Instruction/ maintenance manual of the product 300 XC-W (2013) KTM
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OWNER'S MANUAL 2013 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AUS 200 XC ‑ W USA 250 EXC EU 250 EXC AUS 250 EXC SIX DAYS EU 250 XC ‑ W USA 300 EXC EU 300 EXC AUS 300 EXC SIX DAYS EU 300 XC ‑ W USA Art.
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DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle.
TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 5 1.1 Symbols used ....................................... ............ 5 1.2 Formats used ................................ .................... 5 2 SAFETY ADVICE .
TABLE OF CONTENTS 3 10.14 Adjusting the spring preload of the fork (EXC EU/AUS, XC ‑ W).............. ......................... 44 10.15 Handlebar position ............ ............................ .. 44 10.16 Adjusting the handlebar position x ....
TABLE OF CONTENTS 4 16.6 Checking the basic position of the shift lever ... 101 16.7 Adjusting the basic position of the shift lever x .................................... ................... 101 16.8 Engine characteristic - auxiliary spring (All 250/300 models) .
1 MEANS OF REPRESENTATIO N 5 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding.
2 SAFETY ADVICE 6 2.1 Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.
2 SAFETY ADVICE 7 2.5 Safe operation Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.
3 IMPORTA NT NOTES 8 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net ; otherwise, all warranty claims will be void.
4 VIEW OF VEHICLE 9 4.1 View of vehicle, front left (example) B01138-10 1 Hand brake lever ( p. 13) 2 Kill switch ( p. 13) 3 Clutch lever ( p. 13) 4 Air filter box lid 5 Fuel tap ( p.
4 VIEW OF VEHICLE 10 4.2 View of vehicle, rear right (example) B01137-10 1 Filler cap 2 Bleeder screw, fork leg 3 Throttle grip ( p. 13) 4 Chassis number ( p.
5 SERIAL NUMBERS 11 5.1 Chassis number 303438-10 The chassis number 1 is stamped on the right side of the steering head. 5.2 Type label 303439-10 The type label 1 is fixed to the front of the steering head. 5.3 Key number (All EXC models) 500125-10 The key number 1 for the steering lock is stamped onto the key connector.
5 SERIAL NUMBERS 12 5.6 Shock absorber part number B00786-10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side.
6 CONTROL S 13 6.1 Clutch lever B01140-10 (All 125/200 models) The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01146-10 (All 250/300 models) The clutch lever 1 is fitted on the left side of the handlebar.
6 CONTROL S 14 6.5 Kill switch (XC-W) B01144-10 The kill switch 1 is fitted on the left side of the handlebar. Possible states • Kill switch in basic position – In this position, the ignition circuit is closed and the engine can be started.
6 CONTROL S 15 6.10 Emergency OFF switch (EXC AUS) B01148-10 The emergency OFF switch 1 is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a run- ning engine stops, and a non-running engine will not start.
6 CONTROL S 16 6.14.2 Activation and test 400313-01 Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. Display test To enable you to check that the display is functioning properly, all display segments light up briefly.
6 CONTROL S 17 Condition The motorcycle is stationary. 400318-01 – Press the button briefly and repeatedly until H appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The Setup menu is displayed and the activated functions are shown.
6 CONTROL S 18 400321-01 – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. – Press the button briefly. LAP 1 appears on the left side of the display. – Laps 1-10 can be displayed by pressing the button .
6 CONTROL S 19 6.14.11 Display mode SPEED/LAP (lap time) 400320-01 – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. In the LAP display mode, up to 10 lap times can be timed with the stop watch. Info If the lap time continues after you press the button , 9 memory locations are already occupied.
6 CONTROL S 20 Press the button . Reduces value of TR2 . Press the button for 3 - 5 seconds. Deletes value of TR2 . Press the button briefly. Next display mode 6.14.15 Display mode SPEED/A1 (average speed 1) 400325-01 – Press the button briefly and repeatedly until A1 appears at the top right of the display.
6 CONTROL S 21 6.14.18 Display mode SPEED/S2 (stop watch 2) 400328-01 – Press the button briefly and repeatedly until S2 appears at the top right of the display. S2 (stop watch 2) is a manual stop watch. If S2 is running in the background, the S2 display flashes in the speedometer display.
6 CONTROL S 22 6.15 Opening the filler cap Danger Fire hazard Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
6 CONTROL S 23 6.17 Fuel tap 601157-10 The fuel tap is on the left side of the fuel tank. Tap handle 1 on the fuel tap is used to open or close the supply of fuel to the carbure- tor. Possible states • Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
6 CONTROL S 24 6.20 Kick starter B00787-10 The kick starter 1 is fitted on the right side of the engine. The top part can be swiveled. 6.21 Foot brake lever B00788-10 Foot brake lever 1 is located in front of the right footrest. The foot brake lever is used to activate the rear brake.
6 CONTROL S 25 6.24 Locking the steering (All EXC models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. 400732-01 – Park the vehicle. – Turn the handlebar as far as possible to the right.
7 PREPARIN G FOR USE 26 7.1 Advice on first use Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.
7 PREPARIN G FOR USE 27 – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels.
7 PREPARIN G FOR USE 28 7.4 Preparations for riding on dry sand 600872-10 – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
7 PREPARIN G FOR USE 29 – Change the radiator cap. 600870-01 – Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning.
7 PREPARIN G FOR USE 30 – Change the radiator cap. 600868-01 – Adjust the secondary ratio to the terrain. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive. – Clean the chain. Chain cleaner ( p.
8 RIDING INSTRUCTIO NS 31 8.1 Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level.
8 RIDING INSTRUCTIO NS 32 Info Do not turn the throttle. (125 EXC EU, 125 EXC SIX DAYS EU) – Press the kick starter robustly through its full range. Info Do not turn the throttle. 8.3 Start off Info Before riding, switch on the lights if your vehicle is equipped with a lighting system.
8 RIDING INSTRUCTIO NS 33 – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. 8.6 Stopping, parking Warning Risk of misappropriation Usage by unauthorize d persons.
8 RIDING INSTRUCTIO NS 34 8.8 Refueling Danger Fire hazard Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
9 SERVICE SCHEDUL E 35 9.1 Service schedule S20A S40A Check that the electrical equipment is functioning properly. • • Check and charge the battery. x (All 200/250/300 models) • • Check the front brake linings. ( p. 75) • • Check the rear brake linings.
9 SERVICE SCHEDUL E 36 9.2 Service work (as addition al order) S10N S40A S80A J1A Change the front brake fluid. x • Change the rear brake fluid. x • Change the hydraulic clutch fluid. x ( p. 71) • Grease the steering head bearing. x ( p. 56) • Check/set the carburetor components.
10 TUNING THE CHASSIS 37 10.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
10 TUNING THE CHASSIS 38 (All 250/300 models) Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing.
10 TUNING THE CHASSIS 39 B00792-10 – Turn adjusting screw 1 clockwise with a screwdriver to the last click. Info Do not loosen nut 2 ! – Turn back counterclockwi se by the number of clicks corresponding to the shock absorber type.
10 TUNING THE CHASSIS 40 10.8 Checking the riding sag of the shock absorber 400990-10 – Measure distance A of the unloaded rear wheel. ( p. 39) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
10 TUNING THE CHASSIS 41 Info 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 absorber adjusting ring M5 5 Nm (3.7 lbf ft) Finishing work – Install the shock absorber.
10 TUNING THE CHASSIS 42 401000-01 – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression), harder springs must be fit to avoid damage to the fork and frame.
10 TUNING THE CHASSIS 43 (250/300 EXC SIX DAYS EU) Compression damping Comfort 24 clicks Standard 22 clicks Sport 16 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior.
10 TUNING THE CHASSIS 44 (250/300 EXC SIX DAYS EU) Rebound damping Comfort 20 clicks Standard 18 clicks Sport 18 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.14 Adjusting the spring preload of the fork (EXC EU/AUS, XC ‑ W) B00795-01 – Turn the adjusting screws counterclockwise all the way.
10 TUNING THE CHASSIS 45 10.16 Adjusting the handlebar position x Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar.
11 SERVICE WORK ON THE CHASSIS 46 11.1 Raising the motorcycle with the lift stand B00796-01 (All 125/200 models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine.
11 SERVICE WORK ON THE CHASSIS 47 303391-10 Main work – Remove bleeder screws 1 briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Finishing work – Remove the motorcycle from the lift stand. ( p.
11 SERVICE WORK ON THE CHASSIS 48 11.6 Positioning the fork protection B00800-11 – Position the fork protection on the left fork leg. Mount and tighten screws 1 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line.
11 SERVICE WORK ON THE CHASSIS 49 B01215-10 (EXC SIX DAYS) – Position the fork legs. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs.
11 SERVICE WORK ON THE CHASSIS 50 B00801-10 Main work – Remove screws 1 on the left fork leg. Lift off the fork protector. – Remove the screws on the right fork leg. Lift off the fork protector. 11.10 Installing the fork protector x B00801-10 Main work – Position the fork protection on the left fork leg.
11 SERVICE WORK ON THE CHASSIS 51 11.12 Removing the lower triple clamp x (EXC SIX DAYS) Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) – Remove the front wheel. x ( p. 82) – Remove the headlight mask with the headlight. ( p.
11 SERVICE WORK ON THE CHASSIS 52 B00809-10 – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. Position bleeder screws 4 toward the front.
11 SERVICE WORK ON THE CHASSIS 53 Finishing work – Mount the handlebar cushion. – Install the front fender. ( p. 56) – Install the front wheel. x ( p. 82) – Refit the headlight mask with the headlight. ( p. 90) – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly.
11 SERVICE WORK ON THE CHASSIS 54 B01214-12 – Tighten screws 6 . Guideline Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) B01215-12 – Tighten screw 4 . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B01220-10 – Mount and tighten screw 7 .
11 SERVICE WORK ON THE CHASSIS 55 11.15 Checking the play of the steering head bearing Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.
11 SERVICE WORK ON THE CHASSIS 56 – Tighten screws 1 . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Mount and tighten screw 2 . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ Finishing work – Check the play of the steering head bearing.
11 SERVICE WORK ON THE CHASSIS 57 B00815-10 Main work (All 125/200 models) – Remove screw 1 and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. – Remove screw 2 , push splash protector 3 to the side, and remove the shock absorber.
11 SERVICE WORK ON THE CHASSIS 58 11.22 Removing the seat B00817-10 – Remove screw 1 . Lift up the seat at the rear, pull it back and then remove from above. 11.23 Mounting the seat B00818-01 – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward.
11 SERVICE WORK ON THE CHASSIS 59 11.26 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
11 SERVICE WORK ON THE CHASSIS 60 S00044-10 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 131) Info Only squeeze the air filter to dry it; never wring it out. – Oil the dry air filter with a high quality filter oil.
11 SERVICE WORK ON THE CHASSIS 61 11.32 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components.
11 SERVICE WORK ON THE CHASSIS 62 B00090-10 Main work – Turn handle 1 of the fuel tap to the OFF position. (Figure 601157-10 p. 23) – Pull off the fuel hose. Info Remaining fuel may run out of the fuel hose. – Remove screws 1 with the collar sleeve.
11 SERVICE WORK ON THE CHASSIS 63 B00822-11 – Mount the fuel tank vent hose. – Mount and tighten screw 1 with the rubber bushing. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) (All EXC models) – Position the horn with the horn bracket.
11 SERVICE WORK ON THE CHASSIS 64 400725-01 – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 131) Off-road chain spray ( p. 131) 11.37 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension.
11 SERVICE WORK ON THE CHASSIS 65 101430-10 Main work – Push the chain at the end of the chain sliding component upwards to measure chain tension A . Info The bottom 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 .
11 SERVICE WORK ON THE CHASSIS 66 400987-10 – Pull on the upper part of the chain with the specified weight A . Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance B of 18 chain links in the lower chain section.
11 SERVICE WORK ON THE CHASSIS 67 400985-01 – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. x 100865-10 – Check the chain guide for tightness.
11 SERVICE WORK ON THE CHASSIS 68 11.41 Checking the frame x 401347-01 – Check the frame for cracking and deformation. » If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. x Info A frame that has been damaged due to a mechanical impact must always be changed.
11 SERVICE WORK ON THE CHASSIS 69 B01151-01 (All 250/300 models) – Check the routing of the throttle cable. The throttle cable must be routed behind the handlebar, on the right of the upper frame tube, and to the carburetor. » If the throttle cable is not routed as specified: – Correct the routing of the throttle cable.
11 SERVICE WORK ON THE CHASSIS 70 Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar.
11 SERVICE WORK ON THE CHASSIS 71 11.48 Changing the hydraulic clutch fluid x Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
11 SERVICE WORK ON THE CHASSIS 72 B00042-10 – Inject the liquid into the system until it escapes from hole 6 of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe.
12 BRAKE SYSTEM 73 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.
12 BRAKE SYSTEM 74 12.4 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay.
12 BRAKE SYSTEM 75 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
12 BRAKE SYSTEM 76 12.8 Changing the front brake linings x Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Br ake fluid can cause skin irritation on contact.
12 BRAKE SYSTEM 77 100397-01 – Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly. 100398-10 – Insert the brake linings, insert the pin, and mount the cotter pins.
12 BRAKE SYSTEM 78 B00828-10 – Disconnect spring 1 . – 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 individually, loosen nut 2 and turn screw 3 accordingly.
12 BRAKE SYSTEM 79 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
12 BRAKE SYSTEM 80 Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles.
12 BRAKE SYSTEM 81 400233-10 – Correct the brake fluid level to marking A . Brake fluid DOT 4 / DOT 5.1 ( p. 129) – Mount screw cap 1 with membrane 2 and the O-ring.
13 WHEELS, TIRES 82 13.1 Removing the front wheel x Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) B00055-10 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.
13 WHEELS, TIRES 83 500084-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw 2 . Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc.
13 WHEELS, TIRES 84 400260-10 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. x – Clean and grease shaft seal rings 1 and bearing surface A of the spacers. Long-life grease ( p.
13 WHEELS, TIRES 85 » If the tread depth is less than the minimum permissible depth: – Change the tire. – Check the tire age. Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking.
13 WHEELS, TIRES 86 Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58.
14 ELECTRIC AL SYSTEM 87 14.1 Removing the battery x (All 200/250/300 models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles.
14 ELECTRIC AL SYSTEM 88 14.3 Recharging the battery x (All 200/250/300 models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles.
14 ELECTRIC AL SYSTEM 89 14.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle.
14 ELECTRIC AL SYSTEM 90 14.5 Removing the headlight mask with the headlight B00833-10 – Switch off all power consumers. – Remove screw 1 and take off the clamp.
14 ELECTRIC AL SYSTEM 91 100861-10 Main work – Turn rubber cap 1 together with the underlying lamp socket counterclockwise all the way and remove it. – Pull lamp socket 2 of the parking light out of the reflector. 100862-10 – Press headlight bulb 3 lightly into the lamp socket, turn it counterclockwi se and pull it out.
14 ELECTRIC AL SYSTEM 92 14.9 Checking the headlight setting 400726-10 – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark a distance B under the first mark.
14 ELECTRIC AL SYSTEM 93 100864-10 – Position protection cap 2 and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with the washers.
15 COOLING SYSTEM 94 15.1 Cooling system B00834-10 (All 125/200 models) Water pump 1 in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap 2 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
15 COOLING SYSTEM 95 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot.
15 COOLING SYSTEM 96 B00835-11 (All 250/300 models) – Remove screw 1 . Take off radiator cap 2 . – Completely drain the coolant. – Mount and tighten screw 1 with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 15.
15 COOLING SYSTEM 97 B00836-10 – Fill the radiator completely with coolant. – Mount radiator cap 2 . – Run the engine until it is warm. Finishing work – Check the coolant level.
16 TUNING THE ENGINE 98 16.1 Checking the play in the throttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable.
16 TUNING THE ENGINE 99 The idle speed is adjusted with adjusting screw 1 . The idle mixture is adjusted with the idle air adjusting screw 2 . 500282-01 Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw 1 and the idle air adjusting screw 2 .
16 TUNING THE ENGINE 100 Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 23) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw 2 slowly in a clockwise direction until the idle speed begins to fall.
16 TUNING THE ENGINE 101 16.6 Checking the basic position of the shift lever 400692-10 – Sit on the vehicle in the riding position and determine the distance A between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot 10… 20 mm (0.
16 TUNING THE ENGINE 102 B00057-10 Main work – Remove screws 1 . B00056-11 – Take cap 2 , adjusting spring 3 , auxiliary spring 4 , and spring insert 5 out of the clutch cover. – Pull both springs off of the spring insert. B00058-10 – Mount the required auxiliary spring 4 and adjusting spring 3 and slide them into the clutch cover together.
17 SERVICE WORK ON THE ENGINE 103 17.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. B00049-10 Main work (All 125/200 models) – Remove screw 1 from the opening used to check the gear oil level.
17 SERVICE WORK ON THE ENGINE 104 17.3 Draining the gear oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediatel y with lukewarm water.
17 SERVICE WORK ON THE ENGINE 105 – Mount and tighten the screw cap. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
17 SERVICE WORK ON THE ENGINE 106 – Start the engine and check that it is oil-tight..
18 CLEANING , CARE 107 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc.
18 CLEANING , CARE 108 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding.
19 STORAGE 109 19.1 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor.
20 TROUBLE SHOOTING 110 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) (All 200/250/300 models) Operating error – Carry out the start procedure. ( p. 31) Battery discharged – Recharge the battery. x ( p. 88) – Check the charging voltage.
20 TROUBLE SHOOTING 111 Faults Possible cause Action Engine stalls or is popping into the carburetor Lack of fuel – Turn handle 1 of the fuel tap to the ON posi- tion. – Refuel. ( p. 34) Engine takes in bad air – Check the intake flange and carburetor for tightness.
21 TECHNICA L DATA 112 21.1 Engine 21.1.1 125 EXC EU, 125 EXC SIX DAYS EU Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.
21 TECHNICA L DATA 113 5th gear 17:19 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.
21 TECHNICA L DATA 114 Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X (upper edge of piston to upper edge of cylinder) 0… 0.
21 TECHNICA L DATA 115 Axle for control flap, exhaust control M8 Step 1 3 Nm (2.2 lbf ft) Step 2 (loosen, counter- clockwise) 1/4 turn – Nut, cylinder base M8 30 Nm (22.1 lbf ft) – Screw, kick starter M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, shift drum locating M8 25 Nm (18.
21 TECHNICA L DATA 116 Nut, inner clutch hub M18x1.5 120 Nm (88.5 lbf ft) Loctite ® 2701 Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite ® 648™ 21.3 Capacities 21.3.1 Gear oil Gear oil (All 125/200 models) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p.
21 TECHNICA L DATA 117 Secondary ratio (200 XC ‑ W USA) 14:48 Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase (All 125/200 models) 1,471±10 mm (57.91±0.39 in) Wheelbase (All 250/300 models) 1,482±10 mm (58.
21 TECHNICA L DATA 118 21.7 Fork 21.7.1 125 EXC EU, all 200 models Fork part number 14.18.7L.61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sp.
21 TECHNICA L DATA 119 Weight of rider: 85… 95 kg (187… 209 lb.) 4.4 N/mm (25.1 lb/in) Fork length 940 mm (37.01 in) Air chamber length 110 +10 − 20 mm (4.33 +0.39 − 0.79 in) Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p.
21 TECHNICA L DATA 120 21.8 Shock absorber 21.8.1 All 125/200 models Shock absorber part number 12.18.7L.61 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.
21 TECHNICA L DATA 121 Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in) Spring length 250 mm (9.84 in) Gas pressure 10 bar (145 psi) Static sag 33… 35 mm (1.
21 TECHNICA L DATA 122 Screw, bottom shock absorber M1 2 80 Nm (59 lbf ft) Loctite ® 2701 Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite ® 2701 Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Nut, rear wheel spindle M20x1.
21 TECHNICA L DATA 123 Carburetor identification number BM9 0 Needle position 3rd position from top Jet needle N1EI (N1EH / N1EJ) Main jet 158 (160) Idling jet 40 Starting jet 85 Idle air adjusting screw Open 2.0 turns Throttle slide 7 with cut-out Slide stop - 21.
21 TECHNICA L DATA 124 21.10.8 300 EXC EU, 300 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N2ZJ / N2ZK / N2ZL) Main jet 115 (162/165) Idling jet 38X38 (35) Starting jet 50 (85) Idle air adjusting screw Open 1.
21 TECHNICA L DATA 125 401348-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.
21 TECHNICA L DATA 126 401526-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.
21 TECHNICA L DATA 127 401043-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.
21 TECHNICA L DATA 128 401044-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 21.10.14 General carburetor tuning x 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075-10 1.
22 SUBSTAN CES 129 2-stroke engine oil According to – JASO FC ( p. 133) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.
22 SUBSTAN CES 130 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products.
23 AUXILIAR Y SUBSTANCES 131 Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products.
23 AUXILIAR Y SUBSTANCES 132 Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcy cle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motorex ® products.
24 STANDAR DS 133 JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustio n is achieved even under extreme operating conditions.
INDEX 134 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 installing . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 135 Fork basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 41 Fork legs bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 47 installing .
INDEX 136 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 40 spring preload, setting .
*321 186 1en* 3211861en 06/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM.
An important point after buying a device KTM 300 XC-W (2013) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 300 XC-W (2013) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 300 XC-W (2013) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 300 XC-W (2013) you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 300 XC-W (2013) will certainly help you make a decision on the purchase.
If you already are a holder of KTM 300 XC-W (2013), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 300 XC-W (2013).
However, one of the most important roles played by the user manual is to help in solving problems with KTM 300 XC-W (2013). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 300 XC-W (2013) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
