KTM 300 XC-W 2015

GRAPHICS

New, classy graphics with clear lines visually underscore the exacting standards of what KTM deems a true, cutting-edge offroad bike.

FRAME

The XC-W’s chassis is second to none and for 2015 the bikes will feature the striking Factory orange usually seen only on KTM’s race team machines. The modern and lightweight frame design with exceptional quality and performance created with by WP Performance Systems is made of lightweight, high strength chromoly steel sections. Not only does it provide easy handling and precise cornering, but also outstanding stability.

HANDLEBAR

All XC-W models are fitted with the super strong, tapered Neken handlebar made of high tensile strength aluminum alloy. The proven standard KTM mount allows to fix the handlebar in four different positions. 2015 sees the introduction of hand guards made of a new 2-component polymer for more durability and effective hand protection.

WHEELS

The XC-W’s feature new high-quality black anodized Giant rims with black spokes, that are mated to CNC-machined hubs and lightweight silver aluminum nipples for maximum stability at minimum weight. The XC-W’s feature new Dunlop GEOMAX AT81 tires.

SPEEDOMETER

A new MAE speedometer has been included on the MY 2015’s with a clean, minimalistic and integrated design. This includes the warning and indicator lights in a tidy, single unit with clear and more readily available information.

SUPERIOR SUSPENSION SETTINGS

The XC-W models feature WP suspension, which is specifically designed for Enduro racing and ensures maximum traction comprised with plenty of comfort. As expected, the compression and rebound damping can be adjusted to suit racing conditions and rider preference as well as separate high and low speed shock compression adjustments.

GRIPS

New, softer two-compound grips are used on MY 2015 XC-W models for increased comfort and less stress on the rider’s hands.

BODYWORK

The KTM designer's focus was to achieve complete ergonomic harmony between rider and bike for a more stable ride and effortless movement on the bike. Adding to the improvements is a high-quality seat foam core to maximize comfort and durability. With the new front fender, the designers omitted ribbing on the inside to reduce mud and dirt buildup while increasing rigidity over the previous component by 50%.

BATTERY

The 300 XC-W has a new, lighter 3Ah battery, which also contributes to the overall weight saving of the machine. NEW - shorter gearing on electric starter for higher initial torque and better starting.

OPTIMIZED ENGINE

An unbeatable power-to-weight ratio, low purchase and ownership costs makes the 300 the primary choice for extremely heavy enduro duty. The cutting-edge engine is started effortlessly via an electric starter and has been considered the most successful two-stroke power plant on the market. Best-in-class enduro performance combined with a perfectly geared six-speed transmission and a DDS clutch make this engine the absolute top dog in its segment. NEW - ignition cover with new gasket for improved sealing NEW - gasket on inner clutch cover for improved sealing.

Technical Data / Specifications

22.1 Engine

22.1.1 All 125 models

Design	1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
Displacement	124.8 cm³ (7.616 cu in)
Stroke	54.5 mm (2.146 in)
Bore	54 mm (2.13 in)
Crankshaft bearing	1 grooved ball bearing/1 roller bearing
Conrod bearing	Needle bearing
Piston pin bearing	Needle bearing
Pistons	Aluminum cast
Piston rings	2 half keystone rings
X (upper edge of piston to upper edge of cylinder)	0… 0.10 mm (0… 0.0039 in)
Z (height of control flap)	43.7 mm (1.72 in)
Primary transmission	23:73
Clutch	Multidisc clutch in oil bath/hydraulically activated
Gearbox	6-gear, claw shifted
Transmission ratio
1st gear	12:33
2nd gear	15:31
3rd gear	17:28
4th gear	19:26
5th gear	21:25
6th gear	20:20
Ignition	Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan
Ignition point (BTDC)	1.4 mm (0.055 in)
Spark plug	NGK BR9 ECMVX
Spark plug electrode gap	0.60 mm (0.0236 in)
Starting aid	Kick starter

22.1.2 All 200 models

Design	1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
Displacement	193 cm³ (11.78 cu in)
Stroke	60 mm (2.36 in)
Bore	64 mm (2.52 in)
Crankshaft bearing	1 grooved ball bearing/1 roller bearing
Conrod bearing	Needle bearing
Piston pin bearing	Needle bearing
Pistons	Aluminum cast
Piston rings	2 half keystone rings
X (upper edge of piston to upper edge of cylinder)	0… 0.10 mm (0… 0.0039 in)
Z (height of control flap)	47 mm (1.85 in)
Primary transmission	23:73
Clutch	Multidisc clutch in oil bath/hydraulically activated
Gearbox	6-gear, claw shifted
Transmission ratio
1st gear	12:33
2nd gear	15:31
3rd gear	17:28
4th gear	19:26

5th gear	17:19
6th gear	22:20
Ignition	Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan
Ignition point (BTDC)	1.6 mm (0.063 in)
Spark plug	NGK BR 8 EG
Spark plug electrode gap	0.60 mm (0.0236 in)
Starting aid	Kick starter and electric starter

22.1.3 All 250 models

Design	1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
Displacement	249 cm³ (15.19 cu in)
Stroke	72 mm (2.83 in)
Bore	66.4 mm (2.614 in)
Exhaust valve - Beginning of adjustment	5,700 rpm
Exhaust valve - end of adjustment with red auxiliary spring	7,300 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring	8,000 rpm
Exhaust valve - end of adjustment with green auxiliary spring	8,500 rpm
Crankshaft bearing	1 grooved ball bearing/1 roller bearing
Conrod bearing	Needle bearing
Piston pin bearing	Needle bearing
Pistons	Aluminum cast
Piston rings	2 half keystone rings
X (upper edge of piston to upper edge of cylinder)	0… 0.10 mm (0… 0.0039 in)
Z (height of control flap)	48 mm (1.89 in)
Primary transmission	26:72
Clutch	Multidisc clutch in oil bath/hydraulically activated
Gearbox	6-gear, claw shifted
Transmission ratio
1st gear	14:32
2nd gear	16:26
3rd gear	20:25
4th gear	22:23
5th gear	25:22
6th gear	26:20
Ignition	Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan
Ignition point (BTDC)	1.9 mm (0.075 in)
Spark plug	NGK BR 7 ES
Spark plug electrode gap	0.60 mm (0.0236 in)
Starting aid	Kick starter and electric starter

22.1.4 All 300 models

Design	1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
Displacement	293 cm³ (17.88 cu in)
Stroke	72 mm (2.83 in)
Bore	72 mm (2.83 in)
Exhaust valve - Beginning of adjustment	5,600 rpm
Exhaust valve - end of adjustment with red auxiliary spring	7,200 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring	7,900 rpm
Exhaust valve - end of adjustment with green auxiliary spring	8,400 rpm

Crankshaft bearing	1 grooved ball bearing/1 roller bearing
Conrod bearing	Needle bearing
Piston pin bearing	Needle bearing
Pistons	Aluminum cast
Piston rings	2 half keystone rings
X (upper edge of piston to upper edge of cylinder)	0… 0.10 mm (0… 0.0039 in)
Z (height of control flap)	48.5 mm (1.909 in)
Primary transmission	26:72
Clutch	Multidisc clutch in oil bath/hydraulically activated
Gearbox	6-gear, claw shifted
Transmission ratio
1st gear	14:32
2nd gear	16:26
3rd gear	20:25
4th gear	22:23
5th gear	25:22
6th gear	26:20
Ignition	Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan
Ignition point (BTDC)	1.9 mm (0.075 in)
Spark plug	NGK BR 7 ES
Spark plug electrode gap	0.60 mm (0.0236 in)
Starting aid	Kick starter and electric starter

22.2 Engine tightening torques

22.2.1 All 125/200 models

Screw, membrane core plate (All 125 models)	EJOT DELTA PT® 30x12	1 Nm (0.7 lbf ft)	–
Screw, membrane holder (All 125 models)	EJOT DELTA PT® 35x25	1 Nm (0.7 lbf ft)	–
Screw, outer clamping plate (All 125 models)	EJOT DELTA PT® 30x6	1 Nm (0.7 lbf ft)	–
Screw, membrane (All 200 models)	M4	2 Nm (1.5 lbf ft)	Loctite® 243™
Locking screw for bearing	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, alternator cover	M5	5 Nm (3.7 lbf ft)	–
Screw, centrifugal timer	M5	8 Nm (5.9 lbf ft)	Loctite® 243™
Screw, crankshaft position sensor	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, exhaust control cover	M5	5 Nm (3.7 lbf ft)	–
Screw, exhaust flange	M5	6 Nm (4.4 lbf ft)	–
Screw, ignition system/stator (All 125 models)	M5	6 Nm (4.4 lbf ft)	Loctite® 222™
Screw, lock washer, axle for control flap	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, locking lever	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, water pump wheel	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Adjustment cable, exhaust control	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Bleeder screw, cylinder head	M6	10 Nm (7.4 lbf ft)	–
Screw, alternator cover	M6	8 Nm (5.9 lbf ft)	–
Screw, clutch cover	M6	10 Nm (7.4 lbf ft)	–
Screw, clutch slave cylinder	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, clutch spring	M6	10 Nm (7.4 lbf ft)	–
Screw, engine case	M6	10 Nm (7.4 lbf ft)	–
Screw, exhaust control	M6	10 Nm (7.4 lbf ft)	–

Screw, gear oil level check	M6	10 Nm (7.4 lbf ft)	–
Screw, ignition system/stator (All 200 models)	M6	8 Nm (5.9 lbf ft)	Loctite® 243™
Screw, intake flange/reed valve housing	M6	10 Nm (7.4 lbf ft)	–
Screw, kick starter stop plate	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, shift lever	M6	14 Nm (10.3 lbf ft)	Loctite® 243™
Screw, shifting gate	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, starter motor (All 200 models)	M6	8 Nm (5.9 lbf ft)	–
Screw, water pump cover	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, cylinder head	M7	18 Nm (13.3 lbf ft)	–
Axle for control flap, exhaust control	M8	Step 1 3 Nm (2.2 lbf ft) Step 2 (loosen, counter- clockwise) 1/4 turn	–
Nut, cylinder base	M8	30 Nm (22.1 lbf ft)	–
Screw, kick starter	M8	25 Nm (18.4 lbf ft)	Loctite® 243™
Screw, shift drum locating	M8	25 Nm (18.4 lbf ft)	Loctite® 243™
Stud, cylinder base	M8	35 Nm (25.8 lbf ft)	–
Drain plug, water pump cover	M10x1	15 Nm (11.1 lbf ft)	–
Gear oil drain plug	M10x1	15 Nm (11.1 lbf ft)	–
Nut, rotor	M12x1	60 Nm (44.3 lbf ft)	–
Gear oil drain plug with magnet	M12x1.5	20 Nm (14.8 lbf ft)	–
Spark plug	M14x1.25	25 Nm (18.4 lbf ft)	–
Nut, primary gear	M16LHx1.5	130 Nm (95.9 lbf ft)	Loctite® 243™
Nut, inner clutch hub	M18x1.5	130 Nm (95.9 lbf ft)	Loctite® 243™
Cap nut, exhaust control	M26x1	35 Nm (25.8 lbf ft)	–

22.2.2 All 250/300 models

Screw, clamping plate	EJOT DELTA PT® 30x6	1 Nm (0.7 lbf ft)	–
Screw, membrane core plate	EJOT DELTA PT® 30x12	1 Nm (0.7 lbf ft)	–
Screw, membrane holder	EJOT DELTA PT® 35x25	1 Nm (0.7 lbf ft)	–
Screw, angle lever, exhaust control	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, clutch spring retainer	M5	6 Nm (4.4 lbf ft)	–
Screw, crankshaft position sensor	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, exhaust control cap	M5	5 Nm (3.7 lbf ft)	–
Screw, exhaust control cover	M5	6 Nm (4.4 lbf ft)	–
Screw, locking lever	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, retaining bracket of exhaust control	M5	7 Nm (5.2 lbf ft)	Loctite® 2701™
Screw, water pump wheel	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, alternator cover	M6	8 Nm (5.9 lbf ft)	–
Screw, bearing retainer	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, clutch cover	M6	10 Nm (7.4 lbf ft)	–
Screw, control flap, exhaust control	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, engine case	M6	10 Nm (7.4 lbf ft)	–
Screw, exhaust flange	M6	8 Nm (5.9 lbf ft)	–
Screw, gear oil level check	M6	10 Nm (7.4 lbf ft)	–
Screw, intake flange/reed valve housing	M6	10 Nm (7.4 lbf ft)	–
Screw, intermediate wheel bolt	M6	8 Nm (5.9 lbf ft)	Loctite® 648™
Screw, kick starter spring	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, kick starter stop plate	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, shift drum locating	M6	10 Nm (7.4 lbf ft)	Loctite® 243™

Screw, shift lever	M6	14 Nm (10.3 lbf ft)	Loctite® 243™
Screw, slave cylinder of the clutch	M6	10 Nm (7.4 lbf ft)	–
Screw, starter motor	M6	8 Nm (5.9 lbf ft)	–
Screw, stator	M6	8 Nm (5.9 lbf ft)	Loctite® 243™
Screw, water pump cover	M6	10 Nm (7.4 lbf ft)	–
Screw, cylinder head	M8	27 Nm (19.9 lbf ft)	–
Screw, kick starter	M8	25 Nm (18.4 lbf ft)	Loctite® 2701™
Nut, cylinder base	M10	35 Nm (25.8 lbf ft)	–
Drain plug, water pump cover	M10x1	15 Nm (11.1 lbf ft)	–
Nut, rotor	M12x1	60 Nm (44.3 lbf ft)	–
Gear oil drain plug with magnet	M12x1.5	20 Nm (14.8 lbf ft)	–
Spark plug	M14x1.25	25 Nm (18.4 lbf ft)	–
Nut, inner clutch hub	M18x1.5	120 Nm (88.5 lbf ft)	Loctite® 648™
Nut, primary gear	M18LHx1.5	150 Nm (110.6 lbf ft)	Loctite® 648™

22.3 Capacities

22.3.1 Gear oil

Gear oil (All 125/200 models)	0.70 l (0.74 qt.)	Engine oil (15W/50) ( p. 135)
Gear oil (All 250/300 models)	0.80 l (0.85 qt.)	Engine oil (15W/50) ( p. 135)

22.3.2 Coolant

Coolant

1.2 l (1.3 qt.)

Coolant ( p. 135)

22.3.3 Fuel

Total fuel tank capacity, approx. (EXC EU, EXC Six Days, EXC Factory Edition, 300 EXC BR)	9.5 l (2.51 US gal)	Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 136)
Total fuel tank capacity, approx. (EXC AU, XC‑W, XC-W Six Days)	10 l (2.6 US gal)	Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 136)

Fuel reserve, approx. (EXC EU, EXC Six Days, EXC Factory Edi- tion)	2 l (2 qt.)
Fuel reserve, approx. (EXC AU, XC‑W, XC-W Six Days)	2.5 l (2.6 qt.)

22.4 Chassis

Frame	Central tube frame made of chrome molybdenum steel tubing
Fork (EXC, XC‑W, EXC Factory Edition)	WP Suspension Up Side Down 4860 MXMA PA
Fork (Six Days)	WP Suspension Up Side Down 4860 4CS
Suspension travel
Front	300 mm (11.81 in)
Suspension travel
Rear	335 mm (13.19 in)
Fork offset (All 125/200 models)	22 mm (0.87 in)
Fork offset (All 250/300 models)	20 mm (0.79 in)
Shock absorber	WP Suspension PDS 5018 DCC
Brake system	Disc brakes, brake calipers on floating bearings
Brake discs - diameter
Front	260 mm (10.24 in)
Rear	220 mm (8.66 in)
Brake discs - wear limit

Front	2.5 mm (0.098 in)
Rear	3.5 mm (0.138 in)
Tire air pressure, road (All EXC models)
Front	1.5 bar (22 psi)
Rear	1.5 bar (22 psi)
Tire air pressure off road
Front	1.0 bar (15 psi)
Rear	1.0 bar (15 psi)
Secondary ratio (All 125 models)	14:50 (13:50)
Secondary ratio (200 EXC EU, 200 EXC AU)	14:45
Secondary ratio (200 XC‑W US)	14:48
Secondary ratio (All 250/300 EXC EU/AU models)	14:50 (13:50)
Secondary ratio (All 250/300 XC-W models)	13:50
Secondary ratio (300 EXC BR)	13:52
Chain	5/8 x 1/4"
Rear sprockets available	38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle	63.5°
Wheelbase (All 125/200 models)	1,471±10 mm (57.91±0.39 in)
Wheelbase (All 250/300 models)	1,482±10 mm (58.35±0.39 in)
Seat height unloaded	960 mm (37.8 in)
Ground clearance unloaded	355 mm (13.98 in)
Homologated weight without fuel, approx. (All 125 models)	95 kg (209 lb.)
Homologated weight without fuel, approx. (200 EXC EU, 200 EXC AU)	101.5 kg (223.8 lb.)
Homologated weight without fuel, approx. (All 250/300 EXC EU/AU models, 300 EXC BR)	104 kg (229 lb.)
Weight without fuel, approx. (200 XC‑W US)	99.5 kg (219.4 lb.)
Weight without fuel, approx. (250 XC‑W US)	101.9 kg (224.6 lb.)
Weight without fuel, approx. (300 XC‑W Six Days US, 300 XC‑W US)	102.1 kg (225.1 lb.)
Maximum permissible front axle load	145 kg (320 lb.)
Maximum permissible rear axle load	190 kg (419 lb.)
Maximum permissible overall weight	335 kg (739 lb.)

22.5 Electrical system

Battery (All 200/250/300 EU/AU/US models)	YTX4L-BS	Battery voltage: 12 V Nominal capacity: 3 Ah maintenance-free
Battery (300 EXC BR)	YTX5L-BS	Battery voltage: 12 V Nominal capacity: 4 Ah maintenance-free
Speedometer battery	CR 2430	Battery voltage: 3 V
Fuse (All 200/250/300 models)	58011109110	10 A
Headlight	HS1 / socket BX43t	12 V 35/35 W
Parking light	W5W / socket W2.1x9.5d	12 V 5 W
Indicator lamps	W2.3W / socket W1x4.6d	12 V 2.3 W
Turn signal (All EXC models)	R10W / socket BA15s	12 V 10 W
Brake/tail light	LED
License plate lamp	W5W / socket W2.1x9.5d	12 V 5 W

22.6 Tires

Validity	Front tires	Rear tires
(125 EXC EU)	80/100 - 21 M/C 51M TT MAXXIS MAXX CROSS SI PRO	120/90 - 18 M/C 65R TT MAXXIS MAXX ENDURO
(125 EXC Six Days EU, 125 EXC Fac- tory Edition EU)	90/90 - 21 M/C 54M TT Metzeler 6 DAYS EXTREME	120/90 - 18 M/C 65M TT Metzeler 6 DAYS EXTREME
(200/250/300 EXC EU/AU)	80/100 - 21 M/C 51M TT MAXXIS MAXX CROSS SI PRO	140/80 - 18 M/C 70R TT MAXXIS MAXX ENDURO
(250/300 Six Days EU, 250/300 EXC Factory Edition, 300 EXC BR)	90/90 - 21 M/C 54M TT Metzeler 6 DAYS EXTREME	140/80 - 18 M/C 70M TT Metzeler 6 DAYS EXTREME
(All XC-W models)	90/90 - 21 54M TT Dunlop GEOMAX AT 81 F	110/100 - 18 64M TT Dunlop GEOMAX AT 81

22.7 Fork

22.7.1 125 EXC EU, all 200 models, 125 EXC Factory Edition EU

Fork part number	14.18.7L.61
Fork	WP Suspension Up Side Down 4860 MXMA PA
Compression damping
Comfort	22 clicks
Standard	20 clicks
Sport	18 clicks
Rebound damping
Comfort	20 clicks
Standard	18 clicks
Sport	16 clicks
Spring preload - Preload Adjuster
Comfort	1 turn
Standard	2 turns
Sport	2 turns
Spring length with preload spacer(s)
Weight of rider: 65… 75 kg (143… 165 lb.)	513 mm (20.2 in)
Weight of rider: 75… 85 kg (165… 187 lb.)	513 mm (20.2 in)
Weight of rider: 85… 95 kg (187… 209 lb.)	513 mm (20.2 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)	3.8 N/mm (21.7 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)	4.0 N/mm (22.8 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)	4.2 N/mm (24 lb/in)
Fork length	940 mm (37.01 in)
Air chamber length	110+10 mm (4.33+0.39 in) −20 −0.79

Fork oil per fork leg

620 ml (20.96 fl. oz.)

Fork oil (SAE 4) (48601166S1) ( p. 135)

22.7.2 250/300 EXC EU/AU, XC-W US, 250/300 EXC Factory Edition, 300 EXC BR

Fork part number	14.18.7L.63
Fork	WP Suspension Up Side Down 4860 MXMA PA
Compression damping
Comfort	22 clicks
Standard	20 clicks
Sport	18 clicks
Rebound damping

Comfort	20 clicks
Standard	18 clicks
Sport	16 clicks
Spring preload - Preload Adjuster
Comfort	1 turn
Standard	2 turns
Sport	2 turns
Spring length with preload spacer(s)
Weight of rider: 65… 75 kg (143… 165 lb.)	513 mm (20.2 in)
Weight of rider: 75… 85 kg (165… 187 lb.)	513 mm (20.2 in)
Weight of rider: 85… 95 kg (187… 209 lb.)	513 mm (20.2 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)	4.0 N/mm (22.8 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)	4.2 N/mm (24 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)	4.4 N/mm (25.1 lb/in)
Fork length	940 mm (37.01 in)
Air chamber length	110+10 mm (4.33+0.39 in) −20 −0.79

Fork oil per fork leg

625 ml (21.13 fl. oz.)

Fork oil (SAE 4) (48601166S1) ( p. 135)

22.7.3 125 EXC Six Days EU

Fork part number	24.18.7N.61
Fork	WP Suspension Up Side Down 4860 4CS
Compression damping
Comfort	15 clicks
Standard	13 clicks
Sport	11 clicks
Rebound damping
Comfort	15 clicks
Standard	13 clicks
Sport	11 clicks
Spring length with preload spacer(s)	470 mm (18.5 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)	3.6 N/mm (20.6 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)	3.8 N/mm (21.7 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)	4.0 N/mm (22.8 lb/in)
Fork length	932 mm (36.69 in)
Air chamber length	100 mm (3.94 in)

Oil capacity per fork leg

635 ml (21.47 fl. oz.)

Fork oil (SAE 4) (48601166S1) ( p. 135)

22.7.4 250/300 Six Days

Fork part number	24.18.7N.63
Fork	WP Suspension Up Side Down 4860 4CS
Compression damping
Comfort	15 clicks
Standard	13 clicks
Sport	11 clicks
Rebound damping
Comfort	15 clicks
Standard	13 clicks
Sport	11 clicks
Spring length with preload spacer(s)	470 mm (18.5 in)

Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)	3.8 N/mm (21.7 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)	4.0 N/mm (22.8 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)	4.2 N/mm (24 lb/in)
Fork length	932 mm (36.69 in)
Air chamber length	100 mm (3.94 in)

Oil capacity per fork leg

635 ml (21.47 fl. oz.)

Fork oil (SAE 4) (48601166S1) ( p. 135)

22.8 Shock absorber

22.8.1 All 125/200 models

Shock absorber part number	12.18.7O.61
Shock absorber	WP Suspension PDS 5018 DCC
Compression damping, low-speed
Comfort	25 clicks
Standard	20 clicks
Sport	15 clicks
Compression damping, high-speed
Comfort	2 turns
Standard	1.5 turns
Sport	1.25 turns
Rebound damping
Comfort	28 clicks
Standard	24 clicks
Sport	22 clicks
Spring preload
Comfort	10 mm (0.39 in)
Standard	10 mm (0.39 in)
Sport	10 mm (0.39 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)	63 N/mm (360 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)	66 N/mm (377 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)	69 N/mm (394 lb/in)
Spring length	250 mm (9.84 in)
Gas pressure	10 bar (145 psi)
Static sag	29… 32 mm (1.14… 1.26 in)
Riding sag	100… 110 mm (3.94… 4.33 in)
Fitted length	417 mm (16.42 in)
Shock absorber fluid ( p. 136)	SAE 2.5

22.8.2 All 250/300 models

Shock absorber part number	12.18.7N.63
Shock absorber	WP Suspension PDS 5018 DCC
Compression damping, low-speed
Comfort	25 clicks
Standard	20 clicks
Sport	15 clicks
Compression damping, high-speed
Comfort	2 turns
Standard	1.5 turns
Sport	1.25 turns
Rebound damping

Comfort	28 clicks
Standard	24 clicks
Sport	22 clicks
Spring preload
Comfort	7 mm (0.28 in)
Standard	7 mm (0.28 in)
Sport	7 mm (0.28 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)	66 N/mm (377 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.)	69 N/mm (394 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.)	72 N/mm (411 lb/in)
Spring length	250 mm (9.84 in)
Gas pressure	10 bar (145 psi)
Static sag	33… 35 mm (1.3… 1.38 in)
Riding sag	105… 115 mm (4.13… 4.53 in)
Fitted length	417 mm (16.42 in)
Shock absorber fluid ( p. 136)	SAE 2.5

22.9 Chassis tightening torques

Spoke nipple, front wheel	M4.5	6 Nm (4.4 lbf ft)	–
Spoke nipple, rear wheel	M4.5	6 Nm (4.4 lbf ft)	–
Remaining nuts, chassis	M5	5 Nm (3.7 lbf ft)	–
Remaining screws, chassis	M5	5 Nm (3.7 lbf ft)	–
Screw, battery terminal (All 200/250/300 models)	M5	2.5 Nm (1.84 lbf ft)	–
Screw, shock absorber adjusting ring	M5	5 Nm (3.7 lbf ft)	–
Screws on the main silencer	M5	7 Nm (5.2 lbf ft)	–
Nut, cable on starter motor (All 200/250/300 models)	M6	4 Nm (3 lbf ft)	–
Remaining nuts, chassis	M6	10 Nm (7.4 lbf ft)	–
Remaining screws, chassis	M6	10 Nm (7.4 lbf ft)	–
Screw, ball joint of push rod on foot brake cylinder	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, chain sliding guard	M6	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, front brake disc	M6	14 Nm (10.3 lbf ft)	Loctite® 243™
Screw, rear brake disc	M6	14 Nm (10.3 lbf ft)	Loctite® 243™
Screw, throttle grip	M6	5 Nm (3.7 lbf ft)	–
Nut, foot brake lever stop	M8	20 Nm (14.8 lbf ft)	–
Nut, rear sprocket screw	M8	35 Nm (25.8 lbf ft)	Loctite® 2701™
Nut, rim lock	M8	12 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 (EXC, XC‑W)	M8	15 Nm (11.1 lbf ft)	–
Screw, bottom triple clamp (Six Days, EXC Factory Edition)	M8	15 Nm (11.1 lbf ft)	–
Screw, chain sliding piece	M8	15 Nm (11.1 lbf ft)	–
Screw, engine brace	M8	33 Nm (24.3 lbf ft)	Loctite® 2701™
Screw, fork stub	M8	15 Nm (11.1 lbf ft)	–
Screw, front brake caliper	M8	25 Nm (18.4 lbf ft)	Loctite® 243™
Screw, handlebar clamp	M8	20 Nm (14.8 lbf ft)	–
Screw, side stand attachment	M8	45 Nm (33.2 lbf ft)	Loctite® 2701™
Screw, subframe	M8	35 Nm (25.8 lbf ft)	Loctite® 2701™

Screw, top steering stem (EXC, XC‑W)	M8	20 Nm (14.8 lbf ft)	–
Screw, top steering stem (Six Days, EXC Factory Edition)	M8	17 Nm (12.5 lbf ft)	Loctite® 243™
Screw, top triple clamp (EXC, XC‑W)	M8	20 Nm (14.8 lbf ft)	–
Screw, top triple clamp (Six Days, EXC Factory Edition)	M8	17 Nm (12.5 lbf ft)	–
Engine bracket screw	M10	60 Nm (44.3 lbf ft)	–
Remaining nuts, chassis	M10	45 Nm (33.2 lbf ft)	–
Remaining screws, chassis	M10	45 Nm (33.2 lbf ft)	–
Screw, handlebar support	M10	40 Nm (29.5 lbf ft)	Loctite® 243™
Screw, bottom shock absorber	M12	80 Nm (59 lbf ft)	Loctite® 2701™
Screw, top shock absorber	M12	80 Nm (59 lbf ft)	Loctite® 2701™
Nut, seat fixing	M12x1	20 Nm (14.8 lbf ft)	–
Nut, swingarm pivot	M16x1.5	100 Nm (73.8 lbf ft)	–
Nut, rear wheel spindle	M20x1.5	80 Nm (59 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™
Screw, front wheel spindle	M24x1.5	45 Nm (33.2 lbf ft)	–

22.10 Carburetor 22.10.1 All 125 models

Carburetor type	KEIHIN PWK 36S AG
Carburetor identification number	FK125
Needle position	4th position from top
Jet needle	N84I (N1EF / N1EG)
Main jet	100 (172/175)
Idling jet	38x38 (42/45)
Starting jet	50 (85)
Idle air adjusting screw
Open	2.75 turns
Throttle slide	7 with cut-out
Slide stop	-

 

22.10.2 Carburetor tuning (All 125 models)

Danger

Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only.

• In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.  402138-01

  M/FT ASL	Sea level
  TEMP	Temperature
  ASO	Idle air adjusting screw open
  IJ	Idling jet
  NDL	Needle
  POS	Needle position from above
  MJ	Main jet

   Does not apply to sand surfaces! 22.10.3 200 EXC EU

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	FK027
  Needle position	3rd position from top
  Jet needle	NPRH (N1EH / N1EI / N1EJ)
  Main jet	100 (162/165)
  Idling jet	35x35 (40)
  Starting jet	50 (85)
  Idle air adjusting screw
  Open	1.5 turns
  Throttle slide	7 with cut-out
  Slide stop	Present

  22.10.4 200 EXC AU

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	FK012
  Needle position	2nd position from top
  Jet needle	R1475J (N1EH / N1EI / N1EJ)
  Main jet	162 (165)
  Idling jet	35 (40)
  Starting jet	85
  Idle air adjusting screw
  Open	1.0 turn
  Throttle slide	7 with cut-out
  Slide stop	Present

  22.10.5 200 XC‑W US

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	BZ5
  Needle position	2nd position from top
  Jet needle	N1EI (N1EH / N1EJ)
  Main jet	165 (162)
  Idling jet	40
  Starting jet	85
  Idle air adjusting screw
  Open	2.0 turns
  Throttle slide	7 with cut-out
  Slide stop	-

   

  22.10.6 Carburetor tuning (All 200 models)

  
  

  Danger
  Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only.

• In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402139-01

  M/FT ASL	Sea level
  TEMP	Temperature
  ASO	Idle air adjusting screw open
  IJ	Idling jet
  NDL	Needle
  POS	Needle position from above
  MJ	Main jet

   Does not apply to sand surfaces! 22.10.7 250 EXC EU, 250 EXC Six Days EU, 250 EXC Factory Edition EU

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	FK028
  Needle position	2nd position from top
  Jet needle	N84K (N2ZW / N2ZH / N2ZJ)
  Main jet	110 (172/175)
  Idling jet	38x38 (38/40)
  Starting jet	50 (85)
  Idle air adjusting screw
  Open	1.5 turns
  Throttle slide	7 with cut-out
  Slide stop	Present

  22.10.8 250 EXC AU

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	3600
  Needle position	1. Position from top
  Jet needle	N3CJ (N8RG / N8RH / N2ZH / N2ZJ / N2ZW)
  Main jet	160 (170/172/175)
  Idling jet	35 (38/40)
  Starting jet	85
  Idle air adjusting screw
  Open	3.5 turns
  Throttle slide	7 with cut-out
  Slide stop	Present

  22.10.9 250 XC‑W US

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	BZ6
  Needle position	3rd position from top
  Jet needle	N2ZW (N2ZH / N2ZJ)
  Main jet	175 (172)
  Idling jet	38 (40)
  Starting jet	85
  Idle air adjusting screw
  Open	2.0 turns
  Throttle slide	7 with cut-out
  Slide stop	-

   

  22.10.10 Carburetor tuning (All 250 models)

  
  

  Danger
  Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only.

• In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.  402140-01

  M/FT ASL	Sea level
  TEMP	Temperature
  ASO	Idle air adjusting screw open
  IJ	Idling jet
  NDL	Needle
  POS	Needle position from above
  MJ	Main jet

  Does not apply to sand surfaces! 22.10.11 300 EXC EU, 300 EXC Six Days EU, 300 EXC Factory Edition EU

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	FK029
  Needle position	2nd position from top
  Jet needle	N84K (N8RG / N8RH)
  Main jet	115 (170/172/175)
  Idling jet	38X38 (35)
  Starting jet	50 (85)
  Idle air adjusting screw
  Open	1.75 turns
  Throttle slide	7 with cut-out
  Slide stop	Present

  22.10.12 300 EXC AU

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	3600
  Needle position	1. Position from top
  Jet needle	N3CJ (N8RG / N8RH / N2ZH / N2ZJ / N2ZW)
  Main jet	160 (170/172/175)
  Idling jet	35 (38/40)
  Starting jet	85
  Idle air adjusting screw
  Open	3.5 turns
  Throttle slide	7 with cut-out
  Slide stop	Present

  22.10.13 300 XC‑W Six Days US, 300 XC‑W US, 300 EXC BR

  Carburetor type	KEIHIN PWK 36S AG
  Carburetor identification number	BZ7
  Needle position	3rd position from top
  Jet needle	N8RG (N8RH)
  Main jet	172 (170/175)
  Idling jet	35
  Starting jet	85
  Idle air adjusting screw
  Open	2.0 turns
  Throttle slide	7 with cut-out
  Slide stop	-

  22.10.14 Carburetor tuning (All 300 models)

  Danger
  Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only.

• In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.

402141-01

M/FT ASL	Sea level
TEMP	Temperature
ASO	Idle air adjusting screw open
IJ	Idling jet
NDL	Needle
POS	Needle position from above
MJ	Main jet

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