KTM F7103Q3, Setup Instructions

Page 1: ...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 ...

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Page 3: ...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 2016 KTM Sportmotorcycle GmbH Mattighofen Austria All rights reserved Repr...

Page 4: ...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 Refe...

Page 5: ...e 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 v...

Page 6: ...ws 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...

Page 7: ...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 Pos...

Page 8: ...ft 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 ...

Page 9: ...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 ...

Page 10: ...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 ...

Page 11: ...nector of the turn signal switch Secure turn signal relay with a cable tie and plug in the connector Install the headlight mask with the headlight p 25 S01462 10 Remove the cable tie s Remove screws with washers and hang the CDI unit to the side S01463 01 Route the turn signal cable harness from the front to the back as far as the bat tery compartment Position and secure turn signal cable harness ...

Page 12: ...Remove screw with the collar bushing Remove screw Remove screw with negative cable and contact disk S01416 11 Remove screws Carefully pull the tail light cable out of the frame paying attention to the plug as you do so Take off license plate holder with tail light toward the rear E00491 11 Remove screws and hang the tail light to the side Drill a hole at the marking to the size of the marking ...

Page 13: ...nd mount and tighten screws E00495 11 Carefully pass the tail light cable through the frame paying attention to the plug as you do so Position license plate holder on the rear Mount and tighten screws E00489 11 Mount and tighten screw with the collar bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount a...

Page 14: ...hten screw Guideline Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the battery p 23 Install the fuel tank p 18 E00496 11 Position turn signal on both sides mount nuts with washers and tighten Position license plate lamp on the license plate holder and mount and tighten screws Mount reflector on license plate ...

Page 15: ...ion spring as shown Spring engages in area S01396 11 Press the spring with special tool Pliers for footrest spring 79029083000 The special tool is applied to area on the footrest Mount pin S01397 11 Mount the washer and split pin S01398 10 Position the left footrest and pin Info Only insert the pin to the extent that the spring can still be mounted ...

Page 16: ...d tighten screws Guideline Screw frame protector M5 3 Nm 2 2 lbf ft Mount and tighten screws with the washers Guideline Screw frame protector M5 3 Nm 2 2 lbf ft Mount the cable tie s All Six Days models EXC AU Install the engine guard p 26 Unpack and mount the KTM PowerParts included in the delivery optional Info Read the accompanying KTM PowerParts fitting instructions Apply the sticker included ...

Page 17: ...2 SETUP 15 Position all controls in their exact positions on the handlebar Tighten all screws Prepare the vehicle according to the specifications in the KTM Dealer net for han dover to the customer ...

Page 18: ... can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 3 3 Removing the seat V00342 10 Remove screws Raise the rear of...

Page 19: ...oid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach...

Page 20: ...diately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them V00352 11 Main work Check throttle cable routing p 19 Position the fuel tank and fit the two spoilers to the sid...

Page 21: ... cable must be secured behind the fuel tank contact area rubber band If the throttle cable routing is not as specified Correct throttle cable routing Finishing work Install the fuel tank p 18 Mount the seat p 16 3 8 Installing the shock absorber V00344 11 Main work Push splash protector to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M12 80 Nm...

Page 22: ...om triple clamp M8 15 Nm 11 1 lbf ft V00355 11 All Six Days models Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft E00375 11 Position the brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie s Position the brake line wiring harn...

Page 23: ...ntain environmentally hazardous materials Do not dispose of batteries as household waste Dispose of batteries at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Preparatory work Switch off all power consu...

Page 24: ... minimum clearance from inflammable materials when charging batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged batteries if charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Warning Environmental hazard Batteries contain environmentally hazardous materials Do not dispose...

Page 25: ...ot in use 3 months Finishing work Mount the seat p 16 3 13 Installing the battery All 250 300 models XC W US XC W Six Days US H00386 10 Main work Insert the battery into the battery compartment with the terminals facing forward and secure with holding bracket XC W US XC W Six Days US All 250 300 EU AU US models Battery HJTZ5S FP 300 EXC BR Battery YTX5L BS Mount and tighten screw Guideline Remaini...

Page 26: ... 25 Check the headlight setting p 25 3 15 Removing the headlight mask with the headlight E00355 10 Switch off all power consumers and switch off the engine Detach the brake line and wiring harness from the headlight mask Release rubber bands Slide the headlight mask up and swing it forward E00356 10 All EXC EXC Six Days models Detach plug in connectors and take off the headlight mask with the head...

Page 27: ...cking 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 at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically a distance away from the wall Guideline Distance 5 m 16 ft The rider now sits down on the motorcycle...

Page 28: ...tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoi...

Page 29: ...arning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on th...

Page 30: ...or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed 3 24 Setting the speedometer functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is stationary 400318 01 Repeatedly press the button briefly until H appears at the bottom right of the display Press the butt...

Page 31: ...es Set the hour display with the button and or button Wait 3 5 seconds The next segment of the display flashes and can be set You can set the following segments in the same way as the hours by pressing the button and the button Info The seconds can only be set to zero If no button is pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved a...

Page 32: ...2 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp All stan dard EXC XC W models M8 15 Nm 11 1 lbf ft Screw bottom triple clamp All Six Days models M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 25 Nm 18 4 lbf ft Loctite 2701 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front b...

Page 33: ...31 Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 ...

Page 34: ...uper unleaded ROZ 95 RON 95 PON 91 p 32 Recommended supplier Motorex Cross Power 2T Super unleaded type C ROZ 95 RON 95 PON 91 mixed with 2 stroke engine oil 1 60 Standard classification Beschluss Nr 57 der ANP Agência Nacional do Petróleo ROZ 95 RON 95 PON 91 mixed with 2 stroke engine oil JASO FD p 34 1 60 Mixture ratio 1 60 Engine oil 2 stroke p 32 Super unleaded type C ROZ 95 RON 95 PON 91 p 3...

Page 35: ...6 AUXILIARY SUBSTANCES 33 Long life grease Recommended supplier Motorex Bike Grease 2000 ...

Page 36: ...ification 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 combustion is achieved even under extreme operating conditions ...

Page 37: ... 3213579en 3213579en 08 2016 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...