KTM Exf 250f 2021manual
KTM Exf 250f 2021manual
KTM Exf 250f 2021manual
250 EXC‑F
250 EXC‑F Six Days
Art. no. 3214222en
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art,
DEAR KTM CUSTOMER
sporty motorcycle that you will continue to enjoy for a long time if you maintain it properly.
The Owner's Manual contained the latest information for this model series at the time of going to print. Slight
deviations resulting from continuing development and design of the motorcycles can, however, not be completely
excluded.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
*3214222en*
3214222en
06/2020
TABLE OF CONTENTS
2
TABLE OF CONTENTS
8.7 Preparing the vehicle for riding on 11.16 Adjusting the handlebar position .... 58
wet and muddy circuits .................... 39
12 SERVICE WORK ON THE CHASSIS............... 61
8.8 Preparing vehicle for high
temperatures or slow riding ............... 39 12.1 Raising the motorcycle with the lift
8.9 Preparing the vehicle for low stand .............................................. 61
temperatures or snow ....................... 39 12.2 Removing the motorcycle from the
lift stand ......................................... 61
9 RIDING INSTRUCTIONS.............................. 40
12.3 Bleeding the fork legs....................... 61
9.1 Checks and maintenance measures 12.4 Cleaning the dust boots of the fork
when preparing for use ..................... 40 legs ................................................ 62
9.2 Starting the vehicle .......................... 40 12.5 Removing the fork protector .............. 62
9.3 Activating traction control 12.6 Installing the fork protector............... 63
(EXC‑F Six Days).............................. 41 12.7 Removing the fork legs .................. 63
9.4 Starting off...................................... 42 12.8 Installing the fork legs .................. 64
9.5 Shifting, riding ................................ 42 12.9 Removing the lower triple clamp
9.6 Braking ........................................... 43 (EXC‑F EU/BR) ................................ 65
9.7 Stopping, parking............................. 43 12.10 Removing the lower triple clamp
9.8 Transporting .................................... 44 (EXC‑F Six Days).............................. 65
9.9 Refueling ........................................ 44 12.11 Installing the lower triple clamp
(EXC‑F EU/BR) ................................ 66
10 SERVICE SCHEDULE .................................. 46
12.12 Installing the lower triple clamp
10.1 Additional information ...................... 46 (EXC‑F Six Days).............................. 68
10.2 Required work ................................. 46 12.13 Checking the steering head bearing
10.3 Recommended work ......................... 47 play ................................................ 70
12.14 Adjusting the steering head bearing
11 TUNING THE CHASSIS ............................... 49 play (EXC‑F EU/BR) ...................... 70
11.1 Checking the basic chassis setting 12.15 Adjusting the steering head bearing
with rider's weight............................ 49 play (EXC‑F Six Days) ................... 71
11.2 Compression damping of the shock 12.16 Greasing the steering head
absorber.......................................... 49 bearing ........................................ 72
11.3 Adjusting the low-speed 12.17 Removing front fender ...................... 72
compression damping of the shock 12.18 Installing front fender....................... 73
absorber.......................................... 49 12.19 Removing the shock absorber ........ 74
11.4 Adjusting the high-speed 12.20 Installing the shock absorber ......... 74
compression damping of the shock 12.21 Removing the seat ........................... 74
absorber.......................................... 50 12.22 Mounting the seat ............................ 75
11.5 Adjusting the rebound damping of 12.23 Removing the air filter box cover ....... 75
the shock absorber ........................... 51 12.24 Installing the air filter box cover ........ 76
11.6 Measuring the dimension of the rear 12.25 Removing the air filter .................. 77
wheel unloaded................................ 51
12.26 Installing the air filter ................... 77
11.7 Checking the static sag of the shock
12.27 Cleaning the air filter and air filter
absorber.......................................... 52
box ............................................. 78
11.8 Checking the riding sag of the shock
12.28 Preparing air filter box cover for
absorber.......................................... 52
securing ...................................... 78
11.9 Adjusting the spring preload of the
12.29 Removing the main silencer .............. 79
shock absorber ............................. 53
12.30 Installing the main silencer............... 79
11.10 Adjusting the riding sag ................ 54
12.31 Changing the glass fiber yarn filling
11.11 Checking the basic setting of the
in the main silencer ...................... 79
fork ................................................ 54
12.32 Removing the fuel tank ................. 80
11.12 Adjusting the compression damping
of the fork ....................................... 55 12.33 Installing the fuel tank .................. 82
11.13 Adjusting the rebound damping of 12.34 Checking for chain dirt
the fork........................................... 56 accumulation................................... 83
11.14 Adjusting the spring preload of the 12.35 Cleaning the chain ........................... 84
fork (All EU models)......................... 57 12.36 Checking the chain tension ............... 84
11.15 Handlebar position........................... 58 12.37 Adjusting the chain tension............... 85
3
TABLE OF CONTENTS
12.38 Checking the chain, rear sprocket, 15.7 Installing the headlight mask with
engine sprocket, and chain guide ...... 86 the headlight ................................. 121
12.39 Checking the frame ...................... 89 15.8 Changing the headlight bulb ........... 121
12.40 Checking the link fork ................... 89 15.9 Checking the headlight setting ........ 122
12.41 Checking throttle cable routing.......... 89 15.10 Adjusting the headlight range.......... 122
12.42 Checking the rubber grip .................. 90 15.11 Changing the turn signal bulb ......... 123
12.43 Adjusting the basic position of the 15.12 Changing the combination
clutch lever ..................................... 90 instrument battery.......................... 124
12.44 Checking/correcting the fluid level of 15.13 Diagnostics connector .................... 124
the hydraulic clutch ......................... 91
16 COOLING SYSTEM .................................... 125
12.45 Changing the hydraulic clutch
fluid ............................................ 92 16.1 Cooling system .............................. 125
12.46 Removing the engine guard 16.2 Checking the antifreeze and
(EXC‑F Six Days).............................. 93 coolant level .................................. 125
12.47 Installing the engine guard 16.3 Checking the coolant level .............. 126
(EXC‑F Six Days).............................. 93 16.4 Draining the coolant ................... 126
13 BRAKE SYSTEM ......................................... 94 16.5 Refilling coolant ......................... 127
16.6 Changing the coolant...................... 128
13.1 Checking the free travel of the hand
brake lever ...................................... 94 17 TUNING THE ENGINE............................... 129
13.2 Adjusting the free travel of the
17.1 Checking the throttle cable play ...... 129
handbrake lever ............................... 94
17.2 Adjusting the throttle cable
13.3 Checking the brake discs .................. 94
play .......................................... 129
13.4 Checking the front brake fluid level ... 95
17.3 Adjusting the characteristic map of
13.5 Adding the front brake fluid ........... 96 the throttle response ................... 130
13.6 Checking the front brake linings ........ 97 17.4 Changing the mapping
13.7 Changing the brake linings of the (EXC‑F Six Days)............................ 131
front brake ................................... 97 17.5 Adjusting the idle speed .............. 132
13.8 Checking the free travel of foot 17.6 Programming the throttle valve
brake lever .................................... 100 position......................................... 133
13.9 Adjusting the basic position of the 17.7 Checking the basic position of the
foot brake lever .......................... 100 shift lever...................................... 133
13.10 Checking the rear brake fluid 17.8 Adjusting the basic position of the
level ............................................. 101 shift lever .................................. 134
13.11 Adding rear brake fluid ............... 102
13.12 Checking the rear brake linings ....... 103 18 SERVICE WORK ON THE ENGINE .............. 135
13.13 Changing the rear brake linings .... 103 18.1 Changing the fuel screen ............. 135
14 WHEELS, TIRES ....................................... 106 18.2 Checking the engine oil level........... 136
18.3 Changing the engine oil and oil
14.1 Removing the front wheel ............ 106 filter, cleaning the oil screen ....... 136
14.2 Installing the front wheel ............ 107 18.4 Adding engine oil ........................... 139
14.3 Removing the rear wheel ............. 107
19 CLEANING, CARE ..................................... 140
14.4 Installing the rear wheel .............. 108
14.5 Checking the tire condition ............. 110 19.1 Cleaning the motorcycle ................. 140
14.6 Checking tire pressure .................... 110 19.2 Checks and maintenance steps for
14.7 Checking spoke tension .................. 111 winter operation............................. 141
15.1 Removing the 12-V battery .......... 112 20.1 Storage ......................................... 142
15.2 Installing the 12-V battery ........... 114 20.2 Preparing for use after storage......... 143
15.3 Charging the 12-V battery ........... 115
21 TROUBLESHOOTING ................................ 144
15.4 Changing main fuse ....................... 118
15.5 Changing the fuses of individual 22 BLINK CODE ............................................ 146
power consumers ........................... 119
23 TECHNICAL DATA..................................... 148
15.6 Removing the headlight mask with
the headlight ................................. 120 23.1 Engine .......................................... 148
4
TABLE OF CONTENTS
5
1 MEANS OF REPRESENTATION
All work marked with this symbol requires specialist knowledge and technical understanding.
In the interest of your own safety, have these jobs performed by an authorized KTM workshop!
Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary
tools required.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
6
SAFETY ADVICE 2
Info
This vehicle is only authorized for operation on public roads in the homologated (restricted) version.
The derestricted version of this vehicle must only be operated in closed off areas away from public high-
way traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the
respective use.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
7
2 SAFETY ADVICE
1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace-
ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any
person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencers, baffles, manifolds or any other components which conduct
exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than
those specified by the manufacturer.
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a
safe and environmentally compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
8
SAFETY ADVICE 2
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.9 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the
future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental conscious-
ness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and
regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no
legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad
to advise you.
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website.
International KTM Website: http://www.ktm.com
9
3 IMPORTANT NOTES
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work
on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension
setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in signif-
icantly increased wear of components, such as the drive train, brake system, or suspension components. For this
reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly,
you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5 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 disassemble the component to perform the activity in question. Please follow the instructions
in the text.
10
VIEW OF VEHICLE 4
V01831-10
11
4 VIEW OF VEHICLE
V01832-10
12
SERIAL NUMBERS 5
401945-10
V01808-10
402247-10
H01047-10
13
5 SERIAL NUMBERS
401947-10
H02222-10
14
CONTROLS 6
A00345-10
E01205-10
E01206-10
S01302-10
15
6 CONTROLS
S01303-10
16
CONTROLS 6
V01749-11
Warning
Voiding of the government approval for road use and the
insurance coverage If the combination switch is mounted,
the vehicle’s road permit, if any, expires.
– Only operate the vehicle in closed-off areas remote
from public road traffic if the combination switch is
installed.
H02887-01
17
6 CONTROLS
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
– Press release button 1 , turn the fuel tank filler cap counter-
clockwise, and lift it off.
K01334-10
Info
Route fuel tank breather hose 2 without kinks.
K01334-11
18
CONTROLS 6
Info
Check whether the cold start button has returned to its
basic position.
Possible states
• The cold start button is activated – The cold start button is
pushed in all the way.
• The cold start button is deactivated – The cold start button is
in its basic position.
H02253-10
H02254-10
19
6 CONTROLS
401950-10
401950-11
401956-10
401943-10
20
CONTROLS 6
Info
When you are riding, side stand 1 must be folded up and
secured with rubber strap 2.
401944-10
S01311-10
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Info
Never leave the key for the steering lock in the steering
lock.
21
6 CONTROLS
Info
Never leave the key for the steering lock in the steering
lock.
400731-01
22
COMBINATION INSTRUMENT 7
Info
When the vehicle is delivered, only the SPEED/H and
SPEED/ODO display modes are activated.
V00799-01
400313-01
WS (wheel size)
After the display function check, the wheel circumference WS is
displayed briefly.
Info
The number 2205 equals the circumference of the 21"
front wheel with standard tires.
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
– Repeatedly press the button briefly until Km/h/Mph flashes.
Adjusting the Km/h
– Press the button .
400329-01 Adjusting the Mph
– Press the button .
23
7 COMBINATION INSTRUMENT
– Wait 3 - 5 seconds.
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.
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
Info
If no button is pressed for 10–12 seconds, the settings
are automatically saved.
400318-01
If no button is pressed for 20 seconds, or if an impulse
comes from the wheel speed sensor, the settings are
automatically saved and the setup menu is closed.
24
COMBINATION INSTRUMENT 7
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.
Info
This function can only be opened if lap times have actually been timed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until LAP appears at the
bottom right of the display.
– Briefly press the button .
LAP 1 appears on the left side of the display.
– The laps 1–10 can be viewed with the button .
– Press and hold the button for 3-5 seconds.
The lap times are deleted.
– Briefly press the button .
400321-01
Next display mode
Info
When an impulse is received from the wheel speed sen-
sor, the left side of the display changes back to the
SPEED mode.
25
7 COMBINATION INSTRUMENT
Info
Make the setting according to the country.
When an impulse comes from the front wheel, the left side
of the display changes to the SPEED mode and the current
400317-02
speed is shown.
Info
The service hour counter is necessary for ensuring that
400316-01
service work is carried out at the right intervals.
If the combination instrument is in H display mode when
starting off, it automatically changes to the ODO display
mode.
The H display mode is suppressed during the journey.
400344-01
26
COMBINATION INSTRUMENT 7
Info
Repeatedly press the button briefly until the desired
function is reached.
If no button is pressed for 20 seconds, the settings are
automatically saved.
27
7 COMBINATION INSTRUMENT
Press the but- The display changes to the Setup menu of the
ton for 2–3 clock.
seconds.
Briefly press Next display mode
the button .
400319-01
Press the but- No function
ton for 2–3
seconds.
Briefly press No function
the button .
Info
If the lap time continues running after the button is
pressed, 9 memory locations are occupied.
Lap 10 must be timed using the button .
400320-01
28
COMBINATION INSTRUMENT 7
Press the but- The stop watch and the lap time are reset.
ton for 2–3
seconds.
Briefly press Next display mode
the button .
Press the but- Stops the clock.
ton for 2–3
seconds.
Briefly press Starts the stop watch or stop the current lap
the button . time measurement, stores it and the stop watch
starts the next lap.
Press the but- The stop watch and the lap time are reset.
ton for 2–3
seconds.
400321-01
Briefly press Select a lap from 1–10
the button .
Press the but- No function
ton for 2–3
seconds.
Briefly press View the next lap time.
the button .
29
7 COMBINATION INSTRUMENT
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are
400323-01
automatically reset to 0.0.
30
COMBINATION INSTRUMENT 7
Info
The TR2 value can also be corrected manually during the
journey with the button and the button .
If 999.9 is exceeded, the value of TR2 is automatically
reset to 0.0.
Info
The displayed value can differ from the actual average
speed if S2 was not stopped after the ride.
400326-01
Briefly press Next display mode
the button .
31
7 COMBINATION INSTRUMENT
32
COMBINATION INSTRUMENT 7
33
7 COMBINATION INSTRUMENT
Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12
ton for 2–3 the button . ton for 2–3 the button . seconds. seconds.
seconds. seconds.
Setting TR2 Increases Increases Reduces Reduces Stores and
(trip master 2) value of TR2. value of TR2. value of TR2. value of TR2. closes the
Setup menu.
Display mode Displays of Next display No function No function
SPEED/A1 (aver- TR1, A1 and mode
age speed 1) S1 are reset
to 0.0.
Display mode No function Next display No function No function
SPEED/A2 (aver- mode
age speed 2)
Display mode Displays of Next display No function No function
SPEED/S1 (stop TR1, A1 and mode
watch 1) S1 are reset
to 0.0.
Display mode The displays Next display No function Starts or
SPEED/S2 (stop of S2 and mode stops S2.
watch 2) A2 are set to
0,0.
34
PREPARING FOR USE 8
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
teristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
You will receive a delivery certificate when the vehicle is handed over.
– Before riding for the first time, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust basic position of the clutch lever. ( p. 90)
– Adjust the free travel of the handbrake lever. ( p. 94)
35
8 PREPARING FOR USE
Info
When offroad, it is recommended that you are accompanied by another person on another vehicle so
that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry any luggage, make sure you fix it firmly as close as possible to the center of the vehicle and
ensure even weight distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the maximum permissible weight and maximum permissible axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Check the spoke tension. ( p. 111)
Info
The spoke tension must be checked after half an hour of operation.
36
PREPARING FOR USE 8
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in
significantly increased wear of components, such as the drive train, brake system, or suspension compo-
nents. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
Info
Check the air filter approx. every 30 minutes.
– Check the connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult operating conditions are:
– Rides on dry sand. ( p. 37)
– Rides on wet sand. ( p. 38)
– Rides on wet and muddy circuits. ( p. 39)
– Rides at high temperatures or slow riding. ( p. 39)
– Riding at low temperatures and in snow. ( p. 39)
Info
Observe the fitting instructions for KTM PowerParts.
102136-01
37
8 PREPARING FOR USE
Info
Observe the fitting instructions for KTM PowerParts.
102138-01
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
38
PREPARING FOR USE 8
8.7 Preparing the vehicle for riding on wet and muddy circuits
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
600868-01
Info
The engine oil heats up quickly when the clutch is
operated frequently due to an excessively high sec-
ondary ratio.
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
39
9 RIDING INSTRUCTIONS
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
Info
The spoke tension must be checked regularly as incor-
rect spoke tension will strongly impair riding safety.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
40
RIDING INSTRUCTIONS 9
– Take the motorcycle off side stand 1 and secure the side
stand with rubber strap 2 .
– Shift the transmission into neutral.
– Turn the emergency OFF switch to the position .
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Push the cold start button in all the way.
401944-10
(All EU models)
– Press the start button.
Info
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at
starting.
At temperatures below 15 °C (60 °F), several
attempts at starting may be necessary to warm-up
400733-01 the lithium-ion battery and thereby increase the
starting power.
During the starting process, the malfunction indica-
tor lamp lights up.
(EXC‑F BR)
– Press the start button.
Info
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at
starting.
During the starting process, the malfunction indica-
tor lamp lights up.
Warning
Voiding of the government approval for road use and the insurance coverage If the combination switch is
mounted, the vehicle’s road permit, if any, expires.
– Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch
is installed.
Info
The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, par-
ticularly in wet conditions.
When traction control is switched off, the rear wheel may spin more during high acceleration and on sur-
faces with low grip.
Traction control can be switched on or off during the ride.
The setting most recently selected is activated again when restarting.
41
9 RIDING INSTRUCTIONS
H02885-01
Info
When you are riding, the side stand must be folded up and secured with the rubber strap.
– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throt-
tle carefully.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine
races.
– Do not change into a low gear at high engine speed.
Info
If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized
KTM workshop.
First-gear is used for starting off and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle
while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the
throttle.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This
will barely reduce the speed, but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel con-
sumption.
– To shift down, apply the brakes and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or
shift again.
– Switch off the engine if running at idle speed or stationary for a long time.
Guideline
≥ 2 min
– Avoid frequent and lengthy slipping of the clutch. This causes the engine oil, engine and cooling system to
heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
42
RIDING INSTRUCTIONS 9
9.6 Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
43
9 RIDING INSTRUCTIONS
9.8 Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
401475-01
9.9 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
– Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to
help.)
44
RIDING INSTRUCTIONS 9
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
45
10 SERVICE SCHEDULE
46
SERVICE SCHEDULE 10
47
10 SERVICE SCHEDULE
every 12 months
Every 135 operating hours
Every 70 operating hours when used for motorsports
After 20 operating hours
After 10 operating hours
every 48 months
every 12 months
Perform engine service including removing and installing the engine. (Change ● ●
the spark plug and spark plug connector. Change the piston. Check/measure
the cylinder. Check the cylinder head. Change the valves, valve springs, and
valve spring seats. Check the camshaft and cam lever. Change the connect-
ing rod, conrod bearing and crank pin. Change the radial shaft seal rings of
the water pump. Check the transmission and the shift mechanism. Check the
oil pressure control valve. Change the suction pump. Check the force pump
and lubrication system. Check the timing assembly. Change the timing chain.
Change all engine bearings. Change the freewheel.)
○ One-time interval
● Periodic interval
48
TUNING THE CHASSIS 11
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
401030-01
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
49
11 TUNING THE CHASSIS
Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
V01809-10
Low-speed compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping during compression.
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of turns corresponding
to the shock absorber type.
Guideline
V01810-10
High-speed compression damping
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping during compression.
50
TUNING THE CHASSIS 11
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
Turn clockwise to increase the damping; turn counter-
clockwise to reduce damping when the shock absorber
rebounds.
402415-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
51
11 TUNING THE CHASSIS
402416-10
52
TUNING THE CHASSIS 11
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring
length.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
– Remove the shock absorber. ( p. 74)
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under ten-
sion.
Hook wrench (90129051000)
Info
If the spring cannot be fully released, the spring must
be removed to accurately measure the spring length.
– Measure the total spring length while the spring is not under
tension.
– Tension the spring by turning adjusting ring 2 to specified
dimension A .
Guideline
Spring preload 10 mm (0.39 in)
Info
402659-10
Depending on the static sag and/or the riding sag, it
may be necessary to increase or decrease the spring
preload.
– Tighten screw 1.
Guideline
Screw, shock M5 5 Nm (3.7 lbf ft)
absorber adjusting
ring
Finishing work
– Install the shock absorber. ( p. 74)
– Remove the motorcycle from the lift stand. ( p. 61)
53
11 TUNING THE CHASSIS
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by
changing the spring preload.
Finishing work
– Install the shock absorber. ( p. 74)
– Remove the motorcycle from the lift stand. ( p. 61)
– Check the static sag of the shock absorber. ( p. 52)
– Check the riding sag of the shock absorber. ( p. 52)
– Adjust the rebound damping of the shock absorber. ( p. 51)
Info
For various reasons, no exact riding sag can be determined for the fork.
401000-01
54
TUNING THE CHASSIS 11
Info
The hydraulic compression damping determines the fork suspension behavior.
(EXC‑F BR)
– Turn white adjusting screw 1 clockwise as far as it will
go.
Info
Adjusting screw 1 is located at the upper end of
the left fork leg.
The compression damping is located in left fork
leg COMP (white adjusting screw). The rebound
S03470-10
damping is located in right fork leg REB (red adjust-
ing screw).
Info
Turn clockwise to increase damping; turn counter-
clockwise to reduce damping during compression.
(All EU models)
– Turn white adjusting screw 1 clockwise as far as it will
go.
Info
Adjusting screw 1 is located at the upper end of
the left fork leg.
The compression damping is located in left fork
leg COM (white adjusting screw). The rebound
S03471-10
damping is located in right fork leg REB (red
adjusting screw).
Info
Turn clockwise to increase damping; turn counter-
clockwise to reduce damping during compression.
55
11 TUNING THE CHASSIS
Info
The hydraulic rebound damping determines the fork suspension behavior.
(EXC‑F BR)
– Turn red adjusting screw 1 clockwise as far as it will go.
Info
Adjusting screw 1 is located at the upper end of
the right fork leg.
The rebound damping is located in right fork
leg REB (red adjusting screw). The compression
damping is located in left fork leg COMP (white
V01754-10
adjusting screw).
Info
Turn clockwise to increase the damping; turn coun-
terclockwise to reduce damping when the shock
absorber rebounds.
(All EU models)
– Turn red adjusting screw 1 clockwise as far as it will go.
Info
Adjusting screw 1 is located at the upper end of
the right fork leg.
The rebound damping is located in right fork
leg REB (red adjusting screw). The compression
damping is located in left fork leg COM (white
V01753-10
adjusting screw).
Info
Turn clockwise to increase the damping; turn coun-
terclockwise to reduce damping when the shock
absorber rebounds.
56
TUNING THE CHASSIS 11
Info
Make the adjustment by hand only. Do not use a tool.
Make the same adjustment on both fork legs.
Info
Adjust the spring preload to the numerical values only
as the preload will not engage between the numerical
values.
Turn clockwise to increase the spring preload; turn
counterclockwise to reduce the spring preload.
Adjusting the spring preload has no influence on the
absorption setting of the rebound.
Basically, however, you should set the rebound damp-
ing higher with a higher spring preload.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
57
11 TUNING THE CHASSIS
M00993-10
M00987-10
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
– Change the handlebar if the handlebar is damaged or bent.
58
TUNING THE CHASSIS 11
(EXC‑F EU/BR)
– Remove screws 1 . Take off the handlebar clamps.
Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against dam-
age.
Do not kink the cables and lines.
Info
Position the left and right handlebar supports
evenly.
M00993-11
Info
Make sure the cables and wiring are positioned cor-
rectly.
Info
Make sure the gap widths are even.
59
11 TUNING THE CHASSIS
Info
Cover the components to protect them against dam-
age.
Do not kink the cables and lines.
Info
Position the left and right handlebar supports
evenly.
M00987-11
Info
Make sure the cables and wiring are positioned cor-
rectly.
Info
Make sure the gap widths are even.
60
SERVICE WORK ON THE CHASSIS 12
Note
Danger of damage The parked vehicle can roll away or fall
over.
– Park the vehicle on a firm and level surface.
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Info
When you are riding, the side stand must be folded up
and secured with rubber strap.
401943-10
402556-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
61
12 SERVICE WORK ON THE CHASSIS
K00070-10
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when nec-
essary.
– Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray ( p. 160)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 63)
– Remove the motorcycle from the lift stand. ( p. 61)
V00332-10
62
SERVICE WORK ON THE CHASSIS 12
K00545-10
(EXC‑F EU/BR)
– Loosen screws 3. Remove the left fork leg.
– Loosen screws 4. Remove the right fork leg.
V01756-10
V01784-10
63
12 SERVICE WORK ON THE CHASSIS
(EXC‑F EU/BR)
– Tighten screws 2.
Guideline
Screw, top triple M8 20 Nm
clamp (14.8 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom M8 15 Nm
V01756-11
triple clamp (11.1 lbf ft)
K00546-10
Finishing work
– Install the front wheel. ( p. 107)
– Install the headlight mask with the headlight. ( p. 121)
– Check the headlight setting. ( p. 122)
64
SERVICE WORK ON THE CHASSIS 12
V01785-10 Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
V01757-10
V01787-10
65
12 SERVICE WORK ON THE CHASSIS
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
V01788-10
B01605-10
V01785-11
66
SERVICE WORK ON THE CHASSIS 12
– Tighten screws 6.
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp
V01790-10
– Tighten screw 4.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head
– Tighten screw 7.
Guideline
Screw, top steering M8 20 Nm (14.8 lbf ft)
E01701-10
stem
– Tighten screws 8.
Guideline
Screw, top triple M8 20 Nm (14.8 lbf ft)
clamp
V01790-11
V01792-10
Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 73)
67
12 SERVICE WORK ON THE CHASSIS
B01604-10
V01787-12
68
SERVICE WORK ON THE CHASSIS 12
– Tighten screws 6.
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp
V01793-10
– Tighten screw 4.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head
– Mount and tighten screw 7.
Guideline
Screw, top M8 17 Nm (12.5 lbf ft)
steering stem Loctite®243™
V01794-10
– Tighten screws 8.
Guideline
Screw, top triple M8 17 Nm (12.5 lbf ft)
clamp
V01793-11
V01792-10
Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 73)
– Install the front wheel. ( p. 107)
– Install the headlight mask with the headlight. ( p. 121)
– Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
– Check the steering head bearing play. ( p. 70)
– Remove the motorcycle from the lift stand. ( p. 61)
– Check the headlight setting. ( p. 122)
69
12 SERVICE WORK ON THE CHASSIS
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad
to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
(EXC‑F EU/BR)
– Adjust the steering head bearing play. ( p. 70)
(EXC‑F Six Days)
H01167-01 – Adjust the steering head bearing play. ( p. 71)
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the
entire steering range. There should be no detectable detent
positions.
» If detent positions are detected:
(EXC‑F EU/BR)
– Adjust the steering head bearing play. ( p. 70)
(EXC‑F Six Days)
– Adjust the steering head bearing play. ( p. 71)
– Check the steering head bearing and replace if neces-
sary.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
70
SERVICE WORK ON THE CHASSIS 12
Main work
– Loosen screws 1 and 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head
– Using a plastic hammer, tap lightly on the upper triple clamp
to avoid stresses.
E01702-10
– Tighten screws 1.
Guideline
Screw, top triple M8 20 Nm (14.8 lbf ft)
clamp
– Tighten screw 2.
Guideline
Screw, top steering M8 20 Nm (14.8 lbf ft)
stem
Finishing work
– Check the steering head bearing play. ( p. 70)
– Remove the motorcycle from the lift stand. ( p. 61)
12.15 Adjusting the steering head bearing play (EXC‑F Six Days)
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
Main work
– Loosen screws 1.
– Remove screw 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head
V01795-10
– Using a plastic hammer, tap lightly on the upper triple clamp
to avoid stresses.
– Tighten screws 1.
Guideline
Screw, top triple M8 17 Nm (12.5 lbf ft)
clamp
– Mount and tighten screw 2.
Guideline
Screw, top M8 17 Nm (12.5 lbf ft)
steering stem Loctite®243™
Finishing work
– Check the steering head bearing play. ( p. 70)
– Remove the motorcycle from the lift stand. ( p. 61)
71
12 SERVICE WORK ON THE CHASSIS
H02387-01
V00340-10
V00341-10
K00576-10
72
SERVICE WORK ON THE CHASSIS 12
S01321-10
V00340-10
V00341-10
K00576-10
S01321-10
Finishing work
– Install the headlight mask with the headlight. ( p. 121)
73
12 SERVICE WORK ON THE CHASSIS
V01811-10
Info
The heim joint for the shock absorber on the link fork
is Teflon coated. It must not be lubricated with grease,
nor with any other lubricants. Lubricants dissolve the
Teflon coating, thereby drastically reducing the service
life.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
S03480-10
74
SERVICE WORK ON THE CHASSIS 12
– Raise the rear of the seat, pull the seat back, and lift it off.
H02218-10
H02218-11
S03480-10
V01815-10
75
12 SERVICE WORK ON THE CHASSIS
– Pull off the air filter box cover in area A laterally and take
it off at the front.
V01815-11
Condition
The air filter box cover is not secured.
– Pull off the air filter box cover in area A laterally and take
it off at the front.
V01816-10
V01815-12
V01815-10
Condition
The air filter box cover is not secured.
– Insert the air filter box cover in area A and clip it into
area B .
V01816-11
76
SERVICE WORK ON THE CHASSIS 12
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
– Remove the air filter box cover. ( p. 75)
Main work
– Detach retaining tab 1. Remove air filter with air filter sup-
port.
– Remove air filter from air filter support.
V01812-10
H02459-01
Finishing work
– Install the air filter box cover. ( p. 76)
77
12 SERVICE WORK ON THE CHASSIS
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
– Remove the air filter box cover. ( p. 75)
– Remove the air filter. ( p. 77)
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner ( p. 159)
Info
Only press the air filter to dry it, never wring it out.
102191-01
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 159)
– Clean the air filter box.
– Check the intake flange for damage and looseness.
Finishing work
– Install the air filter. ( p. 77)
– Install the air filter box cover. ( p. 76)
S03499-10
Finishing work
– Install the air filter box cover. ( p. 76)
78
SERVICE WORK ON THE CHASSIS 12
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
(All EU models)
– Detach spring 1.
Spring hook (50305017000C1)
– Remove screws 2 and take off the main silencer with the
catalytic converter.
(EXC‑F BR)
– Detach spring 1.
V01814-10 Spring hook (50305017000C1)
– Remove screws 2 and take off the main silencer.
S02101-10
12.31 Changing the glass fiber yarn filling in 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 before performing any work on the vehicle.
79
12 SERVICE WORK ON THE CHASSIS
Info
Over time, the fibers of the glass fiber yarn escape and the damper “burns” out.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
– Remove main silencer. ( p. 79)
Main work
– Remove screws 1.
– Take off silencer cap 2 with O-ring 3.
– Remove the old glass fiber yarn filling.
– Clean the parts that need to be reinstalled and check for dam-
age.
– Fit new glass fiber yarn filling 4 into the main silencer.
– Mount the O-ring on the silencer cap.
– Position the silencer cap.
– Mount and tighten all of the screws.
Guideline
Screws on main M5 7 Nm (5.2 lbf ft)
silencer
V01734-10
Finishing work
– Install the main silencer. ( p. 79)
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
80
SERVICE WORK ON THE CHASSIS 12
Preparatory work
– Remove the seat. ( p. 74)
Main work
– Unplug connector 1 of the fuel pump.
– Clean quick release coupling 2 thoroughly with compressed
air.
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
V01824-10
Info
Remaining fuel may flow out of the fuel line.
V01825-10
– Remove screws 4.
– Hang the horn and horn bracket to one side.
V01764-10
V01766-10
– Pull both spoilers laterally off the radiator and lift off the fuel
tank.
V01767-10
81
12 SERVICE WORK ON THE CHASSIS
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Main work
– Check throttle cable routing. ( p. 89)
– Position the fuel tank and fit the two spoilers to the sides in
front of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or dam-
aged.
V01767-11
V01766-11
82
SERVICE WORK ON THE CHASSIS 12
V01764-11
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
V01824-11
– Spray silicone spray onto a lint-free cleaning cloth and lightly
lubricate the O-ring of the quick-release coupling.
Silicone spray ( p. 160)
– Join quick release coupling 4.
Info
Route the cable and fuel line at a safe distance from
the exhaust system.
Finishing work
– Mount the seat. ( p. 75)
400678-01
83
12 SERVICE WORK ON THE CHASSIS
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 159)
– After drying, apply chain spray.
Off-road chain spray ( p. 159)
400725-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
84
SERVICE WORK ON THE CHASSIS 12
Main work
– Pull the chain at the end of the chain sliding piece upward to
measure chain tension .A
Info
Lower chain section 1 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 B .
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
V00354-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
– Check the chain tension. ( p. 84)
85
12 SERVICE WORK ON THE CHASSIS
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 left
and right.
Guideline
Chain tension 55 … 58 mm (2.17 …
2.28 in)
Turn adjusting screws 3 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 A . The rear
wheel is then correctly aligned.
– Tighten nuts 2.
– Make sure that chain adjusters 4 are fitted correctly on
adjusting screws . 3
– Tighten nut 1.
Guideline
E00330-10
Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft)
dle
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters 4can be turned by 180°.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
12.38 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 61)
Main work
– Shift the transmission into neutral.
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.
Info
The engine sprocket, rear sprocket, and chain
400227-01
should always be replaced together.
86
SERVICE WORK ON THE CHASSIS 12
Info
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
V01829-10
87
12 SERVICE WORK ON THE CHASSIS
V01830-10
Info
Wear can be seen on the front of the chain guide.
401760-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
88
SERVICE WORK ON THE CHASSIS 12
Info
Always replace a frame that has been dam-
aged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
S01316-10
Info
Always replace a damaged link fork. Repairing
the link fork is not authorized by KTM.
S01317-10
V01828-10
Finishing work
– Install the fuel tank. ( p. 82)
89
12 SERVICE WORK ON THE CHASSIS
Info
The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
401197-01
» If a rubber grip is damaged, worn, or loose:
– Change the rubber grip.
– Check that screw 1 is firmly seated.
Guideline
Screw, fixed M4 5 Nm (3.7 lbf ft)
grip Loctite®243™
K01340-10
90
SERVICE WORK ON THE CHASSIS 12
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
91
12 SERVICE WORK ON THE CHASSIS
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
V00456-10
V01817-10
92
SERVICE WORK ON THE CHASSIS 12
– Inject the liquid into the system until it escapes from open-
ings 6 of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir
to prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws
bleeder screw. Mount the protection cap.
– Correct the fluid level of the hydraulic clutch.
Guideline
E00339-10 Fluid level below container 4 mm (0.16 in)
rim
– Position cover with membrane. Mount and tighten screws.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
H01638-10
H01638-10
93
13 BRAKE SYSTEM
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
– Push the hand brake lever to the handlebar and check free
travel .A
Free travel of hand brake ≥ 3 mm (≥ 0.12 in)
lever
» If the free travel does not match the specification:
– Adjust the free travel of the handbrake lever. ( p. 94)
K01343-10
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will
be glad to help.)
94
BRAKE SYSTEM 13
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
V01775-10
95
13 BRAKE SYSTEM
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. ( p. 97)
96
BRAKE SYSTEM 13
Main work
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
– Remove screws 1.
– Take off cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Level A (brake fluid level 5 mm (0.2 in)
below reservoir rim)
Info
Immediately clean up any brake fluid that has over-
flowed or spilled with water.
V01770-10
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)
97
13 BRAKE SYSTEM
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
V01772-10
98
BRAKE SYSTEM 13
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
– Remove cotter pin 4, pull out pin 5, and remove the brake
linings.
– Clean the brake caliper and the brake caliper bracket.
E00344-10
100397-01
– Insert the new brake linings, insert the pin, and mount the cot-
ter pins.
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
E00345-10
99
13 BRAKE SYSTEM
Info
Immediately clean up any brake fluid that has over-
flowed or spilled with water.
V01770-10
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Disconnect spring 1.
– 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 A
.
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.
402026-10
( p. 100)
– Reconnect spring 1.
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
100
BRAKE SYSTEM 13
– 1.
Detach spring
– Loosen nut 4 and, with push rod 5, turn it back until you
have maximum free travel.
– To adjust the basic position of the foot brake lever to individ-
ual requirements, loosen nut 2
and turn screw 3
accord-
ingly.
Info
The range of adjustment is limited.
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
V01818-10
101
13 BRAKE SYSTEM
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
Preparatory work
– Check the rear brake linings. ( p. 103)
102
BRAKE SYSTEM 13
Main work
– Stand the vehicle upright.
– Remove screw cap 1 with membrane 2 and the O-ring.
– Add brake fluid to level A.
Brake fluid DOT 4 / DOT 5.1 ( p. 157)
– Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
K01347-10
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)
103
13 BRAKE SYSTEM
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
Info
Make sure that you do not press the brake caliper
V01774-10
against the spokes when pushing back the brake piston.
104
BRAKE SYSTEM 13
– Remove cotter pin 3, pull out pin 4, and remove the brake
linings.
– Clean the brake caliper and brake caliper bracket.
E00351-10
– Check that spring plate 5in the brake caliper and sliding
plate6 in the brake caliper bracket are seated properly.
E00352-10
– Insert the new brake linings, insert the pin, and mount the cot-
ter pins.
Info
Always change the brake linings in pairs.
– Operate the foot brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
E00353-01
K01347-10
105
14 WHEELS, TIRES
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
V00363-10
V00364-10
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.
– Hold front wheel and remove wheel spindle. Take front wheel
V00365-10 out of the fork.
Info
Do not actuate the hand brake lever when the front
wheel is removed.
– Remove spacers 3.
H00934-10
106
WHEELS, TIRES 14
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
107
14 WHEELS, TIRES
Main work
– Manually press the brake caliper toward the brake disc to push
back the brake piston.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake piston.
– Remove nut 1.
– Take off chain adjuster 2. Pull out wheel spindle 3 far
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
Cover the components to protect them against damage.
Warning
V00366-10 Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.
– Hold the rear wheel and remove the wheel spindle. Take the
rear wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel
is removed.
– Remove spacers 4.
H03002-10
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
108
WHEELS, TIRES 14
Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease shaft seal rings 1 and contact surfaces A
of the spacers.
Long-life grease ( p. 159)
H03001-10
– Insert the spacers.
V00367-10
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters 3can be turned by 180°.
– Operate the foot brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
V00368-10 point.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 61)
109
14 WHEELS, TIRES
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the
motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
– Check the front and rear tires for cuts, embedded objects, and
other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check tread depth.
Info
Adhere to the legally required minimum tread depth.
400602-10
Minimum tread depth ≥ 2 mm (≥ 0.08 in)
» If the tread depth is less than the minimum tread depth:
– Change the tires.
– Check tire age.
Info
The tire date of manufacture is usually contained in the
tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of
manufacture and the last two digits the year of manu-
facture.
KTM recommends that the tires be changed after 5
H01144-01 years at the latest, regardless of the actual state of
wear.
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
110
WHEELS, TIRES 14
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec-
ondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will
be glad to help.)
Info
The frequency of the sound depends on the spoke
length and spoke diameter.
If you hear different tone frequencies from different
spokes of equal length and diameter, this is an indica-
tion of different spoke tensions.
111
15 ELECTRICAL SYSTEM
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
– Remove the seat. ( p. 74)
Main work
(All EU models)
Warning
Risk of injury 12 V batteries contain harmful sub-
stances.
– Keep 12 V batteries out of the reach of chil-
dren.
V01776-10 – Keep sparks and open flames away from 12 V
batteries.
– Only charge 12 V batteries in well-ventilated
rooms.
– Maintain a minimum clearance from
inflammable materials when charging 12 V
batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries
if the charge is already below the minimum
voltage.
Minimum voltage 9V
before the start of the
charge
– Dispose of 12 V batteries with less than the
minimum voltage correctly.
112
ELECTRICAL SYSTEM 15
(EXC‑F BR)
Warning
Risk of injury Battery acid and battery gases cause
serious chemical burns.
– Keep 12 V batteries out of the reach of chil-
dren.
– Wear suitable protective clothing and safety
glasses.
– Avoid contact with battery acid and battery
gases.
– Keep sparks or open flames away from the
12 V battery.
– Only charge 12 V batteries in well-ventilated
rooms.
– Rinse the affected area immediately with
plenty of water in the event of contact with the
skin.
– Rinse eyes with water for at least 15 minutes
and consult a doctor immediately if battery
acid and battery gases get into the eyes.
V01777-10
V01778-10
113
15 ELECTRICAL SYSTEM
V01779-10
V01778-11
V01777-11
114
ELECTRICAL SYSTEM 15
Info
A
Contact disk must be mounted under screw and 7
cable lug 8 with the claws toward the battery termi-
nal.
Info
V01780-10
A
Contact disk must be mounted under screw and 7
cable lug 8 with the claws toward the battery termi-
nal.
Finishing work
– Mount the seat. ( p. 75)
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even if there is no load on the 12-V battery, it discharges each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and suffer a loss of capacity, destroying the battery.
Preparatory work
– Remove the seat. ( p. 74)
– Remove the 12-V battery. ( p. 112)
115
15 ELECTRICAL SYSTEM
Main work
(All EU models)
Warning
Risk of injury 12 V batteries contain harmful sub-
stances.
– Keep 12 V batteries out of the reach of chil-
dren.
F01568-10 – Keep sparks and open flames away from 12 V
batteries.
– Only charge 12 V batteries in well-ventilated
rooms.
– Maintain a minimum clearance from
inflammable materials when charging 12 V
batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries
if the charge is already below the minimum
voltage.
Minimum voltage 9V
before the start of the
charge
– Dispose of 12 V batteries with less than the
minimum voltage correctly.
116
ELECTRICAL SYSTEM 15
Info
If the charging current, charging voltage, or
charging time is exceeded, the 12 V battery
will be destroyed.
If the 12-V battery is left in a discharged
state for an extended period, it will become
deeply discharged and suffer a loss of
capacity, destroying the battery.
The 12-V battery is maintenance-free.
Never remove cover 1 .
Warning
Risk of injury Battery acid and battery gases cause
serious chemical burns.
– Keep 12 V batteries out of the reach of chil-
dren.
– Wear suitable protective clothing and safety
400240-10 glasses.
– Avoid contact with battery acid and battery
gases.
– Keep sparks or open flames away from the
12 V battery.
– Only charge 12 V batteries in well-ventilated
rooms.
– Rinse the affected area immediately with
plenty of water in the event of contact with the
skin.
– Rinse eyes with water for at least 15 minutes
and consult a doctor immediately if battery
acid and battery gases get into the eyes.
117
15 ELECTRICAL SYSTEM
Info
If the charging current, charging voltage and charg-
ing time are exceeded, electrolyte escapes through
the safety valves. This reduces the capacity of the
12-V battery.
If the 12-V battery is left in a discharged state
for an extended period, it will become deeply dis-
charged and sulfating occurs, destroying the bat-
tery.
The 12-V battery is maintenance-free. The acid
level does not have to be checked.
Never remove cover 1 .
Charge the 12 V battery to a maximum of 10% of
the capacity specified on battery housing 2 .
Finishing work
– Install the 12-V battery. ( p. 114)
– Mount the seat. ( p. 75)
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle.
Preparatory work
– Remove the seat. ( p. 74)
Main work
– Pull starter relay 1 from the holder.
V01776-11
118
ELECTRICAL SYSTEM 15
– 2.
Take off protection caps
– Remove faulty main fuse 3.
Info
A faulty fuse has a burned-out fuse wire A .
A spare fuse 4 is located in the starter relay.
Tip
Insert a spare fuse so that it is available if needed.
V01781-10
Finishing work
– Mount the seat. ( p. 75)
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
– Remove the seat. ( p. 74)
Main work
– Open fuse box cover 1.
– Remove the faulty fuse.
Guideline
(All EU models)
Fuse 1 - 10 A - EFI control unit, lambda sensor, combi-
nation instrument, combination switch (optional), elec-
tronic fuel injection, diagnostics connector, fuse 4
V01801-10 (EXC‑F BR)
Fuse 1 – 10 A – EFI control unit, combination instru-
ment, combination switch (optional), electronic fuel
injection, diagnostics connector, fuse 4
119
15 ELECTRICAL SYSTEM
Info
A faulty fuse has a burned-out fuse wire A.
Warning
Fire hazard Incorrect fuses overload the electrical sys-
tem.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Tip
Put a spare fuse in the fuse box so that it is available if
needed.
V01782-10
S01328-10
120
ELECTRICAL SYSTEM 15
S01328-11
V01782-11
Finishing work
– Check the headlight setting. ( p. 122)
Note
Damage to reflector Grease on the reflector reduces the light intensity.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
– Clean and degrease the bulbs before mounting.
– Do not touch the bulbs with your bare hands.
Preparatory work
– Remove the headlight mask with the headlight. ( p. 120)
Main work
– Turn protection cap 1
together with the underlying bulb
socket counterclockwise all the way and remove it.
– Pull bulb socket 2 of the position light out of the reflector.
V01783-10
121
15 ELECTRICAL SYSTEM
Info
E00359-10
Ensure that O-ring 4 is seated properly.
– Insert the bulb socket of the position light into the reflector.
Finishing work
– Install the headlight mask with the headlight. ( p. 121)
– Check the headlight setting. ( p. 122)
122
ELECTRICAL SYSTEM 15
Main work
– Loosen screw 1.
– Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on the
lower mark for a motorcycle with rider (instructions on how
to apply the mark: Checking the headlight setting).
V00369-10 Info
A change in weight on the vehicle may require a correc-
tion of the headlight range.
– Tighten screw 1.
Note
Damage to reflector Grease on the reflector reduces the light intensity.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
– Clean and degrease the bulbs before mounting.
– Do not touch the bulbs with your bare hands.
Main work
– Remove the screw on the rear of the turn signal housing.
– Carefully remove turn signal glass 1.
– Lightly squeeze orange cap 2 in the area of the holding lugs
and take it off.
– Press the turn signal bulb lightly into the socket, turn it coun-
terclockwise by about 30°, and pull it out of the socket.
Info
Do not touch the reflector with your fingers and keep it
free from grease.
– Press the new turn signal bulb carefully into the socket and
turn it clockwise until it stops.
Turn signal (R10W / socket BA15s) ( p. 152)
– Mount the orange cap.
– Position the turn signal glass.
– Insert the screw and first turn counterclockwise until it
E00360-10
engages in the thread with a small jerk. Tighten the screw
lightly.
Finishing work
– Check that the turn signal system is functioning properly.
123
15 ELECTRICAL SYSTEM
V01807-10
V00372-10
Finishing work
– Install the headlight mask with the headlight. ( p. 121)
– Check the headlight setting. ( p. 122)
– Set the kilometers or miles. ( p. 23)
– Set the combination instrument. ( p. 24)
– Set the clock. ( p. 25)
H00933-12
124
COOLING SYSTEM 16
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the speci-
fied value:
– Correct the antifreeze in the coolant.
400243-10 – Check the coolant level in the radiator.
125
16 COOLING SYSTEM
Coolant ( p. 157)
– Mount the radiator cap.
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
126
COOLING SYSTEM 16
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
Preparatory work
(EXC‑F Six Days)
– Remove the engine guard. ( p. 93)
Main work
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump M6 10 Nm (7.4 lbf ft)
V01819-11
cover
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Main work
– Make sure that the screw 1 is tightened.
– Stand the vehicle upright.
– Pour coolant in up to measurement A above the radiator fins.
Guideline
10 mm (0.39 in)
127
16 COOLING SYSTEM
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
Preparatory work
(EXC‑F Six Days)
– Remove the engine guard. ( p. 93)
Main work
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.
V01819-11
128
TUNING THE ENGINE 17
400192-11
– Push the cold start button in all the way.
When the throttle grip is turned forward, the cold start but-
ton returns to its original position.
» If the cold start button does not return to its original posi-
tion:
– Adjust the throttle cable play. ( p. 129)
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
– Start the engine and let it run at idle speed. Move the handle-
bar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the throttle cable play. ( p. 129)
Info
If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be
removed.
Preparatory work
– Remove the seat. ( p. 74)
– Remove the fuel tank. ( p. 80)
– Check throttle cable routing. ( p. 89)
129
17 TUNING THE ENGINE
Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1.
– Loosen nut 2.
– Turn adjusting screw 3 in as far as possible.
– Loosen nut 4.
– 6 all the way to the stop.
Push cold start button
– Turn adjusting screw 5 so that the cold start button moves to
the basic position when the throttle grip is turned to the front.
– Tighten nut 4.
– Turn adjusting screw 3 so that there is play in the throttle
cable at the throttle grip.
Guideline
Throttle cable play 3 … 5 mm (0.12 … 0.2 in)
– Tighten nut 2.
– Slide on sleeve 1.
V01804-10
– Check the throttle grip for smooth operation.
Finishing work
– Check the throttle cable play. ( p. 129)
Info
On the throttle grip, the characteristic map of the throttle response is changed by changing the guide
plate.
A guide plate with a different characteristic map is supplied.
Main work
– Push back sleeve 1.
– Remove screws 2 and half-shells 3.
– Detach the throttle cables and take off the grip tube.
V01758-10
130
TUNING THE ENGINE 17
Info
The gray guide plate opens the throttle valve more
slowly.
The black guide plate opens the throttle valve more
quickly.
The gray guide plate is mounted upon delivery.
102246-10
– Clean the outside of the handlebar and the inside of the grip
tube. Mount the grip tube on the handlebar.
– Attach the throttle cables to the guide plate and route cor-
rectly.
– Position half-shells 3, mount and tighten screws 2.
Guideline
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
– Slide on sleeve 1 and check the throttle grip for ease of
V01803-10
movement.
Finishing work
– Check the throttle cable play. ( p. 129)
Warning
Voiding of the government approval for road use and the insurance coverage If the combination switch is
mounted, the vehicle’s road permit, if any, expires.
– Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch
is installed.
Info
The desired engine characteristic can be activated via the MAP button on the combination switch.
The setting most recently selected is activated again when restarting.
The traction control can also be activated in each mapping using the TC button.
The mapping can also be changed during the ride.
131
17 TUNING THE ENGINE
H02889-01
H02886-01
Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
– Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Tachometer (45129075000)
H02254-10
Info
Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.
132
TUNING THE ENGINE 17
Info
If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed, then
the malfunction indicator lamp flashes 2x per second.
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Info
If the engine becomes too hot, perform a cool-down
ride at medium revs.
Then do not switch off the engine after this, but leave it
running at idle speed until teaching is completed.
H02263-10
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
133
17 TUNING THE ENGINE
401950-12
Info
The range of adjustment is limited.
The shift lever must not come into contact with any
other vehicle components during the shift procedure.
401951-10 – Mount the screw with the washers and tighten.
Guideline
Screw, shift M6 14 Nm (10.3 lbf ft)
lever Loctite®243™
134
SERVICE WORK ON THE ENGINE 18
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
Info
Remaining fuel may flow out of the fuel hose.
135
18 SERVICE WORK ON THE ENGINE
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Info
After switching off the engine, wait one minute
before checking the level.
V01822-10
The engine oil is at a level between the lower edge A
and the middle of the level viewer B .
» If the engine oil is not up to the lower edge A of the
level viewer:
– Add engine oil. ( p. 139)
18.3 Changing the engine oil and oil filter, cleaning the oil screen
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Drain the engine oil with the engine at operating temperature.
Preparatory work
(EXC‑F Six Days)
– Remove the engine guard. ( p. 93)
– Park the motorcycle on a level surface.
136
SERVICE WORK ON THE ENGINE 18
Main work
– Position an appropriate container under the engine.
– Remove oil drain plug 1 with the magnet and seal ring.
Info
Do not remove screws 2.
K00567-10
K00568-10
K00569-10
K00570-10
Oil drain plug with M12x1.5 20 Nm (14.8 lbf ft)
magnet
– Remove screws 5. Remove the oil filter cover with the O-ring.
K00571-10
137
18 SERVICE WORK ON THE ENGINE
K00572-10
– Lay the motorcycle on its right side and fill the oil filter hous-
ing approx. ⅓ full with engine oil.
– Place the oil filter into the oil filter housing.
– Oil the O-ring of the oil filter cover and mount it together with
oil filter cover 7
.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M6 10 Nm (7.4 lbf ft)
K00573-10
– Stand the motorcycle upright.
– Remove filler plug 8from the clutch cover together with the
O-ring, and fill up with engine oil.
Engine oil 1.0 l (1.1 qt.) Engine oil
(SAE 10W/50)
( p. 157)
Info
Too little engine oil or poor-quality engine oil will result
401955-12 in premature wear of the engine.
– Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.
138
SERVICE WORK ON THE ENGINE 18
Info
Too little engine oil or poor-quality engine oil will result in premature wear of the engine.
Main work
– Remove oil filler plug 1 with the O-ring from the clutch
cover.
– Fill engine oil to the middle A of the level viewer.
Engine oil (SAE 10W/50) ( p. 157)
Info
In order to achieve optimal engine oil performance, it is
not advisable to mix different engine oils.
KTM recommends changing the engine oil.
– Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
V01823-10 – Use effective exhaust extraction when starting or
running the engine in an enclosed space.
139
19 CLEANING, CARE
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
Info
Use warm water containing normal motorcycle cleaner
401061-01
and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always
rinse the vehicle with water first.
Warning
Danger of accidents Moisture and dirt impair the
brake system.
– Brake carefully several times to dry out and remove
dirt from the brake linings and the brake discs.
Info
The heat produced causes water at inaccessible loca-
tions in the engine and on the brake system to evapo-
rate.
140
CLEANING, CARE 19
– Treat bare metal (except for brake discs and the exhaust sys-
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 159)
– Treat all plastic parts and powder-coated parts with a mild
cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 160)
– Lubricate the steering lock.
Universal oil spray ( p. 160)
Info
If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions
against aggressive road salt.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance
the corrosive effects of salt.
Info
After EVERY trip on salted roads, thoroughly clean the
brake calipers and brake linings, after they have cooled
down and without removing them, with cold water and
dry them carefully.
After riding on salted roads, thoroughly clean the vehi-
401060-01
cle with cold water and dry it well.
– Treat the engine, link fork, and all other bare or zinc-plated
parts (except the brake discs) with a wax-based corrosion
inhibitor.
Info
Corrosion inhibitor must not come in contact with the
brake discs as this would greatly reduce the braking
force.
141
20 STORAGE
20.1 Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them per-
formed.
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.
– When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Fuel additive ( p. 159)
– Refuel. ( p. 44)
– Clean the motorcycle. ( p. 140)
– Change the engine oil and oil filter, clean the oil screen.
( p. 136)
– Check the antifreeze and coolant level. ( p. 125)
401058-01
– Check tire pressure. ( p. 110)
– Remove the 12-V battery. ( p. 112)
– Charge the 12-V battery. ( p. 115)
Guideline
Storage temperature of the 0 … 35 °C (32 … 95 °F)
12-V battery without direct
sunlight
– Store the vehicle in a dry location that is not subject to large
fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.
142
STORAGE 20
Info
Avoid running the engine for a short time only. Since
the engine cannot warm up properly, the water vapor
produced during combustion condenses and causes
valves and the exhaust system to rust.
401059-01
143
21 TROUBLESHOOTING
144
TROUBLESHOOTING 21
145
22 BLINK CODE
Info
The blink codes are only displayed by the derestricted version of the vehicle.
146
BLINK CODE 22
147
23 TECHNICAL DATA
23.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 249.91 cm³ (15.2505 cu in)
Stroke 52.3 mm (2.059 in)
Bore 78 mm (3.07 in)
Compression ratio 13.8:1
Idle speed 2,050 … 2,150 rpm
Control DOHC, four valves controlled via cam lever, drive via
timing chain
Valve diameter, intake 32.5 mm (1.28 in)
Valve diameter, exhaust 26.5 mm (1.043 in)
Valve clearance
Intake at: 20 °C (68 °F) 0.08 … 0.15 mm (0.0031 … 0.0059 in)
Exhaust at: 20 °C (68 °F) 0.12 … 0.19 mm (0.0047 … 0.0075 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing Slide bearing
Piston pin bearing Bearing bush
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with 2 trochoidal
pumps
Primary transmission 24:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6 gear transmission, claw shifted
Transmission ratio
First gear 13:32
Second gear 16:30
Third gear 16:24
Fourth gear 23:28
Fifth gear 23:23
Sixth gear 26:20
Alternator 12 V, 200 W
Ignition Contactless controlled fully electronic ignition with
digital ignition adjustment
Spark plug NGK LMAR9AI-10
Spark plug electrode gap 1.0 mm (0.039 in)
Cooling Water cooling, permanent circulation of coolant by
water pump
Starting aid Starter motor
148
TECHNICAL DATA 23
149
23 TECHNICAL DATA
150
TECHNICAL DATA 23
23.3 Capacities
23.3.2 Coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 157)
23.3.3 Fuel
Total fuel tank capacity, approx. 9.25 l (2.444 US gal) Super unleaded (ROZ 95/RON
95/PON 91) ( p. 158) (All EU
models)
Total fuel tank capacity, approx. Super unleaded, type C (ROZ
95/RON 95/PON 91) ( p. 158)
(EXC‑F BR)
23.4 Chassis
Frame Central tube frame made of chrome molybdenum steel
tubing
Fork (EXC‑F BR) WP XPLOR 5348
Fork (All EU models) WP XPLOR 5548
Suspension travel
front 300 mm (11.81 in)
rear 310 mm (12.2 in)
Fork offset 22 mm (0.87 in)
Shock absorber WP XPLOR 5746
Brake system Disc brakes, floating brake calipers
Brake discs - diameter
front 260 mm (10.24 in)
rear 220 mm (8.66 in)
Brake discs - wear limit (EXC‑F EU/BR)
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
Brake discs - wear limit (EXC‑F Six Days)
front 2.5 mm (0.098 in)
rear 3.7 mm (0.146 in)
Offroad tire pressure
front 1.0 bar (15 psi)
rear 1.0 bar (15 psi)
Street tire pressure
151
23 TECHNICAL DATA
152
TECHNICAL DATA 23
23.6 Tires
Validity Front tire Rear tire
(EXC‑F EU) 80/100 - 21 M/C 51M TT 140/80 - 18 M/C 70R M+S TT
MAXXIS Maxx EnduPro MAXXIS Maxx EnduPro
(EXC‑F BR, EXC‑F Six Days) 90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT
Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme
The tires specified represent one of the possible series production tires. Additional information is available in
the Service section under:
http://www.ktm.com
23.7 Fork
23.7.1 EXC‑F BR
Fork article number 14.18.8T.63
Fork WP XPLOR 5348
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring length with preload spacer(s) 474 mm (18.66 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 3.8 N/mm (21.7 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.0 N/mm (22.8 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.2 N/mm (24 lb/in)
Fork length 928 mm (36.54 in)
Fork oil per fork leg 625 ± 10 ml (21.13 Fork oil (SAE 4) (48601166S1)
± 0.34 fl. oz.) ( p. 158)
153
23 TECHNICAL DATA
Standard +0
Sport +3
Spring length with preload spacer(s) 474 mm (18.66 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 3.8 N/mm (21.7 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.0 N/mm (22.8 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.2 N/mm (24 lb/in)
Fork length 928 mm (36.54 in)
Fork oil per fork leg 625 ± 10 ml (21.13 Fork oil (SAE 4) (48601166S1)
± 0.34 fl. oz.) ( p. 158)
154
TECHNICAL DATA 23
155
23 TECHNICAL DATA
156
SUBSTANCES 24
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade
and unsuitable antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec-
tion and lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that
has the relevant properties.
Antifreeze protection to at least −25 °C (−13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs
to be diluted.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.
Recommended supplier
MOTOREX®
– COOLANT M3.0
157
24 SUBSTANCES
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15,
E25, E85, E100).
Info
Do not use fuel made of methanol (e. g. M15, M85, M100).
Do not use fuel with less than 19 % ethanol (e. g. E10).
Do not use fuel with more than 27 % ethanol (e. g. E30, E85, E100).
158
AUXILIARY SUBSTANCES 25
Chain cleaner
Recommended supplier
MOTOREX®
– Chain Clean
Fuel additive
Recommended supplier
MOTOREX®
– Fuel Stabilizer
Long-life grease
Recommended supplier
MOTOREX®
– Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX®
– Moto Clean
159
25 AUXILIARY SUBSTANCES
Silicone spray
Recommended supplier
MOTOREX®
– Silicone Spray
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
– Quick Cleaner
160
STANDARDS 26
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils
according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
161
27 INDEX OF SPECIAL TERMS
OBD On-board diagnosis Vehicle system, which monitors the specified parame-
ters of the vehicle electronics
162
LIST OF ABBREVIATIONS 28
163
29 LIST OF SYMBOLS
Turn signal indicator lamp flashes green – The turn signal is switched on.
164
INDEX
Chain guide
INDEX
1 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12-V battery Chain tension
charging . . . .... . . . . . . . . . . . . . . . . . . 115 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 85
installing . . . .... . . . . . . . . . . . . . . . . . . 114 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 84
removing . . . .... . . . . . . . . . . . . . . . . . . 112 Characteristic map of the throttle response
starting power ... . . . . . . . . . . . . . . . . . . . 37 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 130
A Clutch
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 fluid level, checking/correcting . . . . . . . . . . . 91
Air filter fluid, changing . . . . . . . . . . . . . . . . . . . . . . 92
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 77 basic position, adjusting . . . . . . . . . . . . . . . 90
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Cold start button . . . . . . . . . . . . . . . . . . . . . . . . 19
Air filter box Combination instrument
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 78 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Air filter box cover combination instrument battery, changing . . 124
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 76 kilometers or miles, setting . . . . . . . . . . . . . 23
preparing for securing . . . . . . . . . . . . . . . . . 78 lap time, viewing . . . . . . . . . . . . . . . . . . . . 25
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 75 overview . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Antifreeze setting the clock . . . . . . . . . . . . . . . . . . . . . 25
checking . . . . . . . . . . . . . . . . . . . . . . . . . 125 Compression damping
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . 10 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 55
B Coolant
antifreeze and coolant level, checking . . . . . 125
Basic chassis setting changing . . . . . . . . . . . . . . . . . . . . . . . . . 128
rider's weight, checking with . . . . . . . . . . . . 49 draining . . . . . . . . . . . . . . . . . . . . . . . . . 126
Blink code . . . . . . . . . . . . . . . . . . . . . . . . 146-147 level, checking . . . . . . . . . . . . . . . . . . . . . 126
Brake discs refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 127
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 125
Brake fluid Customer service . . . . . . . . . . . . . . . . . . . . . . . 10
of front brake, adding . . . . . . . . . . . . . . . . . 96 D
of rear brake, adding . . . . . . . . . . . . . . . . . 102 Diagnostics connector . . . . . . . . . . . . . . . . . . . 124
Brake fluid level Difficult operating conditions . . . . . . . . . . . . . . . . 37
of front brake, checking . . . . . . . . . . . . . . . . 95 dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . 37
rear brake, checking . . . . . . . . . . . . . . . . . 101 high temperatures . . . . . . . . . . . . . . . . . . . 39
Brake linings low temperature . . . . . . . . . . . . . . . . . . . . . 39
front brake, checking . .. . . . . . . . . . . . . . . 97 muddy surfaces . . . . . . . . . . . . . . . . . . . . . 39
of front brake, changing . . . . . . . . . . . . . . . 97 slow speed . . . . . . . . . . . . . . . . . . . . . . . . 39
of rear brake, changing .. . . . . . . . . . . . . . 103 snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
rear brake, checking . . .. . . . . . . . . . . . . . 103 wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brake system . . . . . . . . . . . . . . . . . . . . . . . 94-105 wet surfaces . . . . . . . . . . . . . . . . . . . . . . . 39
C E
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . 16
Capacity
coolant . . . . . . . . . . . . . . . . . . . 127-128, 151 Engine
engine oil . . . . . . . . . . . . . . . . . . . . 138, 151 running-in . . . . . . . . . . . . . . . . . . . . . . . . . 36
fuel . . . . . . . . . . . . . . . . . . . . . . . . . 45, 151 Engine guard
Chain installing . . . . . . . . . . . . . . . . . . . . . . . . . . 93
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 86 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 93
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 13
165
INDEX
166
INDEX
167
INDEX
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . 11
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 12
W
Winter operation
checks and maintenance steps . . . . . . . . . . 141
Work rules ............................ 9
168
*3214222en*
3214222en
06/2020