KTM 250 EXC EU User Manual

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30 WIRING DIAGRAM 234

30.5 Page 5 of 5 (250 EXC EU, 300 EXC EU)

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F

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250/300 EXC EU 2014

/1.A7

-A15

-R51

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-X300

BU/18

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308685-01

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

Questions and Answers:

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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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