1 2014 KTM 250-300 Exc XC-W Manual

REPAIR MANUAL 2014
TABLE OF CONTENTS 2
1 MEANS OF REPRESENTATION........................................... 6 6.2.6 Positioning the fork protection........................ 34

1.1 Symbols used........................... 6 6.2.7 Removing the fork legs..................................... 34
1.2 Formats used...................... 6 6.2.8 Installing the fork legs...................................... 34
2 SAFETY ADVICE..................................................................... 7 6.2.9 Removing the fork protector............................. 35
2.1 Repair Manual................................................ 7 6.2.10 Installing the fork protector.............................. 35
2.2 Safety advice............................................................. 7 6.2.11 Performing a fork service................................. 35
2.3 Degrees of risk and symbols...................... 7 6.2.12 Disassembling the fork legs............................. 36
2.4 Work rules................................................................. 7 6.2.13 Removing the spring......................................... 38
3 IMPORTANT NOTES.............................................................. 8 6.2.14 Disassembling the cartridge............................. 39
3.1 Guarantee, warranty................................................. 8 6.2.15 Disassembling the piston rod.......................... 40
3.2 Operating and auxiliary substances........................ 8 6.2.16 Disassembling the hydrostop unit................... 41
3.3 Spare parts, accessories.......................................... 8 6.2.17 Disassembling the seal ring retainer................ 41
3.4 Figures...................................................................... 8 6.2.18 Checking the fork legs...................................... 42
4 SERIAL NUMBERS............................................................... 9 6.2.19 Assembling the seal ring retainer.................... 43
4.1 Chassis number........................................................ 9 6.2.20 Assembling the hydrostop unit........................ 43
4.2 Type label....................................................... 9 6.2.21 Assembling the piston rod............................... 44
4.3 Engine number......................................................... 9 6.2.22 Assembling the cartridge................................. 45
4.4 Fork part number...................................................... 9 6.2.23 Assembling the fork legs................ 46
4.5 Shock absorber article number............................... 9 6.2.24 Greasing the steering head bearing................. 50
5 MOTORCYCLE.............................. 10 6.2.25 Removing the lower triple clamp.................... 50
5.1 Raising the motorcycle with the lift stand........... 10 6.2.26 Installing the lower triple clamp..................... 51
5.2 Removing the motorcycle from the lift stand...... 10 6.2.27 Checking the play of the steering head
5.3 Starting.................................................................... 10 bearing............................................................... 52
5.4 Starting the motorcycle for checking................... 11 6.2.28 Adjusting the play of the steering head
6 FORK, TRIPLE CLAMP....................................................... 12 bearing............................................................... 53
7 HANDLEBAR, CONTROLS.................................................. 54
6.1 EXC EU/AUS, XC-W................................................ 12
6.1.1 Adjusting the compression damping of the 7.1 Handlebar position................................................. 54
fork..................................................................... 12 7.2 Adjusting the handlebar position......................... 54
6.1.2 Adjusting the rebound damping of the fork.... 12 7.3 Adjusting the basic position of the clutch
6.1.3 Adjusting the spring preload of the fork......... 12 lever......................................................................... 54
6.1.4 Bleeding the fork legs...................................... 13 7.4 Checking the routing of the throttle cable........... 55
6.1.5 Cleaning the dust boots of the fork legs.......... 13 7.5 Checking the play in the throttle cable................ 55
7.6 Adjusting the play in the throttle cable................ 56
6.1.6 Loosening the fork protection.......................... 14
8 FRAME................................................................................. 57
6.1.7 Positioning the fork protection........................ 14
6.1.8 Removing the fork legs..................................... 14 8.1 Removing the engine guard
(250/300 SIX DAYS)............................................. 57
6.1.9 Installing the fork legs...................................... 14
8.2 Installing the engine guard
6.1.10 Removing the fork protector............................. 15
(250/300 SIX DAYS)............................................. 57
6.1.11 Installing the fork protector.............................. 15
9 SHOCK ABSORBER, SWINGARM..................................... 58
6.1.12 Performing a fork service................................. 16
9.1 Adjusting the high-speed compression
6.1.13 Disassembling the fork legs............................. 16 damping of the shock absorber............................. 58
6.1.14 Cartridge disassembly...................................... 19 9.2 Adjusting the low-speed compression damping
6.1.15 Disassembling the compression damping of the shock absorber............................................ 58
fitting................................................................. 21 9.3 Adjusting the rebound damping of the shock
6.1.16 Checking the fork legs...................................... 21 absorber................................................................... 59
6.1.17 Assembling the compression damping 9.4 Measuring the sag of the unloaded rear wheel.... 59
fitting................................................................. 22 9.5 Checking the static sag of the shock absorber.... 59
6.1.18 Assembling the cartridge................................. 23 9.6 Checking the riding sag of the shock absorber.... 60
6.1.19 Assembling the fork legs................................... 24 9.7 Adjusting the spring preload of the shock
6.1.20 Greasing the steering head bearing................. 28 absorber................................................................... 60
6.1.21 Removing the lower triple clamp.................... 29 9.8 Adjusting the riding sag........................................ 61
6.1.22 Installing the lower triple clamp..................... 29 9.9 Removing the shock absorber............................... 61
6.1.23 Checking the play of the steering head 9.10 Installing the shock absorber................................ 61
bearing............................................................... 31 9.11 Servicing the shock absorber................................ 62
6.1.24 Adjusting the play of the steering head 9.12 Removing the spring.............................................. 62
bearing............................................................... 31
9.13 Disassembling the damper.................................... 63
6.2 250/300 SIX DAYS................................................. 32
9.14 Disassembling the piston rod............................... 64
6.2.1 Adjusting the compression damping of the
9.15 Disassembling the seal ring retainer.................... 65
fork..................................................................... 32
9.16 Replacing the pilot bushing................................. 66
6.2.2 Adjusting the rebound damping of the fork.... 32
9.17 Checking the damper............................................ 67
6.2.3 Bleeding the fork legs...................................... 32
9.18 Disassembling the rebound adjuster.................... 67
6.2.4 Cleaning the dust boots of the fork legs......... 33
9.19 Removing the heim joint....................................... 68
6.2.5 Loosening the fork protection.......................... 33
9.20 Installing the heim joint......................................... 69
TABLE OF CONTENTS 3
9.21 Assembling the rebound adjuster......................... 70 15.5 Connecting the negative cable of the battery.... 102
9.22 Assembling the seal ring retainer......................... 70 15.6 Removing the battery.......................................... 102
9.23 Assembling the piston rod..................................... 71 15.7 Installing the battery........................................... 103
9.24 Assembling the damper......................................... 72 15.8 Checking the charging voltage........................... 103
9.25 Bleeding and filling the damper.......................... 75 15.9 Checking the closed current............................... 103
9.26 Filling the damper with nitrogen.......................... 77 15.10 Checking the starter relay................................... 104
9.27 Installing the spring.............................................. 78 16 BRAKE SYSTEM............................................................... 105
9.28 Changing the heim joint........................................ 79 16.1 Checking the front brake linings........................ 105
10 EXHAUST............................................................................. 81 16.2 Changing the front brake linings........................ 105
10.1 Removing the main silencer................... 81 16.3 Checking the free travel of the hand brake
10.2 Installing the main silencer.................................. 81 lever...................................................................... 107
10.3 Changing the glass fiber yarn filling of the 16.4 Adjusting free travel of hand brake lever (All
main silencer.......................................................... 81 250/300 EXC EU/AU models)........................... 107
11 AIR FILTER..................................... 83 16.5 Adjusting the basic position of the hand
11.1 Removing the air filter box lid.............................. 83 brake lever (All 250/300 XC-W models)........... 107
11.2 Installing the air filter box lid............................... 83 16.6 Checking the front brake fluid level.................. 108
11.3 Removing the air filter........................................... 83 16.7 Adding front brake fluid...................................... 108
11.4 Installing the air filter............................................ 83 16.8 Changing the front brake fluid........................... 109
11.5 Cleaning the air filter and air filter box............... 84 16.9 Checking the rear brake linings......................... 110
11.6 Sealing the air filter box........ .............................. 84 16.10 Changing the brake linings of the rear brake .... Ill
12 FUEL TANK, SEAT, TRIM.................................................. 85 16.11 Checking the free travel of foot brake lever...... 112
12.1 Opening the filler cap............................................ 85 16.12 Adjusting the basic position of the foot brake
lever...................................................................... 112
12.2 Closing the filler cap............................................. 85
16.13 Checking the rear brake fluid level.................... 113
12.3 Removing the seat................................................. 85
16.14 Adding brake fluid for the rear brake................. 113
12.4 Mounting the seat.................................................. 86
16.15 Changing the rear brake fluid............................. 114
12.5 Removing the fuel tank.......................................... 86
17 LIGHTING SYSTEM, INSTRUMENTS............................. 116
12.6 Installing the fuel tank.......................................... 87
17.1 Checking the headlight setting.......................... 116
12.7 Fuel tap........ .......................................................... 88
17.2 Adjusting the headlight range............................. 116
13 MASK,FENDER................................................................. 89
17.3 EXC EU/AUS, XC-W....... ..................................... 116
13.1 Removing the front fender.................................... 89
17.3.1 Speedometer overview.................................... 116
13.2 Installing the front fender..................................... 89
17.3.2 Activation and test.......................................... 117
13.3 Removing the headlight mask with the
headlight................................................................. 89 17.3.3 Setting kilometers or miles........................... 117
13.4 Installing the headlight mask with the 17.3.4 Adjusting the speedometer functions........... 117
headlight................................................................. 90 17.3.5 Setting the clock.......................... 118
14 WHEELS.............................................................................. 91 17.3.6 Activating the additional functions.............. 118
14.1 Checking the tire air pressure............................... 91 17.3.7 Setting the wheel circumference.................. 119
14.2 Checking the tire condition................................... 91 17.3.8 Querying lap time........................................... 119
14.3 Checking the brake discs...................................... 92 17.4 250/300 SIX DAYS............................................. 120
14.4 Checking the spoke tension................................... 92 17.4.1 Speedometer overview.................................... 120
14.5 Front wheel............................................................. 93 17.4.2 Activation and test.......................................... 120
14.5.1 Removing the front wheel................................ 93 17.4.3 Setting kilometers or miles........................... 120
14.5.2 Installing the front wheel............................ 93 17.4.4 Setting the speedometer functions.............. 121
14.5.3 Removing the brake disc of the front brake.... 94 17.4.5 Setting the clock................................. 121
14.5.4 Installing the brake disc of the front brake .... 94 17.4.6 Setting the wheel circumference.................. 122
14.6 Rear wheel.............................................................. 94 17.4.7 Viewing the lap time...................................... 122
14.6.1 Removing the rear wheel................................. 94 18 ENGINE............................................................................. 123
14.6.2 Installing the rear wheel............................. 95 18.1 Removing the engine.......................................... 123
14.6.3 Removing the brake disc of the rear brake. 96 18.2 Installing the engine............................................ 127
14.6.4 Installing the brake disc of the rear brake. 96 18.3 Engine disassembly............................................. 132
14.6.5 Checking the chain for dirt......................... 96 18.3.1 Clamping the engine into the engine work
14.6.6 Cleaning the chain............................................ 97 stand................................................................ 132
14.6.7 Checking the chain tension.............................. 97 18.3.2 Draining the gear oil....................................... 132
14.6.8 Checking the chain, rear sprocket, engine 18.3.3 Removing the clutch push rod....................... 132
sprocket and chain guide................................. 98 18.3.4 Removing the shift lever................................ 132
14.6.9 Adjusting the chain tension.......................... 100 18.3.5 Removing the engine sprocket....................... 133
15 WIRING HARNESS, BATTERY......................................... 101 18.3.6 Removing the spacer...................................... 133
15.1 Plug-in connection, ignition timing map........... 101 18.3.7 Removing the starter motor........................... 133
15.2 Removing the main fuse..................................... 101 18.3.8 Removing the kick starter.............................. 135
15.3 Installing the main fuse...................................... 101 18.3.9 Removing the cylinder head.......................... 135
15.4 Disconnecting the negative cable of the 18.3.10 Removing the cylinder.................................... 135
battery................................................................... 101 18.3.11 Removing the piston...................................... 136
TABLE OF CONTENTS 4
18.3.12 Removing the water pump cover.................... 137 18.5.7 Installing the reed valve housing.................. 174
18.3.13 Removing the clutch cover............................. 137 18.5.8 Installing the rotor.......................................... 174
18.3.14 Removing the clutch discs............................. 138 18.5.9 Installing the locking lever............................. 175
18.3.15 Removing the clutch basket........................... 139 18.5.10 Installing the shift drum locating unit.......... 175
18.3.16 Removing the kick starter shaft..................... 140 18.5.11 Installing the shift shaft................................ 175
18.3.17 Removing the intermediate kick starter 18.5.12 Installing the intermediate kick starter
gear................................................................... 140 gear................................................................... 175
18.3.18 Removing the shift shaft................................. 140 18.5.13 Installing the kick starter shaft..................... 175
18.3.19 Removing the shift drum locating unit......... 140 18.5.14 Installing the clutch basket........................... 176
18.3.20 Removing the locking lever............................ 140 18.5.15 Installing the clutch discs.............................. 177
18.3.21 Removing the rotor........................................... 141 18.5.16 Installing the clutch cover............................. 178
18.3.22 Removing the reed valve housing................... 141 18.5.17 Installing the water pump cover.................... 179
18.3.23 Removing the left engine case section......... 141 18.5.18 Installing the piston....................................... 179
18.3.24 Removing the shift rails.................................. 142 18.5.19 Installing the cylinder..................................... 180
18.3.25 Removing the shift drum................................ 142 18.5.20 Checking the X-distance................................ 181
18.3.26 Removing the shift forks................................. 142 18.5.21 Adjusting the X-distance................................ 182
18.3.27 Removing the transmission shafts................. 142 18.5.22 Adjusting the Z-distance................................ 182
18.3.28 Removing the crankshaft................................ 143 18.5.23 Installing the cylinder head........................... 184
18.4 work on individual parts...................................... 143 18.5.24 Installing the kick starter............................... 184
18.4.1 Work on the right section of the engine 18.5.25 Installing the starter motor............................. 184
case................................................................. 143 18.5.26 Installing the spacer....................................... 186
18.4.2 Work on the left section of the engine 18.5.27 Installing the engine sprocket....................... 186
case................................................................. 144 18.5.28 Installing the shift lever................................. 186
18.4.3 Removing the crankshaft bearing inner 18.5.29 Installing the clutch push rod...................... 187
race................................................................... 145
18.5.30 Installing the gear oil drain plug................... 187
18.4.4 Installing the crankshaft bearing inner
18.5.31 Removing the engine from the work stand ... 187
race................................................................... 145
19 CARBURETOR................................................................... 188
18.4.5 Changing the connecting rod, conrod
19.1 Choke.................................................................... 188
bearing, and crank pin................................... 145
19.2 Carburetor - adjusting the idle speed ................ 188
18.4.6 Checking the crankshaft run-out at the
bearing pin....................................................... 146 19.3 Emptying the carburetor float chamber............ 189
18.4.7 Checking/measuring the cylinder.................. 147 19.4 Removing the carburetor..................................... 189
18.4.8 Removing the exhaust control....................... 147 19.5 Installing the carburetor..................................... 190
18.4.9 Checking the exhaust control........................ 149 19.6 Checking/adjusting the carburetor
components................................................ 191
18.4.10 Installing the exhaust control........................ 150
19.7 Disassembling the carburetor............................. 192
18.4.11 Cylinder - Nikasil® coating............................. 152
19.8 Checking the choke slide.................................... 193
18.4.12 Checking/measuring the piston..................... 152
19.9 Checking the jet needle...................................... 193
18.4.13 Checking the piston ring end gap................. 153
19.10 Checking the throttle slide................................. 193
18.4.14 Piston/cylinder - measuring the mounting
clearance......................................................... 153 19.11 Checking the float needle valve......................... 194
18.4.15 Disassembling the reed valve housing.......... 154 19.12 Assembling the carburetor................................. 194
18.4.16 Checking the reed valve housing, reed 19.13 Checking/adjusting the float level..................... 195
valve, and intake flange................................. 155 20 CLUTCH............................................................................. 196
18.4.17 Assembling the reed valve housing.............. 155 20.1 Checking/correcting the fluid level of the
18.4.18 Work on the clutch cover............................... 157 hydraulic clutch................................. 196
18.4.19 Checking the clutch....................................... 161 20.2 Changing the hydraulic clutchfluid................... 196
18.4.20 Preassembling the shift shaft........................ 162 21 WATER PUMP, COOLING SYSTEM................................ 197
18.4.21 Checking the shift mechanism..................... 163 21.1 Cooling system.................................................... 197
18.4.22 Disassembling the main shaft....................... 164 21.2 Checking the antifreeze and coolant level........ 197
18.4.23 Disassembling the countershaft.................... 165 21.3 Checking the coolant level................................. 197
18.4.24 Checking the transmission............................. 165 21.4 Draining the coolant............................................ 198
18.4.25 Assembling the main shaft............................. 166 21.5 Refilling with coolant.......................................... 198
18.4.26 Assembling the countershaft......................... 167 22 EXHAUST CONTROL........................................................ 200
18.4.27 Checking the kick starter............................... 169 22.1 Engine characteristic - setting the auxiliary
spring.................................................................... 200
18.4.28 Preassembling the kick starter shaft............ 169
23 LUBRICATION SYSTEM................................................... 201
18.4.29 Checking the electric starter drive................ 171
23.1 Changing the gear oil........................................... 201
18.5 Engine assembly.................................................. 172
23.2 Draining the gear oil............................................ 201
18.5.1 Installing the crankshaft................................ 172
23.3 Refilling with gear oil.......................................... 202
18.5.2 Installing the transmission shafts................. 172
23.4 Checking the gear oil level................................. 202
18.5.3 Installing the shift forks................................. 173
23.5 Adding gear oil.................................................... 202
18.5.4 Installing the shift drum................................ 173
24 IGNITION SYSTEM........................................................... 204
18.5.5 Installing the shift rails................................. 173
24.1 Checking the ignition system.............................. 204
18.5.6 Installing the left engine case section.......... 173
TABLE OF CONTENTS 5
24.2 Ignition coil - checking theprimarywinding........ 204 30.6 Page 1 of 5 (250 EXC SIX DAYS EU,
24.3 Ignition coil - checking the secondary 300 EXC SIX DAYS EU)...................................... 238
winding................................................................. 205 30.7 Page 2 of 5 (250 EXC SIX DAYS EU,
24.4 Checking the spark plug connector................... 205 300 EXC SIX DAYS EU)...................................... 240
24.5 Alternator - checking the charging coil of the 30.8 Page 3 of 5 (250 EXC SIX DAYS EU,
ignition................................................................. 206 300 EXC SIX DAYS EU)....................................... 242
24.6 Alternator - checking the battery winding........ 206 30.9 Page 4 of 5 (250 EXC SIX DAYS EU,
24.7 Alternator - checking the light winding............. 207 300 EXC SIX DAYS EU)....................................... 244
24.8 Checking the ignition pulse generator.............. 207 30.10 Page 5 of 5 (250 EXC SIX DAYS EU,
300 EXC SIX DAYS EU)....................................... 246
24.9 Removing the stator and crankshaft position
sensor.................................................................... 208 30.11 Page 1 of 5 (250/300 EXC AU)......................... 248
24.10 Installing the stator and crankshaft position 30.12 Page 2 of 5 (250/300 EXC AU)......................... 250
sensor.................................................................... 208 30.13 Page 3 of 5 (250/300 EXC AU)......................... 252
25 ELECTRIC STARTER........................................................ 209 30.14 Page 4 of 5 (250/300 EXC AU)......................... 254
25.1 Checking the starter motor................................. 209 30.15 Page 5 of 5 (250/300 EXC AU)......................... 256
26 TECHNICAL DATA............................................................. 210 30.16 Page 1 of 3 (250 XC-W USA,
26.1 Engine................................................................... 210 300 XC-W USA)................................................... 258
26.1.1 All 250 models................................................ 210 30.17 Page 2 of 3 (250 XC-W USA,
300 XC-W USA)................................................... 260
26.1.2 All 300 models................................................ 210
30.18 Page 3 of 3 (250 XC-W USA,
26.2 Engine tolerance, wear limits............................. 211
300 XC-W USA)................................................... 262
26.3 engine tightening torques................................... 212
30.19 Page 1 of 3 (300 XC-W SIX DAYS USA).......... 264
26.4 capacities............................................................. 212
30.20 Page 2 of 3 (300 XC-W SIX DAYS USA)........... 266
26.4.1 Gear oil............................................................. 212
30.21 Page 3 of 3 (300 XC-W SIX DAYS USA)........... 268
26.4.2 Coolant............................................................. 212
31 SUBSTANCES................................................................... 270
26.4.3 Fuel................................................................. 212
32 AUXILIARY SUBSTANCES.............................................. 272
26.5 Chassis..................................... 213
33 SPECIAL TOOLS............................................................... 274
26.6 electrical system................ 214
34 STANDARDS..................................................................... 284
26.7 Tires...................................................................... 214
35 LIST OF ABBREVIATIONS................................................ 285
26.8 Fork....................................................................... 214
INDEX................. ....................................................................... 286
26.8.1 EXC EU/AUS, XC-W................................ 214
26.8.2 250/300 SIX DAYS......................................... 215
26.9 shock absorber.................................................... 215
26.10 chassis tightening torques................................... 216
26.11 carburetor............................................................. 217
26.11.1 250 EXC EU, 250 EXC SIX DAYS EU.......... 217
26.11.2 250 EXC AUS................................................. 217
26.11.3 250 XC-W USA................................................ 217
26.11.4 300 EXC EU, 300 EXC SIX DAYS EU.......... 217
26.11.5 300 EXC AUS................................................. 218
26.11.6 300 XC-W USA,
300 XC-W SIX DAYS USA........................ 218
26.12 carburetor tuning................................................. 219
26.12.1 Carburetor tuning (All250 models)............... 219
26.12.2 Carburetor tuning (All300 models)............... 220
26.12.3 General carburetor tuning.............................. 221
27 CLEANING, CARE............................................................. 222
27.1 Cleaning the motorcycle..................................... 222
27.2 Checks and maintenance steps for winter
operation.............................................................. 223
28 STORAGE........................................................................... 224
28.1 Storage................................................................. 224
28.2 Preparing for use after storage........................... 224
29 SERVICE SCHEDULE....................................................... 225
29.1 Service schedule.................................................. 225
29.2 Service work (as additional order)..................... 226
30 WIRING DIAGRAM........................................................... 228
30.1 Page 1 of 5 (250 EXC EU, 300 EXC EU).......... 228
1 MEANS OF REPRESENTATION 6
1.1 Symbols used

The meaning of specific symbols is described below.
y Indicates an expected reaction (e.g. of a work step or a function).
X 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).
m Indicates information with more details or tips.

i
Indicates the result of a testing step.

»
Denotes a voltage measurement.

V
Denotes a current measurement.
A
Denotes a resistance measurement.
Q
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name® Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.
2 SAFETY ADVICE 7
2.1 Repair Manual

Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
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 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, 0-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
3 IMPORTANT NOTES 8
3.1 Guarantee, warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis
assemble the component to perform the activity in question. Please follow the instructions in the text.
4 SERIAL NUMBERS 9
4.1 Chassis number

The chassis number O is stamped on the right side of the steering head.
4.3 Engine number

The engine number O is stamped on the left side of the engine under the engine
sprocket.
4.4 Fork part number

The fork part number o is stamped on the inner side of the fork stub.
4.5 Shock absorber article number

The shock absorber part number o is stamped on the top of the shock absorber above
the adjusting ring towards the engine side.
5 MOTORCYCLE 10
5.1 Raising the motorcycle with the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
- Always place the vehicle on a firm and even surface.
- Raise the motorcycle at the frame underneath the engine.
Lift stand (54829055000) (•" p. 275)
y Neither wheel is in contact with the ground.

401942-01 - Secure the motorcycle against falling over.
5.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
- Always place the vehicle on a firm and even surface.
Remove the motorcycle from the lift stand.

Remove the lift stand.
To park the motorcycle, press side stand o to the ground with your foot and lean
the motorcycle on it.
• Info
I When you are riding, the side stand must be folded up and secured with the
rubber band.
5.3 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
- Always warm up the engine at low engine speeds.
info
If the motorcycle does not start easily, there may be old fuel in the float chamber. The easily ignitable components of the fuel
evaporate during lengthy periods of disuse.
When the float chamber is filled with fresh, ignitable fuel, the engine will start immediately.
Condition
The motorcycle was stationary for more than 1 week.
- Empty the carburetor float chamber. (*" p. 189)
- Turn handle O of the fuel tap to the ON position. (Figure 602702-10*- p. 88)
y Fuel can flow from the fuel tank to the carburetor.
- Take the motorcycle off of the stand.
- Shift gear to neutral.
(250/300 EXC AU)
- Turn the emergency OFF switch to the position O.
Condition
The engine is cold.
- Pull out the choke lever all the way.
5 MOTORCYCLE 11
- Press the electric starter button or press the kick starter robustly through its full range
• Info
I Do not turn the throttle.
Danger
A Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.

(250/300 EXC AU)
- Turn the emergency OFF switch to the position O.
- Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not open the throttle.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
6 FORK, TRIPLE CLAMP 12
• Info
I The hydraulic compression damping determines the fork suspension behavior.
- Remove protection caps o

- Turn adjusting screws © clockwise all the way.
• Info
I Adjusting screws © are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
- Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline
Compression damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
- Mount protection caps ©
6.1.2 Adjusting the rebound damping of the fork
• Info
I The hydraulic rebound damping determines the fork suspension behavior.
Turn adjusting screws O clockwise all the way.
• Info
I Adjusting screws O are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline
Rebound damping
Comfort 20 clicks
Standard 18 clicks
Sport 16 clicks
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
6.1.3 Adjusting the spring preload of the fork

Turn the adjusting screws counterclockwise all the way.
• Info
I Make the same adjustment on both fork legs.
Turn clockwise by the number of turns corresponding to the fork type.

6 FORK, TRIPLE CLAMP
Guideline
Spring preload - Preload Adjuster
Comfort 1 turn
Standard 2 turns
Sport 2 turns
• Info
I Turn clockwise to increase spring preload; turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.
6.1.4 Bleeding the fork legs

Preparatory work
- Raise the motorcycle with the lift stand. C*- p. 10)
Main work
- Release bleeder screws O-
y Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
Finishing work
- Remove the motorcycle from the lift stand. p. 10)
6.1.5 Cleaning the dust boots of the fork legs

Preparatory work
- Raise the motorcycle with the lift stand. (*" p. 10)
- Loosen the fork protection. (•" p. 14)
Main work
- Push dust boots o of both fork legs downwards.
• Info
I The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
- Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
- Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray (*" p. 273)
- Press the dust boots back into their normal position.

- Remove excess oil.
Finishing work
- Position the fork protection. (*" p. 14)
- Remove the motorcycle from the lift stand. (•" p. 10)
6.1.6 Loosening the fork protection

Remove screws o and take off the clamp.
Remove screws © on the left fork leg. Push the fork protection downwards.
Remove the screws on the right fork leg. Push the fork protection downwards.
6.1.7 Positioning the fork protection

Position the fork protection on the left fork leg. Mount and tighten screws ©
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
Position the brake line and wiring harness. Put on the clamp and mount and
tighten screws ©.
Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
6.1.8 Removing the fork legs

Preparatory work
- Raise the motorcycle with the lift stand. (** p. 10)
- Remove the front wheel. (*“ p. 93)
- Remove the headlight mask with the headlight. (•" p. 89)
Main work
- Remove screws o and take off the clamp.
- Remove cable binder ©
- Remove screws © and take off the brake caliper.
- Hang the brake caliper and the brake line loosely to the side.
- Loosen screws ©. Remove the fork leg on the left.

- Loosen screws ©. Remove the fork leg on the right.
6.1.9 Installing the fork legs

Main work
- Position the fork legs.
• Info
I Grooves are milled into the side of the upper end of the fork legs. The sec
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
Position bleeder screws o toward the front.
- Tighten screws ©.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 Ibf ft)
Tighten screws ©.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 Ibf ft)
Position the brake caliper and mount and tighten screws ©.

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 Ibf ft)
- Mount cable binder

- Position the brake line and wiring harness. Put the clamp on and mount and
tighten screws (s).
Finishing work
- Install the front wheel. (*" p. 93)
- Install the headlight mask with the headlight. (•" p. 90)
- Check the headlight setting. (*" p. 116)
6.1.10 Removing the fork protector

Preparatory work
- Raise the motorcycle with the lift stand. 0*- p. 10)
- Remove the front wheel. (•" p. 93)
- Remove the fork legs. (•" p. 14)
Main work
- Remove screws o on the left fork leg. Lift off the fork protector.
- Remove the screws on the right fork leg. Lift off the fork protector.
6.1.11 Installing the fork protector

Main work
- Position the fork protection on the left fork leg. Mount and tighten screws ©
Guideline
Guideline
Finishing work
- Install the fork legs. (*" p. 14)
6.1.12 Performing a fork service
• Info
I These operations are the same on both fork legs.
Condition
The fork legs have been removed.
- Disassemble the fork legs. (•" p. 16)
- Disassemble the cartridge. (•" p. 19)
- Check the fork legs. (•" p. 21)
- Assemble the cartridge. (•" p. 23)
- Assemble the fork legs. (*" p. 24)
6.1.13 Disassembling the fork legs
• Info
I The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
- Remove protective cover ©.
- Note down the present state of rebound damping © and compression
damping ©.
- Note down of the present state of the spring preload.
- Completely open the adjusters of the rebound damping and compression damping.
- Clamp the fork leg in the area of lower triple clamp.
Clamping stand (T1403S) (*" p. 281)

Loosen Preload Adjuster ©.
Info
The Preload Adjuster cannot be taken off yet
Take out the fork leg and clamp with the axle clamp.
Info
Use soft jaws.
Push the outer tube downward.

Pull the spring downward. Place the special tool on the hexagonal part.
Open-end wrench (T14032) (*“ p. 281)
• Info
I The preload spacers © should be above the special tool.
Clamp the special tool in the bench vise. Loosen Preload Adjuster ©.
Remove Preload Adjuster © with preload spacers ©

Remove adjustment tube 0
Pull the spring downward. Remove the special tool.

Remove the spring.
Drain the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.
gy
Clamp the fork leg with the axle clamp.
Guideline
Use soft jaws.
^ h
; Unscrew and remove the compression damping fitting ©
• Info
li I Place a fluid collector beneath it, as usually some oil will drain out.
__________________________________________________
Remove the cartridge.
Remove dust boot ©.

Remove fork protector ring ©
• Info
I The fork protector ring does not necessarily need to be disassembled for the
further repair.
Remove lock ring ©.
• Info
I The lock ring has a coarsely finished end against which the screwdriver can
be placed.
Warm up the outer tube in area © of the lower sliding bushing.

Guideline
50 °C (122 °F)
Jerk the outer tube out of the inner tube.
• Info
I The lower sliding bushing © must be pulled out of its bearing seat when
doing this.
Remove upper sliding bushing
Info
Gently pull them apart without using any tool.
Take off the lower sliding bushing ©

Take off support ring
Take off seal ring
Take off lock ring ©
Take off dust boot ©
Take out the fork leg.
6.1.14 Cartridge disassembly
Info
The steps are identical for both fork legs.
Preparatory work
Main work
- Remove fluid barrier o from the piston rod.
Clamping stand (T14016S) (•“ p. 281)
- Remove piston rod © from the cartridge.
- Remove washer © and spring seat O from the cartridge.

Degrease the cartridge and clamp using the pecial tool.
Clamping stand (T14015S) p. 280)
Warm up the cartridge in the area of ©■

Guideline
50 °C (122 °F)
Unscrew and remove screwsleeve ©.
• Info
I This step is unnecessary for the further disassembly.
Degrease the piston rod.

Clamp the piston rod with the special tool.
Clamping stand (T14016S) (•“ p. 281)
Remove nut ©
Remove shim stack e completely.
200698-10
Remove piston ©.
Remove shim stack © completely.
Remove spring ©.
Remove tap rebound ©
200700-10
Remove spring ©
Remove valve © of the rebound damping together with the spring.
Take out the piston rod.
6.1.15 Disassembling the compression damping fitting
Info
Preparatory work
Main work
- Clamp the compression damping fitting in a bench vise using soft jaws.
- Remove nut O-
* \ - 4 k ' - Remove the spring.
- - Remove washer ©.
1
--------- -l: 200702-10
- Remove piston ©.
- Remove shim stack ©
- Remove O-ring © and seal ring © from the compression damping fitting.
- Extract the compression damping fitting.
6.1.16 Checking the fork legs

Condition
The fork legs must be disassembled.
- Check the inner tube and axle clamp for damage.
» If there is damage:
- Change the inner tube.
Measure the outside diameter at several locations on the inner tube.
Outside diameter of the inner tube 47.975... 48.005 mm (1.88878...

1.88996 in)
» If the measured value is below the specified value:

Measure the run-out of the inner tube.
Inner tub run-out < 0.20 mm (< 0.0079 in)
» If the measured value is greater than the specified value:

Check the outer tube for damage.

- Change the outer tube.
Check the surface of the sliding bushing.

» If the bronze-colored layer o under the sliding layer © is visible:
- Replace the sliding bushing.
Check the spring length.

Guideline
Spring length with preload spacer(s)
Weight of rider: 65... 75 kg (143... 513 mm (20.2 in)
165 lb.)
187 lb.)
209 lb.)

- Reduce the thickness of the preload spacer.
» If the measured value is less than the specified value:
- Increase the thickness of the preload spacer.
6.1.17 Assembling the compression damping fitting
Info
Clamp the compression damping fitting in a bench vise using soft jaws.
Mount 0-ring O and seal ring ©.
Grease the O-ring.
Lubricant (T158) (•" p. 272)

Mount shim stack ©.

@v „ o
• Info
1 Mount the smaller shims below.
% \
Mount pistons © with O-ring ©.
» '*!S '
m Info
1 The side with the largest inside diameter © faces upward.
— —»____ _2L____ ________ ___________ _
. 200705-10
Grease the piston O-ring.
Fork oil (SAE 4) (48601166S1) (•" p. 270)
Mount washer ©
« l © /° Mount spring © with the tighter coil facing downward.

Mount and tighten nut o
uv-y Guideline
^L. w
-----------?i> ~ , 1
Compression damping fitting nut M6x0.5 3 Nm (2.2 Ibf ft)
1 —— 1
• Info
1 The washer © must have freedom of movement relative to the spring force.
■ T_____ '^“200706-10
Secure the nut by locking.

Extract the compression damping fitting.
6.1.18 Assembling the cartridge
Info
Clamp in the piston rod.
Clamping stand (T14016S) (•" p. 281)
Mount valve O °f the rebound damping, with the spring and O-ring.
Grease the O-ring.
Lubricant (T158) (*~ p. 272)
Mount spring ©
Grease tap rebound © O-ring.
Lubricant (T158) (•* p. 272)
Mount and tighten the tap rebound.

Guideline
Tap rebound M9xl 18 Nm Loctite® 2701™
(13.3 Ibf ft)
Position spring ©.
Mount shim stack ©.
• Info
1 Mount the smaller shims below.
Press the shim stack downward against the spring force.
• Info
1 The shim stack must be pressed downward over the collar.
Mount piston © with the piston ring.

• Info
1 The side with the largest inside diameter faces downward.
Mount shim stack Q.
• Info
1 Align the triangular plate exactly with the piston opening.
Mount and tighten nut ©.

Guideline
Tap rebound nut M6x0.5 5 Nm (3.7 Ibf ft)
Info
Mount the nut with the collar facing downward.
Secure the nut by locking.

Degrease the cartridge and clamp using the special tool.
Mount and tighten screwsleeve ©.

Guideline
Screwsleeve M29xl 46 Nm Loctite® 241
(33.9 Ibf ft)
200749-11
Mount washer © and spring seat
Push piston rod into the cartridge.
Screw on fluid barrier © to the stop.

i
• Info
I The fluid barrier must be screwed on tightly against the stop. Do not use a
tool.
6.1.19 Assembling the fork legs
Info
Preparatory work
- Check the fork legs. (*" p. 21)
- Assemble the cartridge. (*" p. 23)
- Assemble the compression damping fitting. (*" p. 22)
Main work
- Clamp in the inner tube with the axle clamp.
Guideline
Use soft jaws.
Install the special tool.
Protecting sleeve (T1401) (*" p. 280)
Grease and slide on dust boot O-
Lubricant (T511) (•" p. 272)
• Info
1 Always change the dust boot, seal ring, lock ring, and support ring.
Mount the sealing lip with the spring expander facing downward.
Slide on lock ring ©.

Grease and slide on seal ring ©.
Lubricant (T511) (•" p. 272)
• Info
1 The sealing lip should face downward and the open side upward.
Slide on support ring ©.

Remove the special tool.
Roughen, clean, and grease the edges of the sliding bushings using 600 grit sand
paper.
Fork oil (SAE 4) (48601166S1) (•" p. 270)
200670-10
Slide on lower sliding bushing ©.

Mount upper sliding bushing ©.
• Info
1 Gently pull them apart without using any tool.
Slide on the outer tube.

Warm up the outer tube in the lower sliding bushing area of ©.
Guideline
50 °C (122 °F)
Hold the lower sliding bushing with the longer shoulder of the special tool.
Assembly tool (T1402S) (•" p. 281)
Press the outer tube all the way in.

Position the support ring.

Hold the seal ring with the shorter shoulder of the special tool.
Press the outer tube all the way in.
Mount lock ring ©
Info
The lock ring must audibly lock into place.
Install dust boot o

Mount fork protector ring ©
Mount adjustment tube ^ of the rebound damping in the cartridge.

S The adjustment tube extends 5 mm (0.197 in) out from the cartridge and can
be pressed inward against the spring force.
X The adjustment tube extends more than 7 mm (0.276 in) out from the car
tridge and cannot be pressed inward against the spring force.
Screw on water excluder e to the stop.
• Info
1 The water excluder must be screwed on tightly against the stop. Do not use
a tool.
Mount the special tool on the cartridge.
Gripping tool (T14026S1) (*" p. 281)
• Info
1 The special tool must be used in order that the adjustment tube is not
raised. Otherwise, oil will reach the piston rod.
Push the cartridge into the inner tube.

Mount and tighten compression damping fitting ©.
Guideline
Compression damping fitting M29xl 35 Nm
(25.8 Ibf ft)
Info
If the cartridge turns as well, press the piston rod slightly to the side.
- Clamp in the fork vertically.

- Fill with fork oil.
Fork oil per fork 625 ml Fork oil (SAE 4) (48601166S1)

leg (21.13 fl. oz.) (*“ p. 270)
Info
Pull out the piston rod and push back in a number of times to bleed the car
tridge.
Remove pin of the special tool.
Gripping tool (T14026S1) C p. 281)
Pull out the piston rod. Install the spring. Reinstall the pin.
Guideline
Spring rate
Weight of rider: 65... 75 kg (143... 4.0 N/mm (22.8 Ib/in)
165 lb.)
Weight of rider: 75... 85 kg (165... 4.2 N/mm (24 Ib/in)
187 lb.)
Weight of rider: 85... 95 kg (187... 4.4 N/mm (25.1 Ib/in)
209 lb.)
- Pull the spring downward. Place the special tool on the hexagonal part
- Remove the special tool.
Clamp the special tool in the bench vise.

Grease the thread of the piston rod.
Lubricant (T159) p. 272)
Grease the upper edge © of the piston rod.
Screw the Preload Adjuster with preload spacer onto the piston rod.
• Info
I The Preload Adjuster must be screwed in all the way before the piston rod
also begins to turn. In case of tight piston rod threads, it must be held to
keep it from turning. If the Preload Adjuster is not screwed in all the way,
the rebound adjustment will not function.
Tighten the Preload Adjuster.

Guideline
Preload Adjuster on the piston rod M12xl 25 Nm
(18.4 Ibf ft)
Take pressure off of the special tool. Pull the spring downward and remove the spe-
cial tool.
- Push the outer tube upward.

- Clamp the outer tube in the area of lower triple clamp.
- Grease the Preload Adjuster O-ring.
Lubricant (T158) (•“ p. 272)
- Screw on and tighten the Preload Adjuster.

Guideline
Preload Adjuster on the outer tube M51xl.5 50 Nm
(36.9 Ibf ft)
Pin wrench (T103) (•" p. 278)
Alternative 1
- Turn adjusting screw of compression damping © and adjusting screw of
rebound damping © clockwise all the way.
Guideline
Rebound damping
Comfort 20 clicks
Standard 18 clicks
Sport 16 clicks
Compression damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
- Turn the adjusting screw of spring preload © counterclockwise all the way.
- Turn clockwise by the number of turns corresponding to the fork type.
Guideline
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Alternative 2
Warning
A Danger of accident Modifications to the suspension setting may seri
ously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious
deterioration in the handling characteristic and overload components.
- Only make adjustments within the recommended range.

- Ride slowly to start with after making adjustments to get the feel of
the new handling characteristic.
- Set the adjusting screws to the position determined before removal

- Mount protective cover 9
6.1.20 Greasing the steering head bearing

- Remove the lower triple clamp. (*“ p. 29)
- Install the lower triple clamp. (*“ p. 29)
6.1.21 Removing the lower triple clamp

Preparatory work
- Remove the front wheel. (*" p. 93)
- Remove the headlight mask with the headlight. (*" p. 89)
- Remove the fork legs. (*" p. 34)
- Remove the front fender. (*“ p. 89)
- Remove the handlebar cushion.
Main work
- Remove screw o Loosen screw ©. Pull off the upper triple clamp with the han
dlebar and hang it to one side.
• Info
I Protect the components against damage by covering them.
Do not bend the cables and lines.
- Remove O-ring ©. Remove protective ring ©.

- Take off the lower triple clamp with the steering stem.
- Remove the upper steering head bearing.
6.1.22 Installing the lower triple clamp

Main work
- Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease (•* p. 272)
- Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
- Check whether the top steering head seal Q is correctly positioned.
- Mount protective ring ©
500151-10
- Position the upper triple clamp with the steering.

- Position the clutch line and wiring harness.
- Mount screw © but do not tighten yet.
Position the fork legs.
• Info
I Grooves are milled into the side of the upper end of the fork legs. The sec
upper triple clamp.
Tighten screws ©
Guideline
(11.1 Ibf ft)
Tighten screw ©
Guideline
Screw, top steering head M20xl.5 12 Nm (8.9 Ibf ft)
Tighten screw ©.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 Ibf ft)
Tighten screws O
Guideline
(14.8 Ibf ft)
Position the brake caliper. Mount and tighten screws ©

Guideline
(18.4 Ibf ft)
Mount cable binder ©.

tighten screws
Finishing work
- Mount the handlebar cushion.
- Install the front fender. (*" p. 89)
- Install the front wheel. p. 93)
- 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. 31)
- Check the headlight setting. (•" p. 116)
6.1.23 Checking the play of the steering head bearing
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
- Adjust the steering head bearing play without delay.
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam
aged over time.
Preparatory work
- Raise the motorcycle with the lift stand. (•" p. 10)
Main work
- Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:

- Adjust the play of the steering head bearing. (•“ p. 31)
- Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. There
should be no perceptible detent positions.
» If detent positions are noticeable:

- Adjust the play of the steering head bearing. (*" p. 31)
- Check the steering head bearing and replace if required.
Finishing work
- Remove the motorcycle from the lift stand. (*" p. 10)
6.1.24 Adjusting the play of the steering head bearing

Preparatory work
Main work
- Loosen screws O and ©•
- Loosen and retighten screw ©
Guideline
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Tighten screws O-
Guideline
(14.8 Ibf ft)
Tighten screw
Guideline
Screw, top steering stem M8 20 Nm
(14.8 Ibf ft)
Finishing work
- Check the play of the steering head bearing. (*" p. 31)
6.2.1 Adjusting the compression damping of the fork
• Info
I The hydraulic compression damping determines the fork suspension behavior.
Turn the white adjusting screw © all the way clockwise.
• Info
I Adjusting screw © is located at the upper end of the left fork leg.
The compression damping is located in the left fork leg (white adjusting
screw). The rebound damping is located in the right fork leg (red adjusting
screw).

Guideline
Compression damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp
ing.
6.2.2 Adjusting the rebound damping of the fork
• Info
I The hydraulic rebound damping determines the fork suspension behavior.
Turn the red adjusting screw @ all the way clockwise.
• Info
I Adjusting screw © is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg (red adjusting screw).
The compression damping is located in the left fork leg (white adjusting
screw).

Guideline
Rebound damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
• Info
ing.
6.2.3 Bleeding the fork legs

Preparatory work
- Raise the motorcycle with the lift stand. (*“ p. 10)
Main work
- Release bleeder screws Q.
S Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
Finishing work
6.2.4 Cleaning the dust boots of the fork legs

Preparatory work
- Loosen the fork protection. (•" p. 33)
Main work
- Push dust boots o of both fork legs downwards.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
- Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
- Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray (•" p. 273)
- Press the dust boots back into their normal position.

- Remove excess oil.
Finishing work
- Position the fork protection. (*" p. 34)
6.2.5 Loosening the fork protection

- Remove screws © on the left fork leg. Push the fork protection downwards.
- Remove the screws on the right fork leg. Push the fork protection downwards.
6.2.6 Positioning the fork protection

Position the fork protection on the left fork leg. Mount and tighten screws ©.
Guideline
tighten screws ©
Guideline
6.2.7 Removing the fork legs

Preparatory work
Main work
- Remove cable binder ©
- Remove screws © and take off the brake caliper.
- Hang the brake caliper and the brake line loosely to the side.
- Loosen screws ©. Remove the fork leg on the left.

- Loosen screws ©. Remove the fork leg on the right.
6.2.8 Installing the fork legs

Main work
• Info
I The rebound damping is located in the right fork leg REB (red adjusting
screw). The compression damping is located in the left fork leg COMP (white
adjusting screw).
Grooves are milled into the side of the upper end of the fork legs. The sec
upper triple clamp.
Tighten screws ©.
Guideline
(12.5 Ibf ft)
Tighten screws ©.
Guideline
(11.1 Ibf ft)
- Position the brake caliper and mount and tighten screws ©
Guideline
(18.4 Ibf ft)
Mount cable binder ©.

tighten screws ®.
Finishing work
- Install the headlight mask with the headlight. (*" p. 90)
6.2.9 Removing the fork protector

Preparatory work
- Raise the motorcycle with the lift stand. (•“ p. 10)
- Remove the headlight mask with the headlight. (*“ p. 89)
- Remove the fork legs. (•" p. 34)
Main work
- Remove screws o on the left fork leg. Lift off the fork protector.
- Remove the screws on the right fork leg. Lift off the fork protector.
© O »
,t\
\f
i r
c*'
101327-10
6.2.10 Installing the fork protector

Main work
- Position the fork protection on the left fork leg. Mount and tighten screws ©
Guideline
- Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Finishing work
- Install the fork legs. (*" p. 34)
- Install the front wheel. (•" p. 93)
6.2.11 Performing a fork service

Condition
The fork legs have been removed.
Disassemble the fork legs. (•" p. 36)

Remove the spring. (•" p. 38)
Disassemble the cartridge. (*" p. 39)
Disassemble the piston rod. (*" p. 40)
Disassemble the hydrostop unit. (*" p. 41)
Disassemble the seal ring retainer. (*" p. 41)
Check the fork legs. (•" p. 42)
Assemble the seal ring retainer. (*" p. 43)
Assemble the hydrostop unit. (•" p. 43)
Assemble the piston rod. (*" p. 44)
Assemble the cartridge. (** p. 45)
Assemble the fork legs. p. 46)
6.2.12 Disassembling the fork legs
• Info
Condition
The fork legs are disassembled.
- Note down the current state of rebound damping o REB (red adjuster of right fork
leg).
- Note down the current state of compression damping © COMP (white adjuster of
left fork leg).
- Fully open the adjusters of the rebound and compression damping.
- Clamp the fork leg in the area of the lower triple clamp.
- Remove the screw. Remove adjuster ©.
- Release screw cap ©
Special socket (T14047) (•" p. 282)
• Info
1 The cartridge cannot be taken off yet.
201701-10
Unclamp the fork leg.

Push the outer tube down. Drain the fork oil.
Clamp the fork leg with the axle clamp.

Release hydrostop unit © and remove it.
• Info
1 Do not use an impact wrench.
Place a pan underneath since oil will run out.
Remove the cartridge from the fork leg.
Press-out tool (T14051) (*" p. 282)
• Info
1 Removing the 0-ring seat from the cartridge usually requires the application
of force.
Remove dust boot ©.

Remove fork protection ring ©.
• Info
1 The fork protection ring does not necessarily need to be removed for repair
work.
Remove lock ring ©.
• Info
1 The lock ring has a ground end against which a screwdriver can be posi
tioned.
201706-10
Warm the outer tube in area © of the lower sliding bushing.

Guideline
50 °C (122 °F)
Pull the outer tube forcefully off of the inner tube.
• Info
1 The lower sliding bushing © must be pulled out of its bearing seat.
Remove the upper sliding bushing ©.
Info
Do not use a tool; pull the ends apart slightly by hand.
Take off the lower sliding bushing ©

Take off support ring <E>
Take off seal ring
Take off lock ring Q.
Take off dust boot ©
Unclamp the fork leg.
6.2.13 Removing the spring
Info
Preparatory work
Main work
- Pull the spring down. Mount the open end wrench on the hexagonal part.
201722-11
- Clamp the open end wrench in the vise. Release screw cap o but do not remove it
yet.
Special socket (T14047) (** p. 282)
- Pull the spring down. Remove the open end wrench.

- Remove the screw cap.
- Remove the spring with the preload spacer(s).
6.2.14 Disassembling the cartridge
• Info
Preparatory work
- Remove the spring. (*" p. 38)
Main work
- Degrease piston rod o and clamp it in the vise.
- Remove adjusting tube © Unscrew spring guide ©
- Remove spring seat ©.

- Pull the piston rod out of the cartridge.
201726-12
- Clamp the tube of the cartridge into a vise.
- Release seal ring retainer © and remove with the washer.
- Remove lock ring ©.

- Pull reservoir O off of the tube.
- Pull sleeve © out of the reservoir.
© © - Remove spring ©
JwJ
201795-10
- Remove seal rings and O-ring

- Remove pilot bushings ©.
6.2.15 Disassembling the piston rod
• Info
I The steps are identical for both fork legs, except for the hydrostop needle and valve.
Preparatory work
- Disassemble the cartridge. (*" p. 39)
Main work
- Degrease the piston rod.
- Clamp the piston rod with the special tool as far up as possible.
- Release hydrostop needle O and remove it from the piston rod.

The valve © usually remains in the hydrostop needle.
• Info
I © - silver hydrostop needle on compression damping side,
o - red hydrostop needle on rebound damping side.
Remove the rebound shim stack ©

Remove piston ©.
Remove the compression shim stack ©.

Remove spring.
Remove adapter © with spring © and washer.

Remove spring ©.
- Remove valve needle © from the piston rod.
Info
The adjusting tube can be used for this.
6.2.16 Disassembling the hydrostop unit
Info
Preparatory work
Main work
- Mount the hydrostop unit on a fitting hexagon socket and clamp into a vice.
- Remove sleeve ©.
- Remove shim stack ©
- Remove adapter ©.
- Remove hub o with washers 0
• Info
I It is possible that only one washer or no washer is present.
- Remove the O-ring from the hub.
- Remove shim stack 0

- Remove washer 0
- Remove O-ring ©.
6.2.17 Disassembling the seal ring retainer
Info
Preparatory work
- Disassemble the fork legs. (*" p. 36)
- Remove the spring. (*“ p. 38)
- Disassemble the cartridge. (*" p. 39)
Main work
- Remove pilot bushing support ©
- Remove O-ring © and seal ring ©
6.2.18 Checking the fork legs

Condition
The fork legs have been disassembled.
- Check the inner tube and axle clamp for damage.
- Measure the outside diameter at multiple locations of the inner tube.
Outside diameter of inner tube 47.975... 48.005 mm (1.88878...

1.88996 in)
» If the measured value is smaller than the specified value:

- Measure the run-out of the inner tube.
Inner tube run-out < 0.20 mm (< 0.0079 in)
» If the measured value is larger than the specified value:

- Measure the inside diameter at multiple locations of the outer tube.
Inside diameter of outer tube < 49.20 mm (< 1.937 in)

- Check the outer tube for damage.
Check the surface of the sliding bushings.

» If the bronze-colored layer o under sliding layer © is visible or the surface is
rough:
- Change the sliding bushings.
Check the spring length.

Guideline
Spring length with preload spacer(s) 470 mm (18.5 in)

- Reduce the thickness of the preload spacers.
- Increase the thickness of the preload spacers.
200666-10
6.2.19 Assembling the seal ring retainer
Info
- Mount and grease seal ring Q.
Lubricant (T158) (•" p. 272)
- Mount and grease 0-ring ©.
Lubricant (T158) (•" p. 272)
- Position pilot bushing support ©.
6.2.20 Assembling the hydrostop unit
Info
Mount and grease 0-ring ©.
Mount washer ©.
Mount shim stack © with the smaller washers facing downward.
Mount the new O-ring on hub ©.

Mount the hub with washers ©.
# Info
1 It is possible that only one or no washer is present.
Mount and tighten adapter ©.

Guideline
Hydrostop unit adapter M6x0.5 7 Nm (5.2 Ibf ft)
Mount shim stack O w'th the smaller washers facing downward.

Mount and tighten sleeve
Guideline
Hydrostop unit sleeve M6x0.5 7 Nm (5.2 Ibf ft)
Check distance o and total length © of the hydrostop.

Guideline
Hydrostop distance > 1.5 mm (> 0.059 in)
Hydrostop length 108.5... 109.5 mm (4.272...
4.311 in)
» If the dimensions are out of tolerance:

- Add or remove washers ©.
201975-10
6.2.21 Assembling the piston rod
• Info
I The steps are identical for both fork legs, except for the hydrostop needle and valve.
- Degrease the piston rod.

0 - Clamp the piston rod with the special tool.
EbLh
fl - Lubricate the 0-ring. Mount valve needle O in the piston rod.

f rtt-l-
Lubricant (T158) (*" p. 272)
11— I iw y
>
201790-10
Mount spring ©
Mount and tighten adapter © with spring O anc* washer.
Guideline
Adapter of piston rod M6x0.5 12 Nm (8.9 Ibf ft)
201791-10
Position the spring.

Mount the compression shim stack © with the smaller washers facing downward.
Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper.
Clean the piston.
Lubricate the piston ring.
Fork oil (SAE 4) (48601166S1) (•“ p. 270)
Mount the piston with chamfer © facing down.
Mount the rebound shim stack © with the smaller washers facing upward.
Press the piston downward against the spring.

S The piston should not squeeze the shims.
Position valve © in the hydrostop needle © Mount and tighten the hydrostop
needle.
Guideline
Hydrostop needle on piston rod M6x0.5 7 Nm (5.2 Ibf ft)
• Info
i © - silver hydrostop needle on compression damping side,
o - red hydrostop needle on rebound damping side.
- Unclamp the piston rod.
6.2.22 Assembling the cartridge
Info
Preparatory work
- Assemble the seal ring retainer. (*" p. 43)
- Assemble the piston rod. (•" p. 44)
Main work
- Mount and grease seal rings o and 0-ring ©
Lubricant (T158) (•" p. 272)
- Mount and lubricate pilot bushings ©
Fork oil (SAE 4) (48601166S1) (•" p. 270)
- Check the length of the reservoir spring.

Guideline
Reservoir spring length with preload 46 mm (1.81 in)
spacer
» If the length is out of tolerance:

- Correct the preload spacers.
- Position the spring with the preload spacers in the reservoir.
201795-11
Position sleeve © in the reservoir.

Clamp the tube of the cartridge into a vise.
Slide reservoir © onto the tube.
• Info
I Hold the sleeve in the reservoir to prevent it from sliding out.
Mount lock ring ©.
Mount seal ring retainer e with the washer and tighten.

Guideline
Seal ring retainer M23.5x0.75 46 Nm Loctite® 2701™
(33.9 Ibf ft)
Unclamp the cartridge.
Slide piston rod © into the cartridge.
• Info
I Ensure that the piston ring is seated correctly.
Mount spring seat ©
Degrease piston rod © and clamp in the vise.
Clamping stand (T14049S) p. 282)
Screw spring guide <E> all the way on.

• Info
I The nut must be firmly tightened against the stop by hand. Do not use a
tool.
Mount adjusting tube

Unclamp the piston rod. Mount the preload spacer(s).
6.2.23 Assembling the fork legs
Info
When assembling, ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is mounted
on the corresponding screw cap.
Compression damping side - screw cap with mark COMP, brake caliper holder, white adjuster.
Rebound damping side - screw cap with mark REB, no brake caliper holder, red adjuster.
Preparatory work
- Assemble the hydrostop unit. p. 43)
Main work
- Clamp the inner tube with the axle clamp.
Guideline
Use soft jaws.
- Mount special tool.
Protecting sleeve (T1401) (*" p. 280)

Lubricate and mount dust boot O-
Lubricant (T511) (•" p. 272)
• Info
1 Always change the dust boot, seal ring, lock ring and support ring.
Mount the sealing lip with the spring expander facing downward.
Slide on lock ring ©.

Lubricate and slide on seal ring ©.
Lubricant (T511) (•" p. 272)
• Info
1 Mount with the sealing lip facing down and the open side facing up.
Slide on support ring ©.

Grind the edges of the sliding bushings with sandpaper grit 600, clean the bush
ings and lubricate them.
Fork oil (SAE 4) (48601166S1) (•" p. 270)
Slide on the lower sliding bushing ©.

Mount the upper sliding bushing ©.
• Info
1 Do not use a tool; pull the ends apart slightly by hand.
Warm the outer tube in area © of the lower sliding bushing.

Q
Guideline
50 °C (122 °F)
Slide the outer tube onto the inner tube.

Hold the lower sliding bushing with the longer section of the special tool.
Mounting tool (T14040S) (•" p. 282)
Push the sliding bushing all the way into the outer tube.
Position the support ring.

Hold the seal ring with the shorter section of the special tool.
Mounting tool (T14040S) (•" p. 282)
Push the seal ring and support ring all the way into the outer tube.
Mount lock ring ©
Info
The lock ring must engage audibly.
Mount dust boot o

Mount fork protection ring ©
Lubricate the O-ring. Slide the cartridge all the way into the fork leg.
Fork oil (SAE 4) (48601166S1) (*" p. 270)
Turn the fork. Have the entire filling quantity of fork oil available.
Oil capacity per 635 ml Fork oil (SAE 4) (48601166S1)

fork leg (21.47 fl. oz.) (•- P- 270)
Add some of the fork oil while pulling out and pushing in the piston rod numerous
times.
Guideline
Fork oil quantity 510 ml (17.24 fl. oz.)
Mount and tighten hydrostop unit

Guideline
Hydrostop unit M30xl 40 Nm
(29.5 Ibf ft)
Clamp the fork vertically.

Add the remaining quantity of fork oil.
- Pull out the piston rod and push it back in numerous times while pressing it to one
side slightly.
Air bubbles emerge and the cartridge is bled.
- Keep bleeding until no more air bubbles emerge.
S The piston rod moves out automatically to the middle of the total stroke
distance.
• Info
I When fully bled, the correct air chamber length is achieved automatically.
202090-10
- Position spring.
- Pull the spring down. Mount screw cap ©.
• Info
I When assembling, ensure that the screw caps are correctly mounted accord
ing to the hydrostop needles.
Rebound damping side - red hydrostop needle, screw cap with mark REB.
Compression damping side - silver hydrostop needle, screw cap with
mark COMP.
- Pull the spring down. Mount the open end wrench on the hexagonal part.
- Hold the open end wrench. Tighten screw cap (•).
Guideline
Screw cap on piston rod M8x0.75 18 Nm
(13.3 Ibf ft)
- Push the outer tube up.

- Clamp the outer tube in the area of the lower triple clamp.
Clamping stand (T1403S) (** p. 281)
- Tighten screw cap ©

Guideline
Cartridge on outer tube M51xl.5 40 Nm
(29.5 Ibf ft)
- Mount the adjuster. Mount and tighten screw ©

Guideline
Screw, adjuster M4x0.5 2.5 Nm
(1.84 Ibf ft)
Alternative 1
- Turn the adjuster of compression damping (mark COMP) and the adjuster of
rebound damping (mark REB) all the way clockwise.
Guideline
Rebound damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
Compression damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks

Alternative 2
Warning
Danger of accident Modifications to the suspension setting may seri

- Set the adjusters to the positions determined upon removal.
6.2.24 Greasing the steering head bearing

Remove the lower triple clamp. (*" p. 50)
Install the lower triple clamp. (♦" p. 51)
6.2.25 Removing the lower triple clamp

Preparatory work
- Remove the fork legs. (*” p. 34)
- Remove the front fender. (*" p. 89)
- Remove the handlebar cushion.
Main work
- Remove screw O- Remove screw © Pull off the upper triple clamp with the han
dlebar and hang it to one side.
Info
Remove O-ring ©. Remove protective ring ©

Take off the lower triple clamp with the steering stem.
Remove the upper steering head bearing.
6.2.26 Installing the lower triple clamp

Main work
- Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease (•“ p. 272)
- Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
- Check whether the upper steering head seal Q is correctly positioned.
- Mount protective ring © and O-ring ©.
- Position the upper triple clamp with the handlebar.

- Position the clutch line and wiring harness.
• Info
I The upper milled groove in the fork leg must be flush with the upper edge of
the upper triple clamp.
Position bleeder screws e toward the front.
- Tighten screws ©.
Guideline
(11.1 Ibf ft)
- Tighten screw ©
Guideline
Mount and tighten screw

Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 Ibf ft)
Tighten screws @.
Guideline
(12.5 Ibf ft)
Position the brake caliper. Mount and tighten screws ©.

Guideline
(18.4 Ibf ft)
- Mount cable tie(s)

- Position the brake line and wiring harness. Put on the clamp and mount and
tighten screws
- Install the front fender. (*" p. 89)
- Mount the handlebar cushion.
- Install the front wheel. (•" p. 93)
Finishing work
- Check that the wiring harness, throttle cables, and brake and clutch lines can move
freely and are routed correctly.
- Check the play of the steering head bearing. (•" p. 52)
6.2.27 Checking the play of the steering head bearing
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
- Adjust the steering head bearing play without delay.
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam
aged over time.
Preparatory work
Main work
- Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:

- Adjust the play of the steering head bearing. (*" p. 53)
- Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. There
should be no perceptible detent positions.
» If detent positions are noticeable:

- Adjust the play of the steering head bearing. (•" p. 53)
- Check the steering head bearing and replace if required.
Finishing work
6.2.28 Adjusting the play of the steering head bearing

Preparatory work
Main work
- Loosen screws O- Remove screw
- Loosen and retighten screw ©.
Guideline
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Tighten screws Q-
Guideline
(12.5 Ibf ft)
Mount and tighten screw ©.

Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 Ibf ft)
Finishing work
- Check the play of the steering head bearing. (•" p. 52)
- Remove the motorcycle from the lift stand. (•“ p. 10)
7 HANDLEBAR, CONTROLS 54
7.1 Handlebar position

On the upper triple clamp, there are two holes a distance of Q apart.
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. In this way, the handlebar
can be mounted in the position that is most comfortable for the rider.
7.2 Adjusting the handlebar position
Warning
Danger of accidents Handlebar breakage.
- If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle
bar.
Remove screws o . Remove the handlebar clamp. Remove the handlebar and lay it
to one side.
• Info
Remove screws © Remove the handlebar support.

Place the handlebar support in the required position. Mount and tighten
screws ©
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 Ibf ft)
• Info
I Position the left and right handlebar supports evenly.
- Position the handlebar.
• Info
I Make sure cables and wiring are positioned correctly.
- Position the handlebar clamps. Mount screws O and tighten evenly.

Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 Ibf ft)
• Info
I Make sure the gap widths are even.
7.3 Adjusting the basic position of the clutch lever

Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw Q.
• Info
I When the adjusting screw is turned counterclockwise, the clutch lever
moves closer to the handlebar.
When the adjusting screw is turned clockwise, the clutch lever moves away
from the handlebar.
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!
7.4 Checking the routing of the throttle cable

Preparatory work
- Remove the seat. (*" p. 85)
- Remove the fuel tank. (•" p. 86)
Main work
- Check the routing of the throttle cable.
The throttle cable must be routed behind the handlebar, on the right of the
upper frame tube, and to the carburetor.
» If the throttle cable is not routed as specified:

- Correct the routing of the throttle cable.
Finishing work
- Install the fuel tank. (•" p. 87)
- Mount the seat. (•" p. 86)
7.5 Checking the play in the throttle cable

Check the throttle grip for smooth operation.
Move the handlebar to the straight-ahead position. Move the throttle grip back
wards and forwards to ascertain the play in the throttle cable.
Play in throttle cable 3... 5 mm (0.12... 0.2 in)
» If the throttle cable play does not meet specifications:

- Adjust the play in the throttle cable. (•" p. 56)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
- When running the engine, always make sure there is sufficient ventila
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
- Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:

- Adjust the play in the throttle cable. (*” p. 56)
7.6 Adjusting the play in the throttle cable

Main work
- Move the handlebar to the straight-ahead position.
- Push back sleeve O-
- Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster ©.
- Loosen nut ©
- Turn adjusting screw 0 in such a way there is throttle cable play Q in the throt
tle grip.
Guideline
Play in throttle cable 3... 5 mm (0.12... 0.2 in)
- Tighten nut 0
- Slide on sleeve o
Finishing work
- Check the throttle grip for smooth operation.
8 FRAME 57
8.1 Removing the engine guard (250/300 SIX DAYS)

Turn quick release O counterclockwise until it disengages. Remove the engine
guard.
8.2 Installing the engine guard (250/300 SIX DAYS)

Attach the engine guard at the back of the frame and swing it up at front.
Turn quick release o all the way clockwise.
9 SHOCK ABSORBER, SWINGARM 58
9.1 Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
- The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
Turn adjusting screw o all the way clockwise using a socket wrench.
• Info
I Do not loosen nut 0!
Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
• Info
ing.
9.2 Adjusting the low-speed compression damping of the shock absorber
Caution
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
Turn adjusting screw o clockwise with a screwdriver to the last click.
• Info
I Do not loosen nut @!
Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
• Info
ing.
9.3 Adjusting the rebound damping of the shock absorber
Caution
Turn adjusting screw o clockwise with a screwdriver to the last click.
• Info
I Do not loosen nut 0!
Turn back counterclockwise by the number of clicks corresponding to the shock

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

Preparatory work
Main work
- Measure the distance - as vertical as possible - between the rear axle and a fixed
point, for example, a mark on the rear fairing.
- Note down the value as dimension ©.
Finishing work
9.5 Checking the static sag of the shock absorber

Measure distance © of the unloaded rear wheel. p. 59)
Hold the motorcycle upright with the aid of an assistant.
Measure the distance between the rear axle and the fixed point again.
Note down the value as dimension ©.
• Info
I The static sag is the difference between measurements © and ©.
Check the static sag.
Static sag 33... 35 mm (1.3... 1.38 in)
» If the static sag is less or more than the specified value:

- Adjust the spring preload of the shock absorber. (•" p. 60)
9.6 Checking the riding sag of the shock absorber

Measure distance Q of the unloaded rear wheel. (*" p. 59)
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 now measures the distance between the rear axle and the fixed
point.
Note down the value as dimension G
• Info
1 The riding sag is the difference between measurements © and ©•
Check the riding sag.

Guideline
Riding sag 105... 115 mm (4.13... 4.53 in)
» If the riding sag differs from the specified measurement:

- Adjust the riding sag. (*" p. 61)
9.7 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. 61)
- After removing the shock absorber, clean it thoroughly.
Main work
- Loosen screw o
- Turn adjusting ring © until the spring is no longer under tension.
Hook wrench (T106S) (•" p. 278)
- Measure the overall spring length when not under tension.

- Tighten the spring by turning adjusting ring G to measurement ©
Guideline
Spring preload
Comfort 7 mm (0.28 in)
Standard 7 mm (0.28 in)
Sport 7 mm (0.28 in)
• Info
I Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
- Tighten screw O-
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft)
Finishing work
- Install the shock absorber. (•" p. 61)
9.8 Adjusting the riding sag

Preparatory work
- Remove the shock absorber. (•" p. 61)
- After removing the shock absorber, clean it thoroughly.
Main work
- Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65... 75 kg (143... 66 N/mm (377 Ib/in)
165 lb.)
187 lb.)
209 lb.)
• Info
I 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. 59)
- Check the riding sag of the shock absorber. (*“ p. 60)
- Adjust the rebound damping of the shock absorber. (*“ p. 59)
9.9 Removing the shock absorber

Preparatory work
Main work
- Remove screw o and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
- Remove screw © , push splash protector ® to the side, and remove the shock
absorber.
9.10 Installing the shock absorber

Main work
- Push splash protector o to the side and position the shock absorber. Mount and
tighten screw
Guideline
Screw, top shock absorber M12 80 Nm Loctite® 2701™
(59 Ibf ft)
- Mount and tighten screw ©

Guideline
Screw, bottom shock M12 80 Nm Loctite® 2701™
absorber (59 Ibf ft)
• Info
I The heim joint for the shock absorber at the swing arm is Teflon coated.
It must not be lubricated with grease or with other lubricants. Lubricants
dissolve the Teflon coating, thereby drastically reducing the service life.
Finishing work
- Remove the motorcycle from the lift stand. (•“ p. 10)
9.11 Servicing the shock absorber
Caution
A Danger of accidents Disassembly of pressurized parts can lead to injury.
Condition
The shock absorber has been removed.
- Disassemble the damper. (•" p. 63)
- Disassemble the piston rod. (*" p. 64)
- Disassemble the seal ring retainer. (*" p. 65)
- Check the damper. (*” p. 67)
- Disassemble the rebound adjuster. (•” p. 67)
- Remove the heim joint. (*" p. 68)
- Install the heim joint. (•" p. 69)
- Assemble the rebound adjuster. (•" p. 70)
- Assemble the piston rod. (•" p. 71)
- Assemble the damper. (*“ p. 72)
- Install the spring. (** p. 78)
9.12 Removing the spring

Condition
The shock absorber has been demounted.
- Clamp the shock absorber in a bench vise using soft jaws.
- Measure and note down the spring length in a preloaded state.
- Loosen screw O-
- Turn the adjusting ring until the spring is no longer under tension.
Hook wrench (T106S) (*" p. 278)
- Remove O-ring ©.
- Remove spring retainer © and intermediate washer ©.
- Remove the spring.
9.13 Disassembling the damper

Preparatory work
Main work
- Note down the present state of rebound damping O and compression
damping ©
- Completely open the adjustment elements of the rebound damping and compres
sion damping.
- Remove rubber cap ® of the reservoir.
- Slowly unscrew screw ©.

S The pressurized nitrogen is bled off.
201616-10
- Remove locking cap ©
- Press seal ring retainer ® all the way in with the special tool.
Disassembly tool (T1216) (*" p. 280)
- Remove lock ring O-
• Info
I Do not scratch the inner surface.
- Take out the damper.
- Remove screw ®. Drain the oil.

Remove the piston rod. Drain the remaining oil.
Remove adjusting ring with the intermediate washer.
Remove compression adjuster © Remove the spring and piston.
9.14 Disassembling the piston rod

Preparatory work
- Disassemble the damper. (*" p. 63)
Main work
- Clamp the piston rod with the fork in a bench vise.
Guideline
Use soft jaws.
- Remove nut O-
• Info
I If mount © is loosened, apply counteractive force.
- Remove rebound damping shim stack ®
Info
Guide the rebound damping shim stack onto a screwdriver and put them
aside together.
Remove piston ©.
Remove compression damping shim stack ©.
• Info
I Guide the compression damping shim stack onto a screwdriver and put
them aside together.
Unscrew and remove mount ©

Remove rebound damping shim stack ©
• Info
I Guide the rebound damping shim stack onto a screwdriver and put them
aside together.
Remove piston
Remove compression damping shim stack ©
• Info
I Guide the compression damping shim stack onto a screwdriver and put
them aside together.
Remove rebound damping washer ©.
Remove seal ring retainer
Remove locking cap © and bump rubber ©
9.15 Disassembling the seal ring retainer

Preparatory work
- Remove the spring. (•" p. 62)
Main work
- Remove rebound rubber ©
©
- Remove centering disk

I
: —__________________________________________________________ •. — — — —-
•» r •
" 200785-10
1*. *
- Remove seal ring ©.
Jq © - Remove washer © from seal ring ©
a*)
1gpi - ■ »■ ~ w ©r • ■ ^ ^
l. #
200786-10
- Remove washer ©
© - Remove O-ring ©.
• J - Remove dust boot ©.
r - "W ^ *
~ 200787-10
____________________________________________________________________________________________________
9.16 Replacing the pilot bushing

Preparatory work
- Remove the spring. (•" p. 62)
- Disassemble the damper. (*" p. 63)
- Disassemble the seal ring retainer. (*" p. 65)
Main work
© © - Press pilot bushing o out of seal ring retainer © using the special tool.
Press drift (T1504) (•" p. 282)
% <
- ----- - 200796-10
Slide the new pilot bushing O onto the special tool.
Press drift (T1504) (•" p. 282)
Position the pilot bushing in the seal ring retainer using the special tool.
Press drift (T1504) (•" p. 282)
Support seal ring retainer © with the sleeve © of the special tool. Press the pilot
bushing all the way in.
Assembly tool (T150S) {+~ p. 283)
Lubricate the special tool.
Shock absorber fluid (SAE 2.5) (50180751S1) (•“ p. 271)

Calibration pin (T1205) p. 279)
Support seal ring retainer © with the sleeve © of the special tool.
Press the special tool through the new pilot bushing.
Calibration pin (T1205) (•" p. 279)
S The pilot bushing is to be calibrated.

Finishing work
9.17 Checking the damper

Condition
The damper has been disassembled.
- Measure the inside diameter on both ends and in the middle of the damper car
tridge.
Damper cartridge
Diameter 50.08 mm (1.9716 in)

- Replace the damper cartridge.
- Check the damper cartridge for damage and wear.
» If there is damage or wear:
- Replace the damper cartridge.
- Check the heim joint for damage and wear.
- Replace the heim joint.
- Measure the diameter of the piston rod.
Piston rod
Diameter 17.95 mm (0.7067 in)

- Replace the piston rod.
- Measure the run-out of the piston rod.
Piston rod
200812-10
Run-out 0.02 mm (0.0008 in)

- Check the piston rod for damage and wear.
- Check the piston rings for damage and wear.
» If damage or a bronze-colored surface is visible:
- Replace the piston rings.
9.18 Disassembling the rebound adjuster

Preparatory work
Main work
- Warm up the piston rod in the area of the rebound damping valve seat.
w o
\/
m
|B
Guideline
80 °C (176 °F)
IV ,
- Remove rebound damping valve seat ©
■
wII
-- - ■■■ — — —
'200805-10
Remove screwsleeve ©
Remove adjusting screw ©
• Info
I Do not lose balls © and spring.
Remove rubber plug ©

From the opposite side, press rebound needle © out of the piston rod.
9.19 Removing the heim joint

Condition
The shock absorber has been demounted.
- Clamp the shock absorber in a vise using soft jaws.
- Remove the collar bushing of the heim joint.
Pin (T120) (*• p. 278)
- Turn the shock absorber around and remove the second heim joint collar bushing.
- Remove seal ring o on both sides.
- Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) (•" p. 279)
- Remove the second lock ring

Place special tool Q underneath and press out heim joint © using special
tool ©.
Pressing tool (T1207S) (** p. 279)
9.20 Installing the heim joint

Position new heim joint o and special tool.
Pressing tool (T1206) (•" p. 279)
Press in the heim joint all the way.
Press the heim joint against the lock ring using the special tool.
Pressing tool (T1207S) (•" p. 279)
Mount the second lock ring ©.
Mount seal ring © on both sides.
Position both collar bushings o and press in.

9.21 Assembling the rebound adjuster

Grease O-ring O °f the rebound needle.
Lubricant (T158) (♦* p. 272)
Mount rebound needle © in the piston rod.
• Info
I Push in the rebound needle to the point where it is possible to mount the
rebound damping adjusting screw.
Mount rubber plug ©
Lubricate spring, balls © and O-ring ©
Lubricant (T159) (•" p. 272)
Screw in the rebound damping adjusting screw © all the way.

Mount and tighten screw sleeve ©.
Guideline
Screw sleeve M14xl 18 Nm
(13.3 Ibf ft)
Screw out the rebound damping adjusting screw © to the stop.

Grease the O-ring of the rebound damping seat.
Lubricant (T159) C p. 272)
Mount and tighten rebound damping valve seat ©.

Guideline
Rebound damping valve M8xl 6 Nm Loctite® 2701™
seat (4.4 Ibf ft)
• Info
I The rebound damping valve seat must be pressed inward before tightening.
9.22 Assembling the seal ring retainer

- Mount dust boot o with the special tool.
Mounting sleeve (T1204) (*” p. 279)
- Grease the sealing lip of the dust boot.
Lubricant (T625) (•" p. 272)
- Grease the O-ring groove.

© © Lubricant (T158) (•” p. 272)
_/ - Mount O-ring ©
1% - Mount washer ©.
(200793-10
Position washer © on seal ring ©.

Grease the seal ring and mount with the washer facing downward.
Lubricant (T511) (*- p. 272)
Mount centering disk ©

Mount rebound rubber ©
9.23 Assembling the piston rod

Preparatory work
- Assemble the rebound adjuster. (*" p. 70)
Main work
- Clamp the piston rod with the fork in a bench vise.
Guideline
Use soft jaws.
- Mount bump rubber o and locking cap ©

- Position the special tool on the piston rod.
Mounting sleeve (T1215) (•" p. 280)

200773-10 - Grease the dust boot and slide seal ring retainer © onto the piston rod.
Lubricant (T625) (•" p. 272)

Mount rebound damping washer ©
Mount the compression shim stack © with the smaller shims facing downward.
Grind piston © on both sides, using 1200 grit sandpaper on a surfacing plate.
Clean the piston.
Mount the piston.
Guideline
View © Top view of piston
View © Bottom view of piston

Mount rebound damping shim stack 9 with the smaller shims at the top.
Apply thread locker to the threads of the piston rod.
Loctite® 2701™
Screw on mount © to the point where the piston can still be turned.
-200769-10
Mount the compression shim stack (s) with the smaller shims facing downward.
200770-10
Grind piston © on both sides on a surface plate using 1200 grit sandpaper.
Clean the piston.
Mount the piston.
Guideline
View Q Top view of piston
View © Bottom view of piston
Mount rebound damping shim stack 9 with the smaller shims facing upward.
Grease the threads of the mount.
Lubricant (T152) (•" p. 272)
Mount nut 9 , but do not tighten it yet.
200772-10
Align both pistons using the special tool.
Centering sleeve (T1214) (•“ p. 279)
Tighten the nut.

Guideline
Piston rod nut Ml 6x1 40 Nm
(29.5 Ibf ft)
9.24 Assembling the damper

Preparatory work
- Assemble the rebound adjuster. (•" p. 70)
- Assemble the piston rod. (•■ p. 71)
Main work
- Slide the spring and piston onto compression adjuster ©
Grease the O-ring.
Lubricant (T158) (•" p. 272)
Grease the threads.
Lubricant (T159) (•“ p. 272)
Mount and tighten the compression adjuster.

Guideline
Compression adjuster M31xl 50 Nm
(36.9 Ibf ft)
Install adjusting ring © with an intermediate washer.
• Info
1 The adjusting ring cannot be mounted after the piston rod has been assem
bled!
- Grease the O-ring of the seal ring retainer.
- Fill the damper cartridge approximately half way.
Shock absorber fluid (SAE 2.5) (50180751S1) (•" p. 271)
- Carefully mount the piston rod.
- Mount seal ring retainer o and slide it under the ring groove.
- Mount lock ring ©
• Info
I Do not scratch the inner surface.
- Pull out the piston rod in order that the seal ring retainer fits closely against the
lock ring.
- Mount locking cap © of the damper cartridge.

- Bleed and fill the damper. (*" p. 75)
- Fill the damper with nitrogen. (*" p. 77)
- Mount rubber cap © of the reservoir.

- Turn adjusting ring © completely down toward the bottom.
Alternative 1
- Turn adjusting screw © clockwise with a screwdriver up to the last perceptible
click.
- Turn counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Comfort 25 clicks
* J 200780-10 Standard 20 clicks
Sport 15 clicks
- Turn adjusting screw © clockwise with an open end wrench until it stops.
- Turn counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
- 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
Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Alternative 2
Warning

Mount adjusting screws 0 © and 0 in the positions determined when dis

assembling.
• Info
I Before working with the vacuum pump, carefully read the vacuum pump operating manual
Completely open the adjusters of the rebound and compression damping.
Remove the screw from the filling port.

Mount adapter o on the damper.
• Info
I Hand-tighten only without using a tool.
Connect adapter to connector ® of the vacuum pump.
Vacuum pump (T1240S) (•" p. 280)
Clamp the damper with soft jaws or hold it as shown in the photo.
• Info
I Clamp the damper only lightly.
The filling port must be located at the highest point.
The piston rod moves in and out during filling; do not immobilize it by hold
ing it with your hand.
Position the control lever as shown in the photo.

y Control lever External tank ® is set to Closed; Damper o is set to Vacuum;
and Oil reservoir © is set to Vacuum.
Activate On/Off switch ©.
S The suction process begins.
y Pressure gauge © drops to the required value.
< 0 bar
y Vacuum gauge © drops to the required value.
4 mbar
Determine distance © between the floating piston and reservoir hole with the spe
cial tool.
Depth micrometer (T107S) (*" p. 278)
y The floating piston is positioned in the lowermost position.
When the vacuum gauge reaches the required value, turn control lever Oil reser
voir @ to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.

prossuro
0 bar
When the pressure gauge reaches the required value, turn control lever Damper o
to Pressure.
Guideline
0 bar
Oil is pumped into the damper.

3 bar
200268-10
When the pressure gauge reaches the required value, turn control lever Damper ©
to Vacuum.
Guideline
3 bar
v' The pressure gauge drops to the required value.
0 bar
When the pressure gauge reaches the required value, turn control lever Oil reser
voir © to Vacuum.
Guideline
0 bar
v' The vacuum gauge drops to the required value.
8 mbar
When the vacuum gauge reaches the required value, turn control lever Oil reser
voir © to Equalize Pressure.
Guideline
8 mbar
The pressure gauge drops to the required value.
0 bar
Check all oil levels regularly!

When the pressure gauge reaches the required value, turn control lever Damper ©
to Pressure.
Closed Vacuum Guideline
0 bar
Open Vacuum Equalize v' Oil is pumped into the damper.

pressure

External Damper
tank voir
3 bar
200268-10
When the pressure gauge reaches the required value, turn control lever Damper o
to Vacuum.
Guideline
3 bar
y The pressure gauge drops to the required value.

0 bar
When the pressure gauge reaches the required value, activate the On/Off switch.
Guideline
0 bar
y The vacuum pump is switched off.

Slide O-ring © to the end of the special tool by the specified value (distance ©
minus specified value).
Guideline
Push the floating piston into the reservoir to the distance described above using the
special tool.
Info
When the piston rod is fully extended, the floating piston must be at pre
cisely this position; otherwise, damage will occur when the shock absorber
compresses and rebounds.

Remove adapter o from connector © of the vacuum pump.
Info
Hold the damper so that the filling port is at the highest point.
Remove the adapter.

Mount and tighten screw ©
Guideline
Filling port screw MlOxl 14 Nm
(10.3 Ibf ft)
9.26 Filling the damper with nitrogen

- Screw in the screw o approx, two turns, but do not tighten.
• Info
I The piston rod is completely extended.
201616-11
Keep the special tool in place in the bench vise.
Nitrogen filling tool (T170S1) (*" p. 283)
Connect the special tool to the pressure regulator of the filling cylinder.
Filling gas - nitrogen
Adjust the pressure regulator.

Guideline
Gas pressure 10 bar (145 psi)
Position the shock absorber in the special tool.

S The hexagonal part of tap handle ® engages in the hexagon socket of the
screw of the filling port.
Open spigot ©
Fill the shock absorber for at least 15 seconds.
Guideline
Monitor the pressure control valve indicator.

Ensure that the shock absorber has been filled to the specified pressure.
- Screw the filling port shut with tap handle ©

- Close spigot © and remove the damper from the special tool.
- Tighten the screw of the filling port.
Guideline
Reservoir filling port screw M5 3.5 Nm
(2.58 Ibf ft)
9.27 Installing the spring

Ensure that adjusting ring o is screwed on with the intermediate washer.
- Measure the overall spring length when not under tension.

- Position the spring.
Guideline
Spring rate
165 lb.)
187 lb.)
209 lb.)
- Mount intermediate washer © and spring retainer ©.

- Mount ring ©
Alternative 1
- Tighten the spring by turning adjusting ring to measurement.
Guideline
Spring preload
Alternative 2
Warning

- Tighten the spring by turning the adjusting ring to the measured value deter
mined when it was removed.

Tighten screw ©
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft)
9.28 Changing the heim joint

Preparatory work
Main work
- Remove screw o and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
• Info
I Raise the wheel slightly to make it easier to remove the screw.
- Move the shock absorber to the rear.
- Remove spacers © on both sides.
- Remove shaft seal rings © on both sides.
- Mount special tool ©.
Mounting tool, heim joint (50329000044) (*~ p. 274)
- Press out the heim joint by screwing in the screw.

- Position the new heim joint.

- Mount special tool ©.
Mounting tool, heim joint (50329000044) (*" p. 274)
- Press in the heim joint by screwing in the screw.
- Press in shaft seal rings © on both sides with the open side facing inward.
• Info
I The heim joint for the shock absorber at the swing arm 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.
- Mount spacers © on both sides.
- Position the shock absorber.

- Mount and tighten screw ©.
Guideline
Screw, bottom shock M12 80 Nm Loctite® 2701™
absorber (59 Ibf ft)
• Info
I Raise the wheel slightly to make it easier to mount the screw.
Finishing work
10 EXHAUST 81
10.1 Removing the main silencer
Warning
A Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down. Do not touch hot components.
Remove screws ©
Pull the main silencer off of the manifold at the rubber sleeve ©
10.2 Installing the main silencer

Mount the main silencer with rubber sleeve O-
Mount and tighten screws ©.
Guideline
10.3 Changing the glass fiber yarn filling of 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. Do not touch hot components.
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. 81)
10 EXHAUST 82
Main work
- Remove screws o
- Pull out inner tube ©
- Remove glass fiber yarn filling © from the inner tube.
- Clean the parts that need to be reinstalled and check for damage.
- Mount the new glass fiber yarn filling © on the inner tube.
- Position outer tube o over the inner tube with the new glass fiber yarn filling.
- Mount and tighten screws ©
Guideline
Screws on the main silencer M5 7 Nm (5.2 Ibf ft)
Finishing work
- Install the main silencer. C*- p. 81)
11 AIR FILTER 83
11.1 Removing the air filter box lid

Pull off the air filter box lid in area © sideways and remove it toward the front.
11.2 Installing the air filter box lid

Insert the air filter box lid into the rear area Q and clip it into the front area
11.3 Removing the air filter
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
- Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Preparatory work
- Remove the air filter box lid. (*" p. 83)
Main work
- Detach air filter holder o at the bottom and swing it to one side. Remove the air
filter with the air filter support.
- Remove the air filter from the air filter support.
11.4 Installing the air filter

Main work
- Mount the clean air filter on the air filter support.
- Grease the air filter in area O-
Long-life grease (*" p. 272)

11 AIR FILTER 84
- Insert both parts together, position them and fasten them using air filter holder O-
y The arrow of marking UP faces up.
• Info
I If the air filter is not correctly mounted, dust and dirt can enter the engine
and cause damage.
Finishing work
- Install the air filter box lid. (•" p. 83)
11.5 Cleaning the air filter and air filter box
Warning
• Info
I Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the air filter box lid. (•" p. 83)
- Remove the air filter. (•" p. 83)
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner (•" p. 272)
• Info
I Only squeeze the air filter to dry it; never wring it out.
- Oil the dry air filter with a high quality filter oil.
Oil for foam air filter (*" p. 273)
- Clean the air filter box.

- Clean the intake flange and check it for damage and tightness.
Finishing work
- Install the air filter. (•” p. 83)
- Install the air filter box lid. (*" p. 83)
11.6 Sealing the air filter box

Preparatory work
Main work
- Seal the air filter box in the marked area O-
Finishing work
- Install the air filter box lid. ( p. 83)
12 FUEL TANK, SEAT, TRIM 85
12.1 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
- The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
Warning
Press release button 0>turn the filler cap counterclockwise and lift it free.
12.2 Closing the filler cap

Replace the filler cap and turn clockwise until the release button O locks 'n
place.
Info
Run the fuel tank breather hose © without kinks.
12.3 Removing the seat

Remove screw Q. Lift up the seat at the rear, pull it back and then remove from
above.
12.4 Mounting the seat

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

Guideline
12.5 Removing the fuel tank
Danger
Warning
Preparatory work
- Remove the seat. (•" p. 85)
Main work
- Turn handle O of the fuel tap to the OFF position. (Figure 602702-10*" p. 88)
- Pull off the fuel hose.
• Info
I Remaining fuel may run out of the fuel hose.
- Remove screws o with the collar sleeve.

(All 250/300 EXC EU/AU models)
- Hang the horn and horn bracket to one side.
- Remove screw © with the rubber bushing.
- Remove the tube from the fuel tank vent line.
602720-11
Pull both spoilers off of the sides of the radiator bracket ® and lift off the fuel
tank.
12.6 Installing the fuel tank
Danger
Warning
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Main work
- Check the routing of the throttle cable. (•" p. 55)
- Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
- Make sure that no cables are trapped or damaged.
- Mount the fuel tank vent hose.

- Mount and tighten screw o with the rubber bushing.
Guideline

- Position the horn with the horn bracket.
Mount and tighten screws © with the collar sleeve

Guideline
- Connect the fuel hose.
Finishing work
12.7 Fuel tap

The fuel tap is on the left side of the fuel tank.
Tap handle Q on the fuel tap is used to open or close the supply of fuel to the carbu
retor.
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 to the point of reserve capacity.
• Open the fuel reserve supply RES - Fuel can flow from the fuel tank to the carbu
retor. The fuel tank empties fully.
13 MASK, FENDER 89
13.1 Removing the front fender

Preparatory work
Main work
- Remove screws ©
- Remove screws © Remove the front fender.
13.2 Installing the front fender

Main work
- Position the front fender. Mount and tighten screws o
Guideline

Guideline
Finishing work
- Install the headlight mask with the headlight. (*" p. 90)
13.3 Removing the headlight mask with the headlight

Switch off all power consumers and switch off the engine.
Remove screw o and take off the clamp.
Release rubber straps © Slide the headlight mask up and swing it forward.
13 MASK, FENDER 90
Detach plug-in connector ® and take off the headlight mask with the headlight.
13.4 Installing the headlight mask with the headlight

Main work
- Connect plug-in connector ©
- Position the headlight mask and fix it with rubber straps

y The holding lugs engage.
tighten screw ©
Finishing work
14 WHEELS 91
14.1 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 250/300 EXC EU/AU models)

Front 1.5 bar (22 psi)
Rear 1.5 bar (22 psi)
Tire air pressure off road

» If the tire pressure does not meet specifications:

- Correct the tire pressure.
Mount the dust cap.
14.2 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 an important impact on the handling characteristics of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
Check the front and rear tires for cuts, run-in objects and other damage.
» If the tire exhibits cuts, run-in objects or other damage:
- Change the tire.
Check the depth of the tread.
• Info
I Note local national regulations concerning the minimum tread depth.
Minimum tread depth £ 2 mm (£ 0.08 in)
» If the tread depth is less than the minimum permissible depth:

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

- Change the tire.
14 WHEELS 92
14.3 Checking the brake discs
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
- Change the worn brake disc(s) without delay.
Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement ©
• Info
I Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit

Front 2.5 mm (0.098 in)
400257-10 Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:

- Change the brake disc.
Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc exhibits damage, cracking or deformation:
- Change the brake disc.
14.4 Checking the spoke tension
Warning
Danger of accidents Instable handling due to incorrect spoke tension.
- Ensure that the spoke tension is correct.
Info
A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
Briefly strike each spoke with the tip of a screwdriver.
• Info
I The tone frequency depends on the length of the spoke and the spoke diam
eter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.
You should hear a high note.
» If the spoke tension varies:

- Correct the spoke tension.
Check the spoke torque.
Guideline
Spoke nipple, front wheel M4.5 5... 6 Nm (3.7...
4.4 Ibf ft)
Spoke nipple, rear wheel M4.5 5... 6 Nm (3.7...
4.4 Ibf ft)
Torque wrench with various accessories in set (58429094000) (•" p. 277)

14 WHEELS 93
Preparatory work
Main work
- Press the brake caliper onto the brake disc by hand in order to push back the brake
pistons.
• Info
I Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
- Loosen screw o by several rotations.

- Loosen screws ©
- Press on screw Q to push the wheel spindle out of the axle clamp.
- Remove screw
- Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
• Info
I Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam
aged.
- Remove spacers ©
14.5.2 Installing the front wheel
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
- Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
- Change the wheel bearing.
Clean and grease shaft seal rings o and bearing surface © of the spacers.
Insert the spacers.

14 WHEELS 94
Lift the front wheel into the fork, position it, and insert the wheel spindle.
y The brake linings are correctly positioned.
Guideline
Screw, front wheel spindle M24xl.5 45 Nm
(33.2 Ibf ft)
Operate the hand brake lever several times until the brake linings are lying correctly
against the brake disc.
Remove the motorcycle from the lift stand. (*" p. 10)
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
Tighten screws ©.
Guideline
Screw, fork stub M8 15 Nm
(11.1 Ibf ft)
14.5.3 Removing the brake disc of the front brake

Preparatory work
Main work
- Remove screws o . Take off the brake disc.
14.5.4 Installing the brake disc of the front brake

Main work
- Clean the contact surface of the brake disc.
- Position the brake disc with the label facing outward. Mount and tighten
screws o
Guideline
Screw, front brake disc M6 14 Nm Loctite® 243™
(10.3 Ibf ft)
Finishing work
Preparatory work
14 WHEELS 95
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
- Remove nut o
- 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
- Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
• Info
I Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam
aged.
- Remove spacers ©
14.6.2 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 wheel bearing.
- Clean and grease shaft seal rings o and bearing surface © of the spacers.
Long-life grease (•" p. 272)
- Insert the spacers.
- Position the rear wheel and insert wheel spindle ©

S The brake linings are correctly positioned.
- Mount the chain.
14 WHEELS 96
- Position chain adjuster Mount nut O. but do not tighten it yet.

- Make sure that chain adjusters © are fitted correctly on adjusting screws ©.
- Check the chain tension. (•" p. 97)
- Tighten nut ©
Guideline
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
the brake disc and there is a pressure point.
Finishing work
14.6.3 Removing the brake disc of the rear brake

Preparatory work
- Remove the rear wheel. (*" p. 94)
Main work
- Remove screws o . Take off the brake disc.
14.6.4 Installing the brake disc of the rear brake

Clean the contact surface of the brake disc.
Position the brake disc with the label facing outward. Mount and tighten
screws ©
Guideline
Screw, rear brake disc M6 14 Nm Loctite® 243™
(10.3 Ibf ft)
Install the rear wheel. (*" p. 95)
14.6.5 Checking the chain for dirt

Check the chain for heavy soiling.
» If the chain is very dirty:
- Clean the chain. (*•“ p. 97)
14 WHEELS 97
14.6.6 Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
- Remove oil and grease with a suitable cleaning material.
Warning
Warning
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.
Chain cleaner (*" p. 272)

Off-road chain spray (*" p. 273)
Finishing work
- Remove the motorcycle from the lift stand. p. 10)
14.6.7 Checking the chain tension
Warning
A Danger of accidents Danger caused by incorrect chain tension.
- If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.
Preparatory work
14 WHEELS 98
Main work
- Pull the chain at the end of the chain sliding piece upward to measure chain ten
sion O-
• Info
I The bottom chain section O 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. 100)
Finishing work
14.6.8 Checking the chain, rear sprocket, engine sprocket and chain guide
Preparatory work
Main work
- Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
- Change the drivetrain kit.
• Info
I The engine sprocket, rear sprocket, and chain should always be
changed together.
Pull on the upper 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; repeat this measurement at different chain
positions.
Maximum distance ^ at the longest 272 mm (10.71 in)

chain section
» If the distance © is greater than the specified measurement:

- Change the drivetrain kit.
• Info
I When you replace the chain, you should also change the rear
sprocket and engine sprocket.
12 3 16 17 18 New chains wear out faster on old, worn sprockets.
400987-10
14 WHEELS 99
- Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
guard:
- Change the chain sliding guard.
- Check the chain sliding guard for tightness.
» 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 Ibf ft)
- 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 the chain sliding piece for tightness.
» 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 Ibf ft)
- Check the chain guide for wear.
• Info
I 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.
- Check the chain guide for tightness.

» If the chain guide is loose:
- Tighten the screws on the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 Ibf ft)
Finishing work
- Remove the motorcycle from the lift stand. (*~ p. 10)
14 WHEELS 100
14.6.9 Adjusting the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
- If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.
Preparatory work
- Raise the motorcycle with the lift stand. ("•" p. 10)
- Check the chain tension. (•" p. 97)
Main work
- Loosen nut O-
- 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 o
Guideline
Nut, rear wheel spindle M20xl.5 80 Nm (59 Ibf ft)
• Info
I The wide adjustment range of the chain adjusters (32 mm (1.18 in))
enables different secondary ratios with the same chain length.
Chain adjusters o can be turned by 180°.
Finishing work
15 WIRING HARNESS, BATTERY 101
15.1 Plug-in connection, ignition timing map

Plug-in connection o is located on the frame under the fuel tank.
Possible states
• Soft - The plug-in connection is disconnected to achieve better rideability.
• Performance - The plug-in connection is connected to achieve higher
performance.
15.2 Removing the main fuse

Preparatory work
- Switch off all power consumers and switch off the engine.
- Remove the air filter box lid. (•" p. 83)
Main work
- Remove the protection cover O-
• Info
I The main fuse ^ is located in the starter relay © under the filter box
cover.
- Remove main fuse ©
15.3 Installing the main fuse
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
- Use only fuses with the prescribed amperage. Never bypass or repair fuses.
Insert the main fuse.
A reserve fuse O is located in the starter relay.

Replace a burned-out fuse © only by an equivalent fuse.
Replace the protection cover.
400273-10 Install the air filter box lid. (•" p. 83)
15.4 Disconnecting the negative cable of the battery

Preparatory work
- Remove the seat. (*“ p. 85)
Main work
- Disconnect the negative (minus) cable o of the battery.
15.5 Connecting the negative cable of the battery

Main work
- Attach negative cable O-
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 Ibf ft)
• Info
I Contact disk Q must be mounted between battery terminal © and cable
lugs with the claws facing up.
Finishing work
- Mount the seat. (*" p. 86)
15.6 Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
- Keep batteries out of the reach of children.

- 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.
Preparatory work
- Switch off all power consumers and the engine.
Main work
- Disconnect the negative (minus) cable O °f the battery.
- Pull back the plus pole cover © and disconnect the positive (plus) cable of the
battery.
- Detach rubber band © at the bottom.
- Lift the battery out.
15.7 Installing the battery

Main work
- Insert the battery into the battery compartment with the terminals facing to the
front.
Battery (YTX4L-BS) p. 214)
- Attach rubber band O-

- Attach positive cable ©
Guideline
(1.84 Ibf ft)
• Info
I Contact disk © must be mounted between screw © anc* cable socket ©
with the claws facing down.
- Slide positive terminal cover © over the positive terminal.

- Attach negative cable ©.
Guideline
(1.84 Ibf ft)
• Info
I Contact disk © must be mounted between screw © and cable socket ©
with the claws facing down.
Finishing work
15.8 Checking the charging voltage

Condition
The battery must be fully functional and completely charged.
- Carry out the start procedure. (*~ p. 10)
Measure the voltage between the specified points.
Measuring point Plus (+) - Measuring point Ground (-)
Charging voltage
5,000 rpm 13.5... 15.0 V
» If the displayed value is less than the specified value:

- Check the plug-in connections from the alternator to the voltage regulator.
- Check the plug-in connections from the voltage regulator to the wiring har
ness.
- Alternator - check the battery winding. (•" p. 206)
- Alternator - check the light winding. (*“ p. 207)
» If the displayed value is greater than the specified value:
- Change the voltage regulator.
15.9 Checking the closed current

Preparatory work
15 WIRING HARNESS, BATTERY
Main work
- Disconnect the negative (minus) cable of the battery.
- Measure the current between battery ground (-) and the negative cable.
• Info
I The value of the open-circuit current applies only to vehicles in the original
state, i.e. without additional power consumers.
Maximum closed current < 1.0 mA
» If the measured value is higher than the specified value:

- Disconnect the voltage regulator from the wiring harness and perform the
measurement again.
15.10 Checking the starter relay

Preparatory work
Main work
- Disconnect the negative (minus) cable of the battery.
- Pull the starter relay off of the bracket.
- Pull off connector O-
- Disconnect cables © and © from the starter relay.
Connect the starter relay to a 12 V power supply as shown in the figure.

Measure the resistance between the specified points.
Resistance of open circuit 0Q
* r> » If the display does not equal the setpoint value:

- Change the starter relay.
601201-10
16 BRAKE SYSTEM 105
16.1 Checking the front brake linings
Warning
A Danger of accidents Reduced braking efficiency caused by worn brake linings.
- Change worn brake linings immediately.
Check the brake linings for minimum thickness O-
Minimum thickness Q > 1 mm (> 0.04 in)
» If the minimum thickness is less than specified:

- Change the front brake linings. (*" p. 105)
Check the brake linings for damage and cracking.
» If damage or cracking is visible:
- Change the front brake linings. (•" p. 105)
16.2 Changing the front brake linings
Warning
Danger of accident Brake system failure.
- Maintenance work and repairs must be carried out professionally.
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Avoid contact with skin and eyes, and keep out of the reach of children.
- If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
- Change the brake fluid of the front and rear brake according to the service schedule.
Warning
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
- Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
16 BRAKE SYSTEM
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws ©
Remove cover © with membrane ©
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, extract
ing it by suction if it does.
• Info
I Make sure when pushing back the brake pistons that you do not press the
Remove cotter pins ©, pull out pin ©, and remove the brake linings.
Clean the brake caliper and brake caliper support.
Check that leaf spring © in the brake caliper and sliding plate e in the brake
caliper support are seated correctly.
Insert the new brake linings, insert the pin, and mount the cotter pins.
• Info
I Always change the full set of brake linings.
Operate the hand brake lever several times until the brake linings are lying correctly
against the brake disc and there is a pressure point.
Correct the brake fluid quantity to level ©.

Guideline
Dimension (brake fluid level below 5 mm (0.2 in)
top edge of container)
Brake fluid DOT 4 / DOT 5.1 (*" p. 270)
Position the cover with the membrane. Mount and tighten the screws.
• Info
1 Wash off overflowed or spilled brake fluid immediately with water.
16 BRAKE SYSTEM 107
16.3 Checking the free travel of the hand brake lever
Warning
Danger of accidents Brake system failure.
- If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due
to overheating. Adjust the free travel on hand brake lever according to specifications.

- Press the hand brake lever toward the handlebar and check free travel Q
Free travel of hand brake lever t 3 mm (£ 0.12 in)

» If the free travel does not equal the specification:
- Adjust the free travel of the hand brake lever. (•" p. 107)
(All 250/300 XC-W models)

- 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. 107)
16.4 Adjusting free travel of hand brake lever (All 250/300 EXC EU/AU models)
- Check the free travel of the hand brake lever. (*" p. 107)
- Adjust the free travel of the hand brake lever with the adjustment screw ©
• Info
I 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.
16.5 Adjusting the basic position of the hand brake lever (All 250/300 XC-W models)
Check the free travel of the hand brake lever. (*“ p. 107)
Adjust the basic setting of the hand brake lever to your hand size by turning adjust
ing screw O-
• Info
I 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.
16 BRAKE SYSTEM 108
16.6 Checking the front brake fluid level
Warning
- If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding.
Warning
Check the brake fluid level in the viewer ©
» If the brake fluid has dropped below marking 0:
- Add front brake fluid. (*~ p. 108)
16.7 Adding front brake fluid
Warning
Warning
Warning
Warning
Info
brake fluid.
16 BRAKE SYSTEM
Remove screws ©
Add brake fluid to level ©
Guideline
Dimension Q (brake fluid level below 5 mm (0.2 in)
top edge of container)
Brake fluid DOT 4 / DOT 5.1 (*" p. 270)
• Info
I Clean up overflowed or spilt brake fluid immediately with water.
16.8 Changing the front brake fluid
Warning
Warning
Info
Use only clean brake fluid from a sealed container.
Cover the painted parts.
Remove screws ©
Remove cover © with membrane.
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) (•“ p. 275)

Brake fluid DOT 4 / DOT 5.1 (+~ p. 270)
Mount bleeder cover ©.
Bleeder cover (00029013005) p. 274)
Connect the bleeding device.
Bleeding device (00029013100) C*- p. 274)

16 BRAKE SYSTEM 110
Open shut-off valve ©
Info
Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is correctly set at pressure gauge © If necessary,
adjust the filling pressure at pressure regulator ©
Guideline
Filling pressure 2... 2.5 bar (29... 36 psi)
Pull off protection cap 0 of the brake caliper bleeder screw. Connect the hose of
the bleeder bottle.
Bleeding device (00029013100) (•“ p. 274)
Open bleeder screw © by approx, one half turn.
Info
Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
Tighten the bleeder screw.

Close shut-off valve ©
Open the bleeder screw again until brake fluid stops emerging.
• Info
I This prevents overfilling of the brake fluid reservoir.
Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro
tection cap.
Disconnect the bleeding device. Remove the bleeder cover.
Add brake fluid to level ©.
Guideline
Level © 5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 (*~ p. 270)
• Info
Check the hand brake lever for a firm pressure point.
16.9 Checking the rear brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
- Change worn brake linings immediately.
Check the brake linings for minimum thickness ©
Minimum thickness Q t 1 mm (£ 0.04 in)
» If the minimum thickness is less than specified:

- Change the brake linings of the rear brake. (*" p. Ill)
Check the brake linings for damage and cracking.
» If damage or cracking is visible:
- Change the brake linings of the rear brake. (*" p. Ill)
16 BRAKE SYSTEM 111
16.10 Changing the brake linings of the rear brake
Warning
Danger of accident Brake system failure.
- Maintenance work and repairs must be carried out professionally.
Warning
Warning
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
- Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Info
brake fluid.
Position the vehicle vertically.

Remove screw cap Q 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, extracting it by suction if it does.
• Info
I Make sure when pushing back the brake piston that you do not press the
Remove cotter pins ©, pull out pin ©, and remove the brake linings.
Clean the brake caliper and brake caliper support.
16 BRAKE SYSTEM
Check that leaf spring © in the brake caliper and sliding plate © in the brake
caliper support are seated correctly.
Insert the new brake linings, insert the pin, and mount the cotter pins.
• Info
I Always change the brake linings in pairs.
Operate the foot brake lever several times until the brake linings are lying against
the brake disc and there is a pressure point.
Correct the brake fluid level to marking ©
Brake fluid DOT 4 / DOT 5.1 (•" p. 270)
Mount screw cap O with membrane © and the 0-ring.
• Info
I Wash off overflowed or spilled brake fluid immediately with water.
16.11 Checking the free travel of foot brake lever
Warning
- If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.
Disconnect spring o
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. 112)
Reconnect spring O-
16.12 Adjusting the basic position of the foot brake lever
Warning
- If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.
16 BRAKE SYSTEM
Disconnect spring o
Loosen nut © and, with push rod e , turn it back until you have maximum free
travel.
To adjust the basic position of the foot brake lever individually, loosen nut © and
turn screw © accordingly.
• Info
1 The range of adjustment is limited.
Turn push rod © accordingly until you have free travel ©. If necessary, adjust
the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3... 5 mm (0.12... 0.2 in)
Hold screw © and tighten nut ©.

Guideline
Nut, foot brake lever stop M8 20 Nm
(14.8 Ibf ft)
Hold push rod © and tighten nut ©.

Guideline
Remaining nuts, chassis M6 10 Nm (7.4 Ibf ft)
Reconnect spring ©
16.13 Checking the rear brake fluid level
Warning
Warning
Stand the vehicle upright.

Check the brake fluid level in the viewer ©.
» If the fluid has dropped below marking Q in the level viewer:
- Add brake fluid for the rear brake. (*" p. 113)
1
[602760-10
16.14 Adding brake fluid for the rear brake
Warning
Warning
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
16 BRAKE SYSTEM 114
Warning
Warning
Info
brake fluid.
Preparatory work
- Check the rear brake linings. (*" p. 110)
Main work
- Stand the vehicle upright.
- Remove screw cap Q with membrane 0 and the O-ring.
- Add brake fluid to level ©
Brake fluid DOT 4 / DOT 5.1 (*■ p. 270)
- Mount the screw cap with the membrane and the O-ring.
• Info
16.15 Changing the rear brake fluid
Warning
Warning
Info
Use only clean brake fluid from a sealed container.
Cover the painted parts.

Remove screw cap O with membrane and the O-ring.
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) p. 275)

Brake fluid DOT 4 / DOT 5.1 (*” p. 270)
16 BRAKE SYSTEM
Mount bleeder cover ©
Bleeder cover (00029013006) p. 274)
Connect the bleeding device.
Bleeding device (00029013100) C*- p. 274)
Open shut-off valve ©
Info
Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is correctly set at pressure gauge © If necessary,
adjust the filling pressure at pressure regulator ©
Guideline
Filling pressure 2... 2.5 bar (29... 36 psi)
Pull off protection cap © of the bleeder screw. Connect the hose of the bleeder
bottle.
Bleeding device (00029013100) p. 274)
Open bleeder screw 0 by approx, one half turn.

Info
Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
Tighten the bleeder screw.

Close shut-off valve ©.
Open the bleeder screw again until brake fluid stops emerging.
• Info
I This prevents overfilling of the brake fluid reservoir.
Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro
tection cap.
Disconnect the bleeding device. Remove the bleeder cover.
Stand the vehicle upright.
Add brake fluid to level ©.
Brake fluid DOT 4 / DOT 5.1 p. 270)
Fit and tighten the screw cap with the membrane and O-ring.
• Info
Check the foot brake lever for a firm pressure point.

17 LIGHTING SYSTEM, INSTRUMENTS 116
17.1 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 a distance © under the first mark.
Guideline
Distance o 5 cm (2 in)
Position the vehicle vertically a distance Q away from the wall.

Guideline
Distance o 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 driver.
» If the light-dark border does not meet specifications:

- Adjust the headlight range. (** p. 116)
17.2 Adjusting the headlight range

Preparatory work
- Check the headlight setting. (•“ p. 116)
Main work
- Loosen screw
- Adjust the headlight range by swiveling the headlight.
Guideline
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with driver (instructions on how to apply the mark: Checking the
headlight setting).
Info
The headlight range may need to be corrected if luggage is carried on the
vehicle.
- Tighten screw o
- Press the button O to change the display mode or change to one of the Setup
menus.
- Press the button + to control different functions.
- Press the button — to control different functions.
• Info
I When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
17.3.2 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.
upoooo OO’ 00-00

» uQQ.Q 00-0000
TR1 TR2 A1 A2 SI S2
Display test
To enable you to check that the display is functioning properly, all display segments
light up briefly.
SPEED WS Km/h Mph Mies 0D0 LAP CLK H
400313-01
WS (wheel size)
After the display function check, the wheel size WS is displayed briefly.
• Info
I The number 2205 equals the circumference of the 21" front wheel with stan
dard tires.
The display then changes to the last selected mode.
Info
If you change the unit of measure, the 0D0 value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and SI are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
- Press the button O briefly and repeatedly until H appears at the bottom right of the
display.
- Press the button O for 3 - 5 seconds.
TR1 TR2 A1 A2 SI S2 S The Setup menu is displayed and the active functions are shown.
- Press the button O repeatedly until the Km/h/Mph display flashes.
\l/ \l/
^ Km/h Mph ^ LAP CLK H Adjusting Km/h
/IV /|\
- Press the button +.
Adjusting Mph
400329-01 - Press the button —.
S The settings are stored and the Setup menu is closed.
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
17.3.4 Adjusting the speedometer functions
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary
display.
. \(7
^TR1^TR2 A1 A2 SI S2 y The Setup menu is displayed and the activated functions are shown.
/\\
- Change to the desired function by pressing the button O briefly.
Km/h Mph 0D0 LAP CLK H y The selected function flashes.
Activating a function
400318-01 y The symbol remains on the screen and the display changes to the next
function.
Deactivating the function
- Press the button —.
y The symbol on the screen goes out and the display changes to the next
function.
- All desired functions are activated or deactivated accordingly.
y The settings are stored and the Setup menu is closed.
Info
menu is closed.
17.3.5 Setting the clock

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

y The settings are stored and the Setup menu is closed.
• Info
I If no button is pressed for 20 seconds, or if no impulse comes from the
menu is closed.
17.3.6 Activating the additional functions
Danger
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub-
lie roads in the homologated version.
- If the vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle
owner and rider of this.
- If you undertake any modifications, please insist on receiving a signed workshop order from your customer in which you
inform the customer in writing that these modifications are performed at the customer's own risk and that the vehicle will
no longer be approved for use on public roads once modified.
Preparatory work
Main work
- Expose connector CZ Q.
- Sever the black/brown cable ©.

- Insulate both cable ends.
Finishing work
- Install the headlight mask with the headlight. p. 90)
17.3.7 Setting the wheel circumference

Condition
Preparatory work
- Remove the headlight mask with the headlight. {*" p. 89)
- Activate the additional functions. (•" p. 118)
Main work
display.
TR1 TR2 A1 A2 SI S2
y The setup menu is displayed and the active functions shown.
\l/
^WS^m/h Mph 000 LAP CLK H - Press the button O until the WS indicator blinks.
_4JA______ ______________________
400315-01

y The wheel circumference is displayed in millimeters.
Enlarging the wheel circumference
Reducing the wheel circumference
400314-01 y The settings are stored and the setup menu is closed.
Info
menu is closed.
17.3.8 Querying lap time
Info
This function can be called up only if lap times are measured.
Condition
- Press the button O briefly and repeatedly until LAP appears at the bottom right of
the display,
LAP |
y LAP 1 appears on the left side of the display.
nnno jo - Laps 1-10 can be displayed by pressing the button +.
1 UUUODD
LAP - The button — has no function.
y Next display mode
400321-01
• Info
I If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.
- Press the button + to control different functions.

- Press the button — to control different functions.
• Info
I When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
17.4.2 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
™
oooo
oooo 00 00-00
00-00 00
UK
TR1 TR2 A1 A2 SI S2
-
To enable you to check that the display is functioning properly, all display segments
light up briefly.
SPEED WS Km/h Mph Mies ODO LAP CLK H
400313-01
WS (wheel size)
After the display function check, the wheel size WS is displayed briefly.
• Info
I 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
17.4.3 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 SI are cleared when the unit of measure is changed.
Condition
- Repeatedly press the button + briefly until H appears at the bottom right of the
display.
- Press the button 4- for 2-3 seconds.
TR1 TR2 A1 A2 SI S2 y The Setup menu is displayed and the active functions are shown.
- Repeatedly press the button + briefly until Km/h/Mph flashes.
\l/ \l/
^ Km/h Mph ^ ODO LAP CLK H Setting the Km/h
—4W|-\---------------------------------------
Setting the Mph
400329-01 - Press the button —.
- Wait 3-5 seconds
y 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.
17.4.4 Setting the speedometer functions
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
display.
- Press the button + for 2-3 seconds.
^TR1^TR2 A1 A2 SI S2 y The Setup menu is displayed and the active functions are shown.
/i\
• Info
Km/h Mph ODO LAP CLK H I 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.
y The selected function flashes.
Activating the function
y The symbol continues to appear in the display and the next function
appears.
Deactivating a function
y The symbol disappears in the display and the next function appears.
17.4.5 Setting the clock

Condition
- Repeatedly press the button 4- briefly until CLK appears at the bottom right of the
display.
- Press the button 4- for 2-3 seconds.
y The hour display flashes.
- Set the hour display with the button 4- and/or button —.
- Wait 3-5 seconds
y The next segment of the display flashes and can be set.
- You can set the following segments in the same way as the hours by pressing
the button + and the button —.
17 LIGHTING SYSTEM, INSTRUMENTS
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.
17.4.6 Setting the wheel circumference

Condition
Preparatory work
- Activate the additional functions. p. 118)
Main work
display.
- Press the button + for 2-3 seconds.
TR1 TR2 A1 A2 SI S2
- When WS flashes, press the + button briefly.
\l/
^WS^nv'h Mph 0D0 LAP CLK H • Info
______m
I The wheel circumference is displayed in millimeters.
400315-01 Enlarging the wheel circumference

Reducing the wheel circumference
Info
menu is closed.
17.4.7 Viewing the lap time
Info
This function can only be opened if lap times have actually been timed.
Condition
- Repeatedly press the button + briefly until LAP appears at the bottom right of the
display.
- Briefly press the button +.
y LAP 1 appears on the left side of the display.
LAP |
nn.no. z*Q - The laps 1-10 can be viewed with the button —.
1 UUUODJ
LAP - Press and hold the button + for 3-5 seconds.
y The lap times are deleted.
- Briefly press the button +.
400321-01
y 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.
18 ENGINE 123
18.1 Removing the engine

Preparatory work
(250/300 SIX DAYS)
- Remove the engine guard. (•" p. 57)
- Remove the fuel tank. (*" p. 86)
- Disconnect the negative (minus) cable of the battery. (*" p. 101)
- Drain the coolant. (*~ p. 198)
- Remove the main silencer. (•" p. 81)
Main work
- Remove springs O-
Spring hooks (50305017000) C p. 274)
- Loosen screw ©.
- Remove screw
- Loosen screw ©
- Remove screw ©
- Take off the exhaust manifold.
- Remove screw
- Remove the cable binders.
- Take off the frame protector.
- Remove screw ©
- Remove the cable binders.
- Take off the frame protector.
18 ENGINE 124
Push back cover ©

Remove nut © and hang the positive cable to the side.
Release hose clip
Remove screw
Loosen screw ©
Repeat these steps on the opposite side.
Swing up the subframe and secure it.
Remove screw ©
Remove screw ©
Take off the engine sprocket cover.
18 ENGINE 125
Remove screws ©.
Take off the clutch slave cylinder and hang it to one side.
• Info
I Do not kink the clutch line.
Do not activate the clutch lever while the clutch slave cylinder is removed.
Remove the connecting link of the chain.

Take off the chain.
Remove screw ©
Take off the shift lever.
Pull off the spark plug connector.

Pull off vent hose
Disconnect connector ©
Disconnect connector ©
Remove the cable binder and expose the cable.
Remove spring ^).

18 ENGINE 126
Loosen hose clip

Pull off the radiator hose.
Loosen hose clip

Loosen hose clip

Loosen hose clip

Pull the carburetor rearward out of the intake flange and hang it to one side.
Remove fittings
Take off the engine braces.
Remove nut
Remove the swingarm pivot.
Pull the swingarm toward the rear slightly.
18 ENGINE 127
Remove screws ©
Lift out the engine sideways.
• Info
I The help of an assistant is useful in this step.
Ensure that the motorcycle is sufficiently secured against falling over.
Protect the frame and attachments against damage.
18.2 Installing the engine

Main work
- Position the engine in the frame.
- Mount screws o but do not tighten yet.

Guideline
Engine bracket screw M10 60 Nm
(44.3 Ibf ft)
- Position the swingarm.

- Mount the swingarm pivot.
- Mount nut © but do not tighten it yet.
Guideline
Nut, swingarm pivot M16xl.5 100 Nm
(73.8 Ibf ft)
- Position the engine braces.

- Mount and tighten fittings ©.
Guideline
Screw, engine brace M8 33 Nm Loctite® 2701™
(24.3 Ibf ft)
- Tighten screws O anc* nut ©

18 ENGINE 128
Guideline
Engine bracket screw M10 60 Nm
(44.3 Ibf ft)
Nut, swingarm pivot M16xl.5 100 Nm
(73.8 Ibf ft)
Slide the carburetor into the intake flange.

Position and tighten hose clip ©.
Mount the radiator hose.

Position and tighten hose clip 0

Position and tighten hose clip @.

Position and tighten hose clip
Mount spring 0
18 ENGINE 129
Plug in connector ©.
Plug in connector ©.
Route the cable and secure with a cable binder.
Mount the spark plug connector.

Mount vent hose
Position the shift lever.

Mount and tighten screw ®
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 Ibf ft)
Mount the chain.

Connect the chain with connecting link ®
Position the clutch slave cylinder with the O-ring.

Mount and tighten screws ®
Guideline
Screw, slave cylinder of the clutch M6 10 Nm (7.4 Ibf ft)
Position the engine sprocket cover.

Guideline
Screw, slave cylinder of the clutch M6 10 Nm (7.4 Ibf ft)
18 ENGINE 130

Guideline
Remaining screws, chassis M8 25 Nm
(18.4 Ibf ft)
Remove the fixation and position the subframe.
• Info
1 Watch out for the intake flange.
Mount and tighten screw (f).

Guideline
Screw, subframe M8 35 Nm Loctite® 2701™
(25.8 Ibf ft)
Remove screw
Mount and tighten screw flj).
Guideline
Screw, subframe M8 35 Nm Loctite® 2701™
(25.8 Ibf ft)
Repeat these steps on the opposite side.
Position and tighten hose clip ©
Position the positive cable on the starter motor.

Mount and tighten nut £j).
Guideline
Nut, cable on starter motor M6 4 Nm (3 Ibf ft)
Position cover ©
Mount the frame protector.

Tighten screw ^ .
Guideline
Screw, frame protector M5 3 Nm (2.2 Ibf ft)
Mount the cable binder.

18 ENGINE 131
- Mount the frame protector.

- Tighten screw
Guideline
Screw, frame protector M5 3 Nm (2.2 Ibf ft)
- Mount the cable binders.
- Position the exhaust manifold.

- Mount springs ©.
Spring hooks (50305017000) (•" p. 274)
- Mount and tighten screw ©

Guideline
Tighten screw ©.
Guideline

Guideline
Tighten screw
Guideline
- Install the main silencer. (•" p. 81)

- Connect the negative cable of the battery. (*~ p. 102)
- Remove screw cap {J) and add gear oil.
Gear oil 0.80 I (0.85 qt.) Engine oil (15W/50) (•" p. 270)
- Mount and tighten screw cap
Finishing work
- Refill with coolant. (•" p. 198)
- Connect the negative cable of the battery. (•” p. 102)
- Take a short test ride.
- Check the engine for leakage.
- Check the gear oil level. (•” p. 202)
- Check the coolant level. (*" p. 197)
18 ENGINE 132
(250/300 SIX DAYS)

- Install the engine guard. (•" p. 57)
18.3 Engine disassembly
18.3.1 Clamping the engine into the engine work stand

- Mount special tool o on engine work stand ©
Engine assembly stand (61229001000) (*~ p. 277)

Engine fixing arm (56029002030) C p. 276)
- Mount the engine on special tool O-
18.3.2 Draining the gear oil

Remove gear oil drain plug o with the magnet and seal ring.
Completely drain the gear oil.
18.3.3 Removing the clutch push rod

Remove clutch push rod o
18.3.4 Removing the shift lever

Remove screw O with the washers. Take off the shift lever.
18 ENGINE 133
18.3.5 Removing the engine sprocket

Remove lock ring Q. Take off the engine sprocket.
18.3.6 Removing the spacer

Remove spacer o
Remove O-ring ©.
18.3.7 Removing the starter motor

Remove screws ©
Take off cover ©
Remove screws ©
Remove starter motor.
18 ENGINE 134
Remove screws o and ©

Remove the cover.
Remove gasket and dowels ©
ft Remove starter idler gear Q.
Remove screws ©
Remove the alternator cover.
Remove gasket and dowels ©
Take off Bendix

18 ENGINE 135
18.3.8 Removing the kick starter

Remove screw O with the washer.
Remove the kick starter.
18.3.9 Removing the cylinder head

Alternately loosen screws o and remove them.
Remove the cylinder head.
(All 250 models)

- Remove O-rings © and ©.
(All 300 models)

- Remove O-rings © and ©
18.3.10 Removing the cylinder

Remove screws O and ©
Take off both covers.
308131-10
18 ENGINE 136
- Remove retainer © of ball socket ©.

- Pull off the ball socket.
- Remove the gaskets on both sides.
- Remove nuts ©
• Info
I Raise the cylinder slightly to be able to remove the front nuts.
- Carefully slide the cylinder up and take it off.
(All 250 models)

- Take off gasket ©.
(All 300 models)

- Take off gasket 0
18.3.11 Removing the piston

(All 250 models)
- Uncover the crankcase.
- Remove the piston pin retainer o
- Remove piston pin.
- Take off the piston.
18 ENGINE 137
(All 300 models)

- Uncover the crankcase.
- Remove the piston pin retainer Q.
- Remove piston pin.
- Take off the piston.
- Remove the upper conrod bearing ©
18.3.12 Removing the water pump cover

Remove screws ©
Take off the water pump cover.
Remove the form ring.
18.3.13 Removing the clutch cover
- Remove the dowels and clutch cover gasket ©.

18 ENGINE 138
18.3.14 Removing the clutch discs

Remove screws ©
Take off spring retainer ©
Take off spring washer ©
Take off pretension ring ©.
Take off pressure cap
Remove clutch disc pack © entirely.

Remove clutch pressure piece ©
18 ENGINE 139
18.3.15 Removing the clutch basket

Hold the primary gear using special tool O-
Gear segment (56012004000) (** p. 276)
Remove nut © with the washer.
• Info
I Left-handed thread!
Bend up the lock washer.

Hold the inner clutch hub with the special tool. Loosen nut ©
Clutch holder (51129003000) (•" p. 275)
Remove the nut with the lock washer.
Take off inner clutch hub o and washer ©
• Info
I The washer usually sticks to the inner clutch hub.
Take off clutch basket ©.
Take off needle bearing © and collar bushing ©
Take off primary gear ©.

Remove the distance sleeve.
18 ENGINE 140
18.3.16 Removing the kick starter shaft

Remove screw ©.
Remove kick starter shaft © with the washer.
• Info
I Turn the kick starter shaft slightly to the left.
18.3.17 Removing the intermediate kick starter gear

Remove lock ring o
Take off intermediate kick starter gear © with the washer.
18.3.18 Removing the shift shaft

Push sliding plate o away from the shift drum locating unit ©. Remove shift
shaft ® with the washer.
18.3.19 Removing the shift drum locating unit

Remove screw o
Push away locking lever © from shift drum locating unit © and remove the shift
drum locating unit.
Relieve tension from the locking lever.
18.3.20 Removing the locking lever

Remove screw o
Take off locking lever © with the sleeve and spring.
18 ENGINE 141
18.3.21 Removing the rotor

Hold the rotor with special tool O-
Holding spanner, rotor (55129001000) (•" p. 276)
Remove nut © and the washer.
Mount special tool apply counterpressure, and pull off the rotor by screwing in
the screw.
Extractor (58012009000) (•" p. 276)
18.3.22 Removing the reed valve housing

- Remove screws ©
- Take off the intake flange.
- Remove reed valve housing ©.

- Take off the gasket.
18.3.23 Removing the left engine case section

Remove screws ©
Tilt the left section of the engine case upward and remove the screw connections of
the engine fixing arm.
Loosen the left section of the engine case by striking it lightly with a plastic ham
mer and remove it.
• Info
I Do not pry it apart with screwdrivers since the sealing areas are easily dam
aged.
18 ENGINE 142
Remove engine case gasket ©.
18.3.24 Removing the shift rails

- Remove shift rails O with the springs.
18.3.25 Removing the shift drum

- Tilt shift forks Q to the side.
Info
Do not misplace the shift rollers.
- Remove shift drum ©.
18.3.26 Removing the shift forks

Remove shift forks o
Info
Do not misplace the shift rollers.
18.3.27 Removing the transmission shafts

Pull both transmission shafts o out of the bearing seats together.
Info
The stop disks of the transmission shafts usually stick to the bearings.
18 ENGINE 143
18.3.28 Removing the crankshaft

- Take out crankshaft ©
- Remove O-ring
308181-10
18.4 work on individual parts
18.4.1 Work on the right section of the engine case

Remove all dowels.
Remove shaft seal ring O of the crankshaft.
Remove screws © Remove the bearing retainers.
Clean the engine case section thoroughly.
Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section must be removed using
a suitable tool.
Blow out lubrication bore © with compressed air and check that it is clear.
Insert the new cold bearings in the bearing seats of the heated section of the
engine case; if necessary, use a suitable press drift to push them all the way in and
make them flush.
• Info
I When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
- After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
18 ENGINE 144
- Press in shaft seal ring O of the crankshaft so it is flush with the open side facing
in.
- Mount and tighten screws © with the bearing retainers.
Guideline
Screw, bearing retainer M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
- Mount the dowels.
18.4.2 Work on the left section of the engine case

Remove all dowels.
Remove shaft seal ring O °f the crankshaft, © shift shaft and © countershaft.
Clean the engine case section thoroughly.
Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section must be removed using
a suitable tool.
Insert the new cold bearings in the bearing seats of the heated section of the
engine case; if necessary, use a suitable press drift to push them all the way in and
make them flush.
• Info
I When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring; otherwise, the bearings will be
damaged when they are pressed in.
- After the engine case section has cooled, check that the bearings are firmly seated.
• Info
I If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
Press in shaft seal ring o of the crankshaft so it is flush with the open side facing
in.
Press in shaft seal ring © of the shift shaft so it is flush with the open side facing
in.
Press in shaft seal ring © of the countershaft so it is flush with the open side fac
ing in.
Blow out lubrication bore o with compressed air and check that it is clear.
Mount the dowels.
18 ENGINE 145
18.4.3 Removing the crankshaft bearing inner race

Fixate the crankshaft in the vice with special tool Q.
Separator plate (54829009000) (•" p. 275)
• Info
1 Use soft jaws.
Warm up special tool ©.

Guideline
150 °C (302 °F)
Tool for inner bearing race (58429037040) (•" p. 277)
- Push the warmed up special tool © onto the crankshaft bearing inner race, press
firmly together and pull jointly from the crankshaft.
18.4.4 Installing the crankshaft bearing inner race

Fixate the crankshaft in the vice with special tool ©
• Info
1 Use soft jaws.
Fleat the crankshaft bearing inner race in special tool © and mount together.
Guideline
120 °C (248 °F)
Tool for inner bearing race (58429037040) (•" p. 277)
- Ensure that the new crankshaft bearing inner race is flush.
18.4.5 Changing the connecting rod, conrod bearing, and crank pin
Main work
- Position crankshaft O in the press using special tool ©.
- Press the crank pin out of the upper crank web with a suitable tool.
• Info
I Hold the lower crank web.
- Remove the connecting rod and bearing.
Press the crank pin out of the lower crank web.
Press in the new crank pin © as far as possible.

18 ENGINE 146
- Mount new bearing © with washers © and connecting rod ©.
Info
Thoroughly oil the bearing.
- Position special tool e on the press.
Pressing device for crankshaft, complete (75029047000) (•" p. 278)

Insert for crankshaft pressing tool (54829108000) (•" p. 276)
- Insert the crank web with connecting rod and bearing. Position the second crank
web.
- Position special tool © with the heel pointing down.
Insert for crankshaft pressing tool (54829108000) (•" p. 276)
- Press in the upper crank web as far as possible.
• Info
I The press mandrel must be positioned over the crank pin.
- Take the crankshaft out of the special tool and check that the connecting rod can
move freely.
- Measure axial play © between the connecting rod and the crank webs using the
special tool.
Feeler gauge (59029041100) (•“ p. 277)
Connecting rod - axial play of lower 0.60... 0.70 mm (0.0236...

conrod bearing 0.0276 in)
» If the specification is not reached:

- Correct it so the dimension is equal to the specified value.
Finishing work
- Check the crankshaft run-out at the bearing pin. (•" p. 146)
18.4.6 Checking the crankshaft run-out at the bearing pin

Position the crankshaft on a roller block.
Turn the crankshaft slowly.
Check the crankshaft run-out on both bearing pins.
Crankshaft - run-out at bearing pin < 0.03 mm (< 0.0012 in)
» If the crankshaft run-out at the bearing pin is larger than the specification:
- Align the crankshaft.
18 ENGINE 147
18.4.7 Checking/measuring the cylinder

Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
- Change the cylinder and piston.
Measure the cylinder diameter at several locations on the © - and ©-axes using a
micrometer to identify oval wear.
Guideline
Cylinder - drill hole diameter (All 250 models)
Size 1 66.400... 66.412 mm (2.61417...
2.61464 in)
Size II 66.412... 66.425 mm (2.61464...
2.61515 in)
Size 1 72.000... 72.012 mm (2.83464...
2.83511 in)
Size II 72.012... 72.025 mm (2.83511...
2.83562 in)
Info
The cylinder size o is labeled on the right side of the cylinder.
Using a straightedge and the special tool, check the sealing area of the cylinder
head for distortion.
Feeler gauge (59029041100) (•" p. 277)
Cylinder/cylinder head - distortion of < 0.10 mm (< 0.0039 in)

sealing area
» If the measured value does not meet specifications:

- Change the cylinder.
303016-10
18.4.8 Removing the exhaust control

Remove screw O with the bushing and spring.
Take off gear segment ©.

18 ENGINE 148
Remove screws ©
© Remove the retaining bracket.
303068-10
Remove control shaft ©
303069-10
Remove screw ©
Remove screw © with the washer.
Take off the stop plate.
303070-10
Take off gear segment e
303071-10
Remove screws ©
Take off the retaining bracket.
Remove control shaft ©.

18 ENGINE 149
______________________________________________________________________________________________ 303042-10
- Check control shafts o for damage and wear.

- Change the control shaft.
- Check gear segments ® for damage and wear.
- Change the gear segments.
- Check bearing sleeves @ for damage and wear.
- Change the bearing sleeves.
- Check control flap o for damage and wear.
- Change the control flap.
- Check control springs 0 for damage and wear.
- Change the spring.
18 ENGINE 150
18.4.10 Installing the exhaust control

Mount and grease O-rings Q.
Mount the control shafts.
Mount the retaining brackets.

Guideline
Screw, retaining bracket of M5 7 Nm Loctite® 2701™
exhaust control (5.2 Ibf ft)
Mount and grease O-rings
303620-10
Mount and grease bearing sleeves ©
Long-life grease (*“ p. 272)
- Position the control flap.

- Mount O-rings
303622-10
18 ENGINE 151
Degrease the sealing area and coat thinly with sealant.
Loctite® 5910
Position the exhaust flange.

Guideline
Screw, exhaust flange M6 8 Nm (5.9 Ibf ft)
• Info
1 Do not forget the spring hangers.
Position gear segment e
Position the spring with the short leg toward the outside.
Mount screw © with the bushing and spring but do not tighten yet.
Guideline
Screw, control flap, M6 10 Nm Loctite® 243™
Attach the spring to the cylinder pin.

Tighten screw.
Guideline
Position gear segment ©
Position the stop plate.

Mount screw © but do not tighten yet.
Mount screw © with the washer but to not tighten yet.
• Info
I The screws are tightened when the Z-distance is adjusted.
18 ENGINE 152
18.4.11 Cylinder - Nikasil® coating

Nikasil® is a surface protection layer for a coating procedure developed by Mahle. The
name is derived from the two materials used in this procedure - a layer of nickel into
which is embedded the particularly hard silicone carbide.
The most important advantages of the Nikasil® coating are very good heat conductivity,
resulting in much improved performance, low wear, and a lightweight cylinder.
18.4.12 Checking/measuring the piston

(All 250 models)
- Check the piston sliding surface for damage.
» If the piston sliding surface is damaged:
- Replace the piston and, if necessary, the cylinder.
- Check that the piston rings move easily in the piston ring grooves.
» If the piston ring is stiff:
- Clean the piston ring groove.
Tip
An old piston ring can be used to clean the piston ring groove.
- Check the piston rings for damage.

» If the piston ring is damaged:
- Change the piston ring.
• Info
I Mount the piston ring with the marking facing upward.
- Check the piston pins for discoloration or signs of wear.

» If the piston pin shows severe discoloration/signs of wear:
- Change the piston pin.
- Place the piston pin in the connecting rod and check the seating for play.
» If the piston pin seating has excessive play:
- Change the connecting rod and piston pin.
(All 300 models)
- Check the piston sliding surface for damage.
» If the piston sliding surface is damaged:
- Replace the piston and, if necessary, the cylinder.
- Check that the piston rings move easily in the piston ring grooves.
» If the piston ring is stiff:
- Clean the piston ring groove.
Tip
An old piston ring can be used to clean the piston ring groove.
- Check the piston rings for damage.

» If the piston ring is damaged:
• Info
I Mount the piston ring with the marking facing upward.
- Check the piston pins for discoloration or signs of wear.

» If the piston pin shows severe discoloration/signs of wear:
- Change the piston pin.
18 ENGINE 153
- Place the piston pin in the connecting rod and check the seating for play.
» If the piston pin seating has excessive play:
- Change the connecting rod and piston pin.
Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance ©.
Guideline
Distance © 50 mm (1.97 in)
Piston - diameter (All 250 models)
Size 1 66.340... 66.350 mm (2.61181...
2.6122 in)
Size II 66.351... 66.360 mm (2.61224...
2.61259 in)
Size 1 71.940... 71.950 mm (2.83228...
2.83267 in)
Size II 71.951... 71.960 mm (2.83271...
2.83307 in)
• Info
I Piston dimensions o are marked on the piston head.
18.4.13 Checking the piston ring end gap

Remove the piston ring from the piston.
Place the piston ring in the cylinder and align with the piston.
Guideline
Below the upper edge of the cylinder 20 mm (0.79 in)
Measure end gap © with a feeler gauge.

Guideline
Piston ring - end gap
Ring 1 < 0.40 mm (< 0.0157 in)
Ring 2 < 0.40 mm (< 0.0157 in)
» If the end gap is greater than the specified value:

- Check/measure the cylinder. (•" p. 147)
» If cylinder wear lies within the specified tolerance:
- Mount the piston ring with the marking facing toward the piston head.
18.4.14 Piston/cylinder - measuring the mounting clearance

(All 250 models)
- Check/measure the cylinder. (*" p. 147)
- Check/measure the piston. (•" p. 152)
- The smallest piston/cylinder mounting clearance equals the smallest cylinder
bore diameter minus the largest piston diameter. The largest piston/cylinder
mounting clearance equals the largest cylinder bore diameter minus the small
est piston diameter.
Guideline
Piston/cylinder - mounting clearance
303083-10
New condition 0.050... 0.074 mm (0.00197...
0.00291 in)
Wear limit 0.10 mm (0.0039 in)
18 ENGINE 154
(All 300 models)

- Check/measure the cylinder. (*” p. 147)
- Check/measure the piston. (*" p. 152)
- The smallest piston/cylinder mounting clearance equals the smallest cylinder
bore diameter minus the largest piston diameter. The largest piston/cylinder
mounting clearance equals the largest cylinder bore diameter minus the small
est piston diameter.
Guideline
New condition 0.050... 0.085 mm (0.00197...
0.00335 in)
18.4.15 Disassembling the reed valve housing

Remove screws ©
G01315-11
Remove the reed valve housing © from the support plate.
G01316-10
Remove screws © on both sides.

Take off clamping plate © on both sides.
Remove the outer reed valve © on both sides.
G01317-10
Remove screws ©
Separate the reed valve holders. Remove holding strip ©.
18 ENGINE 155
- Check intake flange o for damage and wear.

- Change the intake flange.
- Check membrane © for damage and wear.
- Change the membrane.
- Check reed valve housing for damage and wear.
- Change the reed valve housing.
18.4.17 Assembling the reed valve housing
- Position the inner reed valve o on both reed valve holders.

S The recesses are located on the right side.
18 ENGINE 156
Position holding strip ©.

y The pins engage in the drilled holes.
Position the reed valve holders.
Mount screws © and screw in all the way.
• Info
1 Mount the screws at right angles to prevent damage.
Loosen screws © and tighten again.

Guideline
Screw, inner reed petals EJOT DELTA PT® 1 Nm (0.7 Ibf ft)
35x25
y Distance © is equal on both sides.

Position the outer reed valve o on both sides.
y The recesses are located on the right side.
GO1328-10
Position the clamping plates on both sides.

y After installation, the TOP marking must be visible as shown.
Mount screws © on both sides and screw in all the way.
Loosen screws © and tighten again.
Guideline
Screw, outer reed petals EJOT DELTA PT® 1 Nm (0.7 Ibf ft)
30x6
G01326-11
18 ENGINE 157
- Position gasket ®.
Position the reed valve housing in the support plate.

S The outer recess is located on the right in the direction of travel when
installed.
Mount and tighten screws e
Guideline
Screw, membrane core plate EJOT DELTA PT® 1 Nm (0.7 Ibf ft)
30x12
18.4.18 Work on the clutch cover
Info
Remove the outer clutch cover to avoid damage.
Remove screws o
Remove the locking cap.
f
Remove adjusting spring the auxiliary spring, and the spring insert.
18 ENGINE 158
Remove screw © with the washer.
Take off angle lever ©

Remove linkage ©
Remove adjusting lever © with the washers.
Remove screw
Take off water pump impeller ©
Remove the centrifugal timer.
303037-10
Press out both needle bearings
Remove shaft seal ring flj).

18 ENGINE 159
Press out bearing toward the inside.
Remove shaft seal ring ©
______________________________________________________________________________________________ 303031-10
- Check pin © of the adjusting lever for damage and wear.

- Change the adjusting lever.
- Check ball heads © of the linkage for damage and wear.
- Change the linkage.
- Check centrifugal timer © for damage and wear.
- Change the centrifugal timer.
Press shaft seal ring all the way in.

18 ENGINE 160
Press bearing all the way in to the stop from the inside.
303039-10
Press shaft seal ring so it is flush.

Ensure that the bearing can turn freely and does not touch the shaft seal ring.
Press in both needle bearings ©
Mount the centrifugal timer.

Position water pump impeller ©.
Guideline
Screw, water pump wheel M5 6 Nm Loctite® 243™
(4.4 Ibf ft)
Turn the water pump impeller all the way around to ensure that it can move easily.
Mount adjusting lever © with the washers.
. ©
Position linkage 0
Mount angle lever ©.
18 ENGINE 161
Mount and tighten screw © with the washer.

Guideline
Screw, angle lever, M5 6 Nm Loctite® 243™
303034-10
- Mount adjusting spring © with the auxiliary spring and spring insert.
303033-10
Position the locking cap.

Mount and tighten screws Q
Guideline
Screw, exhaust control cover M5 6 Nm (4.4 Ibf ft)
303032-10
18.4.19 Checking the clutch
Check pressure piece o for damage and wear.

- Change the pressure piece.
Place push rod © on a level surface and check for run-out
» If there is run-out:
- Change the push rod.
Check spring retainer © for damage and wear.
18 ENGINE 162

- Change the spring retainer.
- Check pretension ring o for damage and wear.
- Change the pretension ring.
- Check spring washer © for damage and wear.
- Change the spring washer.
- Check the contact surface of pressure cap © for damage and wear.
- Change the pressure cap.
- Check clutch center © for damage and wear.
- Change the clutch center.
- Check damping rubber pieces © for damage and wear.
- Change the damping rubber pieces.
- Check the inner clutch hub © f°r damage and wear.
- Change the inner clutch hub.
- Check the thrust surfaces of the clutch facing discs in clutch basket © for damage and wear.
- Change the clutch facing discs and the outer clutch hub.
- Check needle bearing © and collar sleeve © for damage and wear.
- Change the needle bearing and collar sleeve.
- Check the intermediate discs © for damage and wear.
» If the intermediate discs are not flat or have punctiform outbreaks:
- Change all intermediate discs.
- Check clutch facing discs © for discoloration and scoring.
» If there is discoloration or scoring:
- Change all clutch facing discs.
- Check the thickness of clutch facing discs ©.
Clutch facing disc - thickness >1.9 mm (£ 0.075 in)
» If the clutch lining disc does not meet specifications:

- Change all clutch facing discs.
18.4.20 Preassembling the shift shaft

- Secure the short end of the shift shaft in the bench vise.
Guideline
Use soft jaws.
Mount sliding plate o with the guide pin facing downward and put the guide pin
on the shift quadrant.
Mount pressure spring ©.
- Slide on spring guide © push return spring © , with the offset end facing
upward, over the spring guide and lift the offset end over abutment bolt ©.
303009-10
- Mount stop disk ©
18 ENGINE 163
18.4.21 Checking the shift mechanism
______________________________________________________________________________________________ 303007-10
- Check shift forks o on disc © for damage and wear (visual check).
- Change the shift fork and gear wheel pair.
- Check shift grooves © of shift drum © for wear.
» If the shift groove is worn:
- Change the shift drum.
- Check the seating of the shift drum in bearings ©
» If the shift drum is not correctly seated:
- Change the shift drum and/or bearings.
- Check bearings ® for smooth operation and wear.
» If the bearings are stiff or worn:
- Change the bearings.
- Check the shift rollers for damage and wear.
- Change the shift rollers.
- Check the springs of shift rails © for damage and wear.
» If the spring is damaged or worn:
- Change the spring of the shift rail.
- Check the shift rails o for run-out on a flat surface.
» If there is run-out:
- Change the shift rail.
- Check the shift rails for scoring, wear and smooth operation in the shift forks.
» If scoring or wear is present or of the shift fork is stiff:
- Change the shift rail.
- Check sliding plate © for wear on contact areas ©
» If the sliding plate is worn:
- Change the sliding plate.
- Check return surface © on the sliding plate for wear.
» If there is severe grooving:
- Check guide bolts for firm seating and wear.
» If the guide bolts are loose or worn:
18 ENGINE 164
Preassemble the shift shaft. (*" p. 162)

Check clearance Q between the sliding plate and the shift quadrant.
Shift shaft - sliding plate/shift quad- 0.40... 0.80 mm (0.0157...

JiE=----------- JM-
rant clearance 0.0315 in)
H » If the measured value does not meet specifications:
303008-10
____
18.4.22 Disassembling the main shaft
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws.
- Remove stop disk Q and 2nd-gear fixed gear

- Remove 5th-gear idler gear © and needle bearing ©
- Remove stop disk ©.
- Remove lock ring ©
- Remove 3rd/4th-gear sliding gear ©
- Remove lock ring ©
- Remove 6th-gear idler gear ©.
- Remove needle bearing
18 ENGINE 165
18.4.23 Disassembling the countershaft
303335-10
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
Use soft jaws
- Remove stop disk O and lst-gear idler gear ©

- Remove needle bearing © and stop disk ©
- Remove 6th-gear sliding gear ©.
- Remove lock ring 0
- Remove 3rd-gear idler gear © and needle bearing ©.
- Remove 4th-gear idler gear ©.
- Remove needle bearing 0
- Remove stop disk 0 and lock ring 0
- Remove 5th-gear sliding gear 0
- Remove lock ring 0
- Remove stop disk 0
- Remove 2nd-gear idler gear 0 and needle bearing 0
18.4.24 Checking the transmission

Condition
The transmission has been disassembled.
18 ENGINE 166
0
©
303336-10
- Check needle bearings O f°r damage and wear.

- Change the needle bearing.
- Check the pivot points of main shaft © and countershaft © for damage and wear.
- Change the main shaft and/or countershaft.
- Check the tooth profiles of main shaft © and countershaft © for damage and wear.
- Change the main shaft and/or countershaft.
- Check the pivot points of idler gears © for damage and wear.
- Change the gear wheel pair.
- Check the shift dogs of idler gears © and sliding gears © for damage and wear.
- Check the tooth faces of idler gears ©, sliding gears © and fixed gear © for damage and wear.
- Check the tooth profiles of sliding gears © for damage and wear.
- Check sliding gears © for smooth operation in the profile of main shaft ©
» If the sliding gear does not move freely:
- Change the sliding gear or the main shaft.
- Check sliding gears © for smooth operation in the profile of countershaft ©.
» If the sliding gear does not move freely:
- Change the sliding gear or the countershaft.
- Check stop disks © for damage and wear.
- Change the stop disks.
- Use new lock rings © with every repair.
18.4.25 Assembling the main shaft
• Info
I Use new lock rings with every repair.
18 ENGINE 167
Preparatory work
- Carefully lubricate all parts before assembling.
- Check the transmission. (*" p. 165)
Main work
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws
- Mount needle bearing ©

- Mount 6th-gear idler gear ©.
- Mount stop disk © and lock ring ©
- Mount 3rd/4th-gear sliding gear © with the small gear wheel facing downward.
- Mount lock ring © and stop disk ©
- Mount needle bearing ©
- Mount 5th-gear idler gear ©
- Mount 2nd-gear fixed gear © and stop disk
- Finally, check all gear wheels for smooth operation.
18.4.26 Assembling the countershaft
Info
Use new lock rings with every repair.
Preparatory work
- Carefully lubricate all parts before assembling.
- Check the transmission. (•" p. 165)
18 ENGINE 168
Main work
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
Use soft jaws
- Mount needle bearing o and 2nd-gear idler gear © onto the countershaft with the protruding collar facing downward.
- Mount stop disk ® and lock ring ©
- Mount 5th-gear sliding gear with the shift groove facing up.
- Mount lock ring © and stop disk ©
- Mount needle bearing © and 4th-gear idler gear ©.

- Mount needle bearing <E>.
- Mount 3rd-gear idler gear ©,
- Mount stop disk © and lock ring ©

- Mount 6th-gear sliding gear © with the shift groove facing downward.
- Mount stop disk ©
- Mount needle bearing <D and lst-gear idler gear ©
- Mount stop disk <D
- Finally, check all gear wheels for smooth operation.
18 ENGINE 169
18.4.27 Checking the kick starter
______________________________________________________________________________________________ 303010-10
- Check the gear mesh and bearing of kick starter gear Q for damage and wear.
- Change the kick starter gear.
- Check the gear mesh and bearing of intermediate kick starter gear © for damage and wear.
- Change the intermediate kick starter gear.
- Check the gear mesh and contact surface of kick starter ratchet wheel © for damage and wear.
- Change the kick starter ratchet wheel.
- Check the gear mesh and bearing of kick starter shaft © for damage and wear.
- Change the kick starter shaft.
18.4.28 Preassembling the kick starter shaft

18 ENGINE 170
Mount driving hub ©

y The cut-out must be aligned with the hole in the kick starter shaft.
303049-10
Mount kick starter spring Q.

y The end of the kick starter spring engages in the hole.
Mount kick starter ratchet wheel © with the spring.
y Marking © is offset by one tooth behind marking ©
Mount washer ©.
18 ENGINE 171
18.4.29 Checking the electric starter drive
______________________________________________________________________________________________ 303006-10
- Check the gear mesh and bearing of starter idler gear Q for damage and wear.
- Change the starter idler gear.
- Check the gear mesh and bearing of Bendix © for smooth operation, damage and wear.
» If damaged or worn, or if the Bendix does not move easily:
- Change the Bendix.
- Check the gear mesh of starter motor for damage and wear
- Change the starter motor.
- Change 0-ring © of the starter motor.
- Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power
supply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is closed:
Mount the starter idler gear in the alternator cover.

Mount cover © with the gasket.
Mount and tighten screws ©
Guideline
Screw, alternator cover M6 8 Nm (5.9 Ibf ft)
Mount and tighten a fitting screw © with the washer and nut.
Guideline
18 ENGINE 172
Move starter idler gear O back and forth in the direction of rotation.
Check for play.
Guideline
Play may not exceed half the tooth width.
» If the play is greater:

- Remove the cover.
- Add enough compensating disks © to eliminate the play.
Remove one compensating disk again.
Guideline
Compensating disk 0.10 mm (0.0039 in)
— Check the play again.

— Grease all pivot points.
Lubricant (T625) (•" p. 272)
18.5 Engine assembly
18.5.1 Installing the crankshaft

- Mount O-ring o
308181-11
- Position the right section of the engine case in the engine work stand.
Engine assembly stand (61229001000) (•" p. 277)

Engine fixing arm (56029002030) p. 276)
Warm up the crankshaft bearing.

Guideline
100 °C (212 °F)
- Slide crankshaft © all the way into the bearing seat of the right section of the
engine case.
18.5.2 Installing the transmission shafts

Oil all bearing.
Engine oil (15W/50) (•* p. 270)
Assemble the two transmission shafts O and slide them into the bearing seats
together.
18 ENGINE 173
18.5.3 Installing the shift forks

Arrange the shift forks as shown above.
Position shift forks o in the shift grooves.
18.5.4 Installing the shift drum

- Push shift drum o into the bearing seat.
- Put shift forks ^ in the shift drum.
• Info
I Do not misplace the shift rollers.
18.5.5 Installing the shift rails

Install shift rail o together with upper spring © and the lower spring.
Install shift rail ® together with upper spring ©
18.5.6 Installing the left engine case section

- Coat the sealing area thinly with grease.
- Mount engine case gasket ©
- Check that dowels © are seated correctly.
18 ENGINE 174
Mount the left section of the engine case.
Info
Do not use the screws to pull the two sections of the engine case together.
Mount screws © and, once all screws of the left section of the engine case have
been mounted, tighten them.
Guideline
Screw, engine case M6x40 10 Nm (7.4 Ibf ft)
Mount screws Q and, once all screws of the left section of the engine case have
been mounted, tighten them.
Guideline
Mount screws @ and tighten all screws in a crisscross pattern.

Guideline
Fix the engine in the engine work stand.

Remove the excess lengths of the engine case gasket in the area of the cylinder
support and the reed valve housing.
18.5.7 Installing the reed valve housing

- Position the gasket.
- Position reed valve housing o in the engine case opening.
- Position the intake flange.

- Mount and tighten screws ©.
Guideline
Screw, intake flange/reed valve housing 10 Nm (7.4 Ibf ft)
18.5.8 Installing the rotor

- Ensure that the woodruff key is seated properly.
- Grease the cone.
- Mount the rotor and hold it with special tool o
Holding spanner, rotor (55129001000) (•" p. 276)
Mount washer and nut ©. Tighten the nut.

Guideline
Nut, rotor Ml 2x1 60 Nm
(44.3 Ibf ft)
18 ENGINE 175
18.5.9 Installing the locking lever

Position locking lever Q with the sleeve and spring ©.
Mount and tighten screw ©.
Guideline
Screw, shift drum locating M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
18.5.10 Installing the shift drum locating unit

Press locking lever Q to the right and position the shift drum locating unit.
Info
The flat surfaces © of the shift drum locating unit are not symmetrical.
Relieve tension from the locking lever.

Guideline
Screw, shift drum locating M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
18.5.11 Installing the shift shaft

Slide shift shaft O with the washer into the bearing seat.
Push sliding plate © away from the shift drum locating unit ©. Insert the shift
shaft all the way.
Let the sliding plate engage in the shift drum locating unit.
Shift through the transmission.
18.5.12 Installing the intermediate kick starter gear

- Mount intermediate kick starter gear o with the high collar facing the engine
case.
- Position the washer.
- Mount lock ring ©
18.5.13 Installing the kick starter shaft

Preparatory work
- Preassemble the kick starter shaft. (•" p. 169)
18 ENGINE 176
Main work
- Mount the preassembled kick starter shaft o with the washer.
- Tension the kick starter spring and mount and tighten screw ©.
Guideline
Screw, kick starter spring M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
• Info
I Ensure that the distance from the kick starter spring to the kick starter shaft
is the same all around.
18.5.14 Installing the clutch basket

Mount the distance sleeve.
• Info
I Do not damage the shaft seal ring.
Position primary gear
Mount collar bushing ©.

Oil and mount needle bearing ©.
Engine oil (15W/50) (*" p. 270)
Slide clutch basket o onto the gearbox main shaft.
Slide on washer © and inner clutch hub ©
Position the new lock washer and mount nut Q. Tighten the nut, holding the inner
clutch hub with a special tool.
Guideline
Nut, inner clutch hub M18xl.5 120 Nm Loctite® 648™
r (88.5 Ibf ft)
18 ENGINE 177
Secure the nut with the lock washer.

Hold the primary gear using special tool ©.
Gear segment (56012004000) (*" p. 276)
Mount and tighten nut © with the washer.

Guideline
Nut, primary gear M18LHxl.5 150 Nm Loctite® 648™
(110.6 Ibf ft)
Crank the engine to ensure that it can move easily.
18.5.15 Installing the clutch discs

Thoroughly oil the clutch facing discs.
Beginning with an intermediate clutch disc, alternately insert all other clutch fac
ing discs and intermediate clutch discs into the clutch basket.
Mount clutch pressure piece o
Position pressure cap ©
Mount pretension ring with the Top marking facing up.
Position spring washer ©.
Position spring retainer © with the X marking.

18 ENGINE 178
Mount screws © and tighten in a crisscross pattern.

Guideline
Screw, clutch spring retainer M5 6 Nm (4.4 Ibf ft)
Using a straightedge and the special tool, check the spring washers for distortion.
Feeler gauge (59029041100) (•“ p. 277)
Spring washer distortion 0... 0.10 mm (0... 0.0039 in)
» If the specified value was not attained:

- Remove screws © and mount the spring retainer with marking Y.
Feeler gauge (59029041100) (•" p. 277)

- Remove screws © and mount the spring retainer with marking Z.
Feeler gauge (59029041100) (*• p. 277)

- Change the clutch facing discs.
18.5.16 Installing the clutch cover

Apply a thin layer of sealing compound in area © on both sides.
Loctite® 5910
Mount the dowels.

Mount clutch cover gasket o
Position the clutch cover. Mount and tighten screws ©

Guideline
Screw, clutch cover M6 10 Nm (7.4 Ibf ft)
18 ENGINE 179
18.5.17 Installing the water pump cover

Mount the form ring.
• Info
I Ensure that the dowels are seated properly.
Position the water pump cover.

Mount and tighten screws O-
Guideline
Screw, water pump cover M6 10 Nm (7.4 Ibf ft)
18.5.18 Installing the piston

(All 250 models)
- Oil the upper conrod bearing and position it in the connecting rod.
- Position the piston.
y Piston marking O must face the exhaust side.
- Slide piston pin © into the connecting rod by hand.
- Cover the engine case opening with a cloth.

- Position the piston pin retainer in the 6 o'clock or 12 o'clock position.
- Ensure that the piston pin retainer is seated properly on both sides.
- Remove the cloth.
(All 300 models)

- Oil the upper conrod bearing and position it in the connecting rod.
- Position the piston.
y Piston marking O must face the exhaust side.
18 ENGINE 180
Slide piston pin © into the connecting rod by hand.
Cover the engine case opening with a cloth.

Position the piston pin retainer in the 6 o'clock or 12 o'clock position.
nuS Ensure that the piston pin retainer is seated properly on both sides.
Remove the cloth.
OCX
303082-10
18.5.19 Installing the cylinder

(All 250 models)
- Position the new cylinder base gasket ©
Info
If neither the piston, cylinder, crankshaft, or engine case need to be
changed, the same gasket thickness can be used as before.
- Oil the cylinder and piston.
- Position the piston ring.

S The anti-rotation lock engages in piston ring end
(All 300 models)

- Position the new cylinder base gasket O-
Info
If neither the piston, cylinder, crankshaft, or engine case need to be
changed, the same gasket thickness can be used as before.
- Oil the cylinder and piston.
Position the piston ring.

S The anti-rotation lock engages in piston ring end
18 ENGINE 181
Slide the cylinder over the piston.

Push the cylinder down carefully.
Mount nuts © on both sides and tighten in a crisscross pattern.

Guideline
Nut, cylinder base M10 35 Nm
(25.8 Ibf ft)
18.5.20 Checking the X-distance
Info
The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and the piston is at top
dead center.
The X-distance must be checked very carefully. If the X-distance is too large, the compression decreases and the engine loses
power. If the X-distance is too small, the engine knocks and overheats.
(All 250 models)

- Apply special tool o to the cylinder.
Adjustment gauge (54829001100) (•" p. 275)
- Position the piston at top dead center.

- Check the X-distance using the special tool.
Feeler gauge (59029041100) (•" p. 277)
X (upper edge of piston to upper 0... 0.10 mm (0... 0.0039 in)

edge of cylinder)
» If the specified value is not attained:

- Adjust the X-distance. (•" p. 182)
(All 300 models)
- Place straightedge o on the cylinder.
- Position the piston at top dead center.
- Check the X-distance using the special tool.
Feeler gauge (59029041100) (*" p. 277)
X (upper edge of piston to upper 0... 0.10 mm (0... 0.0039 in)

edge of cylinder)
18 ENGINE 182
» If the specified value is not attained:

- Adjust the X-distance. (•" p. 182)
18.5.21 Adjusting the X-distance
• Info
I The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses.
Preparatory work
- Check the X-distance. (•" p. 181)
Main work
- Remove nuts o
- Carefully slide the cylinder up and take it off.
- Replace cylinder base gasket © with a cylinder base gasket of the required X-
distance.
Info
Multiple cylinder base gaskets can be combined.
Finishing work
- Install the cylinder. (*“ p. 180)
18.5.22 Adjusting the Z-distance
Info
The Z-distance is the distance from the lower edge of the control flap to the upper edge of the cylinder, measured in the mid
dle of the exhaust port.
Remove screws O and ©

Remove screws o and © but do not tighten yet.
Guideline
18 ENGINE 183
Adjust the Z-distance using the depth gauge.

Guideline
Z (height of control flap) (All 250 mod 48 mm (1.89 in)
els)
Z (height of control flap) (All 300 mod 48.5 mm (1.909 in)
els)
Move control flap © up and position the depth gauge.
Position stop plate © so it is in contact with retaining bracket ©

Tighten screws O and ©
Guideline
Check the Z-distance.

Guideline
Z (height of control flap) (All 250 mod 48 mm (1.89 in)
els)
Z (height of control flap) (All 300 mod 48.5 mm (1.909 in)
els)
Mount gasket ©
Press the control flap all the way down.
Mount ball socket ©.
• Info
I The linkage may only be pulled up slightly.
The control flap may not be moved up.
Check the movement of the linkage.

Guideline
< 1 mm (£ 0.04 in)
» If the linkage is pulled up further:

- Loosen counter nut
- Turn the ball socket accordingly until the linkage has the correct length.
- Tighten the lock nut.
Mount retainer ©.
Position the gasket.

Position both covers.
Mount and tighten screws <E> and
Guideline
Screw, exhaust control cover M5 6 Nm (4.4 Ibf ft)
18 ENGINE 184
18.5.23 Installing the cylinder head

(All 250 models)
- Mount O-rings O and ©.
• Info
I Ensure that the dowels are seated correctly.
(All 300 models)

- Mount O-rings o and ©
• Info
I Ensure that the dowels are seated correctly.
- Put the cylinder head in place. Mount screws ® with the washers and tighten
them in a crisscross pattern.
Guideline
Screw, cylinder head M8 27 Nm
(19.9 Ibf ft)
• Info
I Use new washers.
18.5.24 Installing the kick starter

Position the kick starter. Mount and tighten screw O-
Guideline
Screw, kick starter M8 25 Nm Loctite® 2701™
(18.4 Ibf ft)
18.5.25 Installing the starter motor

Preparatory work
- Check the electric starter drive. (*“ p. 171)
Main work
- Grease and mount Bendix O-
Lubricant (T625) (•" p. 272)

18 ENGINE 185
Mount dowels ©
Position the alternator cover.

Guideline
Grease and mount starter idler gear ©
Lubricant (T625) (•" p. 272)
Mount dowels ©.
Position the cover.

Guideline
Grease the O-ring. Position the starter motor.
Mount and tighten screws Q.

Guideline
Screw, starter motor M6 8 Nm (5.9 Ibf ft)
18 ENGINE 186
Position cover ©
Guideline
18.5.26 Installing the spacer

Before mounting, grease spacer O 'n area © and O-Ring ©.
Position the O-ring in the cut-out of the spacer.
302140-10
Grease the shaft seal ring.
Push spacer © with the O-ring onto the countershaft with a twisting motion.
S The cut-out with the O-ring must face inward.
S The shaft seal ring rests against the spacer along the entire circumference.
18.5.27 Installing the engine sprocket

Slide on the engine sprocket with the collar facing the engine. Mount lock ring
18.5.28 Installing the shift lever

Position the shift lever. Mount and tighten screw © with the washers.
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 Ibf ft)
18 ENGINE 187
18.5.29 Installing the clutch push rod

Mount clutch push rod ©
18.5.30 Installing the gear oil drain plug

- Mount and tighten the gear oil drain plug O with the magnet and the new seal
ring.
Guideline
Gear oil drain plug with magnet M12xl.5 20 Nm
(14.8 Ibf ft)
- Activate the kick starter several times to check whether the engine turns over
freely.
18.5.31 Removing the engine from the work stand

Remove the screw connection from the special tool.
Engine fixing arm (56029002030) 0*" p. 276)
Remove the engine from the work stand.

19 CARBURETOR 188
19.1 Choke
The choke lever o
is fitted on the left side of the carburetor.
Activating the choke function frees an opening in the carburetor through which the
engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a
cold start.
• Info
I If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated - The choke lever is pulled out all the way.
• Choke function deactivated - The choke lever is pushed in all the way.
19.2 Carburetor - adjusting the idle speed

Screw idle air adjusting screw O all the way in.
Turn the idle air adjusting screw to the specified basic setting.
Guideline
Idle air adjusting screw (All 250/300 XC-W models)
Open 2.0 turns
Idle air adjusting screw (250/300 EXC AU)
Open 3.5 turns
Idle air adjusting screw (250 EXC EU, 250 EXC SIX DAYS EU)
Open 1.5 turns
Idle air adjusting screw (300 EXC EU, 300 EXC SIX DAYS EU)
Open 1.75 turns
Run the engine until warm.

Guideline
Warm-up time £ 5 min
Danger
- Adjust the idle speed with adjusting screw ©

Guideline
Choke function deactivated - The choke lever is pushed in all the way.
(•- p. 188)
Idle speed 1,400... 1,500 rpm
- Turn idle air adjusting screw o slowly in a clockwise direction until the idle speed
begins to fall.
- Note the position and turn the idle air adjusting screw slowly counterclockwise until
the idle speed falls again.
- Adjust to the point between these two positions with the highest idle speed.
Info
If there is a large engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of
engine speed, you need to install a smaller idling jet.
After changing the idling jet, repeat the adjusting steps from the beginning.
Following extreme air temperature or altitude changes, adjust the idle speed
again.
19 CARBURETOR 189
19.3 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
- Turn handle O of the fuel tap to the OFF position. (Figure 602702-10*' p. 88)
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.
19.4 Removing the carburetor
Danger
Warning
Warning
Preparatory work
- Remove the fuel tank. (*" p. 86)
19 CARBURETOR 190
Main work
- Loosen hose clip o
- Loosen hose clip ©
- Pull the carburetor out of the intake flange toward the rear.
- Pull the carburetor forward out of the intake flange.
- Remove screws ©
- Remove the throttle slide cover and pull the throttle slide out of the carburetor.
- Drain the remaining fuel.
- Pull back the throttle slide spring and plastic lock ©.

- Detach throttle cable
- Remove the throttle slide.
19.5 Installing the carburetor

Main work
- Attach throttle cable ©
- Position plastic retainer 0
The catch of the plastic retainer engages in the cut-out of the jet needle screw.
- Position the throttle slide and throttle slide cover.

- Mount and tighten screws ©.
Guideline
Screw, throttle slide cover M5 3 Nm (2.2 Ibf ft)
19 CARBURETOR 191
- Position the carburetor on the intake flange.
- Position the carburetor on the intake flange.

- Position and tighten hose clip ©
- Position and tighten hose clip ©
Finishing work
- Check the play in the throttle cable. (•" p. 55)
- Carburetor - adjust the idle speed. (*" p. 188)
19.6 Checking/adjusting the carburetor components

Condition
The carburetor has been removed.
__________________________________________________________________________________________________________________________________________________ 303400-10
- Disassemble the carburetor. (*" p. 192)

- Check the choke slide. (•“ p. 193)
- Check the jet needle. (** p. 193)
- Check the throttle slide. (•" p. 193)
19 CARBURETOR 192
- Check the float needle valve. (•" p. 194)

- Assemble the carburetor. p. 194)
19.7 Disassembling the carburetor

Condition
The carburetor has been removed.
- Remove screws o
- Remove the float chamber.
- Pull the hoses off of the carburetor.
- Remove main jet

- Remove idling jet ©.
- Remove cold start jet ©
303352-10
- Remove fulcrum pin

- Remove float © and the float needle valve.
- Note the setting of the idle air adjusting screw ©

- Remove the idle air adjusting screw with the O-ring.
• Info
I Make sure not to misplace the spring.
- Remove choke slide ©.

19 CARBURETOR 193
Remove needle screw cap ©.

Puli the jet needle out of the throttle slide.
303354-10
The choke slide has been removed.

- Check the choke slide for smooth operation.
» If the choke slide is difficult to move or is dirty:
- Clean the choke slide and check its activation.
- Check the piston of the choke slide for damage and wear.
» If the piston of the choke slide is damaged or worn:
- Change the choke slide.
- Check the rubber sleeve and lock.
» If the rubber sleeve is damaged or brittle, or if the lock is not functioning:
- Change the choke slide.
19.9 Checking the jet needle

Condition
The jet needle has been removed.
- Check the jet needle for bending and wear of the coating.
» If the jet needle is bent, or the coating is damaged or worn:
- Change the jet needle.
- Check the needle clip for tightness.
» If the needle clip is loose:
- Change the needle clip or jet needle.
19.10 Checking the throttle slide

Condition
The throttle slide has been removed.
- Check the throttle slide for damage and wear.
» If the throttle slide is damaged or worn:
- Change the throttle slide.
- Check the coating of the throttle slide for damage and wear.
» If the coating is broken or worn:
- Change the throttle slide.
19 CARBURETOR 194
19.11 Checking the float needle valve

Condition
The float needle valve has been removed.
- Check the float needle valve including the valve seat for deposits.
» If there are deposits:
- Clean the valve seat. Clean or change the float needle valve.
- Check the float needle valve for wear and the sealing area for notches.
» If the sealing area is damaged or worn:
- Change the float needle valve.
19.12 Assembling the carburetor

Mount and tighten choke slide Q.
Guideline
Choke slide M10 5 Nm (3.7 Ibf ft)
Alternative 1
- Mount idle air adjusting screw © with the spring and O-ring.
- Set the idle air adjusting screw to the specified value.
Alternative 2
- Set the idle air adjusting screw to the value determined when it was disassem
bled.
303359-11
- Position the float needle valve and float ©

- Mount fulcrum pin O-
- Mount and tighten main jet ©

Guideline
Main jet M5x0.75 2 Nm (1.5 Ibf ft)
Mount and tighten idling jet ©.

Guideline
Idling jet M5 2 Nm (1.5 Ibf ft)
Mount and tighten cold start jet

Guideline
Cold start jet M5 2 Nm (1.5 Ibf ft)
Check/adjust the float level. (•" p. 195)

19 CARBURETOR 195
Mount the hoses on the carburetor.

Position the float chamber.
Mount and tighten screws ©
Guideline
Other screws, carburetor M4 2 Nm (1.5 Ibf ft)
Position the jet needle in the throttle slide.

Mount and tighten needle screw cap ©.
Guideline
Needle screw cap M8 3.5 Nm
(2.58 Ibf ft)
19.13 Checking/adjusting the float level

Condition
The carburetor and float chamber have been removed.
Tilt the carburetor sideways, preventing the fulcrum pin from falling out.
Tilt the carburetor until the float is resting against the float needle valve, but the
float needle valve is not being pressed together.
~60°
» If the edge of the float is not parallel (max. 1° deviation upwards) to the sealing
area of the float housing in this position:
- Adjust the float level by bending the float lever.
20 CLUTCH 196
Info
The fluid level rises with increasing wear of the clutch lining discs.
- Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
- Remove screws ©
- Remove cover © with membrane ©
- Check the fluid level.
Fluid level under top edge of container 4 mm (0.16 in)
» If the level of the fluid does not meet specifications:

- Correct the fluid level of the hydraulic clutch.
- Position the cover with the membrane. Mount and tighten the screws.
Info
Wash off overflowed or spilled brake fluid immediately with water.
Warning
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws o
Fill bleeding syringe © with the appropriate hydraulic fluid.
Bleed syringe (50329050000) (•" p. 275)

On the slave cylinder of the clutch, remove bleeder screw © and mount bleeding
syringe ©
Inject the liquid into the system until it escapes from hole © of the master cylin
der without bubbles.
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
Remove the bleeding syringe. Mount and tighten the bleeder screw.
Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level under top edge of container 4 mm (0.16 in)
21 WATER PUMP, COOLING SYSTEM 197
21.1 Cooling system

Water pump o
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 cool
ing effect.
21.2 Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
- Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme
diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal
lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of
children.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the coolant antifreeze.
-25... -45 °C (-13... -49 °F)
» If the antifreeze in the coolant does not match the specified value:
- Correct the coolant antifreeze.
Check the coolant level in the radiator.
Coolant level Q above the radiator 10 mm (0.39 in)

fins
» If the coolant level does not match the specified value:

- Correct the coolant level.
Coolant (•" p. 270)
- Mount the radiator cap.
21.3 Checking the coolant level
Warning
Warning
children.
Condition
The engine is cold.

- Remove the radiator cap.
- Check the coolant level in the radiator.
Coolant level O above the radiator 10 mm (0.39 in)

fins
» If the coolant level does not match the specified value:

- Correct the coolant level.
Coolant (•" p. 270)
- Mount the radiator cap.
21.4 Draining the coolant
Warning
Warning
children.
Condition
The engine is cold.
- Position the motorcycle upright.
- Place a suitable container under the water pump cover.
- Remove screw o . Take off radiator cap ©
- Completely drain the coolant.
- Mount and tighten screw o with a new seal ring.
Guideline
Drain plug, water pump cover MlOxl 15 Nm
(11.1 Ibf ft)
21.5 Refilling with coolant
Warning
children.
Make sure that screw o is tightened.

Position the motorcycle upright.
Fill the radiator completely with coolant.
Coolant 1.2 I (1.3 qt.) Coolant (*" p. 270)

Position the vehicle as shown and secure it against rolling away. A height differ
ence of Q must be reached.
Guideline
To ensure that all of the air can escape from the cooling system, the front of
the vehicle must be jacked up. A poorly bled cooling system is less effective
at cooling and may result in overheating of the engine.
Place the vehicle back on a level surface.

- Fill the radiator completely with coolant.
- Mount radiator cap ©
- Run the engine until it is warm.
Finishing work
- Check the coolant level. (*" p. 197)
22 EXHAUST CONTROL 200
22.1 Engine characteristic - setting the auxiliary spring
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
- Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Preparatory work
- Tilt the motorcycle approx. 45° to the left and secure it to prevent it from falling.
Main work
- Remove screws o
- Take cap ® , adjusting spring © auxiliary spring o , and spring insert 0 out of
the clutch cover.
- Pull both springs off of the spring insert.
- Mount the required auxiliary spring o and adjusting spring 0 and slide them
into the clutch cover together.
Auxiliary spring with yellow marking (54637072300)

Auxiliary spring with green marking (54837072100)
Auxiliary spring with red marking (54837072000)
S The recess in spring insert © engages in the angle lever.
• Info
I Screw © must not be turned as this would worsen the engine characteris
tic.
- Check the O-ring in the cap.

- Position the cap.
- Mount and tighten the screws.
Guideline
Screw, exhaust control cover 6 Nm (4.4 Ibf ft)
23 LUBRICATION SYSTEM 201
23.1 Changing the gear oil

Drain the gear oil. (•" p. 201)
Refill with gear oil. (*" p. 202)
23.2 Draining the gear oil
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
- Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Preparatory work
- Park the motorcycle on a level surface.
- Place a suitable container under the engine.
Main work
- Remove the gear oil drain plug with magnet Q.
- Completely drain the gear oil.
- Clean the gear oil drain plug with the magnet thoroughly.
- Clean the sealing area on the engine.
- Mount the gear oil drain plug with magnet O and the seal ring and tighten.
Guideline
Gear oil drain plug with magnet M12xl.5 20 Nm
(14.8 Ibf ft)
23.3 Refilling with gear oil
• Info
I Too little gear oil or poor-quality oil results in premature wear of the transmission.
Main work
- Remove filler plug O anc* fill UP with gear oil.
Gear oil 0.80 I (0.85 qt.) Engine oil (15W/50) (•" p. 270)
- Mount and tighten the oil filler plug.
Danger
- Start the engine and check that it is oil-tight.

Finishing work
- Check the gear oil level. (*“ p. 202)
23.4 Checking the gear oil level
Info
The gear oil level must be checked while the engine is cold.
Preparatory work
Main work
- Remove screw from the opening used to check the gear oil level.
Check the gear oil level.
A small quantity of gear oil should flow out of the opening.
» If gear oil does not flow out:

- Add gear oil. (•” p. 202)
- Mount and tighten the screw in the opening used to check the gear oil level.
Guideline
Screw, gear oil level check M6 10 Nm (7.4 Ibf ft)
23.5 Adding gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear of the transmission.
The gear oil must be added while the engine is cold.
Preparatory work
- Park the motorcycle on a level surface.
Main work
- Remove screw Q from the opening used to check the gear oil level.
Remove screw cap ©.

Add gear oil until it emerges from the opening used to check the gear oil level.
Engine oil (15W/50) (•” p. 270)
Mount and tighten the screw in the opening used to check the gear oil level.
Guideline
Screw, gear oil level check M6 10 Nm (7.4 Ibf ft)
Mount and tighten screw cap ©
Danger
Start the engine and check that it is oil-tight.

24 IGNITION SYSTEM 204
24.1 Checking the ignition system
Warning
Risk of injury The ignition system is under high voltage.
- To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme
diately after measuring.
Shift gear to neutral.

Pull off the spark plug connector and remove the spark plug connector from the
ignition wire.
Remove the spark plug.
Hold the free end of the ignition wire at a distance © from ground.
Guideline
Distance O 5 mm (0.2 in)
Press the kick starter forcefully through its full range.
# Info
1 Do not open the throttle.
Check the ignition spark.

» If no ignition spark is visible:
- Check the emergency OFF switch.
- Check the wiring harness to the emergency OFF switch.
- Check the kill switch.
- Check the ground connection of the CDI controller and ignition coil.
- Check the cable from the CDI controller to the ignition coil.
Info
The CDI controller cannot be tested using simple methods but only
using an ignition test bench.
- Ignition coil - check the primary winding. (*" p. 204)

- Ignition coil - check the secondary winding. (*" p. 205)
- Check the ignition pulse generator. (•" p. 207)
- Alternator - check the charging coil of the ignition. (*" p. 206)
Fit the spark plug connector on the ignition wire again. Insert the spark plug into
the spark plug connector. Hold the spark plug to ground.
Press the kick starter forcefully through its full range.
• Info
I Do not open the throttle.
Check the ignition spark.

» If no ignition spark is visible:
- Check the spark plug connector. (*" p. 205)
- Change the spark plug.
24.2 Ignition coil - checking the primary winding
Warning
A Risk of injury The ignition system is under high voltage.
- To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme
diately after measuring.
Condition
Ignition coil cylinder 1 is disconnected.
Ignition coil cylinder 1 - check the primary winding resistance
Measure the resistance between the specified points
Ignition coil pin 1 (+) - Ignition coil pin 2 (-)
Ignition coil
Primary winding resistance at: 0.255... 0.345 Q
20 °C (68 °F)
» If the displayed value does not correspond to the nominal value:

- Change the ignition coil.
Condition
Ignition coil cylinder 1 is connected.
- Connect the special tool to the multimeter.
• Info
I When using the peak voltage adapter, adjust the measuring range of the
multimeter to DCV.
- Start the motorcycle for checking. (•" p. 11)

Ignition coil cylinder 1 - check the primary winding voltage
Ignition coil pin 1 (+) - Ignition coil pin 2 (-)
Info
Connect the black measuring lead to pin 1 and the red measuring lead
to pin 2 of the ignition coil.
Ignition coil
Voltage, primary winding 150... 200 V

24.3 Ignition coil - checking the secondary winding

Condition
Ignition coil cylinder 1 is disconnected.
Spark plug connector cylinder 1 has been removed.
Ignition coil cylinder 1 - check the secondary winding resistance
Ignition coil pin 2 (-) - Ignition coil pin 3
Ignition coil
Secondary winding resistance at: 5.04... 7.56 kQ
20 °C (68 °F)

24.4 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.

Measuring point 1 - Measuring point 2
Spark plug connector

Resistance at: 20 °C (68 °F) 4.3... 5.7 kQ
» If the specification is not reached:

- Change the spark plug connector.
24.5 Alternator - checking the charging coil of the ignition

Condition
The alternator has been disconnected.
Alternator, charging coil/ignition pulse generator, connector AN pin 1 -
Alternator, charging coil/ignition pulse generator, connector AN pin 2
Alternator
Resistance of ignition charging coil 12... 16.5 a
at: 20 °C (68 °F)
» The specifications have not been met:

- Replace the stator.

Alternator, charging coil/ignition pulse generator, connector AN pin 1 - Measuring point Ground, wiring harness/frame
Resistance 00 Q

24.6 Alternator - checking the battery winding

Condition

Alternator, connector CR pin 1 (White) - Measuring point Ground (-)
Alternator
Battery winding resistance at: 20 °C (68 °F) 0.5... 0.9 Q

24.7 Alternator - checking the light winding

Condition
CR Alternator, connector CR pin 1 (White) - Alternator, connector CR pin 1 (Yel
low)
Alternator
Light winding resistance at: 20 °C 0.1... 0.2 Q
(68 °F)

601221-10
24.8 Checking the ignition pulse generator

Condition
The crankshaft position sensor is disconnected.
Crankshaft position sensor

Resistance at: 20 °C (68 °F) 80... 120 Q

- Change the ignition pulse generator.

Alternator, charging coil/ignition pulse generator, connector AN pin 3 - Measuring point Ground, wiring harness/frame
Resistance 00 Q

- Connect the special tool to the multimeter.
Peak voltage adapter (58429042000) (•" p. 277)
• Info
I When using the peak voltage adapter, adjust the measuring range of the multimeter to DCV.
Start the motorcycle for checking. p. 11)

Check the ignition pulse generator voltage


Voltage 2... 4 V

24.9 Removing the stator and crankshaft position sensor

Condition
The alternator cover has been removed.
- Remove screw o
- Remove cable support sleeve © from the alternator cover.
- Remove screw
- Remove the stator and crankshaft position sensor from the alternator cover.
24.10 Installing the stator and crankshaft position sensor

Position the stator in the alternator cover.
Mount and tighten screws O-
Guideline
Screw, stator M6 8 Nm Loctite® 243™
(5.9 Ibf ft)
Position the crankshaft position sensor.

Guideline
Screw, crankshaft position M5 6 Nm Loctite® 243™
sensor (4.4 Ibf ft)
Position cable support sleeve in the alternator cover.

25 ELECTRIC STARTER 209
25.1 Checking the starter motor

Condition
The starter motor has been removed.
- Clamp the negative cable of a 12 Volt power supply to the housing of the starter
motor. Connect the positive cable of the power supply briefly to the connection of
the starter motor.
» If the starter motor does not turn over when the circuit is closed:
26 TECHNICAL DATA 210
Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and

exhaust control
Displacement 249 cm3 (15.19 cu in)
Stroke 72 mm (2.83 in)
Bore 66.4 mm (2.614 in)
Exhaust valve - Beginning of adjustment 5,600 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,200 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,900 rpm
Exhaust valve - end of adjustment with green auxiliary spring 8,400 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
X (upper edge of piston to upper edge of cylinder) 0... 0.10 mm (0... 0.0039 in)
Z (height of control flap) 48 mm (1.89 in)
Primary transmission 26:72
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear, claw shifted
Transmission ratio
1st gear 14:32
2nd gear 16:26
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Ignition Contactless controlled fully electronic ignition with digital igni
tion adjustment, type Kokusan
Ignition point (BTDC) 1.9 mm (0.075 in)
Spark plug NGK BR 7 ES
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter and electric starter
26.1.2 All 300 models

Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and
exhaust control
Displacement 293 cm3 (17.88 cu in)
Stroke 72 mm (2.83 in)
Bore 72 mm (2.83 in)
Exhaust valve - Beginning of adjustment 5,600 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,200 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,900 rpm
Exhaust valve - end of adjustment with green auxiliary spring 8,400 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
X (upper edge of piston to upper edge of cylinder) 0... 0.10 mm (0... 0.0039 in)
Z (height of control flap) 48.5 mm (1.909 in)
Primary transmission 26:72

Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear, claw shifted
Transmission ratio
1st gear 14:32
2nd gear 16:26
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Ignition Contactless controlled fully electronic ignition with digital igni
tion adjustment, type Kokusan
Ignition point (BTDC) 1.9 mm (0.075 in)
Spark plug NGK BR 7 ES
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter and electric starter
26.2 Engine tolerance, wear limits

Size 1 66.340... 66.350 mm (2.61181... 2.6122 in)
Size II 66.351... 66.360 mm (2.61224... 2.61259 in)
Size 1 71.940... 71.950 mm (2.83228... 2.83267 in)
Size II 71.951... 71.960 mm (2.83271... 2.83307 in)
Size 1 66.400... 66.412 mm (2.61417... 2.61464 in)
Size II 66.412... 66.425 mm (2.61464... 2.61515 in)
Size 1 72.000... 72.012 mm (2.83464... 2.83511 in)
Size II 72.012... 72.025 mm (2.83511... 2.83562 in)
Piston/cylinder - mounting clearance (All 250 models)
New condition 0.050... 0.074 mm (0.00197... 0.00291 in)
Piston/cylinder - mounting clearance (All 300 models)
New condition 0.050... 0.085 mm (0.00197... 0.00335 in)
Piston ring - end gap
Ring 1 < 0.40 mm (< 0.0157 in)
Ring 2 < 0.40 mm (< 0.0157 in)
Cylinder/cylinder head - distortion of sealing area £ 0.10 mm (5 0.0039 in)
Connecting rod - axial play of lower conrod bearing 0.60... 0.70 mm (0.0236... 0.0276 in)
Crankshaft - run-out at bearing pin < 0.03 mm (< 0.0012 in)
Clutch facing disc - thickness £ 1.9 mm (£ 0.075 in)
Contact surface of clutch facing discs in outer clutch hub < 0.5 mm (< 0.02 in)
Shift shaft - sliding plate/shift quadrant clearance 0.40... 0.80 mm (0.0157... 0.0315 in)
26.3 engine tightening torques

Screw, inner reed petals EJOT DELTA PT® 35x25 1 Nm (0.7 Ibf ft) —
Screw, membrane core plate EJOT DELTA PT® 30x12 1 Nm (0.7 Ibf ft) —
Screw, outer reed petals EJOT DELTA PT® 30x6 1 Nm (0.7 Ibf ft) —
Screw, angle lever, exhaust control M5 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, clutch spring retainer M5 6 Nm (4.4 Ibf ft) —
Screw, crankshaft position sensor M5 6 Nm (4.4 Ibf ft) Loctite® 243™

Screw, exhaust control cover M5 6 Nm (4.4 Ibf ft) —
Screw, locking lever M5 6 Nm (4.4 Ibf ft) Loctite® 243™

Screw, retaining bracket of exhaust M5 7 Nm (5.2 Ibf ft) Loctite® 2701™
control
Screw, water pump wheel M5 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, alternator cover M6 8 Nm (5.9 Ibf ft) —
Screw, bearing retainer M6 10 Nm (7.4 Ibf ft) Loctite® 243™

Screw, clutch cover M6 10 Nm (7.4 Ibf ft) —
Screw, control flap, exhaust control M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, engine case M6x40 10 Nm (7.4 Ibf ft) —
Screw, exhaust flange M6 8 Nm (5.9 Ibf ft) —
Screw, gear oil level check M6 10 Nm (7.4 Ibf ft) —
Screw, intake flange/reed valve housing M6 10 Nm (7.4 Ibf ft) —
Screw, kick starter spring M6 10 Nm (7.4 Ibf ft) Loctite® 243™

Screw, kick starter stop plate M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, shift drum locating M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Screw, slave cylinder of the clutch M6 10 Nm (7.4 Ibf ft) —
Screw, starter motor M6 8 Nm (5.9 Ibf ft) —
Screw, stator M6 8 Nm (5.9 Ibf ft) Loctite® 243™

Screw, water pump cover M6 10 Nm (7.4 Ibf ft) —
Screw, cylinder head M8 27 Nm (19.9 Ibf ft) —
Screw, kick starter M8 25 Nm (18.4 Ibf ft) Loctite® 2701™

Nut, cylinder base M10 35 Nm (25.8 Ibf ft) —
Drain plug, water pump cover MlOxl 15 Nm (11.1 Ibf ft) —
Nut, rotor M12xl 60 Nm (44.3 Ibf ft) —
Gear oil drain plug with magnet M12xl.5 20 Nm (14.8 Ibf ft) —
Spark plug M14xl.25 25 Nm (18.4 Ibf ft) —
Nut, inner clutch hub M18xl.5 120 Nm (88.5 Ibf ft) Loctite® 648™
Nut, primary gear M18LHxl.5 150 Nm (110.6 Ibf ft) Loctite® 648™
Total fuel tank capacity, 9.5 1 (2.51 US gal) Super unleaded (95 octane) mixed with 2-stroke engine oil
approx. (250/300 EXC EU, (1:60) (•" p. 271)
EXC SIX DAYS)
Total fuel tank capacity, 10 I (2.6 US gal) Super unleaded (95 octane) mixed with 2-stroke engine oil
approx. (250/300 EXC AU, All (1:60) (*- p. 271)
250/300 XC-W models)
Fuel reserve, approx. (250/300 EXC EU, EXC SIX DAYS) 2 1 (2 qt.)
Fuel reserve, approx. (250/300 EXC AU, All 2.5 1 (2.6 qt.)
26.5 Chassis
Frame Central tube frame made of chrome molybdenum steel tubing
Fork (EXC EU/AUS, XC-W) WP Suspension Up Side Down 4860 MXMA PA
Fork (250/300 SIX DAYS) WP Suspension Up Side Down 4860 4CS
Suspension travel (EXC EU/AUS, XC-W)
Front 300 mm (11.81 in)
Suspension travel (250/300 SIX DAYS)
Front 292 mm (11.5 in)
Suspension travel
Rear 335 mm (13.19 in)
Fork offset 20 mm (0.79 in)
Shock absorber WP Performance Systems 5018 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
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
Tire air pressure, road (All 250/300 EXC EU/AU models)
Tire air pressure off road
Secondary ratio (All 250/300 EXC EU/AU models) 14:50(13:50)
Secondary ratio (All 250/300 XC-W models) 13:50
Chain 5/8 x 1/4"
Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase 1,482±10 mm (58.35±0.39 in)
Seat height unloaded 960 mm (37.8 in)
Ground clearance unloaded 355 mm (13.98 in)
Weight without fuel, approx. (250 XC-W USA) 101.9 kg (224.6 lb.)
Weight without fuel, approx. (300 XC-W USA, 102.1 kg (225.1 lb.)
300 XC-W SIX DAYS USA)
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.)
26.6 electrical system

Battery YTX4L-BS Battery voltage: 12 V
Nominal capacity: 3 Ah
maintenance-free
Speedometer battery CR 2430 Battery voltage: 3 V
Fuse 58011109110 10 A
Headlight HS1 / socket BX43t 12 V
35/35 W
Parking light W5W/socket W2.1x9.5d 12 V
5 W
Indicator lamps W2.3W/socket Wlx4.6d 12 V
2.3 W
Turn signal (All R10W/socket BA15s 12 V
250/300 EXC EU/AU models) 10 W
Brake/tail light LED
License plate lamp W5W/socket W2.1x9.5d 12 V
5 W
26.7 Tires
Validity Front tires Rear tires
(All 250/300 EXC EU/AU models) 80/100-21 M/C 51M 17 140/80- 18 M/C 70R TT
MAXXIS MAXX CROSS SI MAXXIS MAXX ENDURO
(All 250/300 XC-W models) 80/100-21 51M TT 110/100- 18 64M TT
Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51
Additional information is available in the Service section under:
http://www.ktm.com
Fork part number 14.18.7L.63

Fork WP Suspension Up Side Down 4860 MXMA PA
Compression damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Rebound damping
Comfort 20 clicks
Standard 18 clicks
Sport 16 clicks
Comfort 1 turn
Standard 2 turns
Sport 2 turns
Spring length with preload spacer(s)
Weight of rider: 65... 75 kg (143... 165 lb.) 513 mm (20.2 in)
Spring rate
Weight of rider: 65... 75 kg (143... 165 lb.) 4.0 N/mm (22.8 Ib/in)
Weight of rider: 75... 85 kg (165... 187 lb.) 4.2 N/mm (24 Ib/in)
Fork length 940 mm (37.01 in)
Air chamber length 110^8 mm (4.3318:11 in)
Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) (•" p. 270)
26.8.2 250/300 SIX DAYS

Fork part number 24.18.7N.63
Fork WP Suspension Up Side Down 4860 4CS
Compression damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
Rebound damping
Comfort 15 clicks
Standard 13 clicks
Sport 11 clicks
Spring length with preload spacer(s) 470 mm (18.5 in)
Spring rate
Weight of rider-. 65... 75 kg (143... 165 lb.) 3.8 N/mm (21.7 Ib/in)
Weight of rider: 85... 95 kg (187... 209 lb.) 4.2 N/mm (24 Ib/in)
Fork length 932 mm (36.69 in)
Air chamber length 100 mm (3.94 in)
Oil capacity per fork leg 635 ml (21.47 fl. oz.) Fork oil (SAE 4) (48601166S1) (•" p. 270)
26.9 shock absorber

Shock absorber part number 12.18.7N.63
Shock absorber WP Performance Systems 5018 PDS DCC
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Comfort 2 turns
Standard 1.5 turns
Sport 1.25 turns
Rebound damping
Comfort 28 clicks
Standard 24 clicks
Sport 22 clicks
Spring preload
Spring rate
Weight of rider: 65... 75 kg (143... 165 lb.) 66 N/mm (377 Ib/in)
Spring length 250 mm (9.84 in)
Gas pressure 10 bar (145 psi)
Static sag 33... 35 mm (1.3... 1.38 in)
Riding sag 105... 115 mm (4.13... 4.53 in)
Fitted length 417 mm (16.42 in)
Shock absorber fluid (•“ p. 271) SAE 2.5
26.10 chassis tightening torques

Spoke nipple, front wheel M4.5 5... 6 Nm (3.7... 4.4 Ibf ft) —
Spoke nipple, rear wheel M4.5 5... 6 Nm (3.7... 4.4 Ibf ft) —
Screw, frame protector M5 3 Nm (2.2 Ibf ft) —
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft) —
Screw, spoiler on fuel tank (All M5xl2 1.5 Nm (1.11 Ibf ft) —

Remaining nuts, chassis M6 10 Nm (7.4 Ibf ft) —
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft) —
Screw, ball joint of push rod on foot M6 10 Nm (7.4 Ibf ft) Loctite® 243™
brake cylinder
Screw, chain sliding guard M6 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, front brake disc M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Screw, rear brake disc M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Nut, foot brake lever stop M8 20 Nm (14.8 Ibf ft) —
Nut, rear sprocket screw M8 35 Nm (25.8 Ibf ft) Loctite® 2701™

Nut, rim lock M8 12 Nm (8.9 Ibf ft) —
Screw, bottom triple clamp M8 15 Nm (11.1 Ibf ft) —
(250/300 SIX DAYS)

Screw, bottom triple clamp M8 15 Nm (11.1 Ibf ft) —
(EXC EU/AUS, XC-W)

Screw, chain sliding piece M8 15 Nm (11.1 Ibf ft) —
Screw, engine brace M8 33 Nm (24.3 Ibf ft) Loctite® 2701™

Screw, fork stub M8 15 Nm (11.1 Ibf ft) —
Screw, front brake caliper M8 25 Nm (18.4 Ibf ft) Loctite® 243™

Screw, handlebar clamp M8 20 Nm (14.8 Ibf ft) —
Screw, side stand attachment M8 45 Nm (33.2 Ibf ft) Loctite® 2701™

Screw, subframe M8 35 Nm (25.8 Ibf ft) Loctite® 2701™
Screw, top steering stem M8 17 Nm (12.5 Ibf ft) Loctite® 243™
(250/300 SIX DAYS)
Screw, top steering stem M8 20 Nm (14.8 Ibf ft) —
(EXC EU/AUS, XC-W)

Screw, top triple clamp M8 17 Nm (12.5 Ibf ft) —
(250/300 SIX DAYS)

Screw, top triple clamp (EXC EU/AUS, M8 20 Nm (14.8 Ibf ft) —
XC-W)
Engine bracket screw M10 60 Nm (44.3 Ibf ft) —
Screw, handlebar support M10 40 Nm (29.5 Ibf ft) Loctite® 243™

Screw, bottom shock absorber M12 80 Nm (59 Ibf ft) Loctite® 2701™
Screw, top shock absorber M12 80 Nm (59 Ibf ft) Loctite® 2701™
Nut, seat fixing M12xl 20 Nm (14.8 Ibf ft) —
Nut, swingarm pivot M16xl.5 100 Nm (73.8 Ibf ft) —
Nut, rear wheel spindle M20xl.5 80 Nm (59 Ibf ft) —
Screw, top steering head M20xl.5 12 Nm (8.9 Ibf ft) —
Screw-in nozzles, cooling system M20xl.5 12 Nm (8.9 Ibf ft) Loctite® 243™
Screw, front wheel spindle M24xl.5 45 Nm (33.2 Ibf ft) —
Carburetor type KEIHIN PWK 36S AG

Carburetor identification number FK028
Needle position 2nd position from top
Jet needle N84K (N8RW / N8RJ / N8RK)
Main jet 110 (165/ 168)
Idling jet 38x38 (38 7 40 / 42)
Starting jet 50 (85)
Idle air adjusting screw
Open 1.5 turns
Throttle slide 7 with cut-out
Slide stop Present
26.11.2 250EXCAUS
Carburetor identification number 3600
Needle position 1. Position from top
Jet needle N3CJ (N8RW / N8RJ / N8RK / N4DW / N4DJ / N4DK)
Main jet 160 (165/168)
Idling jet 35 (38 / 40 / 42)
Starting jet 85
Open 3.5 turns
Slide stop Present
26.11.3 250 XC-W USA

Carburetor identification number BTO
Needle position 4th position from top
Jet needle N8RJ (N8RW / N8RK)
Main jet 168 (165)
Idling jet 40 (38 / 42)
Starting jet 85
Open 2.0 turns
Slide stop -
26.11.4 300 EXC EU, 300 EXC SIX DAYS EU

Carburetor identification number FK029
Needle position 2nd position from top
Jet needle N84K (N4DW / N4DJ / N4DK)
Main jet 115 (165/ 168)
Idling jet 38X38 (35)
Starting jet 50 (85)
Open 1.75 turns

Slide stop Present
26.11.5 300EXCAUS
Carburetor identification number 3600
Needle position 1. Position from top
Jet needle N3CJ (N8RW / N8RJ / N8RK / N4DW / N4DJ / N4DK)
Main jet 160 (165/ 168)
Idling jet 35 (38/40/42)
Starting jet 85
Open 3.5 turns
Slide stop Present
26.11.6 300 XC-W USA, 300 XC-W SIX DAYS USA

Carburetor identification number BC1
Needle position 4th position from top
Jet needle N4DJ (N4DW / N4DK)
Main jet 168 (165)
Idling jet 35
Starting jet 85
Open 2.0 turns
Slide stop -
26.12 carburetor tuning
26.12.1 Carburetor tuning (All 250 models)
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.
KEIHIN PWK 36S AG
-20°C ... -7°C -6°C ... 5°C 6°C ... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C
M/FT ASL TEMP
\\ ----------- ► -2°F... 20°F 19°F... 41 °F 42°F... 60°F 61 °F... 78°F 79°F... 98°F 99°F... 120°F
3.000 m ASO 2 2 2 2 2,5

10,000 ft IJ 40 40 40 38 38
ii NDL N8R J N8R J N8R J N8R K N8R K
POS 4 4 3 3 2
2.301 m MJ 168 165 162 160 158
7,501 ft
2.300 m ASO 1,5 2 2 2 2 2,5

7,500 ft IJ 40 40 40 40 38 38
l1i NDL N8R W N8R J N8R J N8R J N8R K N8R K
1 POS 4 4 4 3 3 2
1.501 m MJ 170 168 165 162 160 158
5,001 ft
1.500 m ASO 1,5 1,5 2 2 2 2

5,000 ft IJ 42 40 40 40 40 38
i i NDL N8R W N8R W N8R J N8R J N8R J N8R K
POS 4 4 4 4 3 3
751 m MJ 172 170 168 165 162 160
2,501 ft
750 m ASO 1,5 1,5 1,5 2 2 2

2,500 ft IJ 42 42 40 40 40 40
i i NDL N8R H N8R W N8R W N8R J N8R J N8R J
POS 5 4 4 4 4 3
301 m MJ 172 172 170 168 165 162
1,001 ft
300 m ASO 1,5 1,5 1,5 1,5 2 2

1,000 ft IJ 45 42 42 40 40 40
ii NDL N8R H N8R H N8R W N8R W N8R J N8R J
POS 5 5 4 4 4 4
0 m MJ 175 172 172 170 168 165
Oft 401770-01
M/FT ASL Sea level

TEMP Temperature
ASO Idle air adjusting screw open
IJ Idling jet
NDL Needle
POS Needle position from above
MJ Main jet
Does not apply to sand surfaces!

26.12.2 Carburetor tuning (All 300 models)
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.
KEIHIN PWK 36S AG
-20°C ... -7°C -6°C ... 5°C 6°C... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C
M/FT ASL TEMP
\\ -----------► -2°F... 20°F 19°F... 41°F 42°F... 60°F 61°F... 78°F 79°F... 98°F 99°F... 120°F
3.000 m ASO 2 2 2 2,5 2,5

10,000 ft IJ 35 35 35 35 35
i i NDL N4D J N4D K N4D K N4D L N4D L
POS 4 4 3 3 2
2.301 m MJ 168 165 162 160 158
7,501 ft
2.300 m ASO 2 2 2 2 2,5 2,5

7,500 ft IJ 38 35 35 35 35 35
i1II NDL N4D J N4D J N4D K N4D K N4D L N4D L
r POS 4 4 4 3 3 2
1.501 m MJ 170 168 165 162 160 158
5,001 ft
1.500 m ASO 2 2 2 2 2 2,5

5,000 ft IJ 38 38 35 35 35 35
ii NDL N4D W N4D J N4D J N4D K N4D K N4D L
r POS 4 4 4 4 3 3
751 m MJ 172 170 168 165 162 160
2,501 ft
750 m ASO 1,5 2 2 2 2 2

2,500 ft IJ 40 38 38 35 35 35
i i NDL N4D W N4D W N4D J N4D J N4D K N4D K
POS 5 4 4 4 4 3
301 m MJ 172 172 170 168 165 162
1,001 ft
300 m ASO 1.5 1,5 2 2 2 2

1,000 ft IJ 40 40 38 38 35 35
ii NDL N4D H N4D W N4D W N4D J N4D J N4D K
POS 5 5 4 4 4 4
0 m MJ 175 172 172 170 168 165
Oft 401767-01
M/FT ASL Sea level

TEMP Temperature
ASO Idle air adjusting screw open
IJ Idling jet
NDL Needle
POS Needle position from above
MJ Main jet
Does not apply to sand surfaces!

26.12.3 General carburetor tuning
1... 5 Needle position from above
The five needle positions are shown here.

The carburetor tuning depends on the defined ambient and operating conditions.
27 CLEANING, CARE 222
27.1 Cleaning the motorcycle
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
- When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors,
cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component.
Excessive pressure can cause malfunctions or destroy these parts.
Warning
Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunlight on the motorcycle during cleaning.
Close off the exhaust system to prevent water from entering.

Remove coarse dirt particles by spraying gently with water.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft
brush.
Motorcycle cleaner (•” p. 272)
• Info
1 Use warm water containing normal motorcycle cleaner and a soft sponge.
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.
Empty the carburetor float chamber. (*" p. 189)
Remove the plug from the exhaust system.
Warning
A Danger of accidents Reduced braking efficiency due to a wet or dirty brake
system.
- Clean or dry a dirty or wet brake system by riding and braking gently.
After cleaning, take a short ride until the engine reaches operating temperature.
• Info
1 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.
- Clean the chain. (*" p. 97)
- Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Preserving materials for paints, metal and rubber (•" p. 273)
- 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- 273)___________________________________________________________________

- Oil the steering lock.
Universal oil spray p. 273)

27 CLEANING, CARE 223
• Info
I If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro
sion.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of
salt.
Clean the motorcycle. (*" p. 222)

Clean the brakes.
• Info
I After EVERY trip on salted roads, thoroughly wash the brake calipers and
brake linings with cold water and dry carefully. This should be done after
the parts are cooled down and while they are installed.
After riding on salted roads, thoroughly wash the motorcycle with cold water
and dry it well.
Treat the engine, swingarm and all other bright and zinc-plated parts (except for
the brake discs) with a wax-based corrosion inhibitor.
• Info
I Corrosion inhibitor is not permitted to come in contact with the brake discs
as this would greatly reduce the braking force.
- Clean the chain. (*“ p. 97)

28 STORAGE 224
28.1 Storage
Warning
Info
If you want to put the motorcycle into storage for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
Clean the motorcycle. p. 222)

Change the gear oil. (*" p. 201)
Check the antifreeze and coolant level. (•" p. 197)
When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive (+~ p. 272)
Refuel.
Empty the carburetor float chamber. {•" pi. 189)
Check the tire air pressure. (*" p. 91)
Remove the battery. (*" p. 102)
Recharge the battery.
Guideline
Storage temperature of battery without 0... 35 °C (32... 95 °F)
direct sunlight
Store the vehicle in a dry location that is not subject to large fluctuations in tem
perature.
• Info
I KTM recommends raising the motorcycle.
Raise the motorcycle with the lift stand. (•" p. 10)

Cover the vehicle with a tarp or cover that is permeable to air.
• Info
I 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.
28.2 Preparing for use after storage

Remove the motorcycle from the lift stand. (•" p. 10)
Recharge the battery.
Install the battery. (*" p. 103)
Perform checks and maintenance work when preparing the vehicle for use.
Make a test ride.
29 SERVICE SCHEDULE 225
29.1 Service schedule

Every 40 operating hours/after every race
Every 20 operating hours
Check that the electrical equipment is functioning properly. • #
Check and charge the battery. • •
Check the front brake linings. (*" p. 105) • •
Check the rear brake linings. (*" p. 110) • •
Check the brake discs. (•" p. 92) • •
Check the brake lines for damage and leakage. • •
Check the rear brake fluid level. (*” p. 113) • •
Check the free travel of the foot brake lever. p. 112) • •
Check the frame and swingarm. • •
Check the swingarm bearing. •
Check the heim joints at the top and bottom of the shock absorber. • •
Check the tire condition. (*" p. 91) • •
Check the tire air pressure. (*" p. 91) • •
Check the wheel bearing for play. • •
Check the wheel hubs. • •
Check the rim run-out. • •
Check the spoke tension. (*" p. 92) • •
Check the chain, rear sprocket, engine sprocket, and chain guide. (*” p. 98) • •
Check the chain tension. (*" p. 97) • •
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. 196) • •
Check the front brake fluid level. (•" p. 108) • •

Check the free travel of the hand brake lever. (•" p. 107) • •
Check the play of the steering head bearing. p. 52) • •
Change the spark plug and spark plug connector. • •
Check the intake diaphragm. • •
Check the exhaust control for functioning and smooth operation. •
Check the clutch. •
Change the gear oil. (*" p. 201) • •
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing. • •
Check the antifreeze and coolant level. (*" p. 197) • •
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. 84) • •
Change the glass fiber yarn filling of the main silencer. (•" p. 81) • •
Check the screws and nuts for tightness. • •
Check the headlight setting. (•" p. 116) • •
Check the 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. • •
• Periodic interval
29 SERVICE SCHEDULE 226
29.2 Service work (as additional order)

Annually
Every 80 operating hours/every 40 operating hours when used for motorsports
Every 40 operating hours
Once after 10 operating hours
Change the front brake fluid. (*" p. 109) #
Change the rear brake fluid. (** p. 114) •
Change the hydraulic clutch fluid. (•" p. 196) •
Grease the steering head bearing. (*" p. 50) •
Check/set the carburetor components. # •
Perform a fork service. (EXC EU/AUS, XC-W) (•" p. 16) o • •
Perform a fork service. (250/300 SIX DAYS) (*" p. 35) o • •
Service the shock absorber. (•" p. 62) • •
Check the starter drive. • #
Change the piston and check the cylinder. #
Change the connecting rod, conrod bearing and crank pin. •

Check the transmission and shift mechanism. •
Change all engine bearings. •
o One-time interval
• Periodic interval
227
30 WIRING DIAGRAM 228
30.1 Page 1 of 5 (250 EXC EU, 300 EXC EU)

Components:
A15 CDI controller
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
M10 Starter motor
S21 Electric starter button
T20 Voltage regulator

Components:
E13 Low beam, high beam
P15 Horn
P23 High beam indicator lamp
P35 Parking light
S22 Light switch, horn button, kill switch

Components:
B70 Wheel speed sensor, front
B76 Brake light switch, front
B77 Brake light switch, rear
E60 License plate lamp
P13 Speedometer
P36 Brake/tail light
S36 Tripmaster switch
X285 Connector for radiator fan (optional)

Components:
K20 Turn signal relay
P21 Turn signal indicator light
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S25 Turn signal switch

Components:
A15 CDI controller
B37 Crankshaft position sensor
R51 Ignition coil (cylinder 1)
S50 Map switch for ride mode (optional)
X280 Connector, ignition timing map
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30.6 Page 1 of 5 (250 EXC SIX DAYS EU, 300 EXC SIX DAYS EU)
Components:
A15 CDI controller
G10 Battery
G20 Alternator
M10 Starter motor
Components:
P15 Horn
P35 Parking light
Components:
P13 Speedometer
Components:
Components:
A15 CDI controller
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30.11 Page 1 of 5 (250/300 EXC AU)

Components:
A15 CDI controller
G10 Battery
G20 Alternator
M10 Starter motor
S23 Emergency OFF switch, electric starter button
30.12 Page 2 of 5 (250/300 EXC AU)

Components:
A15 CDI controller
P15 Horn
P35 Parking light
S23 Emergency OFF switch, electric starter button
30 WIRING DIAGRAM
30.13 Page 3 of 5 (250/300 EXC AU)
Components:
P13 Speedometer
S36 Tripmaster switch
X285 Connector for radiator fan
30.14 Page 4 of 5 (250/300 EXC AU)

30 WIRING DIAGRAM
Components:
30.15 Page 5 of 5 (250/300 EXC AU)

Components:
A15 CDI controller
S50 Map switch for ride mode
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30.16 Page 1 of 3 (250 XC-W USA, 300 XC-W USA)

Components:
A15 CDI controller
G10 Battery
G20 Alternator
M10 Starter motor
m o CD
• •
n n *n
oo oo oo
o cr cu
wh
ro wh ro
N)
cn
o
W
o
o
X wh
0 wh
co
c co
C/>
>
N)
0 br
1
ro
o
O)
br
br
cn cn
cn CD
oo ro
cn
CO CO
ro
co
m o ro B00032-01
Components:
Ell Low beam
S30 Light switch
S36 Tripmaster switch (optional)
P13 Speedometer
P35 Parking light
P37 Tail light
30.18 Page 3 of 3 (250 XC-W USA, 300 XC-W USA)

Components:
A15 CDI controller
S20 Kill switch
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
30.19 Page 1 of 3 (300 XC-W SIX DAYS USA)

Components:
A15 CDI controller
G10 Battery
G20 Alternator
M10 Starter motor
m o CD
• •
■n -n -n
oo oo oo
O CT ttJ
w
ro o ro
o
X
0
co
X
0
D)
co < co
(/)
C
CO
>
K)
0
*
1
N)
O
G)
cn CJ1
cr> CD
00 ro
CO
01 CO
ro
co
m o ro B00042-01
Components:
Ell Low beam
S30 Light switch
P13 Speedometer
P35 Parking light
P37 Tail light
30.21 Page 3 of 3 (300 XC-W SIX DAYS USA)

Components:
A15 CDI controller
S20 Kill switch
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
Pk Pink
pu Violet
rd Red
wh White
ye Yellow
31 SUBSTANCES 270
Brake fluid DOT4/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
Castro I
- 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. 284)
- SAE (*■ p. 284) (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. 284)
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. 284) (SAE 4)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding
properties.
31 SUBSTANCES 271
Shock absorber fluid (SAE 2.5) (50180751S1)

- SAE (•" p. 284) (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
I 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. 284) (1:60)
Mixture ratio
1:60 Engine oil, 2-stroke (•" p. 270)
Super unleaded (ROZ 95/RON 95/PON 91) (•“ p. 271)
Motorex®
- Cross Power 2T
32 AUXILIARY SUBSTANCES 272
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
Lubricant (T158)
Lubcon®
- Turmogrease® PP 300
Lubricant (T511)
Lubcon®
- Turmsilon® GTI 300 P
Lubricant (T159)
Bel-Ray®
- MC-11®
Lubricant (T625)
Molykote®
- 33 Medium
Lubricant (T152)
Bel-Ray®
- Molylube® Anti-Seize
Motorcycle cleaner
Motorex®
- Moto Clean
32 AUXILIARY SUBSTANCES 273
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
33 SPECIAL TOOLS 274
Bleeder cover
Art. no.: 00029013005
r^ m\
a li
■ 1■
201597-10
Bleeder cover
Art. no.: 00029013006
201598-10
Bleeding device
Art. no.: 00029013100
__ \ V i
,.*. ^5^v. J3r
Spring hooks
Art. no.: 50305017000
a]
Mounting tool, heim joint

Art. no.: 50329000044
-O
Q>^
201428-01
Bleed syringe
Art. no.: 50329050000
& 400058-01
Clutch holder
Art. no.: 51129003000
fa
400289-01
Adjustment gauge
Art. no.: 54829001100
303079-10
Separator plate
Art. no.: 54829009000
303483-10
Lift stand
Art. no.: 54829055000
Insert for crankshaft pressing tool

Art. no.: 54829108000
303484-10
Holding spanner, rotor

Art. no.: 55129001000
Cl
\
302997-10
Gear segment
Art. no.: 56012004000
i 302982-10
Engine fixing arm

Art. no.: 56029002030
302945-10
Extractor
Art. no.: 58012009000
Tool for inner bearing race

Art. no.: 58429037040
Peak voltage adapter

Art. no.: 58429042000
---- bcd- 400083-01
Torque wrench with various accessories in set

Art. no.: 58429094000
1 Jki* * • '■ V 1
200910-10
Feeler gauge
Art. no.: 59029041100
10011M1
Engine assembly stand

Art. no.: 61229001000
V 200306-01
Pressing device for crankshaft, complete

Art. no.: 75029047000
V-
------------- 400185-01
Pin wrench
Art. no.: T103
200734-10
Hook wrench
Art. no.: T106S
Pin
Art. no.: T120
201235-10
Mounting sleeve
Art. no.: T1204
^ 7I
T120-* 1
V “ >*rie h Gstw™ y
200788-10
Calibration pin
Art. no.: T1205
200790-10
Pressing tool
Art. no.: T1206
200583-10
Pressing tool
Art. no.: T1207S
200585-01
Centering sleeve
Art. no.: T1214
200777-10
Mounting sleeve
Art. no.: T1215
300568-10
=i
Disassembly tool
Art. no.: T1216
200816-10
Vacuum pump
Art. no.: T1240S
kBU^T-" m 1
jjgggj 0
200273-10
Protecting sleeve
Art. no.: T1401
200635-10
Clamping stand
Art. no.: T14015S
3 f\
200733-10
Clamping stand
Art. no.: T14016S
200688-10
Gripping tool
Art. no.: T14026S1
V ^
200639-10
Assembly tool
Art. no.: T1402S
\
\V *
200634-10
Open-end wrench
Art. no.: T14032
200640-10
Clamping stand
Art. no.: T1403S
200637-10
Mounting tool
Art. no.: T14040S
200634-10
Special socket
Art. no.: T14047
201710-01
Clamping stand
Art. no.: T14049S
202338-10
Press-out tool
Art. no.: T14051
201779-10
Press drift
Art. no.: T1504
(-■■n— .i,
200789-10
Assembly tool
Art. no.: T150S
1 ^"■l tk—
if****"' ,-»
200791-10
Nitrogen filling tool

Art. no.: T170S1
34 STANDARDS 284
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.
35 LIST OF ABBREVIATIONS 285
Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly
INDEX 286
removing.................................... . . . 189
A technical data - carburetor . . , 217-218
Accessories.................................................................. ..................8 Carburetor - work on individual parts
Air filter choke slide, checking ............. . . . 193
cleaning ................................................................ ............... 84 float level, checking/adjusting . . . 195
installing................................................................ ............... 83 float needle valve, checking . . . . . 194
removing................................................................ ............... 83 jet needle, checking ............... . . . 193
Air filter box throttle slide, checking .......... . . . 193
cleaning ................................................................ ............... 84 Carburetor components
sealing .................................................................. ............... 84 checking/adjusting .................. . . . 191
Air filter box lid Cartridge
installing................................................................ ............... 83 fork legs, assembling ............. . 23,45
removing ................................................................ ............... 83 fork legs, disassembling . 19, 39
Alternator Chain
battery winding, checking ................................. .............206 checking.................................... ____ 98
charging coil of the ignition, checking............. .............206 cleaning .................................... ____ 97
light winding, checking ...................................... .............207 Chain guide
Antifreeze checking................................... ____ 98
checking................................................................ ............. 197 Chain tension
Auxiliary substances ................................................... ..................8 adjusting.................................... . . . 100
checking.................................... ____ 97
B
Charging voltage
Battery
checking.................................... . . . 103
installing................................................................ ............. 103
negative cable, connecting................................. ............. 102 Chassis number ............................... .......... 9
negative cable, disconnecting............................ ............. 101 Choke .............................................. . . . 188
removing................................................................ ............. 102 Clutch
Brake disc fluid level, checking/correcting......................................... 196
front brake, installing ......................................... ............... 94 fluid, changing..................................................................... 196
front brake, removing ......................................... ............... 94 Clutch lever
rear brake, installing........................................... ............... 96 basic position, adjusting .........................................................54
rear brake, removing ........................................... ............... 96 Compression damping
Brake discs fork, adjusting ................................................................ 12, 32
checking................................................................ ............... 92 Compression damping fitting
Brake fluid fork legs, assembling ..............................................................22
front brake, adding .............................................. .............108 fork legs, disassembling .........................................................21
front brake, changing ......................................... .............109 Compression damping, high-speed
rear brake, adding .............................................. ............. 113 shock absorber, adjusting ...................................................... 58
rear brake, changing ........................................... ............. 114
Brake fluid level shock absorber, adjusting ...................................................... 58
front brake, checking ......................................... ............. 108
Coolant
rear brake, checking ........................................... ............. 113
draining ............................................................................... 198
Brake linings refilling.................................................................................. 198
front brake, changing ......................................... ............. 105
Coolant level
front brake, checking ......................................... ............. 105
checking............................................................................... 197
rear brake, changing ........................................... ............. Ill
rear brake, checking ........................................... ............. 110 Cooling system............................................................................. 197
C
checking.................................................................................. 207
Capacity
Cylinder - Nikasil® coating ........................................................ 152
coolant ........................................................................ 198, 212
fuel ................................................................................. 212-213 E
gear oil ............................................................. 131,202,212 Engine
Carburetor assembling .................. 172
assembling .......................................................................... 194 disassembling ............. 132
disassembling ..................................................................... 192 installing....................... 127
float chamber, emptying ................................................... 189 removing....................... 123
idle speed, adjusting........................................................... 188 technical data - engine 210
installing............................................................................... 190 work on individual parts 143
INDEX 287
Engine - work on the individual parts shift shaft, installing...................................... 175

clutch cover.......................................................................... 157 spacer, installing ........................................... 186
clutch, checking................................................................... 161 starter motor, installing ................................. 184
connecting rod, conrod bearing, and crank pin, changing 145 transmission shafts, installing .................... 172
countershaft, assembling................................................... 167 water pump cover, installing ....................... 179
countershaft, disassembling.............................................. 165 X-distance, adjusting...................................... 182
crankshaft bearing inner race, installing.......................... 145 X-distance, checking...................................... 181
crankshaft bearing inner race, removing.......... ..................145 Z-distance, adjusting...................................... 182
crankshaft position sensor, installing..................................208 Engine characteristic
crankshaft position sensor, removing..................................208 auxiliary spring, setting ................................. 200
crankshaft run-out at the bearing pin, checking ..............146
Engine disassembly
cylinder - Nikasil® coating ................................................. 152
clutch basket, removing................................. 139
cylinder, checking/measuring............................................ 147
clutch cover, removing ................................. 137
electric starter drive, checking ......................................... 171
clutch discs, removing ................................. 138
exhaust control, checking ................................................. 149
clutch push rod, removing ............................ 132
exhaust control, installing ................................................. 150
crankshaft, removing...................................... 143
exhaust control, removing ................................... 147
cylinder head, removing................................. 135
intake flange, checking ...................................................... 155
cylinder, removing ......................................... 135
kick starter, checking ........................................................ 169
engine sprocket, removing ............................ 133
left engine case section...................................................... 144
engine, clamping into the engine work stand 132
main shaft, assembling ...................................................... 166
gear oil, draining ........................................... 132
main shaft, disassembling ................................................. 164
intermediate kick starter gear, removing . . . 140
membrane, checking........................................................... 155
kick starter shaft, removing .......................... 140
piston ring end gap, checking........................................... 153
kick starter, removing .................................... 135
piston, checking................................................................... 152
left engine case section, removing............... 141
piston, measuring................................................... 152
locking lever, removing ................................. 140
piston/cylinder, mounting clearance measuring................ 153
piston, removing.............................................. 136
reed valve housing, assembling......................................... 155
reed valve housing, removing ....................... 141
reed valve housing, checking .............................. 155
rotor, removing................................................. 141
reed valve housing, disassembling.................................... 154
shift drum locating unit, removing ............. 140
right engine case section ................................................... 143
shift drum, removing...................................... 142
shift mechanism, checking .............................................. 163
shift forks, removing ...................................... 142
shift shaft, preassembling ................................... 162
shift lever, removing ...................................... 132
stator, installing......................................................................208
shift rails, removing ....................................... 142
stator, removing ..................................................... 208
shift shaft, removing...................................... 140
transmission, checking ...................................................... 165
spacer, removing ........................................... 133
Engine assembly starter motor, removing ................................. 133
clutch basket, installing ...................................... 176 transmission shafts, removing .................... 142
clutch cover, installing ........................................ 178 water pump cover, removing.......................... 137
clutch discs, installing ...................................................... 177
Engine guards
clutch push rod, installing ................................................. 187
installing........................................................... 57
crankshaft, installing........................................................... 172
removing........................................................... 57
cylinder head, installing ................................................... 184
cylinder, installing ............................................................. 180 Engine number........................................................ . 9
engine sprocket, installing................................................. 186 Engine sprocket
engine, removing from the work stand ............................ 187 checking..................................................................................98
gear oil drain plug, installing ............................................ 187
F
intermediate kick starter gear, installing ....................... 175
Figures.............................................................................................. 8
kick starter shaft, installing .............................................. 175
kick starter shaft, preassembling...................................... 169 Filler cap
kick starter, installing ........................................................ 184 closing .................................................................................... 85
left engine case section, installing ................................. 173 opening.................... ...............................................................85
locking lever, installing ...................................................... 175 Foot brake lever
piston, installing ................................................................ 179 basic position, adjusting ................................................... 112
reed valve housing, installing ............................................ 174 free travel, checking ........................................................... 112
rotor, installing........................................................ 174 Fork legs
shift drum locating unit, installing ................................. 175 assembling ........................................................................ 24, 46
shift drum, installing............................................. 173 bleeding .......................................................................... 13, 32
shift forks, installing........................................................... 173 cartridge, assembling ...................................................... 23, 45
shift lever, installing ............................................. 186 cartridge, disassembling .............................................. 19, 39
shift rails, installing ........................................................... 173 checking............................................................................. 21, 42
INDEX 288
compression damping fitting, assembling . . 22 Heim joint

compression damping fitting, disassembling 21 changing....................... 79
disassembling ................................................. , 16, 36 Hydrostop unit
dust boots, cleaning ...................................... . 13, 33 fork legs, assembling . 43
fork service, performing................................. , 16, 35 fork legs, disassembling 41
hydrostop unit, assembling .......................... 43
I
hydrostop unit, disassembling .................... 41
installing........................................................... . 14, 34 Ignition coil
piston rod, assembling ................................. 44 primary winding, checking . 204
piston rod, disassembling ....................... 40 secondary winding, checking 205
removing........................................................... . 14, 34 Ignition system
seal ring retainer, assembling....................... 43 checking............................... 204
seal ring retainer, disassembling.................. 41
Ignition timing map
spring preload, setting.................................... 12
plug-in connection ............. 101
spring, removing.............................................. 38
q L
Fork part number ...................................................
Fork protector Lower triple clamp
installing........................................................... 15, 35 installing........................................................ ............... 29, 51

removing........................................................... 15, 35 removing........................................................ ............... 29, 50
Fork service, performing......................................... 16, 35 M
Front fender Main fuse

installing........................................................... . . 89 installing........................................................ .................... 101
removing........................................................... . . 89 removing........................................................ .................... 101
Front wheel Main silencer
installing........................................................... . . 93 glass fiber yarn filling, changing ............... .......................81
removing........................................................... . . 93 installing........................................................ ....................... 81
Fuel tank removing........................................................ ....................... 81
installing........................................................... . . 87 Motorcycle
removing........................................................... . . 86 cleaning ........................................................ .................... 222
Fuel tap .................................................................. . . 88 raising with lift stand ................................. ....................... 10

removing from lift stand ............................ ....................... 10
Fuse
main fuse, installing.......... ........................... . 101 0
main fuse, removing ...................................... . 101 Open-circuit current
G checking.......... 103
Gear oil Operating substances . 8

adding ......................................... ...................................... 202
changing...................................... ...................................... 201
Piston rod
draining ...................................... ...................................... 201
fork legs, assembling . 44
refilling......................................... ...................................... 202
fork legs, disassembling 40
Gear oil level
Preparing for use
checking...................................... ...................................... 202
after storage ............... 224
H
Hand brake lever

Rear sprocket
basic position, adjusting ................................................... 107
checking.....................................................................................98
free travel, adjusting........................................................... 107
free travel, checking ........................................................... 107 Rear wheel
installing.....................................................................................95
Handlebar position........................................................ 54
removing.....................................................................................94
adjusting..................................................................................... 54
Rebound damping
Headlight
fork, adjusting ................................................................ 12, 32
range, adjusting ..................................................... 116
shock absorber, adjusting ...................................................... 59
Headlight mask with headlight
Riding sag
installing..................................................................................... 90
adjusting.....................................................................................61
removing.....................................................................................89
S
Headlight setting
checking............................................................................... 116 Seal ring retainer
fork legs, assembling ..............................................................43
fork legs, disassembling .........................................................41
INDEX 289
Seat T
mounting ................................. .... 86
Technical data
removing.................................... ____ 85
Capacities ................................................................................212
Service schedule ............................ 225-226 carburetor tuning ................................................................... 219
Servicing the shock absorber .......... ____ 62 chassis ..................................................................................... 213
Shock absorber Chassis tightening torques....................................................216
damper, assembling ............... ____ 72 electrical system ................................................................... 214
damper, bleeding and filling . ____ 75 engine - tolerance, wear limits ............................................ 211
damper, checking.................... ____ 67 Engine tightening torques ....................................................212
damper, disassembling .......... ____ 63 Fork .......................................................................................... 214
damper, filling with nitrogen . ____ 77 shock absorber........................................................................ 215
heim joint, installing............... ____ 69 Tires.......................................................................................... 214
heim joint, removing............... ____ 68 Throttle cable play
installing.................................... ____ 61 adjusting.....................................................................................56
pilot bushing, replacing.......... ____ 66 checking..................................................................................... 55
piston rod, assembling .......... ____ 71
Throttle cable routing
piston rod, disassembling ____ 64
checking..................................................................................... 55
rebound adjuster, assembling . ____ 70
rebound adjuster, disassembling ____ 67 Tire air pressure
removing.................................... ____ 61 checking.....................................................................................91
riding sag, checking ............... ____ 60 Tire condition
seal ring retainer, assembling . ____ 70 checking...................................... 91
seal ring retainer, disassembling ____ 65 Type label............................................................................................ 9
shock absorber, servicing ____ 62
W
spring preload, setting............. ____ 60
spring, installing .................... ____ 78 Warranty............................................................................................... 8
spring, removing....................... ____ 62 Winter operation
static sag, checking ............... ____ 59 checks and maintenance steps............................................ 223
Shock absorber article number . . . .......... 9 Wiring diagram ......................... 228-269
Spare parts ...................................... .......... 8 page 1 of 3 ................................................................ 258, 264
Spark plug connector page 1 of 5 ...................................................... 228, 238, 248

checking.................................... . . . 205 page 2 of 3 ................................................................ 260, 266
page 2 of 5 ..................................................... 230, 240, 250
Speedometer
page 3 of 3 ................................................................ 262, 268
additional functions, activating . . . 118
page 3 of 5 ...................................................... 232, 242, 252
adjusting.................................... . . . 117
page 4 of 5 ...................................................... 234, 244, 254
clock, setting............................ 118, 121
page 5 of 5 ......................... 236, 246, 256
kilometers or miles, setting . . 117,120
setting ...................................... Work rules ..........................................................................................7
. . . 121
speedometer overview ............. 116, 120
wheel circumference, setting . 119,122
Spoke tension
checking.................................... ____ 92
Spring
fork legs, removing .................. ____ 38
Starter motor
checking.................................... . . . 209
Starter relay
checking.......................... . . . 104
Starting .......... ........................... . . 10-11
Steering head bearing
greasing .................................... . 28, 50
Steering head bearing play
adjusting.................................... . 31, 53
checking .................................... . 31, 52
Storage ........................................... . . . 224

1 2014 KTM 250-300 Exc XC-W Manual

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1 2014 KTM 250-300 Exc XC-W Manual

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REPAIR MANUAL 2014

1 MEANS OF REPRESENTATION........................................... 6 6.2.6 Positioning the fork protection........................ 34

1.1 Symbols used

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

X 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).

m Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Proprietary name Identifies a proprietary name.

Name® Identifies a protected name.

Brand™ Identifies a trademark.

2.1 Repair Manual

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Work rules

3.1 Guarantee, warranty

3.2 Operating and auxiliary substances

3.3 Spare parts, accessories

4.1 Chassis number

4.3 Engine number

4.4 Fork part number

4.5 Shock absorber article number

5.1 Raising the motorcycle with the lift stand

- Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000) (•" p. 275)

y Neither wheel is in contact with the ground.

5.2 Removing the motorcycle from the lift stand

- Always place the vehicle on a firm and even surface.

Remove the motorcycle from the lift stand.

- Shift gear to neutral.

- Remove protection caps o

- Turn counterclockwise by the number of clicks corresponding to the fork type.

- Mount protection caps ©

6.1.2 Adjusting the rebound damping of the fork

Turn adjusting screws O clockwise all the way.

Turn counterclockwise by the number of clicks corresponding to the fork type.

6.1.3 Adjusting the spring preload of the fork

Turn clockwise by the number of turns corresponding to the fork type.

6.1.4 Bleeding the fork legs

6.1.5 Cleaning the dust boots of the fork legs

Universal oil spray (*" p. 273)

- Press the dust boots back into their normal position.

6.1.6 Loosening the fork protection

6.1.7 Positioning the fork protection

6.1.8 Removing the fork legs

- Loosen screws ©. Remove the fork leg on the left.

6.1.9 Installing the fork legs

Position the brake caliper and mount and tighten screws ©.

- Mount cable binder

6.1.10 Removing the fork protector

6.1.11 Installing the fork protector

6.1.12 Performing a fork service

6.1.13 Disassembling the fork legs

- Clamp the fork leg in the area of lower triple clamp.

Clamping stand (T1403S) (*" p. 281)

Loosen Preload Adjuster ©.

Push the outer tube downward.

Open-end wrench (T14032) (*“ p. 281)

Remove Preload Adjuster © with preload spacers ©

Pull the spring downward. Remove the special tool.

Drain the fork oil.

Remove the cartridge.