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KTM 300 EXC Six days eu User Manual

KTM 300 EXC Six days eu
150 pages
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OWNER'S MANUAL 2014
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
250 EXC EU
250 EXC AUS
250 EXC SIX DAYS EU
250 XC‑W USA
300 EXC EU
300 EXC AUS
300 EXC SIX DAYS EU
300 XC‑W USA
300 XC‑W SIX DAYS USA
Art. no. 3213034en

Table of Contents

Other manuals for KTM 300 EXC Six days eu

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Repair Manual289 pages

Questions and Answers:

KTM 300 EXC Six days eu Specifications

General IconGeneral
Bore x Stroke72 mm x 72 mm
Transmission6-speed
Seat Height960 mm
StarterElectric starter
Front BrakeDisc brake
Rear BrakeDisc brake
Front Brake Diameter260 mm
Rear Brake Diameter220 mm
Engine Type2-stroke
Displacement293.2 cc
PowerNot available
TorqueNot available
WeightNot available
Front SuspensionWP Xplor 48
Rear SuspensionWP Xplor PDS
CoolingLiquid cooled

Summary

1 Document Representation

1.1 Symbols Used

Explains symbols used in the manual for clarity and warnings.

1.2 Formats Used

Explains the typographical formats used within the document for specific terminology.

2 Safety Advice

2.1 Intended Use

Defines the intended use and limitations of the KTM sport motorcycle.

2.2 General Safety Advice

Provides essential safety instructions for operating the vehicle safely.

2.3 Risk Degrees and Symbols

Explains danger, warning, caution, and note symbols for risk assessment.

2.4 Tampering Warning

Warns against unauthorized modifications to noise control systems and other vehicle components.

2.5 Safe Operation

Covers safe operating practices, including influences of alcohol, drugs, and exhaust gas toxicity.

2.6 Protective Clothing

Emphasizes the importance of wearing appropriate protective clothing for riding.

2.7 Work Rules

Outlines rules for performing maintenance and repair work, including tool requirements.

2.8 Environmental Responsibility

Advises on responsible use and disposal of fluids and components to protect the environment.

2.9 Owner's Manual Importance

Stresses the importance of reading and keeping the owner's manual for safe operation and maintenance.

3 Important Notes

3.1 Guarantee and Warranty

Details warranty conditions and requirements for service work to maintain validity.

3.2 Operating and Auxiliary Substances

Specifies the use of approved fuels, lubricants, and warnings about environmental hazards.

3.3 Spare Parts and Accessories

Recommends using KTM-approved parts and accessories for safety and liability.

3.4 Service Requirements

Highlights the importance of proper service for performance, wear prevention, and longevity.

3.5 Figures in Manual

Notes that figures may show special equipment and some components might not be fully depicted.

3.6 Customer Service

Provides information on seeking assistance from authorized KTM dealers and resources.

4 Vehicle View

4.1 Front Left View

Illustrates and labels key components visible from the front left side of the motorcycle.

4.2 Rear Right View

Illustrates and labels key components visible from the rear right side of the motorcycle.

5 Vehicle Serial Numbers

5.1 Chassis Number Location

Identifies the location of the chassis number stamped on the steering head.

5.2 Type Label Location

Details the location of the type label affixed to the front of the steering head.

5.3 Key Number Identification

Explains where the key number for the steering lock is stamped on the key connector.

5.4 Engine Number Location

Specifies the location of the engine number stamped on the left side of the engine.

5.5 Fork Part Number

Indicates the location of the fork part number stamped on the inner side of the fork stub.

5.6 Shock Absorber Part Number

Shows where the shock absorber part number is stamped on the top of the shock absorber.

6 Motorcycle Controls

6.1 Clutch Lever Operation

Describes the clutch lever for 125/200 and 250/300 models, including its hydraulic operation.

6.2 Hand Brake Lever

Explains the location and function of the hand brake lever used for the front brake.

6.3 Throttle Grip

Identifies the throttle grip and its location on the right side of the handlebar.

6.4 Kill Switch (EXC Models)

Details the kill switch for EXC models and its possible states for ignition control.

6.5 Kill Switch (XC-W Models)

Details the kill switch for XC-W models and its possible states for ignition control.

6.6 Horn Button Operation

Explains the horn button's location and its possible states for operation.

6.7 Light Switch (EXC Models)

Describes the light switch for EXC models and its functions for low beam, high beam, and off.

6.8 Light Switch (XC-W Models)

Explains the light switch for XC-W models and its functions for light on and off.

6.9 Turn Signal Switch

Details the turn signal switch for EXC models and its positions for left, right, and off.

6.10 Emergency OFF Switch

Describes the emergency OFF switch for EXC AUS models and its ignition states.

6.11 Electric Starter Button

Explains the electric starter button for specific EXC EU, SIX DAYS, and XC-W models.

6.12 Electric Starter Button (EXC AUS)

Details the electric starter button for EXC AUS models and its activation states.

6.13 Indicator Lamps Overview (EXC EU/AUS)

Shows the indicator lamps for EXC EU/AUS models, including high beam and turn signal indicators.

6.14 Indicator Lamps Overview (SIX DAYS EU)

Details indicator lamps for SIX DAYS EU models, including high beam, EFI, and low fuel warnings.

6.15 Indicator Lamps Overview (300 XC-W SIX DAYS USA)

Lists indicator lamps for 300 XC-W SIX DAYS USA, including high beam, EFI, and low fuel warnings.

6.16 Opening the Filler Cap

Provides instructions for opening the fuel filler cap, including safety warnings.

6.17 Closing the Filler Cap

Details how to close the fuel filler cap and ensure the fuel tank breather hose is clear.

6.18 Fuel Tap Operation

Explains the fuel tap positions (OFF, ON, RES) for controlling fuel supply to the carburetor.

6.19 Choke Lever Function

Describes the choke lever's function for enriching the fuel-air mixture for cold starts.

6.20 Shift Lever and Gear Positions

Identifies the shift lever location and shows how to identify gear positions, including neutral.

6.21 Kick Starter Operation

Describes the kick starter and its swiveling top part for starting the engine.

6.22 Foot Brake Lever

Explains the foot brake lever's location and its use for activating the rear brake.

6.23 Side Stand Function

Details the side stand's use for parking and the requirement to fold it up during riding.

6.24 Steering Lock

Explains the steering lock for EXC models and its function to prevent steering.

6.25 Locking the Steering

Provides steps and safety notes for locking the motorcycle's steering.

6.26 Unlocking the Steering

Details the procedure for unlocking the motorcycle's steering.

7 Speedometer Operation

7.1 EXC and XC-W Speedometer Overview

Introduces the speedometer, its buttons, and initial activated display modes.

7.1.1 Speedometer Overview

Provides a layout of the speedometer display and its control buttons.

7.1.2 Speedometer Activation and Test

Explains how to activate the speedometer and perform a display test.

7.1.3 Setting Kilometers or Miles

Details the procedure to change the unit of measurement between kilometers and miles.

7.1.4 Adjusting Speedometer Functions

Guides on activating or deactivating various display functions like SPEED/H, SPEED/ODO, etc.

7.1.5 Setting the Clock

Explains how to set the time on the speedometer display, including hour, minute, and second adjustments.

7.1.6 Querying Lap Time

Describes how to view lap times, noting it's only available if lap times have been measured.

7.1.7 Speed Display Mode

Explains how to view the current speed in Km/h or Mph.

7.1.8 Service Hours Display Mode

Describes the display mode showing engine service hours and its importance for maintenance intervals.

7.1.9 Setup Menu Navigation

Details how to enter and navigate the speedometer's setup menu for various functions.

7.1.10 Unit of Measurement Menu

Guides on changing the unit of measurement between Km/h and Mph.

7.1.11 Speed/Clock Display Mode

Explains how to display the current time in CLK mode on the speedometer.

7.1.12 Setting the Clock

Provides instructions for setting the clock on the speedometer, including adjusting hours and minutes.

7.1.13 Speed/Lap Time Display Mode

Describes how to use the stopwatch function for timing lap times.

7.1.14 Viewing Lap Times

Explains how to select and view recorded lap times from 1 to 10.

7.1.15 Odometer Display Mode

Details how to view the total distance traveled in the ODO display mode.

7.1.16 Trip Master 1 Display Mode

Explains the TR1 display mode for measuring trips or distances between refueling stops.

7.1.17 Trip Master 2 Display Mode

Describes the TR2 display mode for manual trip measurement, useful with road books.

7.1.18 Setting Trip Master 2

Guides on manually setting or correcting the TR2 trip master value.

7.1.19 Average Speed 1 Display Mode

Explains the A1 display mode for showing average speed calculated from TR1 and S1.

7.1.20 Average Speed 2 Display Mode

Describes the A2 display mode for average speed based on current speed and running S2 stopwatch.

7.1.21 Stop Watch 1 Display Mode

Explains the S1 display mode for showing journey time based on TR1 and wheel speed sensor input.

7.1.22 Stop Watch 2 Display Mode

Details the S2 display mode for manual stopwatch operation, flashing when running.

7.1.23 Speedometer Function Table

Summarizes functions, button presses, and conditions for various speedometer display modes.

7.1.24 Conditions and Menu Activation Table

Lists conditions (stationary/moving) for activating different speedometer menus and functions.

7.2 SIX DAYS Speedometer Overview

Introduces the speedometer overview for SIX DAYS models and its initial activated display modes.

7.2.2 SIX DAYS Speedometer Activation and Test

Explains how to activate the SIX DAYS speedometer and perform a display test.

7.2.3 Setting Kilometers or Miles (SIX DAYS)

Details the procedure to change the unit of measurement for SIX DAYS models.

7.2.4 Setting Speedometer Functions (SIX DAYS)

Guides on activating/deactivating functions for SIX DAYS models.

7.2.5 Setting the Clock (SIX DAYS)

Provides instructions for setting the clock on the SIX DAYS speedometer.

7.2.6 Viewing Lap Time (SIX DAYS)

Explains how to view lap times on the SIX DAYS speedometer if they have been measured.

7.2.7 Speed Display Mode (SIX DAYS)

Explains how to view the current speed in Km/h or Mph for SIX DAYS models.

7.2.8 Service Hours Display Mode (SIX DAYS)

Describes the service hours display for SIX DAYS models and its relation to maintenance.

7.2.9 Setup Menu Navigation (SIX DAYS)

Details how to navigate the setup menu for SIX DAYS speedometer functions.

7.2.10 Setting Unit of Measurement (SIX DAYS)

Guides on changing the unit of measurement for SIX DAYS models.

7.2.11 Speed/Clock Display Mode (SIX DAYS)

Explains how to display the time in CLK mode for SIX DAYS models.

7.2.12 Setting the Clock (SIX DAYS)

Provides instructions for setting the clock on the SIX DAYS speedometer.

7.2.13 Speed/Lap Time Display Mode (SIX DAYS)

Describes lap time functionality for SIX DAYS models.

7.2.14 Viewing Lap Time (SIX DAYS)

Explains how to view lap times for SIX DAYS models.

7.2.15 Odometer Display Mode (SIX DAYS)

Details odometer display for SIX DAYS models.

7.2.16 Trip Master 1 Display Mode (SIX DAYS)

Explains TR1 display for SIX DAYS models for measuring trips.

7.2.17 Trip Master 2 Display Mode (SIX DAYS)

Describes TR2 display for SIX DAYS models for manual trip measurement.

7.2.18 Setting Trip Master 2 (SIX DAYS)

Guides on manually setting TR2 for SIX DAYS models.

7.2.19 Average Speed 1 Display Mode (SIX DAYS)

Explains A1 display for SIX DAYS models for average speed calculation.

7.2.20 Average Speed 2 Display Mode (SIX DAYS)

Describes A2 display for SIX DAYS models for average speed with S2 stopwatch.

7.2.21 Stop Watch 1 Display Mode (SIX DAYS)

Explains S1 display for SIX DAYS models for journey time.

7.2.22 Stop Watch 2 Display Mode (SIX DAYS)

Details S2 display for SIX DAYS models for manual stopwatch.

7.2.23 Speedometer Function Table (SIX DAYS)

Summarizes functions and button presses for SIX DAYS speedometer modes.

7.2.24 Conditions and Menu Activation Table (SIX DAYS)

Lists conditions for activating SIX DAYS speedometer menus.

8 Preparing for Use

8.1 Advice on First Use

Provides crucial safety advice for initial operation, including hazards and pre-ride checks.

8.2 Running In the Engine

Guides on engine break-in procedures, emphasizing moderate performance and avoiding full throttle.

8.3 Preparing for Difficult Riding Conditions

Outlines preparations for challenging terrains like sand, mud, and varying temperatures.

8.4 Preparations for Dry Sand Riding

Details specific preparations for riding on dry sand, including radiator cap and air filter.

8.5 Preparations for Wet Sand Riding

Outlines preparations for riding on wet sand, focusing on radiator cap checks.

8.6 Preparations for Wet/Muddy Surfaces

Specifies preparations for wet and muddy conditions, like mounting rain covers for air filters.

8.7 Preparations for High Temps/Low Speeds

Advises on preparations for high temperatures and low speeds, including radiator cap checks.

8.8 Preparations for Low Temps/Snow

Details preparations for riding in cold temperatures or snow, focusing on air filter and carburetor tuning.

9 Riding Instructions

9.1 Pre-Ride Checks and Maintenance

Lists essential checks and maintenance tasks before riding for safety and operability.

9.2 Starting the Engine

Provides instructions for starting the engine, including safety warnings and cold start procedures.

9.3 Starting Off

Guides on how to start moving from a stop, including clutch and throttle control.

9.4 Shifting Gears and Riding

Explains gear shifting techniques, engine braking, and general riding advice.

9.5 Braking Techniques

Covers braking principles, warnings about wheel lock-up, and adapting to conditions.

9.6 Stopping and Parking

Details procedures for stopping the motorcycle and parking it safely, including security and cooling.

9.7 Transporting the Motorcycle

Provides guidance on how to safely transport the motorcycle, including securing it.

9.8 Refueling Procedures

Explains the refueling process, fuel types, safety precautions, and tank capacity.

10 Service Schedule

10.1 Routine Service Schedule

Outlines periodic checks and maintenance tasks based on operating hours or race events.

10.2 Additional Service Work

Lists service tasks that can be performed as additional orders, categorized by intervals.

11 Chassis Tuning

11.1 Basic Chassis Setting

Explains how to check and adjust the chassis setting based on rider weight for optimal characteristics.

11.2 Shock Absorber Compression Damping

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

11.3 Adjusting Low-Speed Compression Damping

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

11.4 Adjusting High-Speed Compression Damping

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

11.5 Adjusting Rebound Damping

Explains the procedure for adjusting the rebound damping of the shock absorber.

11.6 Measuring Unloaded Rear Wheel Sag

Describes the process for measuring the sag of the rear wheel when the motorcycle is unloaded.

11.7 Checking Static Sag of Shock Absorber

Details how to check the static sag of the shock absorber and specifies the target values.

11.8 Checking Riding Sag of Shock Absorber

Explains how to measure the riding sag with the rider on the motorcycle.

11.9 Adjusting Shock Absorber Spring Preload

Provides instructions for adjusting the shock absorber spring preload to influence sag.

11.10 Adjusting Riding Sag

Guides on adjusting the riding sag, potentially involving spring replacement, to achieve desired suspension balance.

11.11 Checking Basic Fork Setting

Notes that exact riding sag is not determinable for forks, but basic settings are important.

11.12 Adjusting Fork Compression Damping

Details how to adjust the compression damping for EXC, XC-W, and SIX DAYS fork models.

11.13 Adjusting Fork Rebound Damping

Explains how to adjust fork rebound damping for EXC, XC-W, and SIX DAYS models.

11.14 Adjusting Fork Spring Preload

Guides on adjusting fork spring preload for EXC and XC-W models to influence suspension feel.

11.15 Handlebar Position Options

Describes handlebar mounting options to achieve the most comfortable rider position.

11.16 Adjusting Handlebar Position

Details the steps for adjusting the handlebar position by changing the handlebar mounts.

12 Chassis Service Work

12.1 Raising Motorcycle on Lift Stand

Explains how to safely raise the motorcycle using a lift stand for maintenance.

12.2 Removing Motorcycle from Lift Stand

Details the steps for safely removing the motorcycle from the lift stand.

12.3 Bleeding Fork Legs

Describes the preparatory work for bleeding the fork legs.

12.4 Cleaning Fork Leg Dust Boots

Guides on cleaning fork leg dust boots to prevent seal leakage and maintain fork performance.

12.5 Loosening Fork Protection

Explains how to loosen and remove the fork protection components.

12.6 Positioning Fork Protection

Details how to position and secure the fork protection on the fork legs.

12.7 Removing Fork Legs

Provides step-by-step instructions for removing the fork legs from the motorcycle.

12.8 Installing Fork Legs

Guides on installing the fork legs, including groove alignment and bleeder screw orientation.

12.9 Removing Fork Protector

Explains the procedure for removing the fork protectors.

12.10 Installing Fork Protector

Details how to install the fork protectors onto the fork legs.

12.11 Removing Lower Triple Clamp (EXC, XC-W)

Guides on removing the lower triple clamp for EXC and XC-W models, including related components.

12.12 Removing Lower Triple Clamp (SIX DAYS)

Explains the procedure for removing the lower triple clamp for SIX DAYS models.

12.13 Installing Lower Triple Clamp (EXC, XC-W)

Guides on installing the lower triple clamp for EXC and XC-W models, including bearing greasing.

12.14 Installing Lower Triple Clamp (SIX DAYS)

Details installing the lower triple clamp for SIX DAYS models, including triple clamp and fork leg positioning.

12.15 Checking Steering Head Bearing Play

Explains how to check for play in the steering head bearing and the consequences of loose play.

12.16 Adjusting Steering Head Bearing Play

Provides steps for adjusting steering head bearing play and checking for detent positions.

12.17 Greasing the Steering Head Bearing

Details the procedure for greasing the steering head bearing for different models.

12.18 Removing the Front Fender

Explains how to remove the front fender.

12.19 Installing the Front Fender

Guides on installing the front fender, including mounting and tightening screws.

12.20 Removing the Shock Absorber

Details the procedure for removing the shock absorber for 125/200 and 250/300 models.

12.21 Installing the Shock Absorber

Guides on installing the shock absorber, including splash protector and screw tightening.

12.22 Removing the Seat

Explains how to remove the motorcycle seat by unscrewing and pulling it back.

12.23 Mounting the Seat

Details the process for mounting the seat, ensuring it locks correctly.

12.24 Removing Air Filter Box Lid

Explains how to remove the air filter box lid by pulling it sideways.

12.25 Installing Air Filter Box Lid

Guides on inserting and clipping the air filter box lid back into place.

12.26 Removing the Air Filter

Details how to remove the air filter and its support, with warnings about unfiltered air.

12.27 Installing the Air Filter

Guides on mounting a clean air filter onto the support and greasing it.

12.28 Cleaning Air Filter and Box

Explains how to wash and oil the air filter, and clean the air filter box and intake flange.

12.29 Sealing the Air Filter Box

Describes how to seal the air filter box in the marked area.

12.30 Removing the Main Silencer

Details how to remove the main silencer from the manifold, with warnings about hot components.

12.31 Installing the Main Silencer

Guides on mounting and tightening the main silencer with its rubber sleeve.

12.32 Changing Main Silencer Filling

Explains how to change the glass fiber yarn filling of the main silencer, noting performance impact.

12.33 Removing the Fuel Tank

Provides step-by-step instructions for removing the fuel tank, including fuel tap and hose disconnection.

12.34 Installing the Fuel Tank

Guides on installing the fuel tank, including spoilers, vent hose, and throttle cable routing.

12.35 Checking Chain for Dirt

Explains how to check the chain for heavy soiling and the need for cleaning.

12.36 Cleaning the Chain

Details how to clean and maintain the chain, emphasizing its importance for service life.

12.37 Checking Chain Tension

Explains how to check chain tension and the dangers of incorrect tension.

12.38 Adjusting Chain Tension

Provides detailed steps for adjusting chain tension, including wheel alignment and tightening nuts.

12.39 Checking Chain, Sprockets, and Guide

Guides on checking wear of chain, sprockets, and chain guide, and when to replace the drivetrain kit.

12.40 Checking the Frame

Explains how to check the frame for cracking or deformation and the importance of replacement if damaged.

12.41 Checking the Swingarm

Details how to check the swingarm for damage, cracking, or deformation and stresses replacement if needed.

12.42 Checking Throttle Cable Routing

Explains the correct routing of the throttle cable for proper operation.

12.43 Checking the Rubber Grip

Guides on checking rubber grips for damage, wear, or looseness and replacement.

12.44 Securing the Rubber Grip

Explains how to additionally secure the rubber grip using securing wire.

12.45 Adjusting Clutch Lever Position

Details how to adjust the clutch lever position for rider comfort and hand size.

12.46 Checking/Correcting Hydraulic Clutch Fluid Level

Explains how to check and correct the hydraulic clutch fluid level, noting it rises with clutch wear.

12.47 Changing Hydraulic Clutch Fluid

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

12.48 Removing Engine Guard (SIX DAYS)

Details how to remove the engine guard for SIX DAYS models using a quick release mechanism.

12.49 Installing Engine Guard (SIX DAYS)

Guides on installing the engine guard for SIX DAYS models by attaching and turning a quick release.

13 Brake System

13.1 Checking Hand Brake Lever Free Travel

Explains how to check free travel of the hand brake lever and the risks of no free travel.

13.2 Adjusting Hand Brake Lever Free Travel (EXC)

Guides on adjusting free travel using the adjustment screw for EXC models.

13.3 Adjusting Hand Brake Lever Position (XC-W)

Details adjusting the hand brake lever position for XC-W models for rider comfort.

13.4 Checking Brake Discs

Explains how to check brake disc thickness, damage, cracking, and deformation.

13.5 Checking Front Brake Fluid Level

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

13.6 Adding Front Brake Fluid

Details how to add front brake fluid, including safety warnings about skin irritation.

13.7 Checking Front Brake Linings

Explains how to check front brake linings for minimum thickness and damage.

13.8 Changing Front Brake Linings

Details the procedure for changing front brake linings, including safety and fluid handling.

13.9 Checking Foot Brake Lever Free Travel

Explains how to check free travel of the foot brake lever and the consequences of no free travel.

13.10 Adjusting Foot Brake Lever Position

Guides on adjusting the foot brake lever's basic position for rider comfort.

13.11 Checking Rear Brake Fluid Level

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

13.12 Adding Rear Brake Fluid

Details how to add rear brake fluid, including safety warnings.

13.13 Checking Rear Brake Linings

Explains how to check rear brake linings for minimum thickness and damage.

13.14 Changing Rear Brake Linings

Details the procedure for changing rear brake linings, including safety and fluid handling.

14 Wheels and Tires

14.1 Removing the Front Wheel

Guides on removing the front wheel, including brake caliper and wheel spindle procedures.

14.2 Installing the Front Wheel

Details the process for installing the front wheel, including bearing checks and spacer insertion.

14.3 Removing the Rear Wheel

Explains how to remove the rear wheel, including chain adjuster and wheel spindle.

14.4 Installing the Rear Wheel

Guides on installing the rear wheel, including bearing checks, chain application, and tensioning.

14.5 Checking Tire Condition

Checks tires for cuts, damage, tread depth, and age, recommending KTM-approved tires.

14.6 Checking Tire Air Pressure

Details checking tire air pressure for off-road and road use, emphasizing correct pressure for wear and comfort.

14.7 Checking Spoke Tension

Explains how to check spoke tension regularly and the risks of incorrect tension.

15 Electrical System

15.1 Removing the Battery

Guides on safely removing the battery, including disconnecting cables and handling acid warnings.

15.2 Installing the Battery

Details the process for installing a new battery, including terminal connections and rubber band attachment.

15.3 Recharging the Battery

Explains battery charging procedures, importance of charge state, and environmental disposal.

15.4 Changing the Main Fuse

Guides on locating and changing the main fuse, including fuse identification and spare fuse location.

15.5 Removing Headlight Mask and Headlight

Details how to remove the headlight mask and disconnect the electrical plug.

15.6 Refitting Headlight Mask and Headlight

Guides on refitting the headlight mask, connecting the plug, and ensuring lugs engage.

15.7 Changing Headlight Bulb

Explains how to change the headlight bulb, with a note on reflector care.

15.8 Changing Turn Signal Bulb

Details how to change the turn signal bulb for EXC models, including bulb removal and installation.

15.9 Checking Headlight Setting

Explains how to check headlight aim against marks and the procedure if it doesn't meet specs.

15.10 Adjusting Headlight Range

Guides on adjusting the headlight range by swiveling the headlight, considering luggage.

15.11 Changing Speedometer Battery

Details how to change the speedometer battery for EXC/XC-W and SIX DAYS models.

16 Cooling System

16.1 Cooling System Overview

Explains the function of the water pump and radiator cap in regulating coolant circulation and temperature.

16.2 Checking Antifreeze and Coolant Level

Guides on checking coolant antifreeze and level, with safety warnings about hot coolant and poisoning.

16.3 Checking Coolant Level

Details how to check the coolant level in the radiator and correct it if necessary.

16.4 Draining the Coolant

Explains how to drain the coolant from the engine, with safety warnings.

16.5 Refilling with Coolant

Guides on refilling the cooling system with coolant, ensuring proper bleeding and securing the radiator cap.

17 Engine Tuning

17.1 Checking Throttle Cable Play

Explains how to check and adjust the play in the throttle cable for smooth operation.

17.2 Adjusting Throttle Cable Play

Details the procedure for adjusting the throttle cable play using barrel and adjusting screws.

17.3 Carburetor Idle Setting

Discusses the importance of carburetor idle setting for starting, idling, and response.

17.4 Adjusting Carburetor Idle Speed

Guides on adjusting idle speed and mixture using air adjusting screws, with detailed settings for different models.

17.5 Emptying Carburetor Float Chamber

Explains how to empty the carburetor float chamber, typically for storage or if water is present.

17.6 Checking Basic Shift Lever Position

Explains how to check the shift lever position relative to the rider's boot.

17.7 Adjusting Basic Shift Lever Position

Guides on adjusting the shift lever position for comfort and proper operation.

17.8 Engine Characteristic - Auxiliary Spring (250/300 Models)

Describes the auxiliary spring's role in engine characteristic and its different marking options.

17.9 Engine Characteristic - Setting Auxiliary Spring

Details how to set the auxiliary spring for different engine characteristics on 250/300 models.

18 Engine Service Work

18.1 Checking Gear Oil Level

Explains how to check the gear oil level for 125/200 and 250/300 models, noting the small oil flow requirement.

18.2 Changing the Gear Oil

Outlines the process for draining and refilling the gear oil.

18.3 Draining the Gear Oil

Details how to drain the gear oil, with warnings about hot oil and environmental hazards.

18.4 Refilling with Gear Oil

Guides on refilling the engine with the correct type and amount of gear oil.

18.5 Adding Gear Oil

Explains how to add gear oil to the specified level, with safety warnings and post-addition checks.

19 Cleaning and Care

19.1 Cleaning the Motorcycle

Provides instructions for cleaning the motorcycle, including pressure washer use, cleaner types, and drying procedures.

19.2 Winter Operation Checks and Maintenance

Details maintenance steps for winter operation, focusing on cleaning after salt exposure and corrosion protection.

20 Motorcycle Storage

20.1 Storage Procedures

Outlines steps for storing the motorcycle for extended periods, including cleaning, fluid checks, and battery care.

20.2 Preparing for Use After Storage

Guides on recommissioning the motorcycle after storage, including battery, checks, and test ride.

21 Troubleshooting Guide

Troubleshooting Guide

Lists common faults, possible causes, and recommended actions for troubleshooting engine and electrical issues.

Troubleshooting Guide (Continued)

Continues the troubleshooting guide, covering engine overheating and smoke emissions.

22 Technical Specifications

22.1 Engine Specifications

Lists detailed engine specifications for 125 models, including bore, stroke, transmission, and ignition.

22.1.1 125 Model Engine Specs

Detailed technical data for the 125cc engine, covering design, displacement, bore, stroke, etc.

22.1.2 200 Model Engine Specs

Detailed technical data for the 200cc engine, including bore, stroke, transmission, and ignition.

22.1.3 250 Model Engine Specs

Detailed technical data for the 250cc engine, including bore, stroke, exhaust valve settings, etc.

22.1.4 300 Model Engine Specs

Detailed technical data for the 300cc engine, including bore, stroke, exhaust valve settings, etc.

22.2 Engine Tightening Torques

Lists tightening torques for engine screws and bolts for 125/200 models.

22.2.1 125/200 Model Torque Specs

Torque specifications for various engine screws and bolts for 125/200 models.

22.2.2 250/300 Model Torque Specs

Torque specifications for various engine screws and bolts for 250/300 models.

22.3 Capacities

Lists capacities for gear oil, coolant, and fuel.

22.3.1 Gear Oil Capacities

Specifies gear oil capacities for 125/200 and 250/300 models.

22.3.2 Coolant Capacity

States the coolant capacity for the motorcycle.

22.3.3 Fuel Capacity and Reserve

Provides fuel tank capacity and reserve amounts for different models.

22.4 Chassis Specifications

Details chassis components like frame, fork, shock absorber, and brake system specifications.

22.4 Chassis Specifications (Continued)

Lists brake disc wear limits, tire pressures, secondary ratios, and wheelbase.

22.6 Tire Specifications

Lists front and rear tire sizes and types for different models.

22.7 Fork Specifications

Details fork part numbers, suspension type, damping, preload, and oil for 125/200 and 250/300 models.

22.7.1 125 EXC EU / 200 Model Fork Specs

Specific fork data for 125 EXC EU and all 200 models.

22.7.2 250/300 Model Fork Specs

Specific fork data for 250/300 EXC EU/AUS and XC-W USA models.

22.7 Fork Specifications (Continued)

Continues fork specifications, including spring rate, length, and oil type.

22.8 Shock Absorber Specifications

Details shock absorber part numbers, damping, preload, sag, and oil for 125/200 models.

22.8.1 125/200 Model Shock Absorber Specs

Specific shock absorber data for 125/200 models.

22.8 Shock Absorber Specifications (Continued)

Continues shock absorber specifications for 250/300 models, including damping, preload, and sag.

22.8.2 250/300 Model Shock Absorber Specs

Specific shock absorber data for 250/300 models.

22.9 Chassis Tightening Torques

Lists chassis tightening torques for various screws and nuts across different models.

22.10 Carburetor Specifications

Details carburetor types, identification numbers, and jetting settings for 125 and 200 models.

22.10.1 125 Model Carburetor Specs

Specific carburetor data for 125 models, including jetting and needle positions.

22.10.2 200 EXC EU Carburetor Specs

Specific carburetor data for 200 EXC EU models.

22.10.3 200 EXC AUS Carburetor Specs

Specific carburetor data for 200 EXC AUS models.

22.10.4 200 XC-W USA Carburetor Specs

Specific carburetor data for 200 XC-W USA models.

22.10 Carburetor Specifications (Continued)

Details carburetor specs for 250 EXC EU, SIX DAYS EU, EXC AUS, and XC-W USA models.

22.10.5 250 EXC EU / SIX DAYS EU Carburetor Specs

Specific carburetor data for 250 EXC EU and SIX DAYS EU models.

22.10.6 250/300 EXC AUS Carburetor Specs

Specific carburetor data for 250/300 EXC AUS models.

22.10.7 250 XC-W USA Carburetor Specs

Specific carburetor data for 250 XC-W USA models.

22.10 Carburetor Specifications (Continued)

Details carburetor specs for 300 EXC EU, SIX DAYS EU, XC-W USA models, and tuning for 125 models.

22.10.8 300 EXC EU / SIX DAYS EU Carburetor Specs

Specific carburetor data for 300 EXC EU and SIX DAYS EU models.

22.10.9 300 XC-W USA / SIX DAYS USA Carburetor Specs

Specific carburetor data for 300 XC-W USA and SIX DAYS USA models.

22.10.10 Carburetor Tuning (125 Models)

Provides carburetor tuning guidelines for 125 models, including road use warnings.

22.10 Carburetor Tuning (200 Models)

Provides carburetor tuning charts for 200 models based on altitude and temperature.

22.10 Carburetor Tuning (250 Models)

Provides carburetor tuning charts for 250 models based on altitude and temperature.

22.10 Carburetor Tuning (300 Models)

Provides carburetor tuning charts for 300 models based on altitude and temperature.

22.10.14 General Carburetor Tuning

Explains general carburetor tuning principles and shows needle positions.

23 Recommended Substances

2-Stroke Engine Oil Recommendations

Specifies recommended 2-stroke engine oil types and brands, adhering to JASO FC standards.

Brake Fluid DOT 4 / DOT 5.1

Details recommended brake fluid types, standards, and brands like Castrol and Motorex®.

Coolant Specifications

Covers coolant requirements, mixture ratios for antifreeze protection, and ready-to-use coolant types.

Engine Oil (15W/50) Specifications

Specifies recommended engine oil grades (15W/50) and standards like JASO T903 MA.

Fork Oil (SAE 4) Specifications

Lists the recommended SAE grade and part number for fork oil.

Hydraulic Fluid (15) Specifications

Specifies recommended hydraulic fluid types and brands like Motorex® Hydraulic Fluid 75.

Shock Absorber Oil (SAE 2.5) Specifications

Lists recommended shock absorber oil grades and part numbers.

Super Unleaded Gasoline Specifications

Details specifications for super unleaded gasoline, including ethanol content and methanol warnings.

Super Unleaded Gasoline with 2-Stroke Oil

Specifies the mixture ratio and recommended oils for super unleaded gasoline.

24 Auxiliary Substances

Air Filter Cleaner Recommendations

Lists recommended air filter cleaner products like Motorex® Twin Air Dirt Bio Remover.

Chain Cleaner Recommendations

Specifies recommended chain cleaner products like Motorex® Chain Clean.

Cleaning and Preserving Materials

Lists recommended materials for cleaning and preserving metal, rubber, and plastic parts.

Fuel Additive Recommendations

Specifies recommended fuel additive products like Motorex® Fuel Stabilizer.

High Viscosity Grease Recommendations

Lists recommended high viscosity grease products like SKF® LGHB 2.

Long-Life Grease Recommendations

Specifies recommended long-life grease products like Motorex® Bike Grease 2000.

Motorcycle Cleaner Recommendations

Lists recommended motorcycle cleaner products like Motorex® Moto Clean 900.

Off-Road Chain Spray Recommendations

Specifies recommended off-road chain spray products like Motorex® Chainlube Offroad.

Foam Air Filter Oil Recommendations

Lists recommended foam air filter oil products like Motorex® Twin Air Liquid Bio Power.

Rubber Grip Adhesive

Specifies the recommended rubber grip adhesive product from KTM.

Universal Oil Spray Recommendations

Lists recommended universal oil spray products like Motorex® Joker 440 Synthetic.

25 Industry Standards

JASO FC Standard Explained

Explains the JASO FC classification for 2-stroke engine oils used in racing.

JASO T903 MA Standard Explained

Details the JASO T903 MA standard for 4-stroke motorcycle oils, considering gearbox and clutch lubrication.

SAE Viscosity Classes

Explains the SAE viscosity classification system for oils based on viscosity.

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