Home

english - KTMSHOP.se

Contents

1. pos 6un suuo 3jeusuel one jeq 1 T Jo310duui Pe WUOD se jd ui u y M e ueApy OM UBUM OT uy ep ou YUL PNJ HANS YM OU YAdNS ut zoe uuu 09 v9 ut 9ZT Z 9 2 GZS uD Eet LO gtt pue SEIL YUM puI buis 2 ubiseg OOZ S94 SZT SCT XS SCT OOZ SZT ANIDNG VIVA TWOINHDAL 66 LO doas apis apis JOPUISSI do 3ueuugsn pe Iy 9 9 9 9 9 9 9 l I l I do IZON OZ ON HZON IZON HZON 9ZON IZON HZON 9ZON IZON OZON HZON fitt 9
2. Starting when engine is warm 1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Putthe gear in neutral 4 Open throttle to Y2 and kick down kickstarter vigorously W hat to do when the engine is flooded 1 Close fuel tap 2 Start engine with full throttle If necessary unscrew spark plug and dry it 3 Oncethe engine is running open fuel tap again Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time A WARNING A BEFORE YOU START OFF CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG RIGHT UP TO THE TOP IF THE STAND DRAGS ON THE FLOOR YOU MAY LOSE CONTROL OF YOUR MOTORCYCLE BEFORE STARTING FOR AN OFF ROAD TOUR IT IS RECOMMENDED TO ADDITIONALLY SECURE THE SIDE STAND WITH THE RUBBER BAND ON THE AIR FILTER BOX Shifting Riding You are now in first gear referred to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Turn down the throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and open the throttle If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases alt hough the engine will use less gas Only give as much gas as the engine c
3. eene 4 Clutch Jeer aret tenete er Pe beoe 4 Hand brake lever esses 4 Speedometer indicator lamp 5 Odometer EXC USA 5 Speedometer indicator lamps 5 Ignition cett 5 Short circuit button SX 6 Combination switch ESCH 6 Headlamp switch EXC UA 6 Flasher SWATCH uico aad oen rnt ar ern irata 6 Emergency OFF switch 5 6 FICE Cap t dtr tet RM RORIS 7 Refueling fuels eee eds 7 HH 7 ChokeKnob s antec t qo ento o ete beer 8 Shift leer cor cr ci a Pe bec ce eee c 8 ee 8 Foot brake pedal 8 Compression damping of 8 Rebound damping of fork sse 9 Compression damping of shock absorber 9 Rebound damping of shock 9 Steering lock ntes 9 Center standi eu e rene rd Eu 9 DRIVING INSTRUCTIONS scienne 10 PERIODIC LUBRICATIO N AND M AINTENANCE SCHEDULE 12 M AINTENANCE WORK ON CHASSIS AND ENGINE 13 Changing the original position of the clutch lever 13 Checking and adjusting the steering head bearing 13 Pivotbearirig aet eer ene dts 14 Check chain tension 14 Correct ch
4. pue s3jeus UOISSILUSUeL ACH UJN 09 IXCI Pym 0 520 0 jeipei UJN O 4 de pue UO UNST LW syoq S80 0 002 90 0 eouejeoap DUDU SANOUYOL ONINGLLHDLL SC NOCH ONLLLY SHONVtH IOL JUL Ji 9 ge1 ess Jo3aungue JPN epi Ael JO3oungge J03eJouob ou MOr ou jndino soyessuay CIC NYSNA OA TZ 5 NYSNA Om TZ NYSNA OAJ 545 uoniub do ET Do SZ eS 3e 9609 Gol San 8 JO AGT 3vT IET 945 8 0 uone ugn 1e 9 4G 1090 6 22 61 6 6 22 61 22 61 1090 92 81 92 81 92 81 92 81 92 81 92 81 Je25 yc 62 51 62 51 62 51 62 51 62 51 62 51 62 51 DXN OX W Jest panpe pads UOISSI
5. MOTT AZT ACT JOE baue ou 3ndino E Z NYSNA OA TZ NYSNA OX 545 uoniub NYSNA OX E Z EAZ ZAZ WSN do Do SZ Bes 09 SZJ Ue Ov Sam CT 104 AST 3 3 T 1 5 OF MOZ L O 05 Sje pouds Jeac ecc 02 6L LT ZZ SC TC GZ TC Sc TC uds 92 61 92 61 92 61 92 61 up 827 LT 87 LT 92 LT 87 LT Jeob pig DE DE ST Jeob St c ES St ZE 6 ones wea pejyenpe mep peeds 9 UOISSIUUISUPJ 1945 pedo ur emp 21 27 oneJ Areuuud unds 3n dey JEE 2 de6 ut 8 WLU 0 uuu 09 0 9H 8 98 8169 d DGLE GO ut 900 tuu ot Geo ut 550 0 WL Buug uoniub Ul ZZ O lt lt 0 0 WLU 09 0 pua X uoissaJduuoo uoissaJduuoo euo DUU uo3sid uojsid 35e
6. UU ZZ BL Z eL 99 2 WLU 5 69 79 91055 310g uD 89 WDD 62 WD quauueoe dsip UOJF d Jequueu enbJoL WD pue Wa SAS Jepur A2 e Durs 2 S94 XS S94 00 DA XS OSZ Elte de WSN Jo 3no sjopouu jle 66 SD3 DX4 XS O8 O00E 0SZ ANIDNG VLVd TWOINHDAL do apis apis pu apu pun apu uado 9 9 9 9 9 9mouu 1 I do uonisod IZON H ZON O ZON IZON O ZON H ZON S8N O S8N S8N O S8N IZON H ZON OZON Es S8 3f Bues 0 5 05 0 5 ZLT OLT 89T SLT SLT ZLT 89T OLT 8ZT ZLT OLT SLT SLT ZLT OLT SLT SLT OLT 89T ZZT Pluen 869090 8640 0 865001 865001 865060 Jequunu UPJ UPJ Joyunqe vrivuisnv DA OX 5 vrivuisnv DA OXIA xs ose 598 S93 00 052 DA DXN ose ONLLLS HO
7. F THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL TRAVEL THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS MIXED IN THE FUEL IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Turn off gas and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed A WARNING A WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEAKER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL Stopping and parking Brake motorcycle and shift gears to idling To switch off the engine depress short circuit switch until the engine stops or switch off ignition Close fuel tap A WARNING A NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING THE ENGINE EXHAUST PIPE MUFFLER BRAKE ROTORS AND SHOCK ABSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER STARTING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT
8. JZON IZON OZON JZ ON HZON Sg Sg S8 Sg Sg Sg Sg Pf Sv Sv Sv Sv 8 Jet Jet Gulp S8T Z8T 8LT SLT O8T O8T 081 081 61 261 061 881 OST 561 261 881 06 S61 Z6T 88T yf ute 86S0VT 86S0ST 86SOLT 86 lt 0 8690 86S09T Jequunu Joyounqued 6 Md UE 6 UPJ 6 Md UUJ 6 Md UI 6 Md UPJ 6 UPJ 6 UPJ doyaunqued vVrIVHISnv S93 002 509 See WSN DA 002 SZT sees 155 YOLRRMNEYVD DVd 4 wu S 0 0 lt 0 OCO 100 se ww 05 0 0 Jepui o upon G O LD WUN Sb OT W 6T SSSSANDIDIHL 1906500 2 UJN 9 YJO 72 UJN OOT uuiebuiws INN OZ SC DPI gt 1 96 9 OW S3JOQ LOD pue 88 OCT 904 PNP Juu INN ww eg MU sbuuds Con EET NOST S TX9T peany HT Pods Areuuud 104 INN Ot70 OZ O
9. 449 WNS 9 IN pue ase xuel 913 74 WN OOT 930201 qny uu 490 INN WN OST 272 2311201 GTX8T peasy pods INN vv WN 09 913 SZ WN SE eseq puI SIN 913 SZ WN SE syoq ww pue SYEYS UOISSILUSULI ww Z O O IZO O eouejeep eripe ww yo0 t 0 de pue 08 WLU 8070 SANOYOL ONINGLHOLL 00 900 OSZ lt 0 0 eouejeop DUDU UO SCH NOT TIO SHONVtHIOL LU OU d Je Ai t 295 soJINqUeD JOIN JONA MOET J403eJouob ou MOET JOS ou jndino soyessuay TD TZ NVSNAOW TTA TAZ 5 5 do Do SZ 3629 3e 9609 Gol San 8 10 AGT 3 IET S3e pouds VXSA 1 5 8 0 uone ugn Jeac 1299 S 1090 ub 22 61 6 22 61 6 1090 92 81 92 81 92 81 LCLT 1090 pul 62 51 62 51 62 51 oge Je2c panpe mep pads
10. SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Compression damping of fork The compression damping mechanism is built into the left fork tube It only regulates the degree of damping during compression By turning the adjusting screw C COM the degree of damping of the compression can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD ADJUSTM ENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Type Marzocchi 91 15 clicks Type White Power 918T767 12 clicks White Power 9187768 12 clicks Type White Power 9187769 12 clicks Rebound damping of fork The rebound damping mechanism is built into the right fork tube It only regulates the degree of damping during rebounding By turning the adjusting screw REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTM ENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of for
11. UOISSIUUSUEJ ST3 4H 1945 podo yq ur u anp 251 ejdninuu uon 21 92 One lt ands 3n 1 5 21 52 lt unds o0zZ OGLL DAL 0025 unu 00 5 uiu 00 lt Hes DAL ut 66 T ut z T uuu ut 6T JB nZ 4 UOISUBLULG ut 00 9 0 deb epoupen Woa 8 ON gt ueds Gert 90 0 WW DALE LG ZT U 80 0 tuu rz o S ET U 070 o S ET 00 o ZT U 00 Ww 67 Buug uoniub ut 7OO 0 0 uuu 0 pul saddn Pd sbr dan nX UOISUSUIQ uoissaJduuoo DUU uojsid 35e uojsid 4520 jeg 1 T 3jeusxue1 y UO 04 OI XIU Op T esn Jo INOA Pe WOD se jd ydnop ui u y M IIo epeJ6 Q9 T 06 ones o e ue py 945 J epeJ5 ubiu uy GG ou YLSI PNJ YIdNS ul 862
12. Check thickness of disc brake pads Check brake discs Inspect condition and installation of front and rear brake hoses Check free travel and free movability of hand brake lever and foot brake lever Check the oil level in the master cylinder of the hydraulic clutch Change the oil of the hydraulic clutch Check telescopic fork action Check telescopic fork for leaks Push up the protective bellows and remove the dirt the drain holes must be free of obstructions M arzocchi fork Clean the dust scrabbers of the telescopic force WP Extreme fork Undo the bleeder screws at the fork legs Change oil of telescopic fork Service telescopic fork completely Check steering head bearing free play Clean and regrease steering head bearing Check setting and damping of shock absorber Service shock absorber completely Grease swingarm needle bearings dont grease the pivot bearing for the shock absorber Check for even spoke tension and rim alignment Check wheel bearings Check tires for cuts and air pressure Check cables for damage and free movement Adjust and oil control cables Check electrical system Check battery holder and connections CH Singapore Check adjustment of headlight Apply contact spray to light switches flasher switches and ignition lock Check all bolts nuts screws and clamps for proper tightness Clean and lu
13. FORES 12544007 250 300 380 SX MXC Cod EHS BEDIENUNGSANLEITUNG MANUEL D UTILISATION OWNER S HANDBOOK MANUAL DE INSTRUCCIONES MANUALE D USO ART NR 3 205 51 6 98 IM PO RTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COM PLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PRO PERLY IN YOUR OWN INTEREST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLO WS WARNING A IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE 7 CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE Please insert the series numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited wners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by
14. ter support in the filter box making sure to properly center them and fix them with the filter holding bracket Exhaust system Silencers whose caps is detachable are filled with glass fiber yarn Check this packing in regular intervals Glass fiber yarn that is too loose may cause a drop in performance and curtail the silencer s silencing effect To replace the glass fiber yarn packing G remove the silencer cap and pull off the outer tube Use adhesive tape to attach the new glass fiber yarn packing to the inner tube and slide on outer tube M ount silencer cap Glass fiber yarn packings are available at your authorized KTM dealer WARNING A THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING Do NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN TO AVOID BURNS Cleaning the spark arrestor EXC USA With these models the spark arrestor is part of the exhaust silencer Clean it every 4000 km 2500 miles to guarantee proper functioning Also clean the spark arrestor when replacing the glass fiber yarn filling After assembling the silencer remove the plug and start the motorcycle Close the opening of the muffler with a rag and press the accelerator approximately 20 times The carbon deposits will be blown out through the opening Then turn off the engine and let the exhaust system cool down Grease the plug with molycote grease and mount the plug Carburetor adjustment Basic in
15. 0 08 in Tire pressure should be checked regularly on a cold tire Proper pres sure ensures optimum driving comfort and extends the life of your tires A WARNING A DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE HOMOLOGATED TIRES FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PER FORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unba lanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer A WARNING A SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE L d Tm 19 E Fuse CH Singapore The fuse located below the sea
16. Loosen collar nut loosen lock nuts and turn right and left adju sting screws O equally far Tighten lock nuts Before tightening the collar nut verify that the chain adjusters are sit ting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut to 80 Nm 60 ft Ib A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE Chain maintenance For long chain life good maintenance is very important Chains with out O rings should be cleaned in fireproof solvent regularly and after wards treated with hot grease or chain spray Shell Advance Bio Chain O ring chains on the other hand are very simple to clean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry you can use a special O ring chain spray Shell Advance Bio Chain WARNING A NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS EITHER WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRON GLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL CAUTION WHEN MOUNTING THE CHAIN MASTERLINK CLIP THE CLOSED
17. 1 CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET OTHERWISE THE WATER MIGHT RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE MAILFUNCTIONS 1 LEAD TO THE PREMATURE DESTRUCTION OF THESE PARTS You should use commercially available detergents to clean the motorcycle Heavily soiled parts should also be cleaned with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached its operating temperature and also operate the brakes The heat also causes the water at the inacces sible parts of the engine and the brakes to evaporate Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all the gliding bearing parts Also treat the chain with a chain spray To prevent failures in the electric system you should treat the ignition lock the short circuit switch the short circuit button and the light switch with a contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean
18. 918T768 WP 918T769 WP 1218T712 WP 1218T714 Compression adjuster 12 12 Compression adjuster 5 6 Rebound adjuster 12 12 Rebound adjuster 14 12 Spring 4 2 N mm 4 0 N mm Spring PDS3 250 PDS2 250 Spring preload 5 mm 0 2 in 5 mm 0 2 in Spring preload 5 mm 0 2 in 6 mm 0 23 in Air chamber length 150 mm 5 9 in 155 mm 6 1 in Capacity per fork leg appropx 750 ccm appropx 750 ccm Fork oil SAE 5 SAE 5 NOTE The damping units in the left and the right fork leg are of different design M ake sure not to mix them up in case of repair or service jobs Torques Collar screw front wheel spindle M 10 40 Nm 30 ft Ib Brake caliper front M 8 25 19 10 Loctite 242 Clamping screws upper fork bridge M 8 15 11 10 Clamping screws lower fork bridge M 8 20 15 ft lb Clamping screws fork stubs M 8 15Nm 11 10 Collar nut rear wheel spindle M 20x1 5 80 Nm 59 10 Hexagon nut swing arm bolt M 14x1 5 100 Nm 74 16 Shock absorber top M 12 60 Nm 44 Shock absorber bottom M 12 40Nm 30 ft Ib Other screws on chassis M 6 10Nm_ 7 10 8 25 19 10 10 45 33 10 KTM SPORTMOTORCYCLE AG A 5230 Mattighofen Postfach 91 Austria Internet http www ktm co at FN 102019 d Landesgericht Ried im Innkreis 3 205 51 ARIE S205991 195 125 200 250 800 580 5 EGS BEDIENUNGSAN Esai
19. AND GET BURNED CAUTION CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE O THERWISE THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE KTM rider 125 380 6 98 REGULAR COMPETITION USE OF THE BIKE THE 4000 2500 MILES SERVICE ISTO BE DONE AFTER EVERY RACE after washing 14 service after 1000 km 600 miles or 10 hours after 2000 km 1250 miles or 20 hours 2500 miles or once a year after 4000 km at least once a year Check transmission oil level before each start Change transmission oil Check spark plug and electrode gap Change spark plug Functional testing of the exhaust control system Check intake manifold for leaks and cracks Drain and clean carburetor float chamber Adjust idling Check breather hoses of engine case and gas tank for correct position without buckles Clean and check airfilter element box and carburetor connection boot Check chain sprockets guides and chain wear Clean and oil chain Check chain tension Check coolant level Check quality of antifreeze Check cooling system for leaks visual inspection Check exhaust system for cracks and leaks Replace glass fiber yarn of silencer Check of the exhaust suspension system Check brake fluid level front and rear Change brake fluid
20. GRADE OIL CAN CAUSE EROSION OF THE PISTON USING TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL THE SPARK PLUG AND THE EXHAUST CONTROL SYSTEM N THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID OVERHEATING AND PISTON SEIZURE NOTE If despite a changed adjustment the engine does not run properly look for mechanical faults and check the ignition system Basic information on carburetor wear As a result of engine vibrations throttle valve jet needle and needle jet are subjected to increased wear This wear may cause carbu Definitions Mixture too rich Too much fuel in proportion to air Mixture too lean Not enough fuel in proportion to air Idling range A O peration with closed throttle valve This range is influenced by the posi tion of the air control screw and the idle adjusting screw Only make adjustments when the engine is hot To this end slightly increase the idling speed of the engine by means of the idle adjusting screw Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed Create a E round and stable engine speed using the air control screw basic position of main jet the air control screw open by 1 5 turns Then adjust to the normal idling jet needle speed by means of the idle adjusting screw Opening up B jet needle Engine behavior when the throttl
21. HIGHWAYS FREE WAYS IS AGAINST THE LAW WHEN RIDING YOUR MOTORCYCLE PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE Running in EVEN VERY PRECISELY MACHINED SECTIONS OF ENGINE COMPONENTS HAVE ROUGHER SURFACES THAN COMPONENTS WHICH HAVE BEEN SLI DING ACROSS ONE ANOTHER FOR QUITE SOME TIME THEREFORE EVERY ENGINE NEEDS TO BE BROKEN IN FOR THIS REASON DURING ITS FIRST 500 KILOMETERS 300 MILES OR 5 HOURS THE ENGINE MUST NOT BE REVVED UP TO ITS PERFORMANCE LIMITS APPLY LOW BUT CHANGING LOADS FOR RUNNING IN DO NOT DRIVE AT FULL LOAD FOR THE FIRST 500 KILO M ETERS 300 MILES OR 5 HOURS Starting when engine is cold Open fuel tap Turn on ignition or emergency OFF switch Put the gear in neutral Activate cold starting aid choke Leave throttle closed or open it no more than and kick down kickstarter vigorously all the way A WARNING A TO AVOID INJURY WHEN STARTING THE ENGINE ALWAYS WEAR BOOTS DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILA TION WHILE THE ENGINE IS RUNNING CAUTION Do NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP THE ENGINE WHEN COLD SINCE THE PISTON IS WARMS UP AND EXPANDS FASTER THAN THE WATER COOLED CYLINDER THIS MIGHT CAUSE ENGINE DAMAGE ALWAYS LET ENGINE IDLE UNTIL WARM OR DRIVE IT WARM AT LOW R P M SPEEDS
22. SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION umm 28 85 Also check sprockets and chain guides for wear and replace if necessary p UN Se d Chain wear In order to check the chain wear regard the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 Kilogramm 33 Ib upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different pla ces on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets CAUTION WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14T THE COLLAR MUST BE ON THE INSIDE General information about KTM disc brakes BRAKE CALIPERS The brake calipers of this series use mount This means that the brake calipers are not solidly attached to the caliper support which enables them to float for maximum braking contact BRAKE PADS max 272 mm The motorcycles are delivered with organic brake pads and have also been type coded with these pads Said pads are suitable for almost the entire range of application of these motorcycles It is only for competitive racing in extremely dirty conditions e g water in 23 16 17 18 combination with
23. and experience Hold the handlebar with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated You may only take a passenger along if your motorcycle is fitted and registered for such purposes During the ride the passenger must hold on the straps or to the driver with his feet on the passenger foot rests Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle M otorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you it should be secured as close as possible to the middle of the vehicle dis tribute the weight evenly between the front and the rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet A WARNING A IMPORTANT INSTRUCTIONS FOR MODELS SX MXC AND EXC THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY NO ADDITIONAL PASSENGER ALLOWED NEITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY REGULATIONS AND SAFETY STANDARDS USING THEM ON PUBLIC ROADS
24. circulate properly if the cooling circuit contains no air bubbles Bleeding of the cooling system is therefore required a after adding more than 0 25 cooling liquid and b after refilling the entire cooling system see Bleeding the cooling system Some models are equipped with a thermostat so that the engine reaches its operating temperature more quickly When the engine is cold the liquid coolant circulates in the cylinder the cylinder head and the left radiator in EGS 250 380 models only in the cylinder and the cylinder head As soon as the cooling liquid has reached a temperature of approximately 55 C the thermostat opens and the cooling liquid is also pumped through the two aluminum radiators The cooling liquid is cooled by the air stream This means that the cooling effect decreases with the travelling speed Dirty radiators additionally reduce the cooling effect 10 mm when engine is cold A mixture of 40 antifreeze liquid and 60 water is used as coolant However the anti freeze protection must be at least for 25 C 13 F This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZE Shell Advance Coo lant USING LOWERGRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING Pressure induced by heating of the coolant in the syst
25. dicks Steering lock The handlebar can be locked by means of the lock located on the steering head To lock it turn handlebar all the way to the right insert key turn it to left press it in turn it to right and remove it CAUTION NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK YOU TURN THE HANDLE BAR TO THE LEFT THE KEY COULD GET DAMAGED Center stand Push center stand with your foot to the ground and pull your bike back wards M ake sure that you put your bike on solid ground and in a secure position For off road riding you can use the rubber band to additionally secure the center stand in its folded up position CAUTION ALWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE CENTER STAND AS FAR AS POSSIBLE THE STAND TOUCHES THE GROUND WHILE YOU ARE DRI VING YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE L 2 J 9 DRIVING INSTRUCTIONS W hat you should check before each start When you start off the motorcycle must be in a perfect technbical condition For safety reasons you should make it a habit to perform an overall check of your motorcycle before each start The following checks should be performed 1 CHECK TRANSM ISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank vent
26. motorcycle thoroughly after each riding and let it dry treat engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corrosion agent A WARNING A KEEP ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER CAUTION AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL If you want to put your motorcycle away for longer periods of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil oil filter and micro filter old engine oil contains aggresive contaminations Check antifreeze and amount of cooling liquid Let the engine warm up again close fuel tap and wait until the engine dies off by itself In this way the carburetor jets are preven ted from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate basin Correct tire pressure Lubricate bearing points of the control levers foot rests etc as well as the chain Service the rear suspension linkage Disassemble and charge battery see chapter BATTERY NOTE Only the following model
27. sand and mud that we recommend brake pads that have sintered linings However take notice of the fact that brake pads with sinte red linings have not been type coded Besides they may cause greater wear on the brake discs B 8 E BRAKE FLUID RESERVO IRS The brake fluid reservoirs on front and rear wheel brakes have been desi gned in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake system with Shell Advance Brake DOT 5 1 one of the best brake fluids currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible by DOT 5 1 Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw In this way the position of the point of pressure e the resi stance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size CAUTION AT THE HAND BRAKE LEVER FRE
28. the clutch lever The adjusting screw can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclock wise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS O NLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE Checking and adjusting the steering head bearing Check steering head bearing for play periodically For check put motorcycle on stand so that the front wheel is off the ground Now try to move the fork forward and backward For readjusting loosen the five pinch bolts of the top triple clamp and turn steering stem bolt clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly rap on the triple clamp to release tension Retighten the five pinch bolts to 15 Nm 11 ft Ib A WARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEAT
29. 1 Bleeding the cooling system 21 Cleaning the air filter see 22 Exhaust systern oe eee te 22 Cleaning the spark arrestor EXC 22 Carburetor adiustment 23 Checking the float 24 Checking the oil level of the hydraulic clutch 24 Bleeding of the hydraulic cutch 24 Check transmission oil level 125 200 25 Changing the transmission oil 125 200 25 Check transmission oil level 250 300 380 25 Changing the transmission oil 250 300 380 25 Ee be rea Feat egerat 26 CONSERVATION FOR WINTER OPERATION 26 RAGES otro dmt e bend 26 Use after period of storage 26 TECHNICAL SPECIFICATIONS CHASSIS 125 200 27 TECHNICAL SPECIFICATIONS ENGINE 125 200 28 TECHNICAL SPECIFICATIO NS ENGINE 250 300 380 Only USA occ t OR rr RR tens 30 TECHNICAL SPECIFICATIO NS ENGINE 250 300 380 All models out of USA sssssssseee 32 TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 34 WIRING DIAGRAM ME CARBURETOR SETTING Appendix SERIAL NUMBER LOCATIONS Chassis numb
30. E TRAVEL MUST AT LEAST BE 3 MM 0 1 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PRO VIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING ca cig E 5 mm Checking of brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the hand lebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not drop below the middle of the glass The reservoir should be kept completely full at all times for best performance A WARNING A THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHO RIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir When the brake fluid falls to the middle of the inspection glass new brake fluid has to be added Loosen screws and remove lid and membrane 6 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING A Never use D
31. IS HOT W IPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY l CAUTION ONLY USE PREMIUM GRADE GASOLINE RO Z 98 RESPECTIVELY 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAI LURE DO NOT USE PREMIXED TWO STROKE OILS OILS FOR OUTBOARD ENGINES OR NOR MAL ENGINE OIL TO PREPARE THE MIXTURE DO NOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN ONE WEEK THE LUBRICATION PROPERTIES OF SOME TWO STROKE OILS CAN DETERIORATE VERY RAPIDLY ONLY USE KNOWN BRANDS OF HIGH GRADE 2 STROKE ENGINE OIL NEVER MIX SYNTHETIC OILS AND MINERAL OILS NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON WHEN USING TOO MUCH OIL THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG FUEL EXPANDS WHEN ITS TEM PERATURE RISES THEREFORE DO NOT FILL THE TANK TO THE TOP SEE FIG ENGLISH Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carbure tor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have OFF ON RES backup fuel
32. LD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALLWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the collar screw Loosen the 4 clamping screws on the fork fists Hold the front wheel pull out the wheel spindle NOTICE the wheel spindle may be pulled out more easily if you slide an open end wrench 17mm onto the flat portion G of the wheel spindle Remove front wheel carefully from the fork and take the speedometer drive off the hub CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED Prior to mounting the front wheel clean and grease sealing ring and running surface at the speedometer drive To mount the front wheel lift it into the fork Insert speedometer drive into the hub M ake sure that the driving tabs engage with the slots of the drive Position front wheel and speedometer drive and mount wheel spindle Mount collar screw turn speedometer drive in a way that the flexible speedometer shaft will curve upwards in a slight bow and tighten collar screw to 40 Nm 30 f
33. LTHOSHVO s6uu O GERD peau Jepur A5 ww Z O 5 0 7 0 2 0 seb uuo30q pauinbau se seb ww PND 5 33 WN St SSSSANDIDIHL LEO 9135 61 WN SZ WNOT OW SMAIDS UJO WN 6T 879 9313201 9IX9 Je SE M S peau GO WN OOT vIW 449 9 IN S3JOQ pue eased xUeID WN OOT 931201 qnu upinp uu INN wu yua veu 570 ux6ue suuds ynd OTT WN OST 911201 Pods INN pue SYEYS UOISSILUSUeI vv O9 Jej o ww Z O O IcO O eouejeep 6uueeq pou 5 SZ WN SE W aseq pue WN SE syoq 08 BO O 005 900 052 50 0 HUY uoistd 9NINHLHOLL SCT NOCH ONLLLY SHONVtH IOL TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 SX MXC EXC EGS 99 250 3805 250 300 380 MXC 250 300 380 250 300 380 EGS Frame Central chrome moly steel fr
34. MMING The rear wheel is remounted in reverse order Before tightening the collar nut to 80 Nm 60 ft Ib push the rear wheel forwards so that the chain ten sioners lie on the tension screws WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSI BLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS IT 15 VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE Tires air pressure Tire type tire condition and air pressure level affect the way your motorcy cle rides and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications and in their homolo gation certificate Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Refer to the specific regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm
35. N T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REM O VER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER ENGLISH m a L 18 Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in A WARNING AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD THINNER THAN 1 OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COM PONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IM PARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the rear brake pads Press brake caliper 6 in direction of chain wheel for the brake piston to reach its basic position Remove safety device knock out the guide pin from the brake caliper with a drift towards the chain wheel and remove brake pads Carefully clean the brake caliper with compressed air and check Sleeves of the guide pins for damage Slide left brake pad into the brake caliper and fix it with the pin Slide in the right brake pad and knock the bolt in as far as it will go Mount safety device WARNING A IT 15 VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOU
36. OT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION l DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REM OVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the front brake pads The brake pads can be inspected from below The linings nust be at least 1 mm 0 04 in thick A WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COM PONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IM PARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips and pull out bolt Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary
37. PORT BASELINE 500 speedometer On default factory models a wheel circumference of 2150 mm standard tires is adjusted on the speedometer The blue indicator lamp is lit when the high beam is on Odometer EXC USA The odometer is a mileage indicator and can be set to 0 by means of the adjustment wheel Speedometer indicator lamps EGS The mileage indicator the speedometer indicates overall mileage When the turn indicator is on the green indicator lamp will be flashing in the same rhythm The blue indicator lamp O will be lit when the high beam is on Ignition lock Switch positions of ignition lock 9 Di Ignition off lgnition on parking light on only for models with battery CAUTION DONT TURN THE PARK LIGHT FOR MORE THAN 90 MINUETS WHEN THE MOTOR IS NOT RUNNING BECAUSE THE BATTERY WILL BE COMPLETLY EMPTIED AND DESTRYED The ignition key can be removed when in its amp position I 2 m 5 Short circuit button SX The short circuit button turns off the engine When pressing this button the ignition circuit is short cicuited Combination switch EXC The light switch has 2 respetively 3 switch positions Light off this function is not available in all models Low beam on High beam on You may use button to actuate the horn The red short circuit button amp serves to switch off the engine L
38. S IN THE FRAME WILL BE DESTROYED The steering head bearings should be regreased at least once a year e g Shell Advance Grease HSITDONSGA Pivot bearing The pivot bearing for PDS suspension struts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubri cants Grease and other lubricants cause the Teflon coat to dissolve whe reby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing Check chain tension To check the chain tension park the motorcycle Press chain upward at the end of the chain sliding component The distance between chain and swing arm should be approx 15 mm 0 6 in In the course of this procedure the upper chain portion must be taut see drawing If necessary correct chain tension WARNING A IF CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY TRANSMISSION CHAIN CHAIN WHEELS AND REAR WHEEL BEARINGS WILL BE SUBJECTED TO UNNE CESSARY STRESS RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension
39. UUSUEJ ST3 4H 1945 podo ur u anp 251 ejdninuu uon 21 92 One Areuuud lt ands 3n 5 21 52 lt Inds o0zZ OGLL Am DAL 0025 unu 00 5 UU OoorS Hes DAL ut 661 S OS ut zT uuu ut 67 uuu Jus 2 VOULA ut 7ZO O WLU 9 0 9 WO 8 ueds Dag o ZT U 600 2 2 U 8070 uuu LT ut 40 0 uuu uous U 700 0 0 WLU O DOE da nX u sbuu uoissaJduuoo uojsid 15e uojsid uojsid 3522 uoasid pou jeq 1 T 3jeusyueJ ayes y uo XIU Og T esn 10 uo 3563002 esea d 09 7 OST ones uljoseb o 945 J epes6 YBiy uy GG OU YLSI PNJ YIdNS ut 862 uuu ZZ BL ul 887 Z eL c 992 WLU 69 79 310g uD Uo 6Z UJ jueuueo2e dsip uo3sid enbJoL pue 3sneu
40. ain tension 14 Chain maintenance 14 Chain Wear itte Go eve e fe eene 15 General informations about KTM disc brakes 15 Adjusting of free travel at the hand brake lever 15 Checking of brake fluid level front brake 16 Refilling the front brake fluid 16 INDEX Page Checking the front brake 5 16 Replacing the front brake 5 16 Changing the basic position of the brake pedal 17 Checking rear brake fluid 17 Refilling the rear brake fluid reservoir 17 Checking the rear brake 5 18 Replacing the rear brake 18 Dismounting and mounting the front wheel 18 Dismounting and mounting the rear wheel 19 Tires air ssssssissssiressrisiisrisinrnsnsrenesrerenrises 19 Checking spoke 9 19 Fuse CH Singapore 20 Battery CH Singapore 20 Replacing head light lamp 4 20 Cooling Systeme ct tete RR eT Rs 20 Checking the coolant level 2
41. ame Fork WP Extreme 50 mm Wheel travel front rear 280 320 mm 11 0 12 6 in Rear suspension WP Progressive Damping System shock absorber aluminium swingarm Front brake Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Front tires 80 100 21 51M 80 100 21 51M 90 90 21 54R 90 90 21 54R 80 100 21 51M Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air press road driver only 1 5 bar 21 psi 1 5 bar 21 psi Rear tires 110 90 19 62M 110 100 18 64M 140 80 18 70R 140 80 18 70R 110 100 18 64M Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air press road driver only 2 0 bar 28 psi 2 0 bar 28 psi Fuel tank capacity 7 5 liter 12 liter 9 5 oder 12 liter 9 5 oder 12 liter 2 US gallons 3 2 US gallons 2 5 or 3 2 US gallons 2 5 or 3 2 US gallons Final drive ratio 14 50t 14 52t 14 50t 14 52t 14 50t 15 48t Chain 5 8 x 1 4 Available final sprockets 381 40t 421 45t 48t 50t 52t Steering head angle 63 5 Wheel base 1481 10 mm 58 3 0 4 in Seat height unloaded 925 mm 36 4 in Ground clearance unloaded 385 mm 15 in Dead weight without fuel 101 kg 223 Ibs 102 5 kg 226 3 Ibs 103 7 kg 229 105 109 kg 240 6 Ibs Standard adjustment fork Standard adjustment shock absorber WP
42. an handle Through quick and high revving of throttle the gas consumption increase When shifting down use the brakes if necessary and turn down at the same time Pull clutch lever and shift down to the next lower gear Let clutch lever go slowly and open throttle or shift down again A WARNING A OBSERVE THE TRAFFIC REGULATIONS DRIVE DEFENSIVELY AND TRY TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT YOU RECOGNIZE ANY HAZARDS AS EARLY AS POSSIBLE ADJUST YOUR DRIVING SPEED TO THE CONDITIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN ROADS OR IN UNKNOWN TERRITORY WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE REPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH W HEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES YOU WILL BE PRACTICALLY BLIND AFTER FALLING WITH THE MOTORCYCLE CHECK ALL ITS FUNCTIONS THOROUGHLY BEFORE USING IT AGAIN CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN A LOWER GEAR THE ENGINE WILL OVERREV DAMAGING THE VALVES IN ADDITION THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL
43. ance VSX 4 Check transmission oil level 250 300 380 In order to check the transmission oil level the control screw on the clutch cover is to be removed Oil should just barely escape from the inspection opening when the motorcycle is in an upright position If necessary remove the plug and top up with engine oil 20W 40 i e Shell Advance VSX 4 CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL i e Shell Advance VSX 4 Changing the transmission oil 250 300 380 To change the transmission oil run the engine warm and set up the motorcy cle on a horizontal surface Remove the oil drain screw and drain used oil into a container Clean the magnet of the oil drain screw and reinstall oil drain screw with seal Pour in 0 8 litres 0 21 US gallons engine oil 20 40 i Shell Advance VSX 4 replace plug and check engine for leaks CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL i e Shell Advance VSX 4 ENGLISH CLEANING Clean your motorcycle regularly in order to keep its painted finish looking shiny and new The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge The hard dirt can be removed before with the help of a soft water jet
44. any person Introduction We would like to congratulate you on your purchase of a KTM motorcycle Let us also take this opportunity to thank you for putting your trust in us we will not let you down You are now owner of a sporty and modern motorcycle which you are bound to have a great time with provided you care for it properly Your owner s handbook will furnish you with important information on how to operate and maintain your new KTM motorcycle At the time of printing the handbook covered the most up to date models in this series It is however possible that we may have made slight modifications in the meantime due to development in our motorcycle design M any motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the mainten ance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform those steps marked by found in the chapter entitled Maintenance Work on Chassis and Engine of this manual Take special care to follow the recommended run in inspection and maintenance inter vals Heeding these guidelines will significantly increase the life of your motorcycle Be sure to have any maintenance jobs performed by an authorized KTM dealer Address your special requests to an authorized KTM dealer who should the need arise wi
45. arzocchi 91 WP 9187767 WP 1218T711 WP 1218T713 Compression adjuster 15 12 Compression adjuster 5 6 Rebound adjuster 15 12 Rebound adjuster 14 14 Spring 4 0 N mm 4 0 N mm Spring PDS2 250 PDS1 250 Spring preload 10 mm 0 4in 5 mm 0 2in Spring preload 5mm 0 2 in 6 mm 0 23 in Air chamber length 140 mm 5 5in 150 mm 5 9in Capacity per fork leg appropx 600 ccm appropx 750 ccm Fork oil SAE 7 5 SAE5 ENGLISH NOTE The damping units in the left and the right fork leg are of different design M ake sure not to mix them up in case of repair or service jobs TORQUES Collar screw front wheel spindle M 10 40Nm 30 ft lb Brake caliper front M 8 25Nm 19 10 Loctite 242 Clamping screws upper fork bridge M 8 15Nm 11 ft lb Clamping screws lower fork bridge M8 20Nm 15 ft lb Clamping screws fork stubs M6 7Nm 5 ft lb M arzocchi Clamping screws fork stubs M8 10 7 ft lb WP Extreme Collar nut rear wheel spindle M 20x1 5 80 59 ft lb Hexagon nut swing arm bolt M 14x1 5 100 74 ft lb Shock absorber top M 12 60Nm 44 ft lb Shock absorber bottom M 12 40 30 10 ther screws on chassis 10 7 10 8 25 19 10 10 45 33 YASUI d JOM ess sOJeuNqUeD Joyunques MOTT ACT MO ACT MOTT
46. bricate control lever pivot points MAINTENANCE WORK ON CHASSIS AND ENGINE A WARNING A ALL MAINTENANCE AND ADJUSTEM ENT OPERATIONS THAT ARE MARKED WITH REQUIRE SPECIALIST KNOW LEDGE FOR YOUR OWN SECURITY LET THESE TASKS BE CARRIED O UT BY A KTM DEALER CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CAR BURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION IF THE MOTORCYCLE SHOULD FALL OVER NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT Do NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED REMOVE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC ORDERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE 1 LITER USED OIL CONTAMINATES 1 000 000 LITERS WATER Changing the original position of
47. e opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle setting the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking thot throttle valve SOS LOC air control screw idle adjusting screw JET NEEDLE TYPE RANGE OF ACTION RICHER LEANER NOZD NOZE NOZF NOZG NOZH Part throttle range C Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer Full throttle range D O peration with the throttle fully open flat out This range is influenced by the main jet and the j
48. eave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch O Flasher switch Flasher left gt Flasher right Emergency O FF switch Australia The emergency OFF switch is located next to the throttle grip Primarily designed as safety or emergency OFF switch it should normally not be in its activated state In this position the ignition circuit is shorted if the engine is running it will stall immediately if it is at standstill it will not start C In this position the ignition circuit is enabled the engine should start To open it turn filler cap counter clockwise To close it put filler cap back on and tighten it by turning it clockwise Install tank breather hose without kinks Refueling fuel 125 Unleaded premium gasoline RON 98 mixed with high grade two stroke oil Mixture ratio 1 40 200 380 Unleaded premium gasoline RON 95 mixed with high grade two stroke oil Mixture ratio 1 40 1 60 Fuel and engine oil should only be mixed immediately before use KTM recommends SHELL ADVANCE RACING X A WARNING A GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE
49. em is controlled by a valve in the radiator cap a water temperature of up to 120 248 is admissible therefore having to expect any trouble Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold cf diagram In the event of the coolant being drained always fill and bleed the system A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE CAUTION THE COOLING SYSTEM MUST BLED AFTER DRAINING THE COOLING LIQUID OR AFTER ADDING MORE THAN 0 25 L 0 06 US GALLONS COOLING LIQUID Bleeding the cooling system The cooling system must be bled as described below after draining of the cooling liquid or after adding more than 0 25 0 06 US gallons cooling liquid Make sure that the drain screw is fastened Pour approx 0 5 litres 0 13 US gallons coolant into the system Remove screw at the cylinder head Reinstall it as soon as the cooling liquid emerges free of air bubbles only for 125 200 engines Remove the screw on the right radiator and tilt the motorcycle to the right approx 30 degree angle Now add cooling liquid until it emerges free of bubbles at the right radiator Then immediately mount the screw so that no more air can enter the right radiator Return the motorcycle to its or
50. er The chassis number is stamped on the right side of the steering head tube Write this number into the field on page no 1 Engine number engine type 125 200 The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Please note this number down on page 1 Engine number engine type 250 300 380 Engine number and engine type are stamped on the right hand side of the engine in front of the kickstarter W rite this number into the relevant area on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever is located on the left side of the handlebar The adju sting screw is used to change the original position of the clutch lever see maintenance work on chassis and angine Hand brake lever The hand brake lever is mounted on the handle bars on the right and actua tes the front wheel brake A WARNING A THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER 402 160 180 hm 120 180 Speedometer indicator lamp EXC The mileage indicator in the speedometer indicates overall mileage For further adjustment options and handling see the appended user s guide of the SIGMA S
51. et needle If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings after a short distance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one Checking the float level Arrange the Keihin carburetor diagonally at about 60 so that the spring in the float needle valve is not pressed together In this position the edge of the float should be parallel with the float chamber sealing surface see illustration Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws and cover together with the rubber boot The oil level in the horizontal master cylinder should be 4 mm below the upper edge If necessary add SAE 10 hydraulic oil CAUTION ONLY SAE 10 MINERAL HYDRAULIC OIL Shell Naturelle HF E15 REFILL THE MASTER CYLINDER NEVER USE BRAKE FLUID Bleeding of the hydraulic clutch For bleeding the cover of the master cylinder of the clutch needs to be removed For this purpose remove screws and take off cover 6 together with rubber bellows At the slave cylinder of the clutch remove the blee der nipple It its place mount the bleeder syringe which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubb
52. formation on the original carburetor setting The original carburetor setting was adapted for an altitude of approx 500 meters 1600 ft above sea level and the ambient tempe rature of approx 20 68 mainly for off road use and central European premium grade fuel ROZ 98 respectively 95 M OZ M ixing ratio 2 stroke motor oil super fuel 1 40 125 1 40 1 60 200 250 300 380 Basic information on a change of the carburetor setting Always start with the original carburetor setting the provided factory setting is meant for break in operation after the break in period the carburetor needs to be adjusted according to the carburetor datasheet see appendix Essential requirements are a clean air filter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance RULE OF THUM B high altitude or high temperatures gt choose leaner carburetor adjustment low altitude or low temperatures gt choose richer carburetor adjustment A WARNING A ONLY USE PREMIUM GRADE GASOLINE RO Z 98 RESPECTIVELY 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL O THER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE AND USE OF SAME WILL VOID YOUR WARRANTY ONLY USE HIGH GRADE 2 STROKE ENGINE OIL OF KNOWN BRANDS i Shell Advance Racing X NOT ENOUGH OIL OR LOW
53. he rear disc brake is located on the right side of the motorcycle next to the kickstarter The brake fluid level must not drop below the MIN marking when the vehicle is in an upright position WARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHO RIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir For this purpose it is recommended to remove screw and to pull the brake fluid reservoir outwards Now the screw and the rubber boot O can be removed Add brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 until the brake fluid level reaches the MAX mark then mount the screw cap together with the rubber boot Restore the brake fluid reservoir to its original position and fix it with the screw The connecting hose bet ween the reservoir and the foot brake cylinder must be carefully positioned preventing kinks and keeping a safe distance between the hose and the exhaust pipe Spilled brake fluid must be rinsed off with water WARNING A Never use DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DO
54. iginal position and top up the left radiator until the coolant can be seen approx 10 mm 0 4 in above the radiator fins Check the coolant level again after a short ride ENGLISH m e I I 22 Cleaning the air filter The air filter must be cleaned prior to every race or whenever the motorcycle has been exposed to great quantities of dust For this purpose rotate the two quick release fasteners counter clockwise and pull them outward up to the stop pull the filter box cover forward and remove it Unhook the filter holding brackets at the bottom swing them sideways and take the air filter together with the filter support out of the filter box CAUTION DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAM AGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY PUTOLINE FOR AIR FILTER MAINTENANCE ACTION CLEANER FOR CLEANING PURPOSES AND ACTION FLUID TO OIL THE FOAM FILTER Thoroughly wash the foam filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry foam filter with a high grade filter oil Also clean the air filter box Check carburetor collar for damage and that it is filled correctly Mount the air filter on the filter support Apply grease to the face of the filter to improve its sealing properties M ount the filter together with the fil
55. ing hose is free of kinks CHAIN A loose chain was fall off the chain wheels an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of chain and chain wheels TIRES Check for damaged tyres Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving perfor mance BRAKES Check correct functioning of the braking system Verify that there is sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by an authorized KTM dealer as complete failure of the braking system can be expected Also check the state of the brake hose and the thickness of the brake linings Check free travel at hand brake lever and foot brake lever CABLES Check correct adjustment and easy running of all control cables COOLING FLUID Check the level of cooling fluid when the engine is cold ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights turn indicators indicator lamps and horn while the engine is running LUGGAGE If you are taking luggage with you chec
56. k Type M arzocchi 91 15 clicks Type White Power 918T767 12 clicks Type White Power 9187768 12 clicks Type White Power 9187769 12 clicks Compression damping of shock absorber The damping force of the compression damping can be adjusted with knob The higher the number the higher the damping force STANDARD ADJUSTM ENT White Power 1218T711 5 White Power 1218T712 5 White Power 1218T713 6 White Power 1218T714 6 WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN ANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT Rebound damping of shock absorber By using the adjusting screw the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTM ENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber White Power 1218T711 14 dicks White Power 1218T712 14 dicks White Power 1218T713 14 dicks White Power 1218T714 12
57. k that it is securely fastened WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE SMART KTM DRIVERS ALWAYS WEAR HELMET BOOTS GLOVES AND JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FORA SHORT RIDE THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLO RED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE OF COURSE YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM EXAMPLE FRONT PANELLING CAN IMPAIR THE DRIVING CHARACTERISTICS OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE S DRIVING CHA RACTERISTICS Instructions for your first ride Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs see Customer Service M anual Thoroughly read the whole instruction manual before star ting for your first tour Additionally you should also read the enclosed operating instructions for the spring elements Familiarize yourself with the controls Adjust the clutch lever the hand brake lever and the foot brake pedal to the most comfortable position Get used to handling the motorcycle in an empty parking lot or open space before going for a longer ride Also try to ride as slowly as possible while standing upright to improve your feeling for the vehicle Do not drive along off road trails which go beyond your ability
58. le free state M ake sure that the oil does not over flow The bleeder syringe can be purchased at your KTM dealer CAUTION HAVING COMPLETED THE BLEEDING PROCEDURE YOU HAVE TO VERIFY THAT THE OIL LEVEL IN THE MASTER CYLINDER IS CORRECT FOR FILLING OF THE MASTER CYLINDER USE SAE 10 MINERAL HYDRAULIC OIL ONLY NEVER USE BRACKE FLUID Check transmission oil level 125 200 In order to check the transmission oil level the control screw on the clutch cover is to be removed Oil should just barely escape from the inspection opening when the motorcycle is in an upright position If necessary remove the plug and top up with engine oil 20W 40 i e Shell Advance VSX 4 CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL i e Shell Advance VSX 4 Changing the transmission oil 125 200 To change the gear oil warm up the engine and park the motorcycle on a horizontal surface Remove oil drain plugs and O and drain the used oil into an appropriate container Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets Fill in 0 7 engine oil 20W 40 Shell advance VSX 4 mount the plug and check the engine for leaks CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL i e Shell Adv
59. ll be supported by the KTM importer Riding an off highway motorcycle is a wonderful form of outdoor recreation and we cer tainly hope that you will enjoy it to the full However this enjoyable outdoor activity can cause environmental problems or lead to conflicts with other people Responsible use of the motorcycle will prevent such problems and conflicts You can contribute to securing the future of motorcycling by making sure that you only use the motorcycle within the limits established by the applicable laws making environmental protection one of your top priorities and never violating other people s rights We wish you a lot of fun when driving EM FOR QUALITY SYSTEM ISO 9001 REG NO 12 100 6061 KTM Austria s certificate of achievement for its Quality System ISO 9001 is the beginning of an on going total re engineering quality plan for a brighter tomorrow KTM SPORTM OTORCYCLE 5230 M ATTIGHO FEN AUSTRIA Attachments 1 spare parts manual chassis 1 owner handbook for telescopic fork 1 spare parts manual engine 1 owner handbook for shock absorber ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL SERIAL NUM BER LO 4 ChiassisinumbQr s s asco herir i Pere e 4 Engine number engine type 125 200 4 Engine number engine type 250 300 380 4 OPERATION INSTRUM ENTS
60. next time too Reserve of the 9 5 tank 1 3 0 35 US gallons 7 Reserve of the 12 tank 1 7 1 0 45 US gallons CAUTION SX THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE M XC S SS E Choke knob When pulling the choke knob fully towards the top bore is opened in the carburetor Through this bore the engine can take in additional fuel This encoure the rich fuel air mixture that is needed for a cold start When pressing the choke knob downward in the carburetor the bore is closed again Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located bet ween first and second gear Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled A WARNING A WHEN STARTING THE ENGINE PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJU RIES YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH Foot brake pedal The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to your seat position see maintenance work A WARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS
61. offroad Air press road driver only 80 100 21 51M 1 0 bar 14psi 90 90 21 54R 1 0 bar 14psi 1 5 bar 21psi 90 90 21 54R 1 0 bar 14psi 1 5 bar 21psi 80 100 21 51M 1 0 bar 14psi 90 90 21 54R 1 0 bar 14psi 1 5 bar 21psi 90 90 21 54R 1 0 bar 14psi 1 5 bar 21psi Rear tires Air pressure offroad Air press road driver only 100 90 19 57M 1 0 bar 14psi 120 90 18 65R 1 0 bar 14psi 2 0 bar 28psi 120 90 18 65R 1 0 bar 14psi 2 0 bar 28psi 100 100 18 59M 1 0 bar 14psi 120 90 18 65R 1 0 bar 14psi 2 0 bar 28psi 120 90 18 65R 1 0 bar 14psi 2 0 bar 28psi Fuel tank capacity 7 5 liter 9 5 liter 9 5 or 12 liter 12 liter 9 5 or 12 liter 9 5 or 12 liter 2 US Gallons 2 5 US gallons 2 4 US gallons 3 2 US gallons 2 5 or 3 2 US gallons 2 5 or 3 2 US gallons Final drive ratio 13 50t 13 50t 14 38t 14 48t 14 48t 14 38t Chain 5 8 1 4 Available final sprockets 381 40t 421 45t 48t 50t 52t Steering head angle 63 Wheel base 1461 10 mm 57 3 0 4 in eat height unloaded 925 mm 36 4 in Ground clearance unloaded 385 mm 15 2 in Dead weight without fuel 92 kg 96 kg 100 kg 96 kg 97 kg 101 kg 203 105 212 105 221 105 212 105 214 Ibs 223 Ibs STANDART ADJUSTMENT FORK STANDARD ADJUSTMENT SHOK ABSORBER M
62. ount the right brake pad and fix it with the bolt M ount the left brake pad and insert the bolt until it stops M ount the clips When mounting the brake pads be sure to check for correct fit of the sli ding metal sheet in the caliper support and of the leaf spring A WARNING A IT 15 VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALLWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking rear brake fluid level The brake fluid reservoir of t
63. s are equipped with a battery EGS Singapore EGS Switzerland The storage place should be dry and not be subject to overly great temperature fluctuations Cover the motorcycle with an air permeable tarpaulin or blanket Do not use non air permeable materials as possible humidity might not be able to escape and thereby cause corrosion l CAUTION IT WOULD VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE EXHAUST TO RUST USE AFTER PERIOD OF STORAGE Mount the charged battery regard polarity Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first TECHNICAL SPECIFICATIONS CHASSIS 125 SX EXC EGS 200MXC EXC EGS 99 11 0 12 6 in 11 2 12 6 in 125 SX 125 EXC 125 EGS 200 M XC 200 EXC 200 EGS Frame Central chrome moly steel frame Fork WP Extreme Marzocchi M agnum 45 Code 91 W heel travel front rear 280 320 mm 285 320 mm Rear suspension WP Progressive Damping System shock absorber aluminium swingarm Front brake Disc brake with carbon steel brake d isc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Front tires Air pressure
64. t lb Take the motorcycle off the stand and bounce the fork hard a few times to align the fork legs Then tighten clamping screws to a max torque of 7 Nm 5 ft lbs WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSI BLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT 15 VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIRES AIR PRESSU RE front rear O ff road 1 0 bar 1 0 bar Road driver only 1 5 bar 2 0 bar Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer tou ches the ground Loosen the collar nut remove chain tensioner hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISM OUNTED F THE AXLE 16 DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM JA
65. t protects the flasher system and the battery charge Nominal current 10 A CAUTION NEVER USE A STRONGER FUSE NEVER REPAIR A FUSE IMPROPER TREATMENT CAN DEST ROY THE ENTIRE ELECTRICAL SYSTEM Battery CH Singapore The battery is mounted in the air filter box It is a high quality mainten ance free battery To avoid oxidation of the battery contacts grease them regularly with acid free grease Never open the valves STORAGE Keep battery dry and clean Charge it before storage The best storage tem perature is 0 35 Recharge it after 16 months at the latest If the battery has lost its charge recharge it after one week at the latest CHARGING Nominal voltage 12 V maximum charging current 0 3 Ampere recommended charging current 0 2 Ampere Charging time 4 6 hours depending on charging level Replacing headlight lamp H4 Loosen both rubber bands and tilt headlight mask to the front Remove bulb plug remove rubber cap Turn the supporting ring counter clockwise and remove it from the reflector together with the bulb Insert a new bulb such that the noses fit into the recess Do not touch the glass body of the bulb to keep if free from grease M ount supporting ring rubber cap and plug Position headlight mask with the bottom holders and fasten it with the rubber bands Cooling system The water pump in the engine circulates the cooling liquid However the cooling liquid can only
66. xe UML pejooo pinbr1 ubiseq DXN DA XS DXN 00 DXN 052 XS OSZ vsn Ajuo 66 DX3 DXW XS O8E 00E 0SZ 3NION3 VIWA 1V2INHO3L apu 9 I IZON O ZON H ZON S8 OS Sv 8U 5 1 2121 891 0 1 8640 0 8 A Md apu 9 II S8N O S8N S8 8LT ZLT OLT SLT 865001 8 A Md UU IZON H ZON 9 ZON S8 gtt GLT OLT 89T ZLT 865060 IMd uado maids quauugsnfpe do uonisod 9 peeu pf Pf Jequunu Jonge DA XS DA 00 DA 052 XS OSZ ERE DNLS s6uu O GERD peay sepul AD Z O lt 0 7 0 Z 0 sep pauinbau se puI ww SSSSANDIDIHL LDSVD ww Zt Meu 570 Luet suuds 413 WN St OT IN SZ LIN OT OW SMA DS UJO WN 6T 879 912201 9IX9 Jep Ep peau GC WN OOT

Download Pdf Manuals

Related Search

Related Contents

User Manual    Philips myHomeOffice Table lamp 69225/35/16  Sur l`usage institutionnalisé du MEDIAL dans un centre genevois  LA LANGUE  CamPart Travel KI-0752  MA2012-7  POWX410    

Copyright © All rights reserved. Failed to retrieve file