KTM 250 EXC 2018 User Manual

OWNER'S MANUAL 2018
250 EXC
250 XC‑W
300 EXC
300 XC‑W
300 XC‑W Six Days
Art. no. 3213644en

KTM 250 EXC 2018 Specifications

General

Displacement	249 cm³
Bore x Stroke	66.4 mm x 72 mm
Transmission	6-speed
Fuel System	Carburetor
Cooling	Liquid cooled
Front Suspension	WP Xplor 48 upside-down fork
Rear Suspension	WP Xplor PDS shock absorber
Rear Tire	140/80-18
Front Wheel	1.60 x 21"
Rear Wheel	2.15 x 18"
Ground Clearance	370 mm
Seat Height	960 mm
Engine Type	1-cylinder, 2-stroke
Clutch	Wet multi-disc clutch, hydraulically operated
Frame	Central tube frame made of chrome molybdenum steel
Front Brake	Disc brake
Rear Brake	Disc brake, 220 mm
Front Tire	90/90-21
Starter	Kick and electric starter
Fuel Tank Capacity	9 liters

Summary

2 Safety Advice

2.1 Use Definition – Intended Use

Defines the intended purpose and usage scope for the vehicle model.

2.2 Misuse

Details improper uses of the vehicle and associated dangers.

2.3 Safety Advice

Provides general safety instructions and highlights important safety warnings.

2.4 Degrees of Risk and Symbols

Explains danger, warning, caution, and note symbols and their meaning.

2.5 Tampering Warning

Warns against modifying noise control systems and lists prohibited acts.

2.6 Safe Operation

Outlines critical safety aspects for operating the vehicle responsibly.

2.7 Protective Clothing

Emphasizes the importance of wearing appropriate protective gear during operation.

3 Important Notes

6 Controls

6.1 Clutch Lever

6.2 Hand Brake Lever

6.3 Throttle Grip

6.4 Kill Switch (All EXC models)

Describes the kill switch function and states for EXC models.

6.5 Kill Switch (All XC-W models)

Explains the kill switch function and states for XC-W models.

6.6 Horn Button (All EXC models)

6.7 Light Switch (All EXC models)

6.8 Light Switch (All XC-W models)

6.9 Turn Signal Switch (All EXC models)

6.10 Emergency OFF Switch (EXC AU)

Explains the function and states of the emergency OFF switch for EXC AU.

6.11 Electric Starter Button

6.13 Indicator Lamps Overview (All EXC models)

6.14 Indicator Lamps Overview (All XC-W models)

6.15 Opening the Filler Cap

Provides instructions and safety warnings for opening the fuel filler cap.

6.16 Closing the Filler Cap

6.17 Fuel Tap

6.18 Choke

6.19 Shift Lever

6.20 Kick Starter

6.21 Foot Brake Lever

6.22 Side Stand

6.23 Steering Lock (All EXC models)

Details the steering lock location and its function for securing the vehicle.

6.24 Locking the Steering (All EXC models)

Provides step-by-step instructions for locking the steering.

6.25 Unlocking the Steering (All EXC models)

Details the procedure for unlocking the steering.

7 Combination Instrument

7.1 Combination Instrument Overview

7.2 Activation and Test

7.4 Adjusting the Combination Instrument Function

7.5 Setting the Clock

7.7 Display Mode SPEED (Speed)

7.8 Display Mode SPEED/H (Operating Hours)

7.11 Display Mode SPEED/CLK (Time)

7.12 Setting the Clock

7.15 Display Mode SPEED/ODO (Odometer)

7.16 Display Mode SPEED/TR1 (Trip Master 1)

7.17 Display Mode SPEED/TR2 (Trip Master 2)

8 Preparing for Use

8.1 Advice on First Use

Offers crucial advice for initial operation and safety.

8.2 Running in the Engine

Provides guidelines for the engine break-in period to ensure longevity.

8.4 Preparing the Vehicle for Difficult Riding Conditions

9 Riding Instructions

9.1 Checks and Maintenance Measures When Preparing for Use

Lists essential pre-ride checks and maintenance tasks for safety.

9.2 Starting the Vehicle

Provides instructions and safety warnings for starting the engine.

9.3 Start Off

Guides on how to start moving from a standstill safely.

9.4 Shifting, Riding

Explains gear shifting techniques and general riding advice.

9.5 Braking

Details braking techniques and warnings for safe stopping.

9.6 Stopping, Parking

9.8 Refueling

Offers instructions and safety warnings related to refueling the vehicle.

10 Service Schedule

10.2 Required Work

11 Tuning the Chassis

11.1 Checking the Basic Chassis Setting with the Rider's Weight

Explains how to adjust chassis settings based on rider weight for optimal handling.

11.2 Compression Damping of the Shock Absorber

Introduces high-speed and low-speed compression damping concepts for shock absorbers.

11.3 Adjusting the Low-Speed Compression Damping of the Shock Absorber

Guides on adjusting the low-speed compression damping of the rear shock absorber.

11.4 Adjusting the High-Speed Compression Damping of the Shock Absorber

Details how to adjust the high-speed compression damping of the rear shock absorber.

11.5 Adjusting the Rebound Damping of the Shock Absorber

Explains how to adjust the rebound damping of the rear shock absorber.

11.6 Measuring the Rear Wheel Dimension Unloaded

11.7 Checking the Static Sag of the Shock Absorber

Describes how to check static sag and adjust spring pretension.

11.8 Checking the Riding Sag of the Shock Absorber

Guides on checking riding sag and adjusting it.

11.9 Adjusting the Spring Pretension of the Shock Absorber

Provides detailed steps for adjusting the shock absorber's spring preload.

11.10 Adjusting the Riding Sag

11.11 Checking the Basic Setting of the Fork

11.12 Adjusting the Compression Damping of the Fork

Details how to adjust fork compression damping for different models.

11.13 Adjusting the Rebound Damping of the Fork

Explains how to adjust fork rebound damping for different models.

11.14 Adjusting the Spring Pretension of the Fork (All Six Days models)

12 Service Work on the Chassis

12.3 Bleeding the Fork Legs

12.7 Removing the Fork Legs

12.8 Installing the Fork Legs

12.9 Removing the Lower Triple Clamp (All standard EXC/XC-W models)

12.10 Removing the Lower Triple Clamp (All Six Days models)

12.11 Installing the Lower Triple Clamp (All standard EXC/XC-W models)

12.12 Installing the Lower Triple Clamp (All Six Days models)

12.13 Checking the Play of the Steering Head Bearing

Explains how to check for play in the steering head bearing.

12.14 Adjusting the Steering Head Bearing Play

Guides on adjusting the steering head bearing play to correct issues.

12.18 Removing the Shock Absorber

12.19 Installing the Shock Absorber

12.24 Removing the Air Filter

12.25 Installing the Air Filter

12.29 Removing the Main Silencer

12.30 Installing the Main Silencer

12.32 Removing the Fuel Tank

Details the procedure for removing the fuel tank, with safety warnings.

12.33 Installing the Fuel Tank

Guides on correctly installing the fuel tank, with safety warnings.

12.36 Checking the Chain Tension

Details how to check and measure the drive chain tension.

12.37 Adjusting the Chain Tension

Guides on adjusting the drive chain tension according to specifications.

12.38 Checking the Chain, Rear Sprocket, Motor Sprocket, and Chain Guide

12.41 Checking Throttle Cable Routing

12.43 Adjusting the Basic Position of the Clutch Lever

12.44 Checking/Correcting the Fluid Level of the Hydraulic Clutch

Explains how to check and correct the hydraulic clutch fluid level.

12.45 Changing the Hydraulic Clutch Fluid

Provides instructions for changing the hydraulic clutch fluid, with safety warnings.

13 Brake System

13.1 Checking the Free Travel of the Hand Brake Lever

Explains how to check and set the free travel of the hand brake lever.

13.2 Adjusting Free Travel of Hand Brake Lever (All EXC models)

Guides on adjusting hand brake lever free travel for EXC models.

13.3 Adjusting the Basic Position of the Hand Brake Lever (All XC-W models)

Details how to adjust the hand brake lever position for XC-W models.

13.4 Checking the Brake Discs

Explains how to check brake disc thickness and condition.

13.5 Checking the Front Brake Fluid Level

Guides on checking the front brake fluid level and identifying issues.

13.6 Adding Front Brake Fluid

Provides instructions for adding front brake fluid, with safety warnings.

13.7 Checking the Front Brake Linings

Explains how to check the thickness and condition of front brake linings.

13.8 Changing the Front Brake Linings

Details the procedure for changing front brake linings, with warnings.

13.9 Checking the Free Travel of Foot Brake Lever

Guides on checking and setting the free travel of the foot brake lever.

13.10 Adjusting the Basic Position of the Foot Brake Lever

Explains how to adjust the basic position of the foot brake lever.

13.11 Checking the Rear Brake Fluid Level

Guides on checking the rear brake fluid level and identifying issues.

13.12 Adding Rear Brake Fluid

Provides instructions for adding rear brake fluid, with safety warnings.

13.13 Checking the Brake Linings of the Rear Brake

Explains how to check rear brake lining thickness and condition.

13.14 Changing the Rear Brake Linings

Details the procedure for changing rear brake linings, with warnings.

14 Wheels, Tires

14.1 Removing the Front Wheel

Details the steps for removing the front wheel, including brake caliper and spindle.

14.2 Installing the Front Wheel

Guides on correctly installing the front wheel, including bearings and spindle.

14.3 Removing the Rear Wheel

Explains the procedure for removing the rear wheel.

14.4 Installing the Rear Wheel

Guides on correctly installing the rear wheel, chain, and adjusters.

14.5 Checking the Tire Condition

14.6 Checking the Tire Air Pressure

15 Electrical System

15.1 Removing the Battery

Details the procedure for safely removing the vehicle's battery.

15.2 Installing the Battery

Guides on correctly installing the vehicle's battery.

15.3 Recharging the Battery

Provides instructions and safety precautions for recharging the battery.

15.4 Changing the Main Fuse

Details how to replace the main fuse, with warnings about electrical system safety.

15.5 Removing the Headlight Mask with the Headlight

15.6 Installing the Headlight Mask with the Headlight

15.7 Changing the Headlight Bulb

15.8 Changing the Turn Signal Bulb (All EXC models)

15.9 Checking the Headlight Setting

Guides on checking and verifying the correct headlight beam alignment.

15.10 Adjusting the Headlight Range

Details how to adjust the headlight's vertical beam range.

15.11 Changing the Combination Instrument

16 Cooling System

16.2 Checking the Antifreeze and Coolant Level

Guides on checking antifreeze protection and coolant levels, with warnings.

16.3 Checking the Coolant Level

Details how to check the coolant level in the radiator, with safety warnings.

16.4 Draining the Coolant

16.5 Refilling with Coolant

17 Tuning the Engine

17.1 Checking the Play in the Throttle Cable

Details how to check throttle cable play and its effect on idle speed.

17.2 Adjusting the Play in the Throttle Cable

Provides instructions for adjusting the throttle cable play.

17.3 Carburetor Setting

Explains how different carburetor components affect engine performance.

17.4 Carburetor – Idle

Discusses the importance of idle settings and factory values for various models.

17.5 Carburetor – Adjusting the Idle Speed

Guides on adjusting idle speed using specific screws and checking with a tachometer.

17.6 Ignition Curve Plug-in Connector

17.7 Changing the Ignition Timing Map

17.8 Checking the Basic Position of the Shift Lever

17.9 Adjusting the Basic Position of the Shift Lever

18 Service Work on the Engine

18.1 Emptying the Carburetor Float Chamber

18.2 Checking the Gear Oil Level

Guides on checking the engine's gear oil level when the engine is cold.

18.3 Changing the Gear Oil

Provides instructions for changing the gear oil, with safety and environmental warnings.

18.4 Adding Gear Oil

19 Cleaning, Care

22 Technical Data

22.1 Engine

22.1.1 All 250 Models

22.1.2 All 300 Models

22.3 Carburetor

22.3.1 EXC AU

22.3.2 Carburetor Tuning (EXC AU)

22.3.3 All XC-W Models

22.3.4 Carburetor Tuning (All XC-W models)

22.3.5 EXC BR

22.3.6 Carburetor Tuning (EXC BR)

22.8 Fork

Provides detailed specifications for the front fork, including damping and spring rates.

22.8.1 All 250 Models, EXC AU, 300 XC-W US

Lists fork specifications for specific 250/300 models.

22.8.2 EXC BR

Provides fork specifications for the EXC BR model.

22.8.3 All Six Days Models

Lists fork specifications for All Six Days models.

22.9 Shock Absorber

Details specifications for the rear shock absorber, including damping and spring settings.

22.10 Chassis Tightening Torques