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1. 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 L WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14T THE COLLAR MUST BE ON THE INSIDE SECURE THE SCREWS OF THE CHAIN WHEEL BY APPLYING LOCTITE AND FASTEN THEM IN A CROSSWISE ORDER TIGHTENING TORQUE FOR NUTS 35 NM 25 FT LB TIGHTENING TORQUE FOR SCREWS 50 NM 37 FT LB General information about KTM disc brakes BRAKE CALIPERS The brake calipers of this series use a floating mount This means that the brake calipers are not solidly attached to the caliper support which enables them to float for maximum braking contact Secure the screws of the cali per support with Loctite 243 and tighten to 25 Nm 19 ft Ib BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front and TOSHIBA H 38 sintered lining at the back
2. 4 Head Word Index eiecerunt 44 Headlamp switch EXC 6 How to change the handlebar position 18 KickStanteri iie ed meint pid tn dete 8 Maintenance work an chassis and engine 16 Odometer EXC USA oo eee ce eee 5 Only USA ice etenim etm Eia 40 Operation Instruments ssssssssseeeeeeeee 4 Pivot bearing 18 Radiator cover for the cold 29 RE Iniation After Time of storage 34 Rebound damping of fork ee eect 9 Rebound damping of shock absorber SX MXC EXC 10 Refilling Bleeding the cooling system 29 Refilling the front brake fluid 21 Refilling the rear brake fluid 22 Refueling fuel innert tenete 7 Replacing head light 28 Replacing the battery of the digital speedometer 25 Replacing the front brake pads 22 Replacing the rear brake 23 Serial Number Locations
3. push the button on the back with a sharp object approx 1 second to termi by pushing the right but 4 repeat nos 2 3 until the previously nate the setting procedure ton you jump to the next noted total mileage is indicated the value is thus stored figure N TIME make sure the time is 2 push the left button until the right 3 by pushing the right but indicated and push the figure is showed in the display ton you jump to the next button on the back figure approx 5 seconds time starts blinking 1 sec 5 push the button on the back approx 1 second to terminate 4 repeat nos 2 3 until correct time is indicated the setting procedure WHEEL CIRCUMFERENCE Ws 1 make sure that the indication 2 use the right button to select the position is active and push the but 5 sec to be changed ton on the back approx 5 seconds WS appears J gt o gt ENGLISH N 5 push the button on 4 repeat nos 2 3 until the back for approx 1 3 push the left button until the right figure correct wheel circumfe second to terminate is showed in the display rence is indicated the setting procedure km h WS mm x 3 14 mm x 3 14 i mp h WS mm x 3 14 1 61 p N i S Yy 0 Wheel circumference with standard tires 2205 mm Check set distance of the magnetic sensor T
4. 4 Shift levet ioei eto 8 Short circuit button SX 5 Side stald inii ieget ian ER dnte 8 Speedometer indicator lamps EXC Australia 5 Steering 8 jor 34 Technical specifications chassis 125 200 35 Technical specifications chassis 250 300 380 38 Technical specifications engine 250 300 380 Technical Specifications engine 125 200 36 Technical specifications engine 250 300 380 alir tetris 25 wiring diagramME carburetor setting Appendix
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6. ml U e 37 TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 125 0 06 200 0 055 mm Piston ring end cap max 0 40 mm Connecting rod bearing radial clearance 0 025 0 035 mm Transmission shafts end float 0 20 0 40 mm Clutch springs length new 39 mm minimum length 38 mm GASKET THICKNESSES Crankcase 0 5 mm Clutch cover 0 5 mm Clutch driving cylinder 0 30 0 50 0 75 mm Cylinder bottom gasket as required Available bottom gasket 0 07 0 15 0 20 0 25 0 40 0 50 0 75 mm Cylinder head gasket 125 shapedring O ring 200 1 10 mm O ring BASIC CARBURETOR SETTING 125 SX 200 MXC EXC USA 206 Merida NIS 200 EXC EU Carburetor Keihin PWK 39 Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 020201 010201 051200 041200 Main jet 185 182 188 190 178 180 185 180 178 148 180 185 Idling jet 48 45 50 45 48 35 45 48 35 45 48 Starting jet 85 85 85 85 Jetneedle R 1469 D R 1470 D NOZ F NOZ G R 1475 NOZ G NOZ F R 1472 N NOZ G NOZ F Needle position from top I I IN V Throttle valve 5 5 6 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 1 5 Performance restrictor slide stop 36mm TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 SX MXC EXC 2002 250 380 SX 250 300 380 MXC 250 300 380 EXC Frame Central chrome moly steel frame Fork White Po
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8. 17 Cleaning the spark arrestor EXC 30 Cl tchilever REPRE ein Eun 4 Combination switch EXC 6 Compression damping of 9 Compression damping of shock absorber MXC EXC 10 Compression damping of shock absorber SX 9 Conservation for winter operation 34 Cooling system eet A estere teen 28 Correct chain tension ssssssssssssseeeees 19 Digital sp ed meter is nedi isn 5 Digital speedometer indicator lamp 5 Dismounting and mounting the front wheel 23 Dismounting and mounting the rear wheel 24 Draining of float chamber of the carburetor 30 Page Driving Instructions mee 12 Emergency OFF switch Australia sss 6 Engine number engine type 125 200 4 Engine number engine type 250 300 380 4 Exhaust SyStenT ikisi apii aau arii ai daaa ies 30 Filler Captiva eure ies ottenuti e ute 6 Flasher switch a etn 6 Foot brake pedal 2 2 eet eb ei tegens 8 Fuel ea aa notes 7 General informations about KTM disc brakes 20 Hand brake
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10. Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push dust pro tection bellows into the outer tubes by hand Adjusting the spring preload on the fork SX The spring preload on the SX models can be adjusted changed by 10 mm by turning adjusting screw Turning in a clockwise direction will increase the prestress turning in a counterclockwise direction will decrease the prestress Changing the spring preload will not affect the rebound damping adjustment Generally if the spring preload is higher the rebound damping should also be set higher STANDARD SETTING Unscrew the adjusting screw to the limit and then back 2 turns a J 2 m m EY o0 How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar to the position that is the most convenient for you The upper tri ple clamp O includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support are offset from the cen ter by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws of the handlebar clamps and screws of the handlebar support Position h
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12. IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY IN YOUR OWN INTEREST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS A WARNING A IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE 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 Chassis number Engine number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners 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 any person KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CON
13. 1 0 bar 14psi 2 0 bar 28psi Fuel tank capacity 7 5 liter 2 US Gallons 8 5 liter 2 2 US Gallons 11 liter 2 9 US Gallons 8 5 11 liter 2 2 2 9 US Gallons instrument light brake rear light flasher light 12V 1 2W Sockel W2 1x4 6d 12V 21 5W Sockel BaY15d 12V 10W Sockel Ba15s Final drive ratio 13 50t 14 38t 14 45t 14 48t Final drive ratio USA 13 50t 13 50t 14 48t 14 48t Chain 5 8 x 1 4 Available final sprockets 38t 40t 42t 45t 48t 50t 52t Bulps headlight HS1 12V 35 35W parking light 12V 5W Sockel W2 1x9 5d license plate illmination 12V 1 2W Sockel 1x4 6d 63 1461 10 mm 573 0 4 in 925 mm 36 5 in 385 mm 15 2 in 100 kg 221 Ibs 96 kg 212 165 Steering head angle Wheel base Seat height unloaded Ground clearance unloaded 92 kg 203 Ibs 92 kg 203 Ibs Dead weight Dead weight USA 101 kg 223 Ibs 97 kg 214 165 96 kg 212 165 Dead weight without fuel STANDARD ADJUSTMENT FORK TIGHTENING TORQUES CHASSIS WP 4860 MXMA WP 4357 MXMA Collar nut front wheel spindle M 16 20x1 5 40 30 16 1418W708 0518W710 Brake caliper front M8 25Nm 19 ft lb Compression adjuster 20 20 Loctite 243 Rebound adjuster 16 12 Clamping screws upper fork bridge M8 20 Nm 15 ft Ib Spring 4 0 N mm 3 8 N mm Clamping screws lo
14. These linings provide an optimal combination of dosing brake performance and lifecycle The lining type is stated on the back of the brake pad and also recorded in the homo logation papers Other brake pads are available for competition sports FRONT TOSHIBA H 38 SINTERED harder to dose good brake perfor mance long life for wet slippery terrain FERODO ID 450 ORGANIC easy to dose good brake perfor mance short life for dry terrain low price REAR FERRIT 222 ORGANIC can be dosed better short life cycle for dry terrain FERODO ID 450 ORGANIC easy to dose good brake perfor mance short life for dry terrain low price BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face O of the brake pads decreases At their thinnest point O the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location O outside the contact face Check wear in several locations VVARNING A BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS THEY REACH THE WEAR LIMIT HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID RESERVOIRS 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
15. vice jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your mechanic at the beginning of the next biking season TECHNICAL SPECIFICATIONS CHASSIS 125 SX EXC 200 MXC EXC 2002 125 SX 125 EXC 200 MXC 200 EXC Frame Central chrome moly steel frame Fork WP UP SIDE DOWN 48MA White Power Up Side Down 43 MA Wheel travel front rear 295 320 mm 11 3 12 6 in Rear suspension WP PDS 5018 Progressive Damping System shock absorber aluminium swingarm Front brake Disc brake with carbon steel brake disc amp 260 mm 10 2 in brake caliper floated Front tires USA Air pressure offroad Air pressure road driver only 80 100 21 51M 1 0 bar 14psi 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi 80 100 21 51M 1 0 bar 14psi Rear brake Disc brake with carbon steel brake disc amp 220 mm 8 7 in brake caliper floated Brake discs Wear limit max 0 4 mm 0 016 in Front tires 80 100 21 51M 90 90 21 54R 90 90 21 54R 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi Rear tires Rear tires USA Air pressure offroad Air pressure road driver only 100 90 19 57M 100 90 19 57M 1 0 bar 14psi 120 90 18 65R 100 100 18 59M 1 0 bar 14psi 2 0 bar 28psi 100 100 18 59M 1 0 bar 14psi 120 90 18 65R 100 100 18 59M
16. Check antifreezer and amount of cooling liquid Let the engine warm up again close fuel cock and wait until the engine dies off by itself By this means carburetor jets are preven ted from becoming resinous 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 container Correct tire pressure Lubricate bearing points of the control levers foot rests etc as well as the chain The storage place should be dry and not be subject to too big temperature fluctuations Cover the motorcycle with an air permeated tarp or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and thereby cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST RE INITIATION AFTER TIME OF STORAGE Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you have to check all parts for their function and wear Should any ser
17. Collar screw handlebar clamp M8 20 15 16 Allen head screw handlebar support M 10 40 30ft lb Loctite 243 Shock absorber top M12 60Nm 44 ft lb Shock absorber bottom M12 60 44 ft lb Screw adjusting ring spring preload M6 8Nm 6ft Ib Other screws on chassis M6 10Nm 7 ft lb M8 25Nm 19 16 M 10 45 Nm 33 16 HSITDONG amp qiesul Jam 493g 4lv 9 qe1 ees Suns 10je1nque JOJoUNqJeD 32 14 1 MOLL ACL EAT 101819433 ou c NVSNAOD Mob ACL Cc NVSNAOW 101819433 ou L 3C indjno soyesauay W33sAs uous do L Do GZ 15 1e 19JEM 09 2 nue SANI EL 005 X 8 5 UYD 1O AGL IL 1 sje pouds a gejieny p enr e ue py 9US Ot AAOL Io 8 0 OX3 DXW PXSA 92ue py 945 OV MOT 110 8 8 0 XS 129D 8L C Lc ec 8L C L T ET 8L C 1290 ET LC OC Lc EC LC EC Lc OC Lc EC LC 1290 vC 6L TT 6L bT 6L vC 6L TT 6L 9 6 6 1290 pE 9T 8L 9T 8L 9 81 9 81 9 81 9 81 LCL 1090 pul 6cSL 629 6 629 629 629 62 91 62 1290 sb DXW 2X3 DXW 2X3 DXW 2X3 panpe mep paads UOISSILUSUPLA GL4 4H 11945 ur yaanjo 21 ajdminu Uni
18. OR LOW 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 retor malfunction e g overly rich mixture Therefore these parts should be replaced after 10000 kilometers 6000 miles Definitions Mixture too rich Too much fuel in proportion to air Mixture too lean Not enough fuel in proportion to air Idling range A Operation with closed throttle valve This range is influenced by the posi tion of the air control screw and the air control screw Only make adjustments when the engine is hot To this end slightly increase the idling speed of the engine by means of the air control screw Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed Create a main jet round and stable engine speed using the air control screw basic position of jet needle the air control screw open by 1 5 turns Then adjust to the
19. 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 COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC HSITDONA 2 N 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 Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the sli ding metal sheet 6 in the caliper support and of the leaf spring O A WARNING A IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY
20. W2 1x4 6d 12V 21 5W Sockel BaY15d 12V 10W Sockel Ba15s 12V 1 2W Sockel 1x4 6d Steering head angle 63 5 Wheel base 1481 10 mm 58 3 0 4 in Seat height unloaded 925 mm 36 5 in Ground clearance unloaded 385 mm 15 2 in Dead weight Dead weight USA 102 kg 225 2 165 102 kg 225 2 165 103 5 kg 228 5 Ibs 106 kg 234 lbs 104 5 kg 230 7 lbs Dead weight without fuel STANDARD ADJUSTMENT FORK WP 4860 MXMA WP 4357 MXMA 1418W709 0518W711 Compression adjuster 20 20 Rebound adjuster 16 12 Spring 4 2 N mm 4 0 N mm Spring preload 5 mm 0 20in 5 mm 0 20in Air chamber length 100 mm 4 0 in 140 mm 5 9in Fork oil SAE 5 SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER WP 5018 PDS DCC WP 5018 MCC 1218W736 1218W737 Compression adjuster 15 LS low speed 15 2 HS high speed Rebound adjuster 25 25 Spring PDS7 260 PDS6 260 Spring preload 4 mm 0 16 in 5 mm 0 19 in TIGHENING TORQUES CHASSIS Collar nut front wheel spindle M 16 20x1 5 40Nm 30 16 Brake caliper front M8 25Nm 19 ft lb Loctite 243 Clamping screws upper fork bridge M8 20Nm 15 10 Clamping screws lower fork bridge M8 15 Nm 11 16 Clamping screws fork stubs M8 10Nm 7 16 Collar nut rear wheel spindle M 20x1 5 80Nm 59 ft lb Hexagon nut swing arm bolt M 14x1 5 100 Nm 74 ft Ib
21. WLY 8 e 045 0M Japul AD a Suls pajooo pinbr usisaq 2X3 O8E XS 08 2X3 00 2X3 0ST XS 0SC euiu3 YSN JO 1no sjapow ZOOZ 2X3 XS 08E 00E 0ST 3NIDN3 VIVA IVIINHIIL TIGHTENING TORQUES Flange bolts cylinder head M8 35 Nm 25 ft lb Nuts cylinder base M 10 35Nm 25 ft lb Flywheel collar nut M 12x1 60 44 16 Nut for primary sprocket LH thread M 18x1 5 Loctite 243 150 Nm 110 ft Ib Nut for inner clutch hub M 18x1 5 Loctite 243 100 Nm 74 ft lb Crankcase and cover bolts M6 8Nm 6ftlb Swingarm pivot M 14 100 Nm 74 ft Ib Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm 14 ft Ib Other screws M6 10Nm 7 ft lb M8 25 19 16 M 10 45 Nm 33 ft lb TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 0 06 mm 250 0 06 mm 300 0 08 mm 380 Piston ring end gap 0 3 0 4 mm Connecting rod bearing radial clearance 0 021 0 032 mm Transmission shafts end float 0 1 0 2 mm Clutch springs length 2 5 new 43 mm minimum length 42 mm GASKET THICKNESSES Crankcase 0 5 mm Clutch cover 0 5 mm Cylinder bottom gasket as required Available cylinder bottom gaskets 0 2 0 4 0 5 0 75 mm Cylinder head gasket O rings BASIC CARBURETOR SETTING 250 SX 380 SX 380 SX USA 250 300 EXC throttled Carburetor Keihin PWK 38 AG Ca
22. 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 systems with SHELL ADVANCE BRAKE DOT 5 1 brake fluid one of the best brake fluids that is 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 Never use brake fluid DOT 5 The color of this silicon oil based product is purple red The gaskets and brake hoses of KTM motorcycles are not desi gned for DOT 5 brake fluid N A min 3 mm Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw O In this way the position of the point of pressure i 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 FREE 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 B
23. ft Ib 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 10 Nm 7 ft lbs 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 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 IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED 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 O remove chain tensioner O 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 DISMOUNTED SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED IF THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM J
24. normal idling speed by means of the air control screw s e wu NY S gt jet needle Opening up B mE Engine behavior when the throttle opens The idle jet and the shape of the NNN NN E throttle valve influences this range If despite good idling speed and part SSS b rottle valve throttle setting the engine sputters and smokes when the throttle is fully CAZA IN air control screw opened and develops its full power not smoothly but suddenly at high idle adjusting screw engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking L ml e 31 HSITONGA 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
25. 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 Operation with the throttle fully open flat out This range is influenced by the main jet and the jet 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 porce lain is dark brown or black with soot the main jet must be replaced by a smaller one Checking the float level Arrange the 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 standing master cylin der should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION H KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FI
26. 5 5 35 03005 ALA UIMI WLY e o45 0M Jeput A2 a 8urs pajooo pinbr usisaq 2X3 2XW 00 2X3 2XW 096 XS 0SC euiu3 XS 08 ysn Ajuo eooc 2X3 DXW XS 08 00 0SC INIDNI VIVA 1VDINHDIL TIGHTENING TORQUES ENGINE Flange bolts cylinder head M8 35 25 ft lb Nuts cylinder base M 10 35 25 16 Flywheel collar nut M 12x1 60 44 16 Nut for primary sprocket LH thread M 18x1 5 Loctite 243 150 Nm 110 ft Ib Nut for inner clutch hub M 18x1 5 Loctite 243 100 Nm 74 ft lb Crankcase and cover bolts M6 8Nm 6ftlb Swingarm pivot M 14 100 Nm 74 ft Ib Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm 14 ft Ib Other screws M6 10Nm 7 ft lb M8 25 19 16 M10 45 Nm 33 16 TOLERANCES AND FITTING CLEARANCES Piston fitting clearance 0 06 mm 250 0 06 mm 300 0 08 mm 380 Piston ring end gap 0 3 0 4 mm Connecting rod bearing radial clearance 0 021 0 032 mm Transmission shafts end float 0 1 0 2 mm Clutch springs length 2 5 new 43 mm minimum length 42 mm GASKET THICKNESSES Crankcase 0 5 mm Clutch cover 0 5 mm Cylinder bottom gasket as required Available cylinder bottom gaskets 0 2 0 4 0 5 0 75 mm Cylinder head gasket O rings BASIC CARBURETOR SETTING 250 SX 250 MXC EXC 300 MXC EXC 380 SX MXC EXC Carburetor Keih
27. AMMING 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 A VVARNING A F 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 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 T IS 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 LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE TIRES AIR PRESSURE front rear Off road 1 0 bar 1 0 bar Road driver only 1 5 bar 2 0 bar 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 spec
28. CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALWAYS 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 O The free play at the foot brake pedal must then be adjusted by means of the piston rod O 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 IF 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 the 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 VVARNING 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
29. 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 NOTE The large adjusting range of the chain adjusters 32mm allows you to use different secondary ratios in combination with the same chain length The chain adjusters can be rotated around 180 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 i e 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 i e Shell Advance Bio Chain A WARNING A 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 SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary a J 2 m lt max 272 mm gt 123 16 17 18
30. DITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI TUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT IN THE EVENT OF SUCH MODIFICATIONS PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION WE SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS 2 E W I 2 Introduction We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics even if this means that you have to dedicate some of your valuable time to this task Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out however that there may exist minor discrepancies resulting from further design upgrades of these motorcycles This manual is an important part of your motorbike and should be passed on
31. DLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING THE SPOKES MUST BE TENSIONED TO 5 7 NM Replacing the battery of the digital speedometer After approx 2 years the battery of the digital speedometer will be empty and must be replaced For this purpose the speedometer must be dismounted Remove headlight mask and pull speedometer illumination system 6 out of the speedometer housing Use a screwdriver to lever the blue speedometer glass O downward and out of the speedometer housing The two noses must be disengaged from the speedometer housing Remove screws O and take speedometer out of housing Before you remove the battery do not forget to write down the following data total kilometer reading DST wheel circumference WS KTM standard tires 2205 mm Remove the battery cover on the back of the speedometer and detach the batteries The new batteries must be inserted with the plus pole on top Make sure that the seal ring has the right position on the cover when mounting the battery cover Now total mileage wheel circumference and time have to be entered To mount the speedometer proceed by following the reverse order of the above procedure a5 J U 2 m N TOTAL MILEAGE DST 1 use the right button to 2 push the left button until select the position to be the right figure is showed changed in the display AFTER CHANGING BATTERY
32. E 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 KILOMETERS 300 MILES OR 5 HOURS Starting when the engine is cold AWN 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 15 and kick down kickstarter vigorously all the way A WARNING A FOR STARTING ALWAYS PUT ON YOUR MOTORCYCLE BOOTS TO AVOID INJURIES YOU COULD SLIP OFF THE KICKSTARTER OR THE MOTOR COULD KICK BACK AND FLING YOUR FOOT UPWARDS FORCEFULLY KICK THE KICKSTARTER DOWN THE WHOLE WAY AND DO NOT OPEN THE THROTTLE A KICKSTART WITH TOO LITTLE MOMEN TUM AND AN OPENED THROTTLE INCREASES THE KICKING BACK RISK 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 Starting when the engine is warm 1 Ope
33. ENOUGH MOMENTUM AND AN OPENED THROTTLE GRIP INCREASE THE KICK BACK HAZARD 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 VVARNING A IF 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 Side stand Push the side stand to the ground with your foot and load it with the motorcycle Make sure that you put your bike on solid ground and in a secure position For off road riding you can use the rubber band O to additionally secure the center stand in its folded up position CAUTION l THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE IF YOU GET ON THE MOTORCYCLE AND THUS PUT ADDITIONAL WEIGHT ON THE SIDE STAND THE SIDE STAND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE MAY FALL ON THE SIDE ALWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE SIDE STAND AS FAR AS POSSIBLE IF THE STAND TOUCHES THE GROUND WHILE YOU ARE DRIVING YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE 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 tu
34. FUEL PROPERLY Carburetor adjustment Basic information 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 C 68 F mainly for off road use and central European premium grade fuel 95 ROZ Mixing ratio 2 stroke motor oil super fuel 1 40 1 60 depands on oil quality 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 THUMB 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 ROZ 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER 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 e Shell Advance Racing X ENOUCH OIL
35. IED OUT BY EXTRA ORDER at least once a year every 2 years or 20000 km Check function of exhaust control Complete maintenance of shock absorber Complete maintenance of fork Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact grease Change hydraulic clutch fluid Change break fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 5 HOURS OR 500 KM MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER 5 gt E S oe gt E EE g Check gear box oil level e Check break fluid level e Check break pads for wear e Check lights for function e Check horn for function e Lubricate and adjust cables and nipples e Bleed fork legs regulary e Remove and clean dust bellows regulary e Clean and lubricate chain check tension and adjust if necessary e e Clean air filter and filter box e Check tires for pressure and wear e Check cooling liquid level e Check fuel lines for leaks e Empty and clean float chamber e Check all control elements for sm
36. KING 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 AND GET BURNED CAUTION CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE IF YOU GET ON YOUR MOTOR CYCLE AND THUS PUT ADDITIONAL WEIGHT ON THE MOTORCYCLE THE SIDE STAND OR THE FRAME CAN BE DAMAGED OR THE MOTORCYCLE MAY FALL ON THE SIDE PERIODIC MAINTENANCE SCHEDULE SPORTMOTORCYCLES A washed motorcycle can be checked more quickly which saves money 1 service after 10 hours or 1000 kilometer 125 200 SX MXC EXC 250 300 380 SX MXC EXC after 20 hours or 2000 kilometer after 4000 kilometer or once a year Check gear box oil level Change gear box oil Check spark plugs adjust distance between electrodes Renew spark plugs Check the carburettor connection bo
37. LL UP THE MASTER CYLIN DER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR 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 together with rubber bellows At the slave cylinder of the clutch remove the blee der nipple O At its place mount the bleeder syringe O which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubble free state Make sure that the oil does not over flow The bleeder syringe can be purchased at your KTM dealer Having completed the bleeding procedure you have to verify that the oil level in the master cylinder is correct If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydrau lic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLIN DER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE 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 necessa
38. LY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY CAUTION ONLY USE PREMIUM GRADE GASOLINE ROZ 98 RESPECTIVELY 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE 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 i e SHELL ADVANCE RACING X 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 IF YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER ALWAYS KEEP IN MIND THAT LEADED FUEL WILL DESTROY THE CATALYTIC CONVERTER FUEL EXPANDS WHEN ITS TEMPERATURE RISES THEREFORE DO NOT FILL THE TANK TO THE TOP SEE FIG Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor 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 a
39. NGING DOWN TO 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 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 N 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 IN CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF ROAD TRACKS HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN RIDES ON SALT STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRA KING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEA KER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRA
40. NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN ANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW O CONNECTION 24MM I A l U 2 9 Compression damping of shock absorber MXC EXC The compression damping during compression can be adjusted for the MXC and EXC shock absorbers Mono Compression Control The degree of damping can be adjusted by turning adjusting screw O with a screwdriver Turning in a clockwise direction will increase the damping turning in a counterclockwise direction will decrease the damping STANDARD ADJUSTMENT 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 Type White Power 1218W735 15 clicks Type White Power 1218W737 15 clicks VVARNING 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 NEVER UNSCREW THE BLACK SCREW CONNECTION 24MM Rebound damping of shock absorber SX MXC EXC By using the adjusting screw O 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 ADJUSTMENT Turn the adjusting s
41. RAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING 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 A 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 ENGLISH N Refilling the front brake fluid reservoir Loosen screws and remove lid O and membrane 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 i e Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A VVARNING 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 DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID
42. RT 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 FOR 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 Manual Thoroughly read the whole instruction manual before starting for your first tour 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 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 you
43. S 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 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 ONLY 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 O 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 tripl
44. TENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER Thoroughly wash the air 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 air 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 Mount the filter together with the filter support in the filter box making sure to properly center them and fix them with the filter holding bracket Exhaust system Silencers whose caps O is detachable are filled with glass fiber yarn Let this package be ckecked at least after 4000 km or at once a year Glass fiber yarn that is too loose may cause a drop in performance and curtail the silen cer s silencing effect To replace the glass fiber yarn packing O 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 Mount silencer cap Glass fiber yarn packings are available at your authorized KTM dealer A WARNING A THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING 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 pr
45. YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION l IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the rear brake pads Press brake caliper O 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 O A WARNING A IT IS 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 ALWAYS 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 t
46. andlebar support and tighten screws O to 40 Nm 30 ft lbs Mount handlebar and handlebar clamps and tighten screws to 20 Nm 15 ft lbs The gap between handlebar support and handlebar clamps is to be of equal size in the front and in the rear Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring O changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counter clockwise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw tighten it to 8 Nm 6 ft Ib ADJUSTMENT VALUES SPRING PRELOAD minimum preload 4 mm 0 15 in STANDARD PRELOAD 6 mm 0 24 in maximum 10 mm 0 4 in 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 d
47. crew clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber m 2 O Ja W L 10 Type White Power 1218W734 25 clicks Type White Power 1218W735 25 clicks Type White Power 1218W736 25 Clicks Type White Power 1218W737 25 clicks A 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 NEVER UNSCREW THE BLACK SCREW CONNECTION 15MM E DRIVING INSTRUCTIONS What 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 TRANSMISSION 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 venting 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 damag
48. e clamp to release tension Retighten the five pinch bolts to 20 Nm 15 ft Ib VVARNING 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 YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED The steering head bearings should be regreased at least once a year i e Shell Advance Grease Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs O a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on street it will be enough to have this job performed in the course of the periodical mainten ance service CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK YOUR FORK IS LEAKING IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE SEALS REPLACED Cleaning the dust sleeves of the telescopic fork The dust protection bellows are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak
49. e replaced by pure water CAUTION l FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE I E SHELL ADVANCE COOLANT USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORRO SION AND COOLANT FOAMING Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap a water temperature of up to 120 C 248 F is admissible therefore having to expect any trouble when engine is cold Radiator cover for the cold season To ensure that the engine reaches its operative temperature also at low temperatures the radiator cover O must be mounted For this purpose detach the left radiator protection and mount the cover in front of the left radiator as illustrated Remount the radiator protection NOTE The radiator shutter can be obtained from your KTM dealer 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 BE BLED AFTER DRAINING THE COOLING LIQUID OR AFTER ADDING MORE THAN 0 25 L 0 06 US GALLONS COOLING LIQUID o ENGLISH Refilling Bleeding the c
50. ed 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 check that it is securely fastened A WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE SMART KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A SHO
51. er 0518W710 12 clicks Type White Power 0518W711 12 clicks Damping action during compression of shock absorber SX The shock absorber on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber com pression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counter clockwise will decrease the damping STANDARD LOW SPEED SETTING Turn the adjusting screw to the limit in a clockwise direction using a screwdriver Unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Type White Power 1218W734 15 clicks Type White Power 1218W736 15 clicks STANDARD HIGH SPEED SETTING Turn the adjusting screw to the limit in a counterclockwise direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber in a clockwise direction Type White Power 1218W734 2 turns Type White Power 1218W736 2 turns VVARNING THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION
52. he 2 clamping screws on the left side of the fork fists Loosen and remove the collar nut loosen the clamping screews on the right side of the fork fist Hold the front wheel pull out the wheel spindle O NOTE The wheel spindle can be easily removed if you slightly revolve it with a ring span ner SW 21 mm or a hexagon socket screw key 6 mm Remove front wheel carefully from the fork and take the speedometer drive off the hub NOTE Models with a digital speedometer have a distance bushing instead of the speed ometer drive CAUTION Do NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED Prior to mounting the front wheel clean and grease sealing ring and running surface O at the speedometer drive Lift front wheel into fork and insert speedometer drive or distance sleeve into hub Make sure that the driving tabs engage with the slot of the drive Position front wheel and speedometer drive or distance sleeve and mount wheel spindle I A ml U 2 23 The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer Mount collar nut O turn speedometer drive in a way that the flexible spee dometer shaft will curve upwards in a slight bow see pict and tighten collar nut to 40 Nm 30
53. he distance between magnet O and sensor O must be 2 4 mm otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing in or off the sensor O 2 Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the par king light lamp with holder carefully out of the reflector Pull connector off the headlamp and remove rubber cap Disengage retaining clip and take bulb out of reflector When changing the parking light lamp sim ply pull it out of the holder Insert new lamp such that the noses O engage the recesses O When doing so do not touch the glass body of the lamp so that it remains free from fat Engage retaining clip mount rubber cap and connector If the parking light lamp is to be replaced simply insert it into the holder Reinsert parking light lamp together with holder Engage the bottom end of headlamp mask at the retaining pins and fix the mask by means of the rubber bands Cooling system The water pump in the engine circulates the cooling liquid However the cooling liquid can only 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 thermos
54. ific 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 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 F 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 HAN
55. in PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 061200 030201 040201 050201 Main jet 170 168 172 178 175 180 175 172 178 170 168 172 Idling jet 48 45 50 45 48 45 48 45 48 Starting jet 85 85 85 85 Jet needle NOZ E NOZ F D NOZ E NOZ F NOZ H NOZ I NOZ G NOZ H Needle position from top IN IV IN I Slide 6 5 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 1 5 Performance restrictor Power jet jet AB adA ureoj Jom 9 qei 995 Sunjes 2 opi s 1e j 5 MOLL AZL Joyejauas ou MOLL AZL Joyeiauas ou jndino soyesauayH C NVSP O 1Z AZ NYSNION L AZ NVSQ O W91s4s uous do EL Do GZ 15291 1 9509 2 Ue 950r S Y E L 1091009 10 GL IL JEL sj9 pouds p EN OURAPY OH MOL 10 8 8 0 PXSA S9ULAPY 949 10 auraus 8 0 IN JAYS ot MOL 10 8 0 pXSA 2ouenpy 945 0 0 80 8 0 uoneouqn Jear BLES 8L EC Je2D 4G OC Vc C Vc OC Vc EC Ic 129D qp CC 6L VC 6L SC6l 1290 pE 9T 8L 9T 8L 9T 8L LTL 12970 ul 6T SL 6C SL 6 91 66 91 Je27 Jean payenjoe mep paads UOISSILUSUPLA G13 4H 1945
56. ions about KTM disc brakes 20 Adjusting of free travel at the hand brake lever 21 WIRING DIAGRAMME CARBURETOR SETTING Appendix m Z n a 4 SERIAL NUMBER LOCATIONS Chassis number 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 Write this number into the relevant area on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever O 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 engine Hand brake lever The hand brake lever is mounted on the handle bars on the right and actua tes the front wheel brake A VVARNING 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 Digital speedometer indicator lamp EXC The green cont
57. l level 250 300 380 33 Rebound damping of shock absorber SX MXC EXC 10 Changing the transmission oil 250 300 380 33 DRIVING INSTRUCTIONS 12 fanke aa 34 CONSERVATION FOR WINTER OPERATION 34 PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE 14 STORAGE x itua e goa te e RR ak Ra 34 MAINTENANCE WORK ON CHASSIS AND ENGINE 16 RE Iniation After Time of storage 34 Changing the original position of the clutch lever 16 Checking and adjusting the steering head bearing 16 TECHNICAL SPECIFICATIONS CHASSIS 125 200 35 Breather plug front 17 Cleaning the dust sleeves of the telescopic fork 17 TECHNICAL SPECIFICATIONS ENGINE 125 200 36 Adjusting the spring preload on the fork SX 17 How to change the handlebar position 18 TECHNICAL SPECIFICATIONS CHASSIS 250 300 380 38 Changing the spring preloading of the shock absorber 18 TECHNICAL SPECIFICATIONS ENGINE 250 300 380 Pivot bearing os puri iae ter 18 Check chain tension 19 SUN 59 12 TECHNICAL SPECIFICATIONS ENGINE 250 300 380 Chain maintenance 19 All models out of 42 Chain wear 20 HEAD WORD INDEX 44 General informat
58. n fuel tap 2 Turn on ignition or emergency OFF switch 3 Putthe gear in neutral 4 Open throttle to and kick down kickstarter vigorously What 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 Once the 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 ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE 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 le
59. nce ssssssssee ee 19 Chain Wear seu dampna et ence 20 Changing the basic position of the foot brake pedal 22 Changing the original position of the clutch lever 16 Changing the spring preloading of the shock absorber 18 Changing the transmission oil 125 200 33 Changing the transmission oil 250 300 380 33 Chassis riutmbetz ssi ie esten pied mitan 4 Check chain tension sssssssem 19 Check transmission oil level 125 200 33 Check transmission oil level 250 300 380 33 Check set distance of magnetic 27 Checking and adjusting the steering head bearing 16 Checking of brake fluid level front brake 21 Checking rear brake fluid 22 Checking spoke tension sssssssseee 25 Checking the coolant 29 Checking the float level oo eect treet 32 Checking the front brake 5 21 Checking the oil level of the hydraulic clutch 32 Checking the rear brake 23 Choke knob entrent rre 7 Cleaning 35 metae ie eiae 34 Cleaning the air filter ssssssssseeee 30 Cleaning the dust sleeves of the telescopic fork
60. nce of magnetic sensor 27 Flasher switch 6 Replacing head light lamp 28 Emergency OFF switch Australia 6 Cooling system sisse 28 6 Radiator cover for the cold season 29 Refueling 7 Checking the coolant level 29 ahi 7 Refilling Bleeding the cooling system 29 A 7 Cleaning the air filter 30 Exhaust system 30 SNINE TEVEN onm assa asa a onse Cleaning the spark arrestor EXC USA 30 Kickstarter esee n nn 8 Draining of float chamber of the carburetor 30 Foot brake 8 Carburetor adjustment 31 Side stand 8 Checking the float level 32 Steering lock a zo cs escrito nm ete iet ta sia 8 Checking the oil level of the hydraulic clutch 32 Compression damping of fork 9 Bleeding of the hydraulic clutch 32 Rebound damping of fork 9 Check transmission oil level 125 200 33 Compression damping of shock absorber 5 9 Changing the transmission oil 125 200 33 Compression damping of shock absorber MXC EXC 10 Check transmission oi
61. of brake fluid level front brake 21 Chassis 4 Refilling the front brake fluid reservoir 21 Engine number engine type 125 200 4 Checking the front brake pads 21 Engine number engine type 250 300 380 4 Replacing the front brake 22 Changing the basic position of the foot brake pedal 22 OPERATION INSTRUMENTS 4 Checking rear brake fluid level 22 Refilling the rear brake fluid reservoir 22 Clutch lever oannes mee tee EE 4 i Hand brake lever emp 4 VICI ss N eu Replacing the rear brake pads 23 Digital speedomieter indicator EAE inde 2 Dismounting and mounting the front wheel 23 Digital Speedormeler Rake prd et aay pat 5 Dismounting and mounting the rear wheel 24 Odometer EXC USA 5 Tires air pressure 25 Speedometer indicator lamps EXC Australia 5 Checking spoke tension 25 Short circuit button 5 5 Replacing the battery of the digital speedometer 25 Combination switch 6 Adjustin digital speedometer 26 Headlamp switch EXC USA 6 Check set dista
62. ontainer Clean the magnet of the oil drain screw and reinstall oil drain screw with seal Pour in O 8 litres engine oil see technical data engine replace plug and check engine for leaks CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECT TO EXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL w ENGLISH CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS Befor cleaning with water plug the exhaust pipe to prevent water ingress You should use normal brand name detergents to clean the motorcycle Especially dirty parts should be cleaned additionally 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 the working temperature and also use the brakes By warming these components the residual water can evaporate from inacce
63. ooling system The cooling system must be bled as described below after draining of the cooling liguid or after adding more than 0 25 0 06 US gallons cooling liguid Make sure that the drain screw is fastened Pour approx 0 5 litres 0 13 US gallons coolant into the system Remove screw O at the cylinder head Reinstall it as soon as the cooling liguid emerges free of air bubbles only for 125 200 engines Remove the screw O on the right radiator Now add cooling liguid until it emerges free of bubbles at the right radia tor Then immediately mount the screw so that no more air can enter the right radiator 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 UJ 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 O counter clockwise and pull them outward up to the stop pull the filter box cover forward and remove it Unhook the filter holding brackets O at the bottom swing them sideways and take the air filter O together with the filter support O out of the filter box L CAUTION DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER MAIN
64. ooth operation e Check break performance e e Treat blank metal parts with the exception of brake and exhaust systems e with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray e Check tightness of screws nuts and hose clamps regular e MAINTENANCE WORK ON CHASSIS AND ENGINE A WARNING A MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK REQUIRES EXPERT SKILLS AND TECHNICAL KNOW HOW FOR YOUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF 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 NUT
65. oper functioning Also clean the spark arrestor when replacing the glass fiber yarn filling After assembling the silencer remove the plug O 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 Draining of float chamber of the carburetor Following every wet cleaning procedure the float chamber of the carbure tor should be drained in order to remove any water that may have penetra ted into it Water in the float chamber leads to engine malfunction Make sure you do this while the engine is cold Close the fuel tap and place a cloth under the carburetor which is capable of absorbing the leaking fuel Unscrew the plug O and clean it with compressed air Then mount plug together with gasket open fuel tap and check float chamber for leaks A WARNING A FUEL IS EASILY FLAMMABLE AND TOXIC WHEN HANDLING FUEL BE SURE TO EXERCISE THE UTMOST CAUTION NEVER PERFORM ANY WORK ON THE FUEL SYSTEM IN THE PRO XIMITY OF OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE THE
66. ot for cracks and leaks ADD ON PARTS Check idle speed setting Check that vent hoses are not damaged or bent Check cooling system for leaks check quantity of anti freeze Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check oil level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems low high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button CHASSIS Check break fluid level lining thickness break lining Check break lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of break system screws Check shock absorber and fork for leaks and function Clean dust bellows Bleed fork legs Check swing arm bearings Check adjust steering head bearings Check tightness of all chassis screws triple clamps fork leg axle passage axle nuts and screws swing arm bearings shock absorber WHEELS Check spoke tension and rim join Check tyres and air pressure Check chain rear sprockets and chain guides for wear fitment and tension Lubricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARR
67. r 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 Motorcycles 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 REGU LATIONS AND SAFETY STANDARDS USING THEM ON PUBLIC ROADS HIGHWAYS FREEWAYS ETC 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 SOM
68. ramatically 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 O must be taut see drawing If necessary correct chain tension A 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 F THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut O loosen lock nuts O and turn right and left adjusting screws equally far Tighten lock nuts Before tightening the collar nut verify that the chain adjusters O are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut O 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
69. rburetor setting number 061200 Main jet 170 168 172 Idling jet 48 45 50 Starting jet 85 Jet needle NOZ E NOZ F D Needle position from top Keihin PWK 38 AG 050201 170 168 172 45 48 85 NOZ G NOZ H Keihin PWK 38 AG 061200 175 172 178 180 35 45 48 85 R 1475 J NOZ E H Ill Slide 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 Performance restrictor slide stop 34mm Power jet jet BASIC CARBURETOR SETTING 250 EXC USA 300 EXC AUS 300 MXC EXC throttled USA Performance restrictor Power jet jet Carburetor Keihin PWK 38 AG Carburetor setting number 030201 Main jet 178 175 180 Idling jet 45 48 Starting jet 85 Jet needle NOZ E NOZ F Needle position from top IV Slide 6 5 Air adjustment screw open 1 5 Keihin PWK 38 AG 070201 170 172 168 45 48 85 NOZ G NOZ H 6 5 1 5 slide stop 36mm Keihin PWK 38 AG 040201 175 178 172 45 48 85 NOZ H NOZ I tl 6 5 1 5 HEAD WORD INDEX Page Adjustin digital 26 Adjusting of free travel at the hand brake lever 21 Adjusting the spring preload on the fork SX 17 All models out of USA 42 Bleeding of the hydraulic 32 Breather plug front fork sss 17 Carburetor adjustment 31 Chain maintena
70. rn it to right and remove it CAUTION NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK IF YOU TURN THE HANDLEBAR TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjusting scr ews at the bottom of the fork legs Remove the protecting cap Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD ADJUSTMENT 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 White Power 1418W708 20 clicks Type White Power 1418W709 20 clicks Type White Power 0518W710 20 clicks Type White Power 0518W711 20 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebo und 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 ADJUSTMENT 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 White Power 1418W708 16 clicks Type White Power 1418W709 16 clicks Type White Pow
71. rol lamp O flashes when the indicator is working in the same rhythm as the flashing indicator The blue control lamp lights up when the high beam is on Speedometer digital Some models are equipped with a digital speedometer Speed max 200 km h is always indicated Aside from speed indication the following indications can be selected Trip distance STP Stopwatch max 10 h automatic start stop function DST Total distance up to 99 999 km CLK clock See maintenance work for change of battery and basic setting I n ml U e 5 Odometer EXC USA The odometer is a mileage indicator and can be set to O by means of the adjustment wheel O Speedometer indicator lamps EXC AUS The mileage indicator in the speedometer indicates overall mileage When the turn indicator is on the green indicator lamp O will be flashing in the same rhythm The blue indicator lamp O will be lit when the high beam is on 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 O Light off this function is not available in all models Low beam on Q High beam on You may use button O to actuate the horn The red short circuit button serves to
72. ry remove the plug and top up with oil see technical data engine 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 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 O 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 oil see tech nical data engine 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 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 O and top up with oil see technical data engine CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECT TO EXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL 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 c
73. s possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Reserve of the 8 5 tank 1 2 0 32 US gallons Reserve of the 11 tank 1 7 I 0 45 US gallons CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE Choke knob When pulling the choke knob 6 fully towards the top a 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 L a l U e 7 Shift lever DL 27 i The shift lever is mounted on the left side of the engine The position of the a gears is shown in the illustration Neutral or the idle speed is located bet G g 12 3 4 5 6 f ween first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled A WARNING A IF YOU WANT TO START THE ENGINE MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MIGHT SLIP OFF THE KICK STARTER OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE KICKING THE KICKSTARTER WITH NOT
74. ss gas Only give as much gas as the engine can 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 WHEN 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 A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED DO NOT ADJUST THE HANDLEBAR IT WILL LOSE STA BILITY 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 CHA
75. ssable parts of the engine and the brakes 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 Treat the chain with a chain spray too To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch the short circuit button the light switch and the socket connectors with 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 motorcycle thoroughly and let it dry after each riding 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 STORAGE Should you desire to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil old engine oil contains aggresive contaminants
76. switch off the engine Leave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch Flasher switch Flasher left gt Flasher right Emergency OFF 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 In this position the ignition circuit is enabled the engine should start Filler cap 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 O without kinks SX MXC EXC Refueling fuel 125 380 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 IS HOT WIPE UP SPILLS PROMPT
77. tat so that the engine reaches its operating temperature more quickly When the engine is cold the liquid coolant circulates in the cylinder and the cylinder head As soon as the coo ling liquid has reached a temperature of approximately 55 C the ther mostat opens and the cooling liquid is also pumped through the two alumi num 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 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 SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS N CASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN IN CASE COOLANT IS INGESTED GO SEE A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR A mixture of 40 anti freeze liquid and 60 water is used as coolant However the anti freeze protection must be at least 25 C 13 F This mixture offers anti freeze protection but also good corrosion protection and should therefore not b
78. this purpose it is recommended to remove screw and to pull the brake fluid reservoir outwards Now the screw cap O 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 A 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 DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER 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 VVARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR
79. to any subsequent owner in case you decide to sell it Many 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 maintenance 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 described in the chapter entitled Maintenance Work on Chassis and Engine of this manual For your own safety use only KTM approved parts and accessories KTM is not liable for damage that arises in connection with the use of other products Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle Have services carried out by a KTM dealer so that your warranty claim remains intact We wish you a lot of fun when driving TUV 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 SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL by KTM SPORTMOTORCYCLE AG AUSTRIA All rights reserved INDEX Page Page SERIAL NUMBER LOCATIONS 4 Checking
80. wer Up Side Down 48 MA White Power Up Side Down 43 MA Wheel travel front rear 295 320 mm 11 3 12 6 in Rear suspension WP PDS 5018 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 Brake discs Wear limit max 0 4 mm 0 016 in Front tires 80 100 21 51M 90 90 21 54R Front tires USA Air pressure offroad Air pressure road driver only 80 100 21 51M 1 0 bar 14psi 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi 80 100 21 51M 1 0 bar 14psi 1 5 bar 21psi Rear tires Rear tires USA Air pressure offroad Air pressure road driver only 100 90 19 62M 100 90 19 62M 1 0 bar 14psi 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi 140 80 18 70R 100 100 18 64M 1 0 bar 14psi 2 0 bar 28psi Fuel tank capacity 7 5 liter 2 US Gallons 11 liter 2 9 US Gallons 8 5 11 liter 2 2 2 9 US Gallons Final drive ratio 14 50t 15 48t 14 50t Final drive ratio USA 14 50t 14 52t 14 52t Chain 5 8x 1 4 Available final sprockets 38t 401 421 45t 48t 50t 52t Bulps headlight HS1 12V 35 35W parking light 12V 5W Sockel W2 1x9 5d instrument light brake rear light flasher light license plate illmination 12V 1 2W Sockel
81. wer fork bridge M8 15 Nm 11 ft lb Spring preload 5 mm 0 2in 5 mm 0 2in Clamping screws fork stubs M8 10Nm 7 ft lb Air chamber length 100 mm 5 1in 140 mm 5 9in Collar nut rear wheel spindle M 20x1 5 80 Nm 59 ft Ib Fork oil SAE 5 SAE 5 Hexagon nut swing arm bolt M 14x1 5 100 Nm 74 ft lb Collar screw handlebar clamp M8 20Nm 15 ft lb STANDARD ADJUSTMENT SHOCK ABSORBER Allen head screw handlebar support M10 40 30 ft Ib WP 5018 PDS DCC WP 5018 PDS MCC S 1218W734 1218W735 Shock absorber top M 12 60 44 ft lb Compression adjuster 15 LS low speed 15 Shock absorber bottom M 12 60 44 ft Ib 2 HS high speed Screw adjusting ring spring preload M6 8Nm _ 6 16 Rebound adjuster 25 25 Other screws on chassis M 19 m ts ib Spring PDS6 260 PDS5 260 M 10 45 Nm 33 Spring preload 4 mm 0 2 in 5 mm 0 2 in suojfen SN 493 E L UPI Io uoneouqn ayesedas 10 pu OSI OIJEI JOJ Io 8 exoJjs z JO Z en e xueApy 945 eusio 8 uoneouqn ayesedas uomneouqn NOILVIIHENI ALVYVdIS 3X3 00T are d ureo JOM JY YI 9 qe3 295 1 5 10JIINJALI 2 32 10J9INJILI AZL Joyejauas ou jndino 103e18uer T AT NVSNAOM L Z NYSN OXNI WSN uejsKs uous MOLL AZL M OLL ACL ou jndino 1

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