression damping, general . . . . . . . . . . . . . . . . . . 41
Use definition ................................. 6
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 V
riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 44 View of vehicle
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 44 front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 44 rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 W
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Speedometer
Winter operation
battery, changing . . . . . . ... . . . . . . . . . . . . . . . . . . 97
checks and maintenance steps . . . . . . . . . . . . . . . . . 116
clock, setting . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 21
kilometers or miles, setting .. . . . . . . . . . . . . . . . . . . 20 Work rules ................................... 7
overview . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 20
setting . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 21
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Steering
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering head bearing
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Swingarm
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 130
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 127
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
engine tightening torques . . . . . . . . . . . . . . . . . . . . 123
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
*3213477en*
3213477en
07/2016
KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria Photo: Mitterbauer/KTM
http://www.ktm.com

KTM Exc 2017

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OWNER'S MANUAL 2017

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

We hope you enjoy your new vehicle!

Enter the serial numbers of your vehicle below.

Engine number ( p. 12)

© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria

ISO 9001(12 100 6061)

KTM Sportmotorcycle GmbH

This document is valid for the following models:

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

1.1 Symbols used

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

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

Indicates information with more details or tips.

Indicates the result of a testing step.

1.2 Formats used

Name® Identifies a protected name.

Brand™ Identifies a brand available on the open market.

2.1 Use definition – intended use

(All XC‑W/XC‑W Six Days models)

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Tampering warning

2.5 Safe operation

2.6 Protective clothing

2.7 Work rules

2.9 Owner's Manual

3.1 Manufacturer and implied warranty

3.2 Operating and auxiliary substances

3.3 Spare parts, accessories

3.6 Customer service

A list of authorized KTM dealers can be found on the KTM website.

4.1 View of vehicle, front left (example)

1 Hand brake lever ( p. 14)

4.2 View of vehicle, rear right (example)

5.1 Chassis number

5.2 Type label

5.4 Engine number

(All 250/300 models)

5.5 Fork part number

5.6 Shock absorber article number

6.1 Clutch lever

6.2 Hand brake lever

6.3 Throttle grip

6.5 Kill switch (XC‑W US, XC‑W Six Days US)

(All EXC/EXC Six Days models)

6.8 Light switch (XC‑W US, XC‑W Six Days US)

6.9 Turn signal switch (All EXC/EXC Six Days models)

6.10 Emergency OFF switch (EXC AU)

6.12 Indicator lamps overview (All EXC/EXC Six Days models)

Fuel level warning lamp – inoperative

6.13 Indicator lamps overview (All XC‑W/XC‑W Six Days models)

Malfunction indicator lamp – inoperative

Fuel level warning lamp – inoperative

6.14 Opening the filler cap

6.15 Closing the filler cap

6.16 Fuel tap

6.18 Shift lever

The gear positions can be seen in the photograph.