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2014 KTM 250-300 EXC XC-W 6 Days Repair manual

2014 KTM 250-300 EXC XC-W 6 Days Repair manual

Online PDF 2014 KTM 250-300 EXC XC-W Six Days Repair manual

Read this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was 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 repair 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 repair work will be performed by a fully trained mechanic.

Ail specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical speciticetions, 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain speccial equipment that does not belong to the regular scope of supply.

10  KTM 250-300 EXC XC-W manual EXHAUST. ...  83
10.1  KTM 250-300 EXC XC-W manual Removing the manifold. .    83
10.2  KTM 250-300 EXC XC-W manual Installing the manifold. ....   83
10.3  KTM 250-300 EXC XC-W manual Removing main silencer. .... 84
10.4  KTM 250-300 EXC XC-W manual Installing the main silencer. .....  84
10.5  KTM 250-300 EXC XC-W manual Changing the glass fiber yarn filling of the main silencer. .  84

11  KTM 250-300 EXC XC-W manual KTM 250-300 EXC XC-W manual AIR FILTER. . 86
11.1  KTM 250-300 EXC XC-W manual Removing the air filter box lid. .. 86
11.2  KTM 250-300 EXC XC-W manual Installing the air filter box lid. ... 86
11.3  KTM 250-300 EXC XC-W manual Sealing the air filter box. ..  86
11.4  KTM 250-300 EXC XC-W manual Removing the air filter. ....  86
11.5  KTM 250-300 EXC XC-W manual Installing the air filter. .  87
11.6  KTM 250-300 EXC XC-W manual Cleaning the air filter and air filter box. .  87 

12  KTM 250-300 EXC XC-W manual FUEL TANK, SEAT, TRIM. . 89
12.1  KTM 250-300 EXC XC-W manual Opening filler cap. ...   89
12.2  KTM 250-300 EXC XC-W manual Closing filler cap. ..  89
12.3  Removing the seat.  89
12.4  KTM 250-300 EXC XC-W manual Mounting the seat. .  90
12.5  KTM 250-300 EXC XC-W manual Removing the fuel tank. ..... 90
12.6  KTM 250-300 EXC XC-W manual Installing the fuel tank. ....  91
12.7  KTM 250-300 EXC XC-W manual Changing the fuel screen. .  92
12.8  KTM 250-300 EXC XC-W manual Changing the fuel filter. ..... 93
12.9  KTM 250-300 EXC XC-W manual Changing the fuel pump. ..  95
12.10  KTM 250-300 EXC XC-W manual Checking the fuel pressure.    96 

13  KTM 250-300 EXC XC-W manual MASK, FENDER.. . .. 98
13.1  KTM 250-300 EXC XC-W manual Removing the front fender. .. 98
13.2  KTM 250-300 EXC XC-W manual Installing the front fender.  98
13.3  KTM 250-300 EXC XC-W manual Removing headlight mask with headlight. .... 98
13.4  KTM 250-300 EXC XC-W manual Refitting the headlight mask with the headlight.  99

14  KTM 250-300 EXC XC-W manual WHEELS. ..  100
14.1 KTM 250-300 EXC XC-W manual Checking the tire air pressure. . 100
14.2 KTM 250-300 EXC XC-W manual Checking the tire condition. ....  100
14.3 KTM 250-300 EXC XC-W manual Checking the brake discs. .. 101
14.4 KTM 250-300 EXC XC-W manual Checking spoke tension. .  101
14.5  KTM 250-300 EXC XC-W manual Front wheel. .  102
14.5.1  KTM 250-300 EXC XC-W manual Removing the front wheel. .. 102
14.5.2  KTM 250-300 EXC XC-W manual Installing the front wheel. ...  102
14.5.3  KTM 250-300 EXC XC-W manual Removing the front brake disc. .... 103
14.5.4  KTM 250-300 EXC XC-W manual Installing the front brake disc. .... 103
14.6  KTM 250-300 EXC XC-W manual Rear wheel. .... 103
14.6.1  KTM 250-300 EXC XC-W manual Removing the rear wheel. ...  103
14.6.2  KTM 250-300 EXC XC-W manual Installing the rear wheel. ....  104
14.6.3  KTM 250-300 EXC XC-W manual Removing the rear brake disc. ..... 105
14.6.4  KTM 250-300 EXC XC-W manual Installing the rear brake disc.  105
14.6.5  KTM 250-300 EXC XC-W manual Checking the chain tension. ..  106
14.6.6  KTM 250-300 EXC XC-W manual Adjusting the chain tension. .  106
14.6.7  KTM 250-300 EXC XC-W manual Checking the chain, rear sprocket, engine sprocket and chain guide. ...  107
14.6.8  KTM 250-300 EXC XC-W manual Checking for chain dirt accumulation. ....  109
14.6.9  KTM 250-300 EXC XC-W manual Cleaning the chain. ..... 109 

15  KTM 250-300 EXC XC-W manual WIRING HARNESS, BATTERY. .... 110
15.1  KTM 250-300 EXC XC-W manual Changing the main fuse. .  110
15.2  KTM 250-300 EXC XC-W manual Changing the fuses of individual power consumers.  . Ill
15.3  KTM 250-300 EXC XC-W manual KTM 250-300 EXC XC-W manual Removing the battery. ..... 112
15.4  KTM 250-300 EXC XC-W manual Installing the battery.  112
15.5  KTM 250-300 EXC XC-W manual Checking the charging voltage. ..  113
15.6  KTM 250-300 EXC XC-W manual Checking the quiescent current.  113 

16  KTM 250-300 EXC XC-W manual BRAKE SYSTEM.   114
16.1  KTM 250-300 EXC XC-W manual Checking the front brake linings. ..... 114
16.2  KTM 250-300 EXC XC-W manual Changing the front brake linings. ..... 114
16.3  KTM 250-300 EXC XC-W manual Checking free travel of hand brake lever. ... 116
16.4  KTM 250-300 EXC XC-W manual Adjusting the basic position of the hand brake lever (XC-W). ..  116
16.5  KTM 250-300 EXC XC-W manual Adjusting free travel of hand brake lever (all EXC models). .  116
16.6  KTM 250-300 EXC XC-W manual Checking the brake fluid level of the front brake.    117
16.7 KTM 250-300 EXC XC-W manual Adding front brake fluid. .  117
16.8 KTM 250-300 EXC XC-W manual Changing the front brake fluid. ..  118
16.9 KTM 250-300 EXC XC-W manual Checking the rear brake linings.  119
16.10 KTM 250-300 EXC XC-W manual Changing the rear brake linings.  119
16.11 KTM 250-300 EXC XC-W manual Checking the free travel of foot brake lever. ..... 121
16.12  KTM 250-300 EXC XC-W manual Adjusting the basic position of the foot brake lever.    121
16.13  KTM 250-300 EXC XC-W manual Checking the rear brake fluid level. .  122
16.14  KTM 250-300 EXC XC-W manual Adding rear brake fluid. ..  122
16.15  KTM 250-300 EXC XC-W manual Changing the rear brake fluid. . 123 

17  KTM 250-300 EXC XC-W manual LIGHTING SYSTEM, INSTRUMENTS. ..  125
17.1  KTM 250-300 EXC XC-W manual Checking the headlight setting. .  125
17.2  KTM 250-300 EXC XC-W manual Adjusting the headlight range. . 125
17.3  KTM 250-300 EXC XC-W manual EXC EU/AUS/USA, XC-W. .. 125
17.3.1  KTM 250-300 EXC XC-W manual Speedometer overview. .. 125
17.3.2  KTM 250-300 EXC XC-W manual Activation and test. ..... 126
17.3.3  KTM 250-300 EXC XC-W manual Setting kilometers or miles. ..  126
17.3.4  KTM 250-300 EXC XC-W manual Adjusting the speedometer functions. ... 126
17.3.5 KTM 250-300 EXC XC-W manual Setting the clock. . 127
17.3.6 KTM 250-300 EXC XC-W manual Setting the wheel circumference. .... 127
17.3.7 KTM 250-300 EXC XC-W manual Querying lap time . .....  128
17.4  KTM 250-300 EXC XC-W manual EXC SIX DAYS. ...  128
17.4.1  KTM 250-300 EXC XC-W manual Speedometer overview. .. 128
17.4.2  KTM 250-300 EXC XC-W manual Activation and test. ..... 129
17.4.3 KTM 250-300 EXC XC-W Setting kilometers or miles. ..  129
17.4.4 KTM 250-300 EXC XC-W Setting the speedometer functions.   129
17.4.5 KTM 250-300 EXC XC-W Setting the clock. .  130
17.4.6  KTM 250-300 EXC XC-W Activating the additional functions.   130
17.4.7  KTM 250-300 EXC XC-W Setting the wheel circumference. .... 131
17.4.8  KTM 250-300 EXC XC-W Viewing the lap time. .   131 

18 KTM 250-300 EXC XC-W ENGINE. ...  133
18.1  KTM 250-300 EXC XC-W Removing the engine.  133
18.2  KTM 250-300 EXC XC-W Installing the engine. .  137
18.3  KTM 250-300 EXC XC-W Engine disassembly. ..  142
18.3.1  KTM 250-300 EXC XC-W Preparations. ..  142
18.3.2  KTM 250-300 EXC XC-W Draining the engine oil. . 142
18.3.3  KTM 250-300 EXC XC-W Removing the clutch push rod. ...  143
18.3.4  KTM 250-300 EXC XC-W Removing the oil filter. .. 143
18.3.5  KTM 250-300 EXC XC-W Removing the starter motor. ..  144
18.3.6  KTM 250-300 EXC XC-W Removing the kickstarter. ... 144
18.3.7  KTM 250-300 EXC XC-W Removing the spark plug. ... 144
18.3.8  KTM 250-300 EXC XC-W Removing the valve cover. ... 144
18.3.9  KTM 250-300 EXC XC-W Removing the alternator cover. .... 145
18.3.10  KTM 250-300 EXC XC-W Positioning the engine at ignition top dead center. . 145
18.3.11  KTM 250-300 EXC XC-W Removing the timing chain tensioner. ... 146

Managing the Vehicle Damage Repair Process
In the event that your vehicle requires damage repairs, GM recommends that you take an active role in its repair. If you have a pre-determined repair facility of choice, take your vehicle there, or have it towed there. Specify to the facility that any required replacement collision parts be original equipment parts, either new Genuine GM parts or recycled original GM parts. Remember, recycled parts will not be covered by your GM vehicle warranty.

Insurance pays the bill for the repair, but you must live with the repair. Depending on your policy limits, your insurance company may initially value the repair using aftermarket parts. Discuss this with your repair professional, and insist on Genuine GM parts. Remember if your vehicle is leased you may be obligated to have the vehicle repaired with Genuine GM parts, even if your insurance coverage does not pay the full cost.

If another party’s insurance company is paying for the repairs, you are not obligated to accept a repair valuation based on that insurance company’s collision policy repair limits, as you have no contractual limits with that company. In such cases, you can have control of the repair and parts choices as long as cost stays within reasonable limits.

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