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KTM 125 User's Manual

1. 34 SHE ever susu u 12 Dismounting and mounting the front wheel 34 ax eri eh lauf intero 13 Dismounting and mounting the rear wheel 35 FOOL Drake 13 36 BIS 13 Checking the spoke 36 oC ueste ton uu a m Madara nt Du sus g 13 Replacing the battery of the electronic speedometer 36 Compression damping of fork 14 Setting the clock of the electronic speedometer 37 Rebound damping of 14 Checking setting the distance of the magnetic sensor 38 Compression damping of shock absorber 5 14 Replacing the headlight lamp 38 COON e 39 Compression damping of shock absorber MXC EXC 15 etre damp 9 MNE EN M Checking the coolant evel 3 Refilling Bleeding the cooling system 40 GENERAL TIPS AND WARNINGS FOR STARTING THE Cleaning the air filter 40 MOTORGYGLE 3 2 ore bee udi eu PME 16 Changing the original position of the clutch lever 41 Instructions for your first ride
2. Brio Q G __ Lll S r EN O HH ge ge 8 JUL 17 i bl w 5 E 9 pt U KOKUSAN 5 ge FE 2 2K 3 18 zd ge AIM 125 300 EXC 2003 48 03 2002 Scheinwerfer headlight faro phare Standlicht position light Blinker 1 vo turn indic left fr r APPENDIX APENDICE luce di posizione Lampegg ant sn feu de position clignoteur av gauche lampegg ant dx clignoteur av droit tachimetro spia abbagliante turn indic right fr speedometer high beam indicator Blinker re vo Tacho compteur Fernlichtkontrolle Blinkerkontrolle LL a z a lt 9 2 lt I z lt temoin feu route UJ turn indicator spia lampeggiatori temoin de clignoteur CO 0 CO connettore a 2 poli connect multiple 2 connettore a 3 poli 2 pol Stecker multip cont plug 2 3 pol Stecker multip cont plug 3 CO connect multiple 3 zum Kombi schalter to combinat switch 10 multicomando commodo Bremslichtsch vo stoplight switch f int luce arresto ant contact de stop av Bremslichtsch hi stoplight switch r 12 int luce arresto post Horn horn 13 clacson NO contact Harr de stop OO klaxon centrale clignot CDI bougie Blinkgeber turn indicator 14 trasmett di lam
3. 18 JOCK 13 STOPPING Pari 19 DORA RC is bates since deca face tartan 45 Technical specifications chassis 125 200 46 Technical specifications chassis 250 300 50 Technical specifications engine 125 200 48 Technical specifications engine 250 300 52 Tiiessalrpiesoi ey a amalan ua Rs 36 7 LS HDS TE AUO einan 45 What to do when the engine is flooded 18 What you should check before each start 17 Wiring diagram carburetor setting Appendix ADIGNAdV XIGNdddV jolaNiddV gt 5 mi Z z gt lt i gt 2 z rT N JoIaN3ddV DNVHNV SERVICE Modell Kabelstrangnummer vorne 503 11 075 800 Land hinten 503 14 040 100 EU AUS Dutu None Blinkerstrang vorne 590 11 080 000 EXC2003 EXC 2003 Blinkerstrang hinten 590 11 081 000 18 03 02 125 300 89 6 c Imi 55 0990 gt 4 1001100 ____ 22 3 OV 0 g 2 m i o l br br 5 06 o
4. Loot L 2 cmm K a P 10 mm when engine is cold 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 thermostat 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 cooling 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 traveling speed Dirty radiators additionally reduce the cooling effect A WARNING A F 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 TH
5. uado 25 SV HOST CSL 88 88 W PAI 295 r r F G SOd HDEN HDEN HDEN ODEN ODEN 41044N 8v 8v 8v 8 0 2 0001 L L L L L SV 0086 081 CSL 88 W LOOL SOd LOE HDEN HDEN HDEN HDEN ODEN 11434 8r 8r 8r 8 8 0062 L L L L SV 0954 L L L y G y y 8 1 081 28 28 rw 1062 y cOd LG MEN HOEN HOEN HOEN HOEN GV 8v 8v 8v SV 31 0005 gl gl SV 0051 GZL g l 08 28 28 rw 1005 v SOd LOSL MOEN MIEN HEN HEN HEN GV 8 8v 8v J 006 gl gl gl SV 0062 cL 8 1 081 28 rw 1052 Z sod LOEZ MOEN MIEN MIEN HEN HEN 87 87 J 00001 eu gl SV 0008 91 4066 1286 91 4062 184 0 419 1209 dolt O1 461 0 doc a IGNGILIV 26 519 DLE 2e8 514 DGC 519 DIL 204 SIQ 259 2054 SIG D 9 514 DoOC unlVvi3dWil JHOHS3 33W DV 8 Md E007 WSN ENA XIXW OST WLM ANHANG APPENDICE APPENDIX APENDICE XIGNdAddV JDIGN4ddV DNVHNV V G6 ZOYJ papeajun J nj G 9 Sadna ISN AVMHDIH LON 479 apis 419 19491425 jalurey W G6 ZOU
6. HOST 881 C 069r V 98 069r V 08 DOLVLY 9t c 84 L DOLVLY 9t 91 466 067 C 089r V 8v 88 069r V 98 069r V CV C 069r V OV D L 08 L DOLVLY OV C L c 86 0 do C6l 089r LH 0G V V O6L 2 089r LH 8v 881 C 069r V v E 98 069r VL CV C 069r V OV D L 84 0 do G6L 089r V CG L 089r V 0G D L O6L C 089r V 9v C L 881 069r V L 98 069r V CV C 09 0 CV do 86 049v Vu GG v G6L 049v V CG L C6l 089r V OS D L O6L C 089r V av C L 881 069r V v E L Ly 0 Ao 6L do 099r V 84 86 r 049v Vu GG v 049v V CG L 089r VL 0G V V O6L C 089r V 8v C L OZ 01 d W SOd 11433 SV W SOd 11433 SV W SOd 11433 SV W SOd 31033N SV W SOd 41d44N SV 295 0001 0086 J 1094 LOEC J OOOOL 0006 JHOHS3333W _______ 51 4 D 9 514 DoOC XS 00C W 26 SIC DLE 519 229 204 514 259 DV 6 E007 WSN VdO in3 ANHANG APPENDICE APPENDIX
7. 32 Checking the oil level of the hydraulic clutch 41 Checking the rear brake fluid level 33 Checking the rear brake pads 34 Checking the shock absorber and spring 26 Checking the spoke qe 36 Checking the transmission oil level 125 200 44 Checking the transmission oil level 250 300 44 Checking setting the distance of the magnetic sensor 38 CHOKE KIO o CN 12 CI CAINS AMPH HERE MAINS 45 Cleaning THE atr filter esc u 40 Cleaning the dust sleeves of the telescopic fork 25 Cleaning the spark arrestor EXC USA 42 S Wire HEV ER uu a khas 5 Combination switch 00 0 0 11 Compression damping of fork 14 Compression damping of shock absorber MXC EXC 15 Compression damping of shock absorber SX 14 Conservation for winter operation 45 a 39 Correct the chain tension 29 Determining the riding sag of the shock absorber 26 Determining the static sag of the shock
8. 16 Checking the oil level of the hydraulic clutch 41 delatae 16 Bleeding of the hydraulic 54 SAIS umet ro CER DR 41 Cleaning the spark arrestor EXC USA 42 DRIVING INSTRUCTIONS 17 Carburetor 42 What you should check before each start 17 Draining the float chamber of the carburetor 43 Starting when the engine is 18 Checking the float level 43 Starting when the engine is warm 18 2 P TOME anging the transmission oil 125 200 poa s ie transmission oil level 250 300 44 MM 18 Changing the transmission oil 250 300 AA Shine Rida aaa nu 18 19 CHEANING Co motui se A ee 45 STOO DINE ua aoo 19 19 CONSERVATION FOR WINTER OPERATION 9 PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE _ 20 STORAGE 45 TNE MALO Ms 45 MAINTENANCE WORK ON CHASSIS AND ENGINE
9. 5 Periodic lubrication and maintenance schedule 20 PIN OF DOE dtt 28 Radiator cover for the cold season 39 Rebound damping 14 Rebound damping of shock absorber SX MXC EXC 15 Refilling Bleeding the cooling 40 Refilling the front brake fluid reservoir 32 Refilling the rear brake fluid reservoir 33 DRM bit 19 Replacing fork Spring S uuu na pa d Vids 27 Replacing the battery of the electronic speedometer 36 Replacing the front brake pads 33 Replacing the headlight lamp 38 Replacing the rear brake pads 34 PS UII 16 Serial 5 Setting the clock of the electronic speedometer 37 SAI 12 Saine Ride u uuu mu 18 Short circuit button P 11 SNCS 13 SSE I aor Mm 18 Starting when the engine is cold 18 Starting when the engine 15
10. yeusyues gt ouijose IO x SULY e ueApy 90245 apeJ8 usiu ui G6 ou aUeDO uoJeesaiJ YAdNS papeajun Ul 88 C 78 2 EZ CZ U v8 c 690 ZZ 799 92045 9108 W Ly pue 15 5 ysneyxa UML WLY 8 Japul AD a 3UIS US 2X3 2XW 00 2X3 2XW 0S 00 C OOE OSC ANIONS TWOINHD4AL UO 0 xiu esn 10 1591 02 aseajd uauM io 9045 OM YSIY SUISN 09 TIGHTENING TORQUES Other screws 10 7 ft lb 25 Nm 19 16 45 Nm 33 ft Ib BASIC CARBURETOR SETTING 250 300 EXC 250 EXC USA 300 EXC AUS 300 MXC EXC throttled throttled USA Carburetor Keihin PWK 38 Keihin PWK 38 AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting number 120202 140202 130202 150202 Main jet 175 182 185 182 185 175 172 178 175 172 178 Idling jet 35 48 48 35 45 48 45 48 Starting jet 85 85 85 85 Jet needle R 1475 J N3CH N3CW N3CH N3CW R1475 NOZ 1 NOZH NOZ I Needle position from top IV Slide 6 5 6 5 6 5 6 5 Air adjustment screw open 1 5 1 5 1 5 1 5 Performance restrictor slide stop 34mm slide stop 34mm Power jet nozzle _ Page Adjusting the free travel at the ha
11. 24 TECHNICAL SPECIFICATIONS CHASSIS 125 200 46 Checking and adjusting the steering head bearing 24 How to change the handlebar position 25 TECHNICAL SPECIFICATIONS ENGINE 125 200 48 Breather plug front fork 25 Cleaning the dust sleeves of the telescopic fork 25 TECHNICAL SPECIFICATIONS CHASSIS 250 300 50 Basic suspension setup for the weight of the driver 26 Checking the shock absorber and spring 26 TECHNICAL SPECIFICATIONS ENGINE 250 300 22 Determining the static sag of the shock absorber 26 Detciminin s or die O bn s ic LE NE RTT 54 Checking the basic setup of the telescopic fork 27 WIRING DIAGRAM CARBURETOR 5 Appendix Changing the spring preload on the telescopic fork SX models 27 SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube Enter this number in 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 Enter this number on page 1 Engine number engine type 250 300 Engine number and engine type are stamped on the right hand side of the engine in front of the kickstarter Enter this
12. ZG WW OL 29 pepeojun juSIeu 1295 aseq uAA o Sue peau Suu 1s p9 px eseq MZ L ATL sc jeg aseq MOL AZL 1481 J9usep PGLAeg 9seq MG LZ AZL p9 pXL 9seq MZ L ATL CM SLA MG ACL 1481 Supped MGE GE ATL LSH uoneuruun 1481 1291 o xe1q 1481 15 sqing 18v VV 18r vV suoje8 sn 6 2 2 c LL 6 5882 req O Z 159 O L W6S 81 OOL OOL 849 8 06 07L 169 10S 18r IGP Wer 10v 18 u V V X 8 9 sSuollPO sn 6 Z S1 1I LL suo e5 SN sia 94 suo e5 sn 62 sie 6 5882 req 022 sdy O L W6S 81 OOL OOL 15491 O L WZS 6L 06 00L WZS 6L 06 00L 15491 O L W6S 8 OOL OOL 469 8L 06 01 suo eD SN c 5791 GZ 15991 O L WZS 6L 06 001 WZS 6L O6 00L 5192 20105 o qe reAv VSN feul feul yur jani 9 peou 91 55914 p oJ4Jjo YSN 5914 S311 5417 L 159 L O L WLG LZ 001 08 LZ 06 06 sdy O L WLG LZ 001 08 15491 O L LZ 001 08 WLG LZ 001 08 U 9100 p O Xew pwj 13M isd z 159 1 071 LZ 001 08 LZ 06 06 Ul
13. to change to the next display without changing any settings press and hold the MODE BUTTON 3 sECONDS to store the settings and change to the SPEED H mode Kilometers or miles The unit kilometers or miles can also be changed The ODO figure will be retained and converted accordingly The TRP1 AVS1 STP1 TRP2 and AVS2 figures will be cleared To select the unit select the SPEED H mode and hold the MODE button for 3 seconds to access the SETUP menu Press the MODE button 10 times until the KMH MPH function blinks Press the button to move to the options Press the button for KMH or the button for MPH If no button is pressed for 20 seconds the setting will be stored automatically and the display will return to the SPEED H mode The setting can be stored immediately by holding the MODE button for a few seconds until the display returns to the SPEED H mode BUTTON to access the menu to activate the KMH setting BUTTON to activate the MPH setting press the MODE to change to the next mode press and hold the MODE BUTTON sECONDS to store the setting and return to the SETUP menu NOTE If you retrofit this Tripmaster on another motorcycle the power can also be supplied by the 12 V vehicle electric system You will need an additional cable harness spare part no 583 14 069 210 which you can order from your KTM dealer ual e 37 F H i WW W 1 sA mm x
14. 1J lq Jadns ouny do uogisod di Sod uaqo uonisod di SOd 148 355 4165 LHOIN jal Suipi 7 1 pazeas Ajjny uado SV HOST W SOd 11433 SV W SOd 41d44N SV W SOd 31033N SV W SOd 11433 SV W SOd 11433 SV 295 5 W 0001 ul 0086 J 1094 LOEC JJ 00001 0006 JoOCL 91 466 1286 464 128 91 419 1209 dolt 01 461 0 doc IGNGILIV JHOHS3333W E cd 26 SIC DLE 519 DIL 204 SIQ DI SIG D 9 54 DoOC OV 8 Md E007 WSN ENA 2X3 2XW 00 W 20286 5149 DGC ONILLAS 1 5 3 CINI 110 319A09HO01L0W eujsny JINVAGY q uajouSimew 0229 21177 9 LECT ASNS DV 3129A2948HOLOW LNHOdS 6VOLCE
15. 002 70 0 SINOIDDNYISNI TWANVW 43139424010MWI1UH0dS OSN d JIVANYW AOOYAUNVH SH3NA MO ONNLIFINVSONANAIGIG DXI OXW XS OOE OSZ O07Z STL IMPORTANT PLEASE 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 INTE REST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS A WARNING A IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE S TRAFFIC SAFETY Please insert the serial numbers of your motorcycle in the boxes below 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 mainte nance 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 SPE
16. 4 5 M5 5 Nm Other screws on chassis Brake disk rear M 6 Loctite 243 15 Engine brace Other collar nuts on chassis 13414 adA 9 9 qe1 295 Sunjes JOJAINGUeD JOJAINGUeD 3 ae ae AZL jndino soyesauay CC OXW YSN Waysds uoniu MOLL ACL 5 5 5 uous do 81 Do GZ 1599 19 u9 eA 09 SIP E L 206000 uw X 10 791 271 ZEL s xooids urey 08 d3 1999 945 aulsua 8 0 uone uqn 1299 1298 1298 1298 1298 pul Jeas 9021 Jean jndino payenjoe paads UOISSIUISU J GLJ 4H 11945 peyesado ApeoineipKu uyeq sip 21 82 51 8 unds 44312115 UILU OGZZ 0004 uado DAL 0064 0006 uado 3215 DAL u Z 200 c 6p 7 uOISuauliq 090 de opou29 3 3 Z meds LO JOA t6 L LO JOA 6 UONISU HOO 0 0 L O O 4 X UOISUIWIG uojsid a8pa Jaddn sgun uoissaJduuoo OM SUL uojsid p u Suueaq uid uojsiqd p u Suueoq Sunosuuo Suueaq 19j 0J Jopui Ao Suueoq jeq 8
17. 8 072 ISIP YIM SIA sdy 124 O L WLG LZ 001 08 LZ 001 08 uo peos aunssaid YSN sen 1u04J 5941 1UOJJ 5251 o eJg o eq 1823 1edi eo Ul 2707 092 251 9915 2 ISIA WJeESUIMS 72045 uu 1s s Suidureq 55 SLOG SAd U 272 1 8 LL WW GEE OOE 11014 uoisuedsns 1291 3001 9 8 29UAA VW 8t apisdp 19 9915 5 404 2X3 002 IXW 002 XS 00 2X43 GCL 00Z DX3 DXW XS 007 5 SZL SISSWHD SNOILLWDISIDAdS TWOINHDAL STANDARD ADJUSTMENT FORK WP 4860 MXMA 1418X725 WP 4860 MXMA WP 5018 PDS DCC 1418X735 1218X756 Compression adjuster 20 22 STANDARD ADJUSTMENT SHOCK ABSORBER WP 5018 PDS MCC Compression adjuster 17 LS low speed Rebound adjuster 20 Spring 4 0 N mm 20 2 HS high speed 3 8 N mm Rebound adjuster 28 Spring preload 5 mm 0 2in 5 mm 0 2in Spring 71 90 260 Air chamber length 100 mm 5 1in 110 mm 4 3in Spring preload 6 mm 0 2 in Fork oil SAE 5 SAE 5 TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M 24x1 5 40 Nm Brake caliper front M 8 Loctite 243
18. 9 11 liter 2 3 2 9 US Gallons Final drive ratio _ 15 48t 14 50t Final drive ratio USA 14 52t 14 52t Available final sprockets 38t 40t 42t 45t 48t 50t 52t Bulbs headlight HS1 12V 35 35W parking light 12V 5W base W2 1x9 5d instrument light 12V 1 2W base W2 1x4 6d brake rear light 12V 21 5W base BaY15d flasher light 12V 10W 155 license plate illumination 12V 1 2W base 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 STANDARD ADJUSTMENT SHOCK ABSORBER WP 4860 MXMA WP 5018 MCC Compression adjuster 20 Compression adjuster 17 Spring preload 5 mm 0 20in Spring preload 7 mm 0 27 in Air chamber length 110 mm 4 3 in Fork oil SAE 5 TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M 24x1 5 40 Nm Brake caliper front M Loctite 243 25 Nm Brake disk front M610 9 Loctite243 15 Nm 8 Clamping screws upper fork bridge M 8 20 Nm Clamping screws lower fork bridge M 8 15 Nm Clamping screws fork stubs 8 10 Nm Collar nut rear wheel spindle M 20x1 5 80 Nm 20 Nm Allan head screw handlebar support M 10 Loctite 243 40 Nm 2 so Nm Sprocket screws M 8 Loctite 243 35 Nm M6 Loctite 243 10 Nm Engine mounting bolt M 10 45 Nm M 8 33 Nm Screw adjusting ring spring preload shock abs M6 8 Nm Spoke nipple
19. 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 HIGH PRESSURED CLEANER OR 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 Before 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 also be cleaned with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable 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 To prevent failu
20. MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KIM DEALER AS SOON AS POSSIBLE 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 IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT 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 remove chain tensioner hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION Do NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED MAKE 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 JAMMING The rear wheel is remounted in the reverse order Before tightening the collar nut to 80 Nm 60 ft lb push the rear wheel forwards so that the chain tensioners lie on the tension screws A WARNING A F YOU DON T HAPPEN TO HAVE A
21. 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 2 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 3 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 the chain and chain wheels 4 TIRES Check for damaged tires 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 performance 5 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 of the hand brake lever and foot brake lever A WARNING A IF THE RESISTANCE
22. 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 whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing Check chain tension To check the chain tension park the motorcycle Press the chain upward at the end of the chain sliding component The distance between the chain and the swing arm should be approx 15 mm 0 6 in In the course of this procedure the upper chain portion must be taut see drawing If necessary correct the chain tension A WARNING A IF THE CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY TRANSMISSION CHAIN CHAIN WHEELS AND REAR WHEEL BEARINGS WILL BE SUBJECTED TO UNNECESSARY STRESS RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut loosen lock nuts and turn right and left adjusting screws equally far Tighten lock nu
23. 3 14 Y Check set distance of the magnetic sensor The distance between the magnet and the sensor must be 2 4 mm otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing the sensor in or off KMH WS mm x 3 14 MPH WS mm x 3 14 1 61 Replacing the headlight lamp parking light lamp Loosen both rubber bands and tilt the headlight mask to the front Pull the parking light lamp with holder carefully out of the reflector Pull connector O off the headlamp and remove rubber Disengage retai ning clip and take the bulb out of the reflector When changing the par king light lamp simply pull it out of the holder Insert a new lamp such that the noses engage the recesses 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 par king light lamp is to be replaced simply insert it in the holder Reinsert par king light lamp together with the holder Engage the bottom end of the headlamp mask at the retaining pins and fix the mask by means of the rubber bands n RM _ L m i LL Lud eo
24. APENDICE 20286 5 4 DGC ONILLAS 8 ONRd3r09335V933A ADIGNAdV XIGNdddV OY JDIGNaddV DNVHNV Siar iniko ioaneisiss 9 5 G 9 1 q lu5S G6 ZOM Jadns oinz l urew WG asnpidney qH ISN AVMHDIH LON COMO SS Oe ueqo uonisod di SOd G6 20 Jedns o4n3 91 Supp C osnpjne i99 13 4 355 165 und LHDIN pajees Aj nj uado 5 SV 4 251 W SOd npe AIUS 9199 W 4 y 0001 SV ul OOF Ww SOd JIO33N SV W SOd 11433 SV W SOd 41d44N SV W LOSZ SOd LOEZ JIGIIN 00001 SV 000 91 466 1286 01 464 128 0 419 1209 dolt 0 461 120 0 doc a IGNGILIV 26 SIC DLE 20286 514 DGC 519 DIL 204 514 259 2024 SIG 9 SIG DoOC UNLV JHOHS3 33W DV 8 Md E007 WSN YNA 00 G6 705 papeajun J nj 19qne S197 9 apls 9 1949125 ISN AVMMHDIH LON aon wy asnpijdneH G6 ZOU 9 Jedns oJn3 do uonisod SOd uaqo uonisog 415 SOd 55 815 403 LHOIN jal Suipi 5 199 qi
25. O6L W C C r G SOd Vs 9 Lv Vs 9 V Q69rv Vs as9r ly 89r V CV v E L 08 Q0Zr Vs OV C SLL C 027 Vs SE D L GLL L la 8t c CLL L qL 74 C L Q0Zr Vs CV L 08 Q0Zr Vs OV C SLL C Q0Zr 9t GLL L 8v D L 98 9 V C bL L Q0Zr Vs CV 08 COZvld OV C 84 C Q0Zr Vs SE 09 L 88 9 ly 8v D L 98 4 Vs L ly CV v E 08 Q0Zrv Vs OV CG v O6L 422484 04 L 881 a69r ly 8v V V 98 4 ly C L Q0Zr Vs CV GG C V C6l r as9r ly CG 061 422484 04 L 881 a69r ly 8v D L 98 d69r ly 11433 SV W SOd 11433 SV W SOd 11433 SV W SOd 31033N SV W SOd 11433 J 0001 0086 J 1094 LOEC SE 86 J 00001 ViEC Ch bet v V c C C L SV 0006 91 466 1286 01 464 128 0 419 1209 dolt 0 461 doc IGNGILIV JHOHS3333W lt lt 26 519 DLE 519 DIL 204 SIQ 259 2024 SIG D 9 SIG DoOC 6 00 VSN VdOMfi3 XS ANHANG APPENDICE APPENDIX APENDICE 20286 5 4 DGC ONILLAS 8 SN0 0
26. SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER OF USED OIL CONTAMINATES 1 000 000 LITERS OF WATER Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcycle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward For readjusting loosen the five pinch bolts of the top triple clamp and turn steering stem bolt clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly tap on the triple clamp to release tension Retighten the five pinch bolts to 20 Nm 15 A WARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLA
27. WILL DECREASE QUICKLY ON NEW WHEELS IF YOU CONTINUE TO DRIVE WITH LOOSE SPOKES THE SPOKES MAY CRACK AND LEAD TO UNSTABLE HANDLING SEE CHECKING THE SPOKE TENSION 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 NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING A WARNING A THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY NO ADDITIONAL PASSENGER ALLOWED NEITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY REGULATIONS AND SAFETY STANDARDS USING THEM ON PUBLIC ROADS HIGHWAYS FREEWAYS ETC IS AGAINST THE LAW WHEN RIDING YOUR MOTORCYCLE PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE DRIVING INSTRUCTIONS What you should check before each start When you start off the motorcycle must be in a perfect technical condition For safety reasons you should make it a habit to perform an overall check of your motorcycle before each start
28. 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 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 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 1218X756 28 clicks Type White Power 1218X757 28 clicks Type White Power 1218X759 26 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 MAINTE NANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 15MM GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 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 on an empty
29. absorber 26 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 Draining the float chamber of the carburetor 43 I2EIVITIE dETSEFHIGCTOTIS eed 17 Electronic SpGGSdollieter zo NN 6 Electronic speedometer indicator lamp EXC 6 Emergency OFF switch Australia 11 INDEX Page Engine number engine type 125 200 5 Engine number engine type 250 300 5 EXIalist Sen ete p DU Tata 41 EU 12 Flasher 11 FOOL prake 13 UCM GAD mM 12 General information about KTM disc brakes 31 General tips and warnings for starting the motorcYcle 16 Hand brake Te Vel bonded ondes dose feces 5 Headlamp switch EXC USA 11 How to change the handlebar position 25 NRCS ETE E 54 Instructions Tor your first ride 16 13 Maintenance work chassis and engine 24 Operation
30. in Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be broken in For this reason during its first 500 kilometers 300 miles or 5 hours the engine must not be revved up to its performance limits Apply low but changing loads for running in CAUTION DO NOT DRIVE AT FULL LOAD FOR THE FIRST 500 KILOMETERS 300 MILES OR 5 HOURS A WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE SMART KTM DRIVERS ALWAYS WEAR HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A SHORT RIDE THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE OF COURSE YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM FOR EXAM PLE 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 CHARACTERISTICS THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE BE SURE TO CHECK THE SPOKE TENSION AFTER MINUTES RUNNING TIME THE SPOKE TENSION
31. job performed in the course of the periodical mainte nance service CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK IF 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 Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them downward Clean the dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push the dust protection bellows into the outer tubes by hand lt lt PDS 1218 756 PDS 1218 759 250 300 76 95 260 71 90 260 66 86 260 SPRING RATE 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork shock absorber swing arm and frame from being damaged the basic setup of the suspension components must be suitable for your weight At delivery 5 offroad motorcycles are set to accommodate a driver weighing 70 80 kg wearing full protective clothing If yo
32. minutes and seconds at the bottom of the display If no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped Hold the MODE button for 3 seconds in the SPEED LAP mode to clear the stored lap times BUTTON changes to the next lap time BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON sECONDs to change to the next mode ual e 7 SPEED CLK clock display mode CLK will display time in hours minutes and seconds BUTTON function BUTTON function press the MODE to change to the next mode press and hold the MODE BUTTON 3 sECONDS to set the time in the menu see SETTING THE CLOCK SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display mode will automatically change from SPEED ODO to SPEED H H shows the operating hours The operating hour counter starts to count as soon as you start the engine The displayed figure cannot be cleared Service intervals are indicated in operating hours for some KTM offroad motorcycles making the operating hour counter a very practical function BUTTON function BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON 5 to change to the SETUP mode see REVEALING CONCEALING functions SPEED TRP1 trip 1 display mode The
33. 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 your motorcycle is fitted and registered for such purposes During the ride the passenger must hold on to the straps or to the driver with his feet on the passenger footrests 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 Pay attention to running in procedure Running
34. passed on to any subsequent owner in case you decide to sell it We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chassis and engine must be performed by a KTM workshop If mainten ance work should become necessary during a competition it must be performed by a trained mechanic For your own safety use KTM approved parts and accessories only 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 inter vals 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 Off road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others We wish you a lot of fun when driving KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL by SPORTMOTORCYCLE AG A
35. press again to hold Press again to continue timing Press the MODE button to change to the next mode The STP2 display will blink in the other modes if STP2 continues to run in the background To stop STP2 return to the SPEED STP2 mode and press the button BUTTON starts and stops the stop watch BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON SECONDs to reset STP2 figures to 0 OVERVIEW OF TRIPMASTER FUNCTIONS SPEED MAX no function next display mode resets MAX to 0 B starts stops LAP stops LAP stores LAP next display mode clears all LAP figures Standing motorcycle Driving motorcycle next display mode no function figure LAP remains figure resets LAP to 0 X LAP LAP no function next display mode next display mode X SPEED CLK no function next display mode set clock menu m SPEED H no function next display mode display setup menu next display mode resets TRP1 STP1 and AVS1 to 0 777 SPEED TRP2 increases TRP2 figure decreases TRP2 figure next display mode resets TRP2 to 0 SPEED AVS2 no function next display mode next display mode SPEED STP2 starts stops STP2 no function next display mode sets STP2 to 0 next display mode resets TRP1 STP1 and 51 to 0 next display mode resets TRP1 STP1 and 51 to 0 Short circuit button SX The short circuit button turns off the engine When pr
36. saves money Check gear box oil level Change gear box oil Check spark plugs adjust distance between electrodes Renew spark plugs Check the carburetor connection boot for cracks and leaks Check idle speed setting Check that vent hoses are not damaged or bent ENGINE Check cooling system for leaks check quantity of antifreeze 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 beam high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button ADD ON PARTS Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks Check adjust smooth operation and free travel of handbrake foot brake lever Check tightness of brake 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 CHASSIS BRAKES Check spoke tension and rim joint Check tires and air pressure Check chain rear sprockets and
37. 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 SUBJECTED EXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL Check transmission oil level 250 300 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 E te m OUT 1 54 opening when the motorcycle is in an upright position If necessary remove pening cycle pright p ry E 2277 54 the plug and top up with see technical data engine INE j ie SO CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECTED 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 To change the transmission oil run the engine warm and set up the motorcy cle on a horizontal surface Remove the oil drain screw and drain used oil into a container Clean the magnet of the oil drain screw and reinstall oil drain screw with seal Pour in 0 8 litres 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
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40. 218 756 17 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 1218 756 2 turns AN 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 MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 24MM 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 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 1218X757 17 clicks Type White Power 1218X759 17 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
41. 25 Nm Brake disk front Brake disk rear M 6 10 9 Loctite 243 15 Nm Loctite 243 15 Nm Clamping screws upper fork bridge 20 Nm Clamping screws lower fork bridge Clamping screws fork stubs 8 15 Nm Collar nut rear wheel spindle M 20x1 5 Hexagon nut swing arm bolt Hexagon collar screw handlebar clamp M 14x1 5 20 Nm Allan head screw handlebar support Loctite 243 40 Nm Shock absorber top Shock absorber bottom 60 Nm 60 Nm Sprocket screws Loctite 243 35 Nm Ball joint for push rod Engine mounting bolt Loctite 243 10 Nm Engine brace Screw adjusting ring spring preload shock abs Spoke nipple M4 5 M5 Other screws on chassis M6 8 M 10 Other collar nuts on chassis M6 M 8 M 10 ENGLISH Pasul 1911 adA 19 indino soyessuay VSN 1 545 uoniu9 nd no soyessuay 9 qe1 oes Sun1 s JOJOINGIeD opi s 1e M Ov AZL 0 OU 0 OU NVSNAODI L AIC C c NVSNAOD L AIC MOLL AZL 0 OU MOLL 0 OU EAC NVSNAODI L AIC EAC NVSNAOD L AIC do EL Do GZ 15 09 92994 QU 950p 5 Z L S 10 ZGL 2 1 Z L PXSA 92ue py 945 Op MOC 0 uI8u Z O 08 43
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45. ALER 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 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 NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE IF YOU GET ON YOUR MOTORCYCLE 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 Refueling fuel 125 300 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 REFU
46. CIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PRIOR NOTICE IN THE EVENT OF SUCH MODIFICATIONS PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION 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 cha racteristics even if this means that you will 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 minor discrepancies may exist resulting from further design upg rades of these motorcycles This manual is an important part of your motorbike and should be
47. Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED MAINTENANCE WORK ON CHASSIS AND ENGINE A VV ARN ING 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
48. E STEAM MAY CAUSE SERIOUS BURNS IN 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 CONSULT A DOCTOR IMMEDIATELY F COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR A mixture of 40 antifreeze liquid and 60 water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE 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 without having to expect any trouble Radiator cover for the cold season To ensure that the engine reaches its operative temperature also at low temperatures the radiator cover 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 s
49. E VENTILATION 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 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 JAUN Starting when the engine is warm 1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Put the 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 CON TROL OF YOUR MOTORCYCLE BEFORE STARTING FOR AN OFF ROAD TOUR IT IS RECOMMENDED TO ADDITIONALLY SECURE THE SIDE STAND WITH THE RUBBER BAND ON THE AIR FILTER BOX Shifting Riding You are now in first gear referred to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Turn down the throttle at the same time pull the clutch lever in and shift to the next higher gear Let the clutch lever
50. ED ODO mode SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display mode will automatically change from SPEED ODO to SPEED H H shows the operating hours The operating hour counter starts to count as soon as you start the engine The displayed figure cannot be cleared Service intervals are indicated in operating hours for some KTM offroad motorcycles making the operating hour counter a very practical function Anzeigemodus SPEED ODO The SPEED ODO mode shows the speed and the total kilometers traveled When the front wheel stops turning the display will automatically change to the SPEED H mode The information will disappear in the display when the front wheel stops turning for 1 minute NOTE A Tripmaster switch is available as an accessory and enhances the electronic speedometer by providing the following functions 2x Tripmaster 2x chronometer for the lap time Average speed Maximum speed Clock Display in miles L 2 1 211 Tripmaster switch The switch has three buttons MODE plus and minus A WARNING A DO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT Electronic speedometer functions provided by the Tripmaster switch The display modes on the electronic speedometer will change in the follo wing order If not pl
51. ELING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY 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 NORMAL 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 SMO KING AND FOUL THE SPARK PLUG F YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER ALWAYS KEEP IN MIND THAT LEADED FUEL WILL DESTROY THE CATALY TIC CONVERTER FUEL EXPANDS WHEN ITS TEMPERATURE RISES THEREFORE DO NOT FILL THE TANK TO THE TOP SEE FIG 125 200 SX MXC EXC PERIODIC MAINTENANCE SCHEDULE 52592 151 service after 10 hours 20 hours or or 1000 kilometers 2000 kilometers SPORTMOTORCYCLES after 4000 kilometer or once a year after A clean motorcycle can be checked more quickly which
52. GAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 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 NOTE The wheel spindle can be easily removed if you slightly revolve it with a ring spanner SW 21 mm Carefully remove the front wheel from the fork 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 To install the front wheel lift it into the fork position and mount the axle shaft Mount the collar nut tighten the clamping screws on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm 30ft Ib Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 10 Nm 7 ft Ibs A WARNING A F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND
53. 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 6 CABLES Check correct adjustment and easy running of all control cables 7 COOLING FLUID Check the level of cooling fluid when the engine is cold 8 ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights turn indicators indicator lamps and horn while the engine is running 9 LUGGAGE If you are taking luggage with you check that it is securely fastened 4 2 e Tr Starting when the engine is cold Open fuel tap Turn on ignition or emergency OFF switch Put the gear in neutral Activate cold starting aid choke Leave throttle closed or open it no more than and kick down kickstar ter 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 MOMENTUM 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 ADEQUAT
54. Jduuoo OM guu uoissaJduuoo ure d auo SUL uojsid Suueaq uojsiqd sgun uoissaJduuoo OM Suu uoissaJduuoo ure d auo uojsid 1522 p u p u Suueoq Sunosuuo yeusyues gt 901 0599 9 OJ S 9104 uojsid 19j 0J JapuljAd Suueoq jeq 8 4no 1591002 aseajd 1dnop uauM x Survey usS Io 92045 apeJ8 UBIY SUISN UBYM 09 L 9041s apeJ8 USI G6 ou 9UL DO pepeejun Ul 9 WW 09 79 U Gp c OTL tS O ss up 8721 1sneux pue 8 5 8 5 pejooo pinbr3 PBS 2X3 002 DXW 002 XS 002 2X3 GZL XS GZL 00C O0 C SCL ANIONS VIVA TIVWOINHD4L TIGHTENING TORQUES ENGINE Flange bolts cylinder head Nuts cylinder base Flywheel collar nut Nut for primary sprocket LH thread Nut for inner clutch hub Crankcase and clutch cover bolts Spark plug M 12x1 M 16x1 5 M 18x1 5 M 14x1 25 Swingarm pivot Other screws M 6 M 8 M 10 BASIC CARBURETOR SETTING 18 Nm 30Nm 60 Nm 180 Nm 120 Nm 8 Nm 20 Nm 10 Nm 25 Nm 45 Nm 200 EXC AUS 125 EXC EU 125 5 200 MXC EXC USA 200 SX 200 EXC EU 125 EXC AUS Carburetor
55. Keihin PWK 39 Keihin PWK 38 AG Carburetor setting number 060202 080202 Main jet 185 188 190 178 180 185 Idling jet 48 45 45 48 Starting jet 85 85 Jet needle R 1469 D R 1470 D NOZ E Needle position from top Throttle valve 5 5 6 6 5 Air adjustment screw open 1 5 1 5 Performance restrictor Keihin PWK 39 Keihin PWK 38 AG Keihin PWK 38 AG 090202 100202 070202 190 188 192 180 178 148 180 185 48 45 35 45 48 35 45 48 85 85 85 R 1468G R1469G R 1475 NOZ E NOZ R 1472 E NOZ V 5 5 6 5 6 5 1 5 1 5 1 9 slide stop 36mm TECHNICAL SPECIFICATIONS CHASSIS 250 300 MXC EXC 2003 250 300 MXC 250 300 EXC Central chrome moly steel frame Fork White Power Up Side Down 48 MA 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 2 220 mm 8 7 in brake caliper floated Front tires 90 90 21 54R Front tires USA 80 100 21 51M 80 100 21 51M Air pressure offroad 1 0 bar 14psi 1 0 bar 14psi Air pressure road driver only 1 5 bar 21psi 1 5 bar 21psi Rear tires 140 80 18 ZOR Rear tires USA 100 100 18 64M 100 100 18 64M Air pressure offroad 1 0 bar 14psi 1 0 bar 14psi Air pressure road driver only 2 0 bar 28psi 2 0 bar 28psi Fuel tank capacity 11 liter 2 9 US Gallons
56. N APPROVED BY 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 unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer A WARNING A SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING THE SPOKES MUST BE TENSIONED TO 5 NM Replacing the battery of the digital speedometer Remove the headlight mask and disassemble the electronic speedometer Remove the screw connection insert the battery type Duracell CR 2430 with the writing facing up and rei
57. RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary Chain wear To check the chain wear observe the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 kilograms 33 Ib upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different pla ces on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets CAUTION WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14 T 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 TIGHTENING TORQUE FOR SCREWS 50 NM lt 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
58. S BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHO RIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir For this purpose it is recommended to remove screw and to pull the brake fluid reservoir outwards Now the screw cap and the rubber boot 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 Return the brake fluid reservoir to its original position and fix it with the screw The connecting hose between the reservoir and the foot brake cylinder must be carefully positioned pre venting 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 DOTS 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 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 r
59. T 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 the 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 BRAKING 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 BRAKING SYSTEM CAN FAIL F 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 DE
60. TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSI BLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS 15 VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE TIRES AIR PRESSURE Tires air pressure Tire type tire condition and air pressure level affect the way your motorcy cle rides and 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 the homolo gation certificate Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Refer to the specific regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm 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 BEE
61. TOSHIBA H 38 sintered lining at the back These linings provide an optimal combination of dosing brake performance and life cycle 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 of the brake pads decreases At their thinnest point 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 outside the contact face Check wear at several locations A WARNING 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 the front and rear wheel brakes have been designed in such a way that even if the brake pads ar
62. TRP1 trip meter is always active and counts to 999 9 It is used to mea sure the length of a trip or the distance between 2 refueling stops is linked to AVS1 and STP1 The calculation of these figures is activa ted by the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The 51 and STP1 figures are automatically reset to O after passing 999 9 BUTTON no function BUTTON function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to automatically reset the TRP1 AVS1 and STP1 figures to O SPEED AVS1 average speed 1 display mode AVS1 is always active and shows the average speed based on the and STP1 figures The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1 AVS1 and STP1 figures to O SPEED STP1 stop 1 display mode STP1 shows the traveling time based on 1 and continues to count whe never it receives impulses from the wheel sensor The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse
63. USE 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 front brake pads The brake pads can be inspected from below The linings must 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 Replacing the 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 sliding metal s
64. USTRIA All rights reserved IMPORTANT WARRANTY AND GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in th
65. X MXC EXC 71 90 260 66 86 260 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE LL 125 SX 250 300 MXC EXC 1418X725 1418X736 4 2 N mm 4 0 N mm 3 8 N mm 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE 125 EXC 200 SX MXC EXC 1418X735 4 0 N mm 3 8 N mm 3 6 N mm 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons Similar to the shock absorber smaller deviations in your weight can be compensated by adjusting the spring preload However if your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Changing the spring preload on the telescopic fork SX models The telescopic forks of the SX models come with a preload adjuster for easy adjustment of the spring preload You can adjust the spring preload 9 mm by turning the adjusting screws basic position middle position NOTE Always turn the adjusting screws the same distance on both fork legs Diff
66. Y 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 e g Shell Advance Grease How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper tri ple clamp 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 the handlebar support and tighten scr ews to 40 Nm 30 165 Mount the handlebar and handlebar clamps and tighten screws to 20 Nm 15 ft lbs The gap between the handlebar support and the handlebar clamps should be the same size in the front and in the rear A WARNING A THE SCREWS MUST BE SECURED WITH LOCTITE 243 Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 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 the road it will suffice to have this
67. ad of the shock absorber must be increased if the static sag is reduced the spring preload must be higher See chapter Changing the spring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 510 mm 90 The riding sag should lie between 90 and 105 mm If the riding sag is less than 90 mm the spring is too hard the spring rate is too high If the riding sag is more than 105 mm the spring is too soft the spring rate is too low The spring rate is written on the outside of the spring e g 71 90 260 The type number of the shock absorber is embossed on the bottom of the tank The illustrations show which spring should be installed The standard spring is shown in bold print e g 1218X756 After installing a different spring readjust the static sag to 35 mm 2 mm PDS 1218X757 125 EXC 200 S
68. chain guides for wear fitment and tension WHEELS Lubricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE VVORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least every 2 years once a year 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 INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN HOURS OR KM MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each After every cleaning For cross country use Once a year Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fu
69. ck 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 footrests etc as well as the chain The storage place should be dry and not be subjected to too big temperature fluctuations Cover the motorcycle with an air permeated tarp or blanket Do not use non airtight 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 WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST USE AFTER A PERIOD OF STORAGE Fill up the tank with fresh fuel Check the 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 should check all parts for their function and wear Should any service 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 shop at the beginning of the next biking season u Z GL G8E p peojun punon Ul 496 GZ6 U Y O F
70. e rent spring preloads on the fork legs will reduce the telescopic fork s res ponse Changing the spring preload on the telescopic fork MXC EXC models The telescopic forks for these models must be partly disassembled to adjust the spring preload see WP manual Pretension spacers are available in heights of 1 5 2 5 and 5 mm see spare parts catalog The fork springs may not be pretensioned by more than 20 mm The preload adjuster used in the SX models can easily be retrofitted for the telescopic forks of the MXC EXC models NOTE WP precisely adjusts the spring pressure by inserting pretension spacers Fluctuations in production are compensated with pretension spacers in various heights This can cause the fork springs in the fork legs to have dif ferent degrees of pretension Fork springs and pretension spacers should always stay together Replacing fork springs If you weigh less than 70 kg or more than 80 kg you should install the res pective fork springs The correct spring rate is shown in the illustrations The standard spring is shown in bold print The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork If you are uncertain which spring to use contact your KTM workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks fo
71. e 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 biode gradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegrada ble hydraulic oil is available from your KTM dealer 50 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 Exhaust system Silencers whose cap 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 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 DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN TO AVOID BURNS Cleaning the spark arrestor EXC USA With these models the spark arrestor is part of the exhaust sile
72. e maintenance schedule has been reached THE SX SXS AND MXC MODELS ARE PROHIBITED ON PUBLIC ROADS The EXC models are only allowed public roads in the original homologated throttled version Without this performance restriction i e dethrottled these models are only allowed to be driven off road but not on public roads The EXC models are designed for off road sports endurance competitions enduro and not suitable for predominant motocross use In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality REG NO 12 100 6061 TABLE OF CONTENTS Page Page SERIAL NUMBER LOCATIONS 5 Changing the spring preload on the telescopic fork MXC EXC models 27 CASSIS esos 5 Replacing fork Springs atat 27 Engine number engine type 125 200 5 Adjusting the spring preload on the fork SX 28 Engine number engine type 250 300 5 Changing the spring preloading of the shock absorber 28 PIVO 91 21 28 OPERATION INSTRUMENTS 5 Checking the chain tension 29 Gluten a Sha ae a aret 5 Correct the chain ten
73. e work i i 4 ur Y Pu 4 7 E A Biz my STE 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 to additionally secure the center stand in its folded up position Steering lock The handlebar can be locked by means of the lock located on the steering head To lock it turn the handlebar all the way to the right insert the key turn it to the left press it in turn it to teh 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 screws 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 1418X725 20 clicks Type White Power 1418X735 22 clicks Type White Power 1418X736 20 clicks Rebound damping of fork Hydraulic reb
74. e worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are comple tely 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 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 with 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 designed for DOT 5 brake fluid A WARNING A HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL s 4 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw In this way the position of the point of pressure i e the resis tance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand si
75. eaks 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 NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURA TED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF THE FUEL PROPERLY 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 Check transmission oil level 125 200 In order to check the transmission oil level the control screw on the clutch cover is to be removed Oil should just barely escape from the inspection opening when the motorcycle is in an upright position If necessary remove the plug and top up with oil see technical data engine CAUTION TRANSMISSION AND CLUTCH WILL BE SUBJECTED EXCESSIVE 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 and and drain the used oil into an appropriate container Clean the magnets of
76. ear The thickness of the linings may not be less than 1 mm 0 04 in 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 Replacing the rear brake pads Press the brake caliper in the direction of the chain wheel for the brake piston to reach its basic position Remove the safety device knock out the guide pin from the brake caliper with a drift towards the chain wheel and remove the brake pads Carefully clean the brake caliper with compres sed air and check the sleeves of the guide pins for damage Slide the 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 the safety device 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 AFTER WORKING 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 A
77. ease read the chapter ACTIVATING AND DEACTIVA TING THE DISPLAY MODE SPEED ODO display mode SPEED displays the speed in KPH or MPH The displayed figure cannot be cleared ODO displays the kilometers or miles traveled The displayed figure cannot be cleared BUTTON function BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON sECONDs to change to the next mode SPEED MAX display mode MAX displays the maximum speed It is always active BUTTON function BUTTON no function press the MODE BuTToN to change to the next mode press and hold the MODE BUTTON sECONDs to reset the MAX figure to 0 SPEED LAP display mode LAP displays the stopped lap time in hours minutes and seconds BUTTON Starts and stops the stop watch The lap time is not reset to O BUTTON Stops the running stop watch stores the lap time and restarts the stop watch The time is reset to O A total of 10 lap times can be stored and read in the SPEED LAP display mode To clear all of the stored lap times hold the MODE button for 3 seconds in the SPEED LAP mode press the MODE to change to the next mode If no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all stored lap times to O LAP LAP display mode The lap number is shown at the top and the lap time in hours
78. el lines for leaks Empty and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly RECOMMENDED INSPECTION OF THE 125 200 250 300 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM wORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP 120 135 hours hours e Check the reed type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear RECOMMENDED INSPECTION OF THE 125 200 250 300 EXC ENGINE USED FOR HOBBY ENDURO BY YOUR KTM wORKSHOP 180 240 270 hours hours hours CADDITIONAL ORDER FOR THE KTM wORKSHOP SES N O Check the reed type intake valve for wear Check the clutch shoes for wear
79. essing this button the ignition circuit is short circuited Combination switch EXC The light switch has 2 respectively 3 switch positions Light off this function is not available in all models Low beam on High beam on You may use button to actuate the horn The red short circuit button serves to 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 The flasher switch is a separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dismount the entire turn indicator system without affecting the function of the remaining electrical system 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 n 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 tan
80. ge If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer Full throttle range D 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 Draining the 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 and clean it with compressed air Then mount the plug together with the gasket open the fuel tap and check the float chamber for l
81. 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 although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of throttle the gas consumption will increase When shif ting down use the brakes if necessary and turn down at the same time Pull the clutch lever and shift down to the next lower gear Let the clutch lever go slowly and open the throttle or shift down again A WARNING A 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 HAND LEBAR IT WILL LOSE STABILITY 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 TO BE TAKEN NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVERREV DAMAGING THE VALVES IN ADDITION THE REAR WHEEL WILL BLOCK SO THAT THE MOTORCY CLE CAN EASILY GET OUT OF CONTROL F THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL TRAVEL THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO ENSURE THA
82. great quantities of dust For this purpose rotate the two quick release fasteners counter clockwise and pull them outward up to the stop pull the filter box cover forward and remove it Unhook the filter holding brackets at the bottom swing them sideways and take the air filter together with the filter support amp out of the filter box CAUTION DO NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER MAINTENANCE 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 the 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 center them and fix them properly with the filter holding bracket 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 increase
83. heet in the caliper support and of the leaf spring 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 AFTER WORKING ON THE BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION 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 the 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 A WARNING A IF THE BRAKE FLUID LEVEL DROP
84. hould be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system A WARNING A IF POSSIBLE ALWAYS CHECK THE LEVEL OF COOLING LIQUID WHEN THE 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 Refilling Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0 25 0 06 US gallons cooling liquid Make sure that the drain screw is fastened Pour approx 0 5 litres 0 13 US gallons coolant into the system Remove screw at the cylinder head Reinstall it as soon as the cooling liquid emerges free of air bubbles only for 125 200 engines Remove the screw on the right radiator Now add cooling liquid 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 Cleaning the air filter The air filter must be cleaned prior to every race or whenever the motorcycle has been exposed to
85. is received BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1 AVS1 and STP1 figures to O JL 270 SPEED TRP2 trip 2 display mode The TRP2 trip meter is always active and counts to 999 9 Contrary to TRP1 the displayed figure can be changed using the and buttons This is a very useful function for trips taken according to a roadbook TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received BUTTON increases the TRP2 figure BUTTON decreases the TRP2 figure press the MODE BuTToN to change to the next mode press and hold the MODE BUTTON SECONDS to reset TRP2 to SPEED AVS2 average speed 2 display mode AVS2 shows the average speed based on the TRP2 and STP2 figures The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 was not stopped after the trip BUTTON function BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON sECONDS to change to the next mode SPEED STP2 stop 2 display mode STP2 is a manual stop watch Start the stop watch by pressing the but ton
86. k breather hose without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can 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 as 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 9ltank 1 3 0 32 US gallons Reserve of the 11 tank 1 7 0 45 US gallons Choke knob When pulling the choke knob fully towards the top a bore is opened in the carburetor Through this bore the engine can take in additional fuel This results in a rich fuel air mixture that is needed for a cold start When pressing the choke knob downward in the carburetor the bore is closed again Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located bet ween first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled 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 maintenanc
87. mance m e T 42 RULE OF THUMB high altitude or high temperatures choose leaner carburetor adjustment low altitude or low temperatures 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 WILL VOID YOUR WARRANTY ONLY USE HIGH GRADE 2 STROKE ENGINE OIL OF KNOWN BRANDS e g Shell Advance Racing X NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON IF YOU USE TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL THE SPARK PLUG AND THE EXHAUST CONTROL SYSTEM IN 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 the engine does not run properly despite a changed adjustment 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 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 p
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89. ncer Clean it every 4000 km 2500 miles to guarantee proper functioning Also clean the spark arrestor when replacing the glassfiber yarn filling After assembling the silencer remove the plug and start the motorcycle Close the opening of the muffler with a rag and press the accelerator approximately 20 times The carbon deposits will be blown out through the opening Then turn off the engine and let the exhaust system cool down Grease the plug with molycote grease and mount the plug Carburetor adjustment Basic 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 temperature 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 depends on oil quality Basic information on changing the carburetor 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 perfor
90. nd brake lever 32 Adjusting the spring preload on the fork 5 28 Basic suspension setup for the weight of the driver 26 Bleeding of the hydraulic clutch 41 sienne m 19 Breather plug front fork DU ete 25 iode imei 42 30 Chain WEAN 30 Changing the basic position of the foot brake pedal 33 Changing the original position of the clutch lever 41 Changing the spring preload on the telescopic fork MXC EXC models 27 Changing the spring preload on the telescopic fork SX models 27 Changing the spring preloading of the shock absorber 28 Changing the transmission oil 125 200 44 Changing the transmission oil 250 300 44 Chassis sf 5 Checking and adjusting the steering head bearing 24 Checking the basic setup of the telescopic fork 27 Checking the brake fluid level front brake 32 Checking the chain tension 29 Checking the coolant 39 Checking the TOU e Vel uu n Bites vk et ete unas 43 Checking the front brake
91. nstall the screw connection N61 000 WE LAP 2 AS 00 MAX LAP K H H Setting the clock To set the clock switch the ignition off and select the SPEED CLK mode Press and hold the MODE button for 3 seconds The blinking digits can be changed using the and buttons Press the MODE button to move to the next digit If no button is pressed for 20 seconds the settings will be stored automati cally and the display will return to the SPEED CLK mode BUTTON time BUTTON time press the MODE to change to the next digit press and hold the MODE BUTTON sECONDs to store the time and return to the SPEED CLK mode Activating deactivating the display modes It may not be necessary to display all of the display modes functions at the same time It is possible to conceal any information not currently required By deactivating certain functions the MODE button will only allow you to select from the activated modes In the SPEED H mode press and hold the MODE button for 3 seconds to access the SETUP menu The blinking function can be activated by pressing the button and deactivated by pressing the button If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode BUTTON activates the blinking display BUTTON deactivates the blinking display press the MODE
92. number in the relevant field on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever is located on the left side of the handlebars The adjust ing 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 handlebars on the right and actu ates the front wheel brake e OOOO Li Wo CI DIDI ri I SP ODO MAX LAP OK H SPEED Electronic speedometer indicator lamp EXC The green control lamp flashes in the same rhythm as the flashing indicator when the indicator is working The blue control lamp lights up when the high beam is on Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move The engine must be started in order for the speedometer to be supplied with electricity from the generator An impulse must be received from the wheel sensor to activate the display the front wheel must turn at least one time TEST All of the display elements will light up for 1 second for the function test WS wheel size The display will change and briefly show the diameter of the front wheel in millimeters If the front wheel does not turn the display will automatically change to the SPEED H mode If the front wheel turns the display will automatically change to the SPE
93. osi 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 round and stable engine speed using the air control screw basic position of the air control screw open by 1 5 turns Then adjust to the normal idling speed by means of the air control screw EB eee S main jet jet needle jet needle idle jet throttle valve b D XS OO air control screw idle adjusting screw JET NEEDLE RANGE OF ACTION TYPE RICHER LEANER Opening up B Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle setting the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking 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 ran
94. ound damping determines the reaction when the fork is rebound 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 1418X725 20 clicks Type White Power 1418X735 20 clicks Type White Power 1418X736 20 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 compression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping STANDARD LOW SPEED SETTING Turn the adjusting screw O 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 1
95. peg CDI CD 1 15 CDI Z ndkerze spark plug 16 candela 1 Ul bobine allumage Z ndspule Ignition coil 17 bobina 5 Generator generator 18 dinamo generateur CO Kondensator capacitor 19 condensatore condensateur NO regulateur generateur 16 contact clignateur Spannungsregler voltage regulator 20 regol di tens NO Impulsgeber pulser coil 2 trasmett d impulsi Blinkerschalter blink switch 22 int lampeggiatori N N G N 6 pol Stecker multip cont plug 6 23 connettore a poli connect multiple 6 Blinker li hi blinker left rear 24 lampegg post sn Blinker re hi blinker right rear 25 lampegg post dx NO clign arr gauche NO clign arr droite NO OD Brems Schlulicht rear stoplight 26 fanal post di freno feu arr et de stop bl bl bl bl blau bl blue blu bleu azul br braun br brown br marrone brun marron ge gelb ge yellow ge giallo jaune amarillo gr grau gr grey gr grigio gris gris g grun g green g verde vert ver de oronge orange arancione orange naran ja rot red rosso rouge rojo schwarz black nero noir negro violett violet violetto violet violeta weih white bianco blanc blanco faro luz de posicion interm izquierdo delantero Intermitente derecho delantero tacometro lampara aviso luces largas lampara aviso intermitentes conector multiple 2 conector multiple 3 interruptor combinado interr luz de freno del interr luz de fre
96. r a harder spring ual e 27 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 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 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
97. res 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 the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent A WARNING A KEEP THE ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS 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 wish 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 aggressive contaminants Check antifreeze and amount of cooling liquid Let the engine warm up again close fuel cock and wait until the engine dies off by itself In this way the carburetor jets are preven ted from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate ki
98. s 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 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 O The oil level in the horizontaly positioned master cylinder 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 50 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 Bleeding of the hydraulic clutch To bleed 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 bleeder nipple In its place mount the bleeder syringe which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubble free state Make sure that the oil does not overflow Th
99. sion uestes rere 29 Hand brake pu 5 Chain maintenance sien u uu 30 Electronic speedometer indicator lamp 6 er TR 30 Electronic speedometer ce ui 6 General information about KTM disc 31 7 Adjusting the free travel at the hand brake lever 32 Short circuit button SX 11 Checking the brake fluid level front 32 Combination switch EXC 11 Refilling the front brake fluid reservoir 32 Headlamp switch EXC 11 Checking the front brake pads 32 11 Replacing the front brake 33 Emergency OFF switch Australia 11 Changing the basic position of the foot brake pedal 33 gli gt u 12 C ir 33 P Refilling the rear brake fluid reservoir 33 Rel tap udis OE b brem rebate 12 Checking th 34 th redr brake no m RO SUCHEN EROR 12 Replacing the rear brake pads
100. ts 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 to 80 Nm 60 ft Ib A WARNING A F YOU DON T HAPPEN HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A DEALER AS SOON AS POSSIBLE 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 by 180 CoC OGBL ICS max 272 mm 16 17 18 Chain maintenance For long chain life good maintenance is very important X ring chains require only modest maintenance The best way is to use lots of water but never use brushes or solvents After letting the chain dry you can use a special X ring chain spray Shell Advance Bio Chain A WARNING A NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL CAUTION WHEN MOUNTING THE CHAIN JOINT THE CLOSED SIDE THE SAFETY DEVICE MUST POINT IN
101. ur weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accordingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring is suitable for your weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined Determining the static sag of the shock absorber The static sag should be as close as possible to 35 mm Deviations of more than 2 mm can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the gro und Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm suec eee ee 45 35 mm If the static sag is lower the spring prelo
102. ze 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 BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking the brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar 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 LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws and remove lid 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 e g Shell Advance Brake DOT 5 1 Replace membrane and lid tighten scr ews 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 CA

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