2008-2016 KTM 125/200/250/300 EXC, 200/250/300 XC-W (incl. Six Days)Maintenance schedule

Enduro / cross-country - 125-300cc two-stroke

Scheduled against engine operating hours, plus a per-race trigger and an annual item.

Verified

Every interval on this page was read directly from the OEM chart.

Intervals

S20A - Every 20 operating hours
S40A - Every 40 operating hours / after every race
S10N - Once after 10 operating hours
S40A - Every 40 operating hours
S80A - Every 80 operating hours / every 40 operating hours when used for motorsports
J1A - Annually

Full schedule (54 items)

2008-2016 KTM 125/200/250/300 EXC, 200/250/300 XC-W (incl. Six Days) scheduled maintenance items and intervals
Item	Action	Interval	Chart
Change the gear oil	Replace	Every 20 hrs	Service schedule
Change the glass fiber yarn filling of the main silencer	Replace	Every 20 hrs	Service schedule
Change the spark plug and spark plug connector	Replace	Every 20 hrs	Service schedule
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing	Inspect	Every 20 hrs	Service schedule
Check and charge the battery. (All 250/300 models)	Inspect	Every 20 hrs	Service schedule
Check that the electrical equipment is functioning properly	Inspect	Every 20 hrs	Service schedule
Check that the throttle cables are undamaged, routed without sharp bends and set correctly	Inspect	Every 20 hrs	Service schedule
Check the antifreeze and coolant level	Inspect	Every 20 hrs	Service schedule
Check the brake discs	Inspect	Every 20 hrs	Service schedule
Check the brake lines for damage and leakage	Inspect	Every 20 hrs	Service schedule
Check the cables for damage and routing without sharp bends	Inspect	Every 20 hrs	Service schedule
Check the chain tension	Inspect	Every 20 hrs	Service schedule
Check the chain, rear sprocket, engine sprocket, and chain guide	Inspect	Every 20 hrs	Service schedule
Check the fluid level of the hydraulic clutch	Inspect	Every 20 hrs	Service schedule
Check the frame and swingarm	Inspect	Every 20 hrs	Service schedule
Check the free travel of the foot brake lever	Inspect	Every 20 hrs	Service schedule
Check the free travel of the hand brake lever	Inspect	Every 20 hrs	Service schedule
Check the front brake fluid level	Inspect	Every 20 hrs	Service schedule
Check the front brake linings	Inspect	Every 20 hrs	Service schedule
Check the headlight setting. (All EXC models)	Inspect	Every 20 hrs	Service schedule
Check the heim joints at the top and bottom of the shock absorber	Inspect	Every 20 hrs	Service schedule
Check the idle	Inspect	Every 20 hrs	Service schedule
Check the intake diaphragm	Inspect	Every 20 hrs	Service schedule
Check the play of the steering head bearing	Inspect	Every 20 hrs	Service schedule
Check the rear brake fluid level	Inspect	Every 20 hrs	Service schedule
Check the rear brake linings	Inspect	Every 20 hrs	Service schedule
Check the rim run-out	Inspect	Every 20 hrs	Service schedule
Check the screws and nuts for tightness	Inspect	Every 20 hrs	Service schedule
Check the spoke tension	Inspect	Every 20 hrs	Service schedule
Check the tire air pressure	Inspect	Every 20 hrs	Service schedule
Check the tire condition	Inspect	Every 20 hrs	Service schedule
Check the wheel bearing for play	Inspect	Every 20 hrs	Service schedule
Check the wheel hubs	Inspect	Every 20 hrs	Service schedule
Clean the air filter and air filter box	Clean	Every 20 hrs	Service schedule
Final check: Check the vehicle for safe operation and take a test ride	Inspect	Every 20 hrs	Service schedule
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation	Lubricate	Every 20 hrs	Service schedule
Make the service entry in KTM DEALER.NET and in the service record	Inspect	Every 20 hrs	Service schedule
Perform a fork service	Inspect	Every 30 hrs	Maintenance work (as an additional order)
Change the piston and check the cylinder. (125 EXC EU, 125 EXC SIX DAYS EU)	Replace	Every 40 hrs	Maintenance work (as an additional order)
Check the clutch	Inspect	Every 40 hrs	Service schedule
Check the exhaust control for functioning and smooth operation	Inspect	Every 40 hrs	Service schedule
Check the starter drive. (All 250/300 models)	Inspect	Every 40 hrs	Maintenance work (as an additional order)
Check the swingarm bearing	Inspect	Every 40 hrs	Service schedule
Service the shock absorber	Inspect	Every 40 hrs	Maintenance work (as an additional order)
Change all engine bearings	Replace	Every 80 hrs	Maintenance work (as an additional order)
Change the connecting rod, conrod bearing and crank pin	Replace	Every 80 hrs	Maintenance work (as an additional order)
Change the piston and check the cylinder. (All 200/250/300 models)	Replace	Every 80 hrs	Maintenance work (as an additional order)
Check the transmission and shift mechanism	Inspect	Every 80 hrs	Maintenance work (as an additional order)
Check/set the carburetor components	Inspect	Every 80 hrs / 12 mo	Maintenance work (as an additional order)
Change the foot brake cylinder seals	Replace	Every 12 mo	Maintenance work (as an additional order)
Change the front brake fluid	Replace	Every 12 mo	Maintenance work (as an additional order)
Change the hydraulic clutch fluid	Replace	Every 12 mo	Maintenance work (as an additional order)
Change the rear brake fluid	Replace	Every 12 mo	Maintenance work (as an additional order)
Grease the steering head bearing	Lubricate	Every 12 mo	Maintenance work (as an additional order)

Every row above is factory schedule, straight from the chart. Intervals are shown in hrs.

Specs

From the 2012 manual's technical data section. Check yours before buying — these change between model years.

Displacement: 124.8 cm3 (125), 193 cm3 (200), 249 cm3 (250), 293 cm3 (300)
Idle speed: 1,400-1,500 rpm
Spark plug: NGK BR9 ECMVX (125), NGK BR 8 EG (200), NGK BR 7 ES (250/300)
Plug gap: 0.60 mm (0.0236 in)
Gear oil: capacity: 0.70 l (0.74 qt) on 125/200; 0.80 l (0.85 qt) on 250/300
spec: Engine oil 15W/50
Coolant: capacity: 1.2 l (1.3 qt)
Fuel: tank: 9.5-10 l (2.5-2.6 US gal) depending on model
spec: Super unleaded premixed with 2-stroke engine oil at 1:60
Tire pressure (cold): off-road front: 1.0 bar (15 psi)
off-road rear: 1.0 bar (15 psi)
road front: 1.5 bar (22 psi)
road rear: 1.5 bar (22 psi)
Secondary ratio: 14:50 (13:50) on 125 and 250/300 EXC; 14:45 on 200 EXC; 14:48 on 200 XC-W; 13:50 on 250/300 XC-W
Drive chain: 5/8 x 1/4"

Legend

periodic — Item is marked in this interval column

From the manual

Any further work resulting from the required or recommended work must be ordered and invoiced separately.
Different service intervals may apply in your country depending on local operating conditions.
Work in the service schedule must be carried out by an authorised KTM workshop and recorded, otherwise warranty claims are void.

Source: KTM Owner's Manual 2012 125/200/250/300 EXC and XC-W (Art. no. 3211718en), section 8 Service Schedule · Chart read from the 2012 manual. Intervals change between model years — confirm against yours.

Always confirm intervals, torque specs and part numbers against your own service manual. This site is a shopping aid, not a repair manual.

Open the hour meter tool