KTM 25 EXC 2016 Manual

SETUP INSTRUCTIONS 2016

125 EXC

200 EXC

200 XC‑W

250 EXC

250 XC‑W

300 EXC

300 XC‑W

Art. no. 3213437en

INTRODUCTION 1

*3213437en*

3213437en

11/2015

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest

of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It

is assumed that the work will be performed by a fully trained mechanic.

All specifications 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 production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-

ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not

belong to the regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to

the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

5230 Mattighofen, Austria

This document is valid for the following models:

125 EXC EU (F7103P6)

125 EXC Six Days EU (F7103P2)

200 EXC EU (F7203P6)

200 EXC AU (F7260P6)

200 XC‑W US (F7275P3)

250 EXC EU (F7303P6)

250 EXC AU (F7360P6)

250 EXC Six Days EU (F7303P2)

250 XC‑W US (F7375P3)

300 EXC EU (F7403P6)

300 EXC AU (F7460P6)

300 EXC BR (F7440P6)

300 EXC Six Days EU (F7403P2)

300 XC‑W US (F7475P3)

300 XC‑W Six Days US (F7475P2)

1 MEANS OF REPRESENTATION 2

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).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained

in the glossary.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

B02176-10

Package 2

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup, leave the protective

film on the vehicle until you have finished.

–Remove the separate enclosure and unpack it. Check that the scope of supply

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (78129955100)

–Carefully loosen and remove the tension belt of the footrest mount.

Info

An assistant prevents the motorcycle from falling over.

402050-01

–Together with an assistant, take the vehicle off the palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

B02008-10

Package 12

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup, leave the protective

film on the vehicle until you have finished.

–Remove the separate enclosure and unpack it. Check that the scope of supply

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (78129955100)

–Together with an assistant, take the vehicle off the palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

402051-01

–Install the shock absorber. ( p. 11)

2 SETUP 4

B02183-01

–Route the clutch line with the clutch master cylinder toward the front between

the upper and lower triple clamps.

V00037-01

(XC-W, 300 EXC BR)

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

Info

Grooves are milled into the side of the upper end of the fork legs.

The second milled groove (from the top) must be flush with the top

edge of the upper triple clamp.

Position the bleeder screws toward the front.

V00036-01

(Six Days, EXC EU/AU)

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

Info

The rebound damping is located in right fork leg REB (red adjusting

screw). The compression damping is located in left fork leg COMP

(white adjusting screw).

Grooves are milled into the side of the upper end of the fork legs.

The topmost milled groove must be flush with the top edge of the

upper triple clamp.

Position the bleeder screws toward the front.

M00993-11

(XC-W, 300 EXC BR)

–Remove screws . Take off the handlebar clamps.

–Remove screws . Take off the handlebar supports.

–Place the handlebar supports in the required position. Mount and tighten

screws .

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

2 SETUP 5

M00987-11

(Six Days, EXC EU/AU)

–Remove screws . Take off the handlebar clamps.

–Remove screws . Take off the handlebar supports.

–Place the handlebar supports in the required position. Mount and tighten

screws .

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

B02184-01

–Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

–Position the handlebar clamps. Mount and tighten the screws evenly.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

The markings on the handlebar should be at the center of the handlebar

clamps.

Keep the gap widths equal when tightening.

–Position the speedometer and connector board. Mount and tighten the screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B02185-01

(XC-W, Six Days, EXC EU, 300 EXC BR)

–Position the controls on the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

V00042-01

(EXC AU)

–Position the controls on the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

2 SETUP 6

V00040-01

(All EXC models)

–Position the controls on the left half of the handlebar.

Info

The figure shows how to route the clutch line and wiring harness.

V00041-01

(XC-W, 300 XC‑W Six Days US)

–Position the controls on the left half of the handlebar.

Info

The figure shows how to route the clutch line and wiring harness.

B01750-01

(All EXC models)

–Remove the fuel tank. ( p. 10)

–Disconnect the plug-in connector on the main wiring harness.

–Connect the plug-in connector of the turn signal wiring harness with the plug-in

connector of the main wiring harness.

–Position the turn signal wiring harness against the main wiring harness and

secure with cable ties.

–Install the fuel tank. ( p. 11)

–Position the turn signal indicator lamp in the speedometer holder.

B02188-10

–Insert the black and violet cables of bulb included in the separate enclosure

into the socket and position it in the turn signal indicator lamp.

–Secure turn signal relay with a cable tie and plug in the connector.

–Position the turn signal on each side and mount and tighten nuts .

–Connect the plug-in connector of the right turn signal with the connector

marked green on the wiring harness.

–Connect plug-in connector of the left turn signal with the connector marked

red on the wiring harness.

402148-01

(All EXC models)

–Mount the turn signal switch and connect the plug-in connector on the wiring

harness.

2 SETUP 7

B01747-11

(XC-W, 300 XC‑W Six Days US)

–Connect pull switch with the yellow and white cables.

–Install the front fender. ( p. 14)

–Mount the fuel tank breather correctly.

–Install the front wheel. ( p. 12)

–Refit the headlight mask with the headlight. ( p. 15)

B02187-01

–Mount the handlebar cushion.

101019-01

–Mount the footrests with the springs and pins. Secure the pins using the washers

and cotter pins.

Pliers for footrest spring (58429083000)

B00908-01

(All EXC models)

–Mount the license plate holder with the license plate lamp, turn signals, and

reflector.

–Connect the electrical components.

–Connect the connector of the right turn signal with the connector that is marked

green.

–Connect the connector of the left turn signal with the connector that is marked

red.

800035-10

(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.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in

well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If

battery acid gets in the eyes, rinse with water for at least 15 minutes

and contact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 13)

–Install the battery. ( p. 14)

2 SETUP 8

B00097-01

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts fitting instructions.

–Apply the label included in the delivery (optional).

H01060-01

(All EXC models)

–Mount the mirror clamps on both sides.

B00909-01

–Mount and tighten the rear mirror on both sides.

–Mount the reflector.

–Set kilometers or miles. ( p. 17)

–Set the speedometer functions. ( p. 18)

–Set the clock. ( p. 18)

–Position all controls in their exact positions on the handlebar. Tighten all screws.

–Refuel. ( p. 17)

–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-

dover to the customer.

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