KTM 250 XC-W User Manual

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OWNER'S MANUAL 2016

125 EXC EU

125 EXC Six Days EU

200 EXC EU

200 EXC AU

200 XC‑W US

250 EXC EU

250 EXC AU

250 EXC Six Days EU

250 XC‑W US

300 EXC EU

300 EXC AU

300 EXC Six Days EU

300 EXC BR

300 XC‑W US

300 XC‑W Six Days US

Art. no. 3213334en

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual9
3 Important Notes10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Service10
- Figures10
- Customer Service10
4 View of Vehicle11
- View of Vehicle, Front Left (Example)11
- View of Vehicle, Rear Right (Example)12
5 Serial Numbers13
- Chassis Number13
- Type Label13
- Key Number (All EXC Models)13
- Engine Number13
- Fork Part Number13
- Shock Absorber Part Number14
6 Controls15
- Clutch Lever15
- Hand Brake Lever15
- Throttle Grip15
- Kill Switch (All EXC Models)15
- Kill Switch (All XC-W Models)16
- Horn Button (All EXC Models)16
- Light Switch (All EXC Models)16
- Light Switch (All XC-W Models)16
- Turn Signal Switch (All EXC Models)16
- Emergency off Switch (EXC AU)17
- Electric Starter Button (All 200/250/300 EU/US Models, 300 EXC BR)17
- Electric Starter Button (EXC AU)17
- Overview of Indicator Lamps (All EXC Models)17
- Overview of Indicator Lamps (All XC-W Models)17
- Opening the Filler Cap18
- Closing the Filler Cap18
- Fuel Tap19
- Choke19
- Shift Lever19
- Kick Starter20
- Foot Brake Lever20
- Side Stand20
- Steering Lock (All EXC Models)20
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)21
7 Speedometer22
- Speedometer Overview22
- Activation and Test22
- Setting Kilometers or Miles22
- Setting the Speedometer Functions23
- Setting the Clock23
- Viewing the Lap Time23
- Display Mode SPEED (Speed)24
- Display Mode SPEED/H (Service Hours)24
- Setup Menu25
- Setting the Unit of Measurement25
- Display Mode SPEED/CLK (Time)26
- Setting the Clock26
- Display Mode SPEED/LAP (Lap Time)26
- Viewing the Lap Time27
- Display Mode SPEED/ODO (Odometer)27
- Display Mode SPEED/TR1 (Trip Master 1)27
- Display Mode SPEED/TR2 (Trip Master 2)28
- Setting TR2 (Trip Master 2)28
- Display Mode SPEED/A1 (Average Speed 1)28
- Display Mode SPEED/A2 (Average Speed 2)29
- Display Mode SPEED/S1 (Stop Watch 1)29
- Display Mode SPEED/S2 (Stop Watch 2)29
- Table of Functions30
- Table of Conditions and Menu Activation31
8 Preparing for Use32
- Advice on First Use32
- Running in the Engine33
- Preparing the Vehicle for Difficult Riding Conditions33
- Preparations for Riding on Dry Sand34
- Preparations for Riding on Wet Sand34
- Preparations for Riding on Wet and Muddy Surfaces35
- Preparations for Riding at High Temperatures and Low Speeds35
- Preparing for Riding at Low Temperatures or in Snow36
9 Riding Instructions37
- Checks and Maintenance Work When Preparing for Use37
- Starting37
- Start off38
- Shifting, Riding38
- Braking38
- Stopping, Parking39
- Transport39
- Refueling40
10 Service Schedule41
- Service Work (as Additional Order)42
11 Tuning the Chassis43
- Checking the Basic Chassis Setting with the Rider's Weight43
- Compression Damping of Shock Absorber43
- Adjusting the Low-Speed Compression Damping of the Shock Absorber43
- Adjusting the High-Speed Compression Damping of the Shock Absorber44
- Adjusting the Rebound Damping of the Shock Absorber44
- Measuring the Sag of the Unloaded Rear Wheel45
- Checking the Static Sag of the Shock Absorber45
- Checking the Riding Sag of the Shock Absorber46
- Adjusting the Spring Preload of the Shock Absorber46
- Adjusting the Riding Sag47
- Checking the Basic Setting of the Fork47
- Adjusting the Compression Damping of the Fork48
- Adjusting the Rebound Damping of the Fork49
- Adjusting the Spring Preload of the Fork (EXC, XC-W)50
- Handlebar Position51
- Adjusting the Handlebar Position52
12 Service Work on the Chassis54
- Raising the Motorcycle with the Lift Stand54
- Removing the Motorcycle from the Lift Stand54
- Bleeding the Fork Legs54
- Cleaning the Dust Boots of the Fork Legs55
- Removing the Fork Protector55
- Installing the Fork Protector56
- Removing the Fork Legs56
- Installing the Fork Legs57
- Removing the Lower Triple Clamp (200 XC-W US, 250 XC-W US, 300 EXC BR, 300 XC-W US)58
- Removing the Lower Triple Clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days)59
- Installing the Lower Triple Clamp59
- (200 XC-W Us, 250 XC-W Us, 300 Exc Br, 300 XC-W Us)59
- Installing the Lower Triple Clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days)61
- Checking the Play of the Steering Head Bearing64
- Adjusting the Play of the Steering Head Bearing65
- Greasing the Steering Head Bearing66
- Removing the Front Fender66
- Installing the Front Fender67
- Removing the Shock Absorber67
- Installing the Shock Absorber67
- Removing the Seat68
- Mounting the Seat68
- Removing the Air Filter Box Lid69
- Installing the Air Filter Box Lid69
- Removing the Air Filter69
- Installing the Air Filter70
- Cleaning the Air Filter and Air Filter Box70
- Sealing the Air Filter Box71
- Removing the Main Silencer71
- Installing the Main Silencer71
- Changing the Glass Fiber Yarn Filling of the Main Silencer71
- Removing the Fuel Tank72
- Installing the Fuel Tank73
- Checking the Chain for Dirt74
- Cleaning the Chain74
- Checking the Chain Tension74
- Adjusting the Chain Tension75
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide76
- Checking the Frame77
- Checking the Swingarm78
- Checking the Routing of the Throttle Cable78
- Checking the Rubber Grip79
- Additionally Securing the Rubber Grip79
- Adjusting the Basic Position of the Clutch Lever79
- Checking/Correcting the Fluid Level of the Hydraulic Clutch80
- Changing the Hydraulic Clutch Fluid80
- Removing the Engine Guard82
- Installing the Engine Guard82
13 Brake System83
- Checking the Free Travel of the Hand Brake Lever83
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)83
- Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)83
- Checking the Brake Discs84
- Checking the Front Brake Fluid Level84
- Adding Front Brake Fluid84
- Checking the Front Brake Linings85
- Changing the Front Brake Linings86
- Checking the Free Travel of Foot Brake Lever87
- Adjusting the Basic Position of the Foot Brake Lever87
- Checking the Rear Brake Fluid Level88
- Adding Brake Fluid for the Rear Brake89
- Checking the Rear Brake Linings89
- Changing the Brake Linings of the Rear Brake90
14 Wheels, Tires92
- Removing the Front Wheel92
- Installing the Front Wheel92
- Removing the Rear Wheel93
- Installing the Rear Wheel94
- Checking the Tire Condition94
- Checking the Tire Air Pressure95
- Checking the Spoke Tension95
15 Electrical System97
- Removing the Battery (All 200/250/300 Models)97
- Installing the Battery (All 200/250/300 Models)97
- Recharging the Battery (All 200/250/300 Models)98
- Changing the Main Fuse (All 200/250/300 Models)99
- Removing the Headlight Mask with the Headlight100
- Refitting the Headlight Mask with the Headlight100
- Changing the Headlight Bulb101
- Changing the Turn Signal Bulb (All EXC Models)101
- Checking the Headlight Setting102
- Adjusting the Headlight Range102
- Changing the Speedometer Battery103
16 Cooling System104
- Checking the Antifreeze and Coolant Level104
- Checking the Coolant Level105
- Draining the Coolant105
- Refilling with Coolant106
17 Tuning the Engine108
- Checking the Play in the Throttle Cable108
- Adjusting the Play in the Throttle Cable108
- Carburetor - Idle108
- Carburetor - Adjusting the Idle Speed109
- Emptying the Carburetor Float Chamber110
- Checking the Basic Position of the Shift Lever111
- Adjusting the Basic Position of the Shift Lever111
- Engine Characteristic - Auxiliary Spring (All 250/300 Models)111
- Engine Characteristic - Setting the Auxiliary Spring (All 250/300 Models)111
18 Service Work on the Engine113
- Checking the Gear Oil Level113
- Changing the Gear Oil113
- Draining the Gear Oil114
- Refilling with Gear Oil114
- Adding Gear Oil115
19 Cleaning, Care117
- Cleaning the Motorcycle117
- Checks and Maintenance Steps for Winter Operation118
20 Storage119
- Preparing for Use after Storage119
21 Troubleshooting120
22 Technical Data122
- Engine122
- All 125 Models122
- All 200 Models122
- All 250 Models123
- All 300 Models123
- Engine Tightening Torques124
- All 125/200 Models124
- All 250/300 Models125
- Capacities126
- Gear Oil126
- Coolant126
- Fuel126
- Chassis126
- Electrical System127
- Tires128
- Fork128
- EXC EU, All 200 Models128
- 250/300 Exc Eu/Au, XC-W Us, 300 Exc Br128
- EXC Six Days EU129
- 250/300 Six Days129
- Shock Absorber130
- All 125/200 Models130
- All 250/300 Models130
- Chassis Tightening Torques131
- Carburetor133
- 22.10.1 All 125 Models133
- 22.10.2 200 Exc Eu133
- 22.10.3 200 Exc Au133
- 22.10.4 200 XC-W Us133
- 22.10.5 250 EXC EU, 250 EXC Six Days EU134
- 22.10.6 250 Exc Au134
- 22.10.7 250 XC-W Us134
- 22.10.8 300 EXC EU, 300 EXC Six Days EU134
- 22.10.9 300 Exc Au135
- 22.10.10 300 Exc Br135
- 22.10.11 300 XC-W US, 300 XC-W Six Days US135
23 Carburetor Tuning136
- Carburetor Tuning136
- Carburetor Tuning (All 125 Models)136
- Carburetor Tuning (All 200 Models)137
- Carburetor Tuning (All 200 Models)138
- Carburetor Tuning (All 250 Models)139
- Carburetor Tuning (All 300 EXC Eu/Au/Six Days, 300 XC-W Us/Six Days)140
- Carburetor Tuning (300 EXC BR)141
- General Carburetor Tuning142
24 Substances143
25 Auxiliary Substances146
26 Standards148
27 List of Abbreviations149
28 Lisy of Symbols150
- Yellow and Orange Symbols150
- Green and Blue Symbols150
- Index151

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KTM 250 XC-W Specifications

General

Displacement	249 cm³
Bore x Stroke	66.4 mm x 72 mm
Starter	Electric starter
Transmission	6-speed
Fuel System	Carburetor
Cooling	Liquid cooled
Front Suspension	WP XPLOR-USD, Ø 48 mm
Front Brake	Disc brake
Rear Brake	Disc brake
Ground Clearance	370 mm
Seat Height	960 mm
Engine Type	2-stroke
Frame	Chromium Molybdenum Steel
Rear Suspension	WP Xplor PDS
Fuel Tank Capacity	9 liters

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