KTM 250 EXC EU User Manual

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REPAIR MANUAL 2014

250 EXC EU

250 EXC SIX DAYS EU

250 EXC AUS

250 XC‑W USA

300 EXC EU

300 EXC SIX DAYS EU

300 EXC AUS

300 XC‑W USA

300 XC‑W SIX DAYS USA

Art. no. 3206179en

Table of Contents

Default Chapter4
- Table of Contents4
- Table of Contents 24
1 Means of Representation8
- Symbols Used8
- Formats Used8
2 Safety Advice9
- Repair Manual9
- Degrees of Risk and Symbols9
- Work Rules9
3 Important Information10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Figures10
4 Serial Numbers11
- Chassis Number11
- Type Label11
- Engine Number11
- Fork Part Number11
- Shock Absorber Part Number11
5 Motorcycle12
- Raising the Motorcycle with the Lift Stand12
- Removing the Motorcycle from the Lift Stand12
- Starting12
- Starting the Motorcycle for Checking13
6 Fork, Triple Clamp14
- Exc Eu/Aus, XC-W14
- Adjusting the Compression Damping of the Fork14
- Adjusting the Rebound Damping of the Fork14
- Adjusting the Spring Preload of the Fork14
- Bleeding the Fork Legs15
- Cleaning the Dust Boots of the Fork Legs15
- Loosening the Fork Protection16
- Positioning the Fork Protection16
- Removing the Fork Legs16
- Installing the Fork Legs16
- Removing the Fork Protector17
- Installing the Fork Protector17
- Performing a Fork Service18
- Disassembling the Fork Legs18
- Cartridge Disassembly21
- Disassembling the Compression Damping Fitting23
- Checking the Fork Legs23
- Assembling the Compression Damping Fitting24
- Assembling the Cartridge25
- Assembling the Fork Legs26
- Greasing the Steering Head Bearing31
- Removing the Lower Triple Clamp31
- Installing the Lower Triple Clamp32
- Checking the Play of the Steering Head Bearing33
- Adjusting the Play of the Steering Head Bearing34
- 250/300 Six Days34
- Adjusting the Compression Damping of the Fork34
- Adjusting the Rebound Damping of the Fork35
- Bleeding the Fork Legs35
- Cleaning the Dust Boots of the Fork Legs35
- Loosening the Fork Protection36
- Positioning the Fork Protection36
- Removing the Fork Legs36
- Installing the Fork Legs37
- Removing the Fork Protector37
- Installing the Fork Protector38
- Performing a Fork Service38
- Disassembling the Fork Legs38
- Removing the Spring40
- Disassembling the Cartridge41
- Disassembling the Piston Rod42
- Disassembling the Hydrostop Unit43
- Disassembling the Seal Ring Retainer44
- Checking the Fork Legs44
- Assembling the Seal Ring Retainer45
- Assembling the Hydrostop Unit46
- Assembling the Piston Rod46
- Assembling the Cartridge48
- Assembling the Fork Legs49
- Greasing the Steering Head Bearing52
- Removing the Lower Triple Clamp53
- Installing the Lower Triple Clamp53
- Checking the Play of the Steering Head Bearing55
- Adjusting the Play of the Steering Head Bearing55
7 Handlebar, Controls56
- Handlebar Position56
- Adjusting the Handlebar Position56
- Adjusting the Basic Position of the Clutch Lever56
- Checking the Routing of the Throttle Cable57
- Checking the Play in the Throttle Cable57
- Adjusting the Play in the Throttle Cable58
8 Frame59
- Removing the Engine Guard (250/300 SIX DAYS)59
- Installing the Engine Guard (250/300 SIX DAYS)59
9 Shock Absorber, Swingarm60
- Adjusting the High-Speed Compression Damping of the Shock Absorber60
- Adjusting the Low-Speed Compression Damping of the Shock Absorber60
- Adjusting the Rebound Damping of the Shock Absorber61
- Measuring the Sag of the Unloaded Rear Wheel61
- Checking the Static Sag of the Shock Absorber61
- Checking the Riding Sag of the Shock Absorber62
- Adjusting the Spring Preload of the Shock Absorber62
- Adjusting the Riding Sag63
- Removing the Shock Absorber63
- Installing the Shock Absorber63
- Servicing the Shock Absorber64
- Removing the Spring64
- Disassembling the Damper65
- Disassembling the Piston Rod66
- Disassembling the Seal Ring Retainer67
- Replacing the Pilot Bushing68
- Checking the Damper69
- Disassembling the Rebound Adjuster69
- Removing the Heim Joint70
- Installing the Heim Joint71
- Assembling the Rebound Adjuster72
- Assembling the Seal Ring Retainer72
- Assembling the Piston Rod73
- Assembling the Damper74
- Bleeding and Filling the Damper77
- Filling the Damper with Nitrogen79
- Installing the Spring80
- Changing the Heim Joint81
10 Exhaust83
- Removing the Main Silencer83
- Installing the Main Silencer83
- Changing the Glass Fiber Yarn Filling of the Main Silencer83
11 Air Filter85
- Removing the Air Filter Box Lid85
- Installing the Air Filter Box Lid85
- Removing the Air Filter85
- Installing the Air Filter85
- Cleaning the Air Filter and Air Filter Box86
- Sealing the Air Filter Box86
12 Fuel Tank, Seat, Trim87
- Opening the Filler Cap87
- Closing the Filler Cap87
- Removing the Seat87
- Mounting the Seat88
- Removing the Fuel Tank88
- Installing the Fuel Tank89
- Fuel Tap90
13 Mask, Fender91
- Removing the Front Fender91
- Installing the Front Fender91
- Removing the Headlight Mask with the Headlight91
- Refitting the Headlight Mask with the Headlight92
14 Wheels93
- Checking the Tire Air Pressure93
- Checking the Tire Condition93
- Checking the Brake Discs94
- Checking the Spoke Tension94
- Front Wheel95
- Removing the Front Wheel95
- Installing the Front Wheel95
- Removing the Brake Disc of the Front Brake96
- Installing the Brake Disc of the Front Brake96
- Rear Wheel96
- Removing the Rear Wheel96
- Installing the Rear Wheel97
- Removing the Brake Disc of the Rear Brake98
- Installing the Brake Disc of the Rear Brake98
- Checking the Chain for Dirt98
- Cleaning the Chain99
- Checking the Chain Tension99
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide100
- Adjusting the Chain Tension101
15 Wiring Harness, Battery103
- Plug-In Connection, Ignition Timing Map103
- Removing the Main Fuse103
- Installing the Main Fuse103
- Recharging the Battery103
- Disconnecting the Negative Cable of the Battery104
- Connecting the Negative Cable of the Battery105
- Removing the Battery105
- Installing the Battery106
- Checking the Charging Voltage106
- Checking the Closed Current106
- Checking the Starter Relay107
16 Brake System108
- Checking the Front Brake Linings108
- Changing the Front Brake Linings108
- Checking the Free Travel of the Hand Brake Lever110
- Adjusting Free Travel of Hand Brake Lever (All 250/300 EXC Models)110
- Adjusting the Basic Position of the Hand Brake Lever (All 250/300 XC-W)110
- Checking the Front Brake Fluid Level111
- Adding Front Brake Fluid111
- Changing the Front Brake Fluid112
- Checking the Rear Brake Linings113
- Changing the Brake Linings of the Rear Brake114
- Checking the Free Travel of Foot Brake Lever115
- Adjusting the Basic Position of the Foot Brake Lever115
- Checking the Rear Brake Fluid Level116
- Adding Brake Fluid for the Rear Brake116
- Changing the Rear Brake Fluid117
17 Lighting System, Instruments119
- Checking the Headlight Setting119
- Adjusting the Headlight Range119
- Exc Eu/Aus, XC-W119
- Speedometer Overview119
- Activation and Test120
- Setting Kilometers or Miles120
- Adjusting the Speedometer Functions120
- Setting the Clock121
- Activating the Additional Functions121
- Setting the Wheel Circumference122
- Querying Lap Time122
- 250/300 Six Days123
- Speedometer Overview123
- Activation and Test123
- Setting Kilometers or Miles123
- Setting the Speedometer Functions124
- Setting the Clock124
- Setting the Wheel Circumference125
- Viewing the Lap Time125
18 Engine126
- Removing the Engine126
- Installing the Engine130
- Engine Disassembly135
- Clamping the Engine into the Engine Work Stand135
- Draining the Gear Oil135
- Removing the Clutch Push Rod135
- Removing the Shift Lever135
- Removing the Engine Sprocket135
- Removing the Spacer136
- Removing the Starter Motor136
- Removing the Kick Starter137
- Removing the Cylinder Head138
- Removing the Cylinder138
- Removing the Piston139
- Removing the Water Pump Cover140
- Removing the Clutch Cover140
- Removing the Clutch Discs140
- Removing the Clutch Basket141
- Removing the Kick Starter Shaft142
- Removing the Intermediate Kick Starter Gear142
- Removing the Shift Shaft143
- Removing the Shift Drum Locating Unit143
- Removing the Locking Lever143
- Removing the Rotor143
- Removing the Reed Valve Housing144
- Removing the Left Engine Case Section144
- Removing the Shift Rails144
- Removing the Shift Drum145
- Removing the Shift Forks145
- Removing the Transmission Shafts145
- Removing the Crankshaft145
- Work on Individual Parts146
- Work on the Right Section of the Engine Case146
- Work on the Left Section of the Engine Case147
- Removing the Crankshaft Bearing Inner Race147
- Installing the Crankshaft Bearing Inner Race148
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin148
- Checking the Crankshaft Run-Out at the Bearing Pin149
- Checking/Measuring the Cylinder149
- Removing the Exhaust Control150
- Checking the Exhaust Control152
- Installing the Exhaust Control152
- Cylinder - Nikasil ® Coating154
- Checking/Measuring the Piston155
- Checking the Piston Ring End Gap156
- Piston/Cylinder - Measuring the Mounting Clearance156
- Checking the Reed Valve Housing, Reed Valve, and Intake Flange157
- Work on the Clutch Cover157
- Checking the Clutch161
- Preassembling the Shift Shaft162
- Checking the Shift Mechanism163
- Disassembling the Main Shaft164
- Disassembling the Countershaft165
- Checking the Transmission165
- Assembling the Main Shaft166
- Assembling the Countershaft167
- Checking the Kick Starter169
- Preassembling the Kick Starter Shaft169
- Checking the Electric Starter Drive171
- Engine Assembly172
- Installing the Crankshaft172
- Installing the Transmission Shafts172
- Installing the Shift Forks173
- Installing the Shift Drum173
- Installing the Shift Rails173
- Installing the Left Engine Case Section173
  - Installing the Reed Valve Housing174
  - Installing the Rotor174
  - Installing the Locking Lever175
  - Installing the Shift Drum Locating Unit175
  - Installing the Shift Shaft175
  - Installing the Intermediate Kick Starter Gear175
  - Installing the Kick Starter Shaft175
  - Installing the Clutch Basket176
  - Installing the Clutch Discs177
  - Installing the Clutch Cover178
  - Installing the Water Pump Cover179
  - Installing the Piston179
  - Installing the Cylinder180
  - Checking the X-Distance181
  - Adjusting the X-Distance182
  - Adjusting the Z-Distance182
  - Installing the Cylinder Head184
  - Installing the Kick Starter184
  - Installing the Starter Motor184
  - Installing the Spacer186
  - Installing the Engine Sprocket186
  - Installing the Shift Lever186
  - Installing the Clutch Push Rod187
  - Installing the Gear Oil Drain Plug187
  - Removing the Engine from the Work Stand187
19 Carburetor188
- Choke188
- Carburetor - Adjusting the Idle Speed188
- Emptying the Carburetor Float Chamber189
- Removing the Carburetor189
- Installing the Carburetor190
- Checking/Adjusting the Carburetor Components191
- Disassembling the Carburetor192
- Checking the Choke Slide193
- Checking the Jet Needle193
- Checking the Throttle Slide193
- Checking the Float Needle Valve194
- Assembling the Carburetor194
- Checking/Adjusting the Float Level195
20 Clutch196
- Checking/Correcting the Fluid Level of the Hydraulic Clutch196
- Changing the Hydraulic Clutch Fluid196
21 Water Pump, Cooling System197
- Cooling System197
- Checking the Antifreeze and Coolant Level197
- Checking the Coolant Level197
- Draining the Coolant198
- Refilling with Coolant198
22 Exhaust Control200
- Engine Characteristic - Setting the Auxiliary Spring200
23 Lubrication System201
- Changing the Gear Oil201
- Draining the Gear Oil201
- Refilling with Gear Oil202
- Checking the Gear Oil Level202
- Adding Gear Oil202
24 Ignition System204
- Checking the Ignition System204
- Ignition Coil - Checking the Primary Winding204
- Ignition Coil - Checking the Secondary Winding205
- Checking the Spark Plug Connector205
- Alternator - Checking the Charging Coil of the Ignition206
- Alternator - Checking the Battery Winding206
- Alternator - Checking the Light Winding207
- Checking the Ignition Pulse Generator207
- Removing the Stator and Crankshaft Position Sensor208
- Installing the Stator and Crankshaft Position Sensor208
25 Electric Starter209
- Checking the Starter Motor209
26 Technical Data210
- Engine210
- All 250 Models210
- All 300 Models210
- Engine Tolerance, Wear Limits211
- Engine Tightening Torques212
- Capacities212
- Gear Oil212
- Coolant212
- Fuel213
- Chassis213
- Electrical System214
- Tires214
- Fork214
- Exc Eu/Aus, XC-W214
- 250/300 Six Days215
- Shock Absorber215
- Chassis Tightening Torques216
- Carburetor217
- Exc Eu, 250 Exc Six Days Eu217
- Exc aus217
- XC-W Usa217
- Exc Eu, 300 Exc Six Days Eu217
- Exc aus218
- XC-W Usa, 300 XC-W Six Days Usa218
- Carburetor Tuning219
- Carburetor Tuning (All 250 Models)219
- Carburetor Tuning (All 300 Models)220
- General Carburetor Tuning221
27 Cleaning, Care222
- Cleaning the Motorcycle222
- Checks and Maintenance Steps for Winter Operation223
28 Storage224
- Preparing for Use after Storage224
29 Service Schedule225
- Service Work (as Additional Order)226
30 Wiring Diagram228
- 250 Exc Eu, 300 Exc Eu)228
- 250 Exc Eu, 300 Exc Eu)230
- 250 Exc Eu, 300 Exc Eu)232
- 250 Exc Eu, 300 Exc Eu)234
- 250 Exc Eu, 300 Exc Eu)236
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)238
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)240
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)242
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)244
- 250 Exc Six Days Eu, 300 Exc Six Days Eu)246
- 250/300 Exc Aus)248
- 250/300 Exc Aus)250
- 250/300 Exc Aus)252
- 250/300 Exc Aus)254
- 250/300 Exc Aus)256
- 250 XC-W Usa, 300 XC-W Usa)258
- 250 XC-W Usa, 300 XC-W Usa)260
- 250 XC-W Usa, 300 XC-W Usa)262
- 300 XC-W Six Days Usa)264
- Page 1 of 3 (300 XC‑W SIX DAYS USA)264
- 300 XC-W Six Days Usa)266
- Page 2 of 3 (300 XC‑W SIX DAYS USA)266
- 300 XC-W Six Days Usa)268
- Page 3 of 3 (300 XC‑W SIX DAYS USA)268
31 Substances270
32 Auxiliary Substances272
33 Special Tools274
34 Standards284
- Index285

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KTM 250 EXC EU Specifications

General

Transmission	6-speed
Ignition	Kokusan
Front Wheel	1.60 x 21"
Rear Wheel	2.15 x 18"
Seat Height	960 mm
Engine Type	2-stroke
Displacement	249 cm³
Bore x Stroke	66.4 mm x 72 mm
Cooling	Liquid-cooled
Front Suspension	WP Xplor 48, USD fork
Rear Suspension	WP XPLOR shock absorber with linkage
Front Brake	Disc brake
Rear Brake	Disc brake
Fuel Capacity	9 l

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