KTM 125 XC-W EU 2017 Handbuch

SETUP INSTRUCTIONS 2017

125 XC‑W

150 XC‑W

250 EXC

250 XC‑W

250 EXC Six Days

300 EXC

300 EXC Six Days

300 XC‑W Six Days

Art. no. 3213579en

INTRODUCTION 1

*3213579en*

3213579en

08/2016

INTRODUCTION

Perform the work described in these setup instructions 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 XC‑W EU (F7103Q3)

150 XC‑W US (F7175Q3)

250 EXC EU (F7303Q6)

250 EXC AU (F7360Q6)

250 XC‑W US (F7375Q3)

250 EXC Six Days EU (F7303Q2)

300 EXC EU (F7403Q6)

300 EXC AU (F7460Q6)

300 EXC BR (F7440Q6)

300 XC‑W US (F7475Q3)

300 EXC Six Days EU (F7403Q2)

300 XC‑W Six Days US (F7475Q2)

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

Condition

Packaging V2

–Remove the box and the plastic film.

Info

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 everything is

included and complete using 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 pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

H01768-10

(All EXC/EXC Six Days models)

–Position the turn signal indicator lamp in the speedometer bracket.

–Remove the headlight mask with the headlight. ( p. 24)

B02008-10

Condition

Packaging V12

–Remove the box and the plastic film.

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 and unpack the separate enclosure and attachments. Check that every-

thing is included and complete using the enclosed packing list.

–Have a lift stand available.

Lift stand (78129955100)

–Remove the two cable ties on the triple clamp.

402051-01

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

–Position the vehicle on a lift stand.

–Check the vehicle and attachments for transport damage.

–Install the shock absorber. ( p. 19)

2 SETUP 4

H01768-10

(All EXC/EXC Six Days models)

–Position the turn signal indicator lamp in the speedometer bracket.

402736-10

(all EXC/EXC Six Days models, 125 XC‑W)

–Position the connector retainer and speedometer on the upper triple clamp.

–Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

402737-10

(XC‑W US, XC‑W Six Days US)

–Position the speedometer on the upper triple clamp.

–Mount and tighten screws with the collar bushings.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

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

the upper and lower triple clamps.

–Install the fork legs. ( p. 20)

S01414-10

(All standard EXC/XC-W models)

–Remove screws and take off handlebar supports.

–Move the handlebar supports to the desired position and 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.

E00483-01

–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)

2 SETUP 5

Info

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

clamps.

Keep the gap widths equal when tightening.

S01415-10

(All Six Days models)

–Remove screws and take off handlebar supports.

–Move the handlebar supports to the desired position and 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.

S01413-01

–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.

S01450-01

(125 XC‑W EU)

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

S01451-01

(All XC‑W/XC‑W Six Days models, EXC EU, EXC Six Days EU, 300 EXC BR)

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

2 SETUP 6

S01452-01

(EXC AU)

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

S01453-01

(all EXC/EXC Six Days models, 125 XC‑W)

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

S01454-01

(XC‑W US, XC‑W Six Days US)

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

402148-01

(All EXC/EXC Six Days models)

–Mount the turn signal switch.

S01455-10

Condition

Packaging V12

(all EXC/EXC Six Days models, 125 XC‑W)

–Connect all plug-in connectors to the plug-in holder.

–Route the cable without tension and secure with cable tie.

2 SETUP 7

S01456-10

(XC‑W US, XC‑W Six Days US)

–Connect all plug-in connectors.

–Connect light pull switch with the yellow and white cables.

–Route the cable without tension and secure with cable tie.

S01457-10

–Route the cable without tension and secure with cable ties and cable holder.

H01060-01

(All EXC/EXC Six Days models)

–Mount the mirror clamps on both sides.

S01458-01

–Mount both rear mirrors with the adapter.

2 SETUP 8

E00475-01

–Preassemble the hand guards on the left and right.

S01461-10

–Mount the left hand guard.

–Mount the right hand guard.

S01459-01

–Secure the handlebar cushion with two cable ties.

–Install the front fender. ( p. 24)

–Install the front wheel. ( p. 20)

(XC‑W US, XC‑W Six Days US, All 250/300 EU/AU/US models)

–Remove the battery. ( p. 21)

–Recharge the battery. ( p. 22)

(All XC‑W/XC‑W Six Days models)

–Install the headlight mask with the headlight. ( p. 25)

(All EXC/EXC Six Days models)

–Remove the fuel tank. ( p. 17)

S01393-11

–Position turn signal cable harness.

–Insert the indicator lamp with the black and violet cable colors into socket .

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