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1. Short circuit button SX Combination switch EXC Headlamp switch EXC USA Flasher switch Emergency OFF switch Australia Filler cap Fuel tap Choke knob shift lever Kickstarter Foot brake pedal Side stand Steering lock Compression damping of fork Rebound damping of fork Damping action during compression of shock absorber SX Compression damping of shock absorber MXC EXC Rebound damping of shock absorber SX MXC EXC GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for your first ride Running in DRIVING INSTRUCTIONS What you should check before each start starting when the engine is cold starting when the engine is warm What to do when the engine is flooded starting off shifting Riding Braking Stopping and parking Refueling fuel PERIODIC MAINTENANCE SCHEDULE MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the spring preload of the shock absorber Pivot bearing Basic suspension setup for the weight of the driver Checking the shock absorber and spring Determining the static sag of the shock absorber Determining the riding sag of the shock absorber Checking the basic setup of the telescopic fork Changing the spring preload on the telescopic fork Replacing fork springs Breather plug front fork Cleaning the dust sleeves of the telescopic fork Changing the fork offset SX Checking and adjusting the steering head bearing How to change the handlebar position 2 23
2. 2 turns WARNING eee THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION 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 6 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 1 with a screwdriver Turning in a clockwise direction will increase the damping turn ing 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 Typ White Power 12187A02 15 clicks Typ White Power 12187A04 15 clicks WARNING eee THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION 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 2 CONNECTION 24MM Rebound damping of shock absorber SX MXC EXC By using the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the
3. Off road Road AND ENGIN 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 motor cycle 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 AN WARNING eee DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE HOMOLOGATED TIRES FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PER FORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Checking spoke tension The correct spoke tension is very importan
4. A A JU A CHASSIS 300 MXC 250 300 EXC Frame Central chrome moly steel frame Fork White Power Upside down 48 MA Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension WP PDS 5018 Progressive Damping System shock absorber aluminium swingarm Front brake Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Wear limit 2 50 mm 0 1 in front 3 50 mm 0 14 in rear Front tires 80 100 21 51M M59 90 90 215 83 Front tires USA 80 100 21 51M M59 80 100 21 51M M59 Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 1 5 bar 21 psi 1 5 bar 21 psi Rear tires 110 90 19 62M M7O 140 80 18 MT 83 Rear tires USA 110 100 64M M402 110 100 18 64M M402 Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 2 0 bar 21 psi 2 0 bar 21 psi Fuel tank capacity 7 5 liters 2 US gallons 10 5 liters 2 8 US gallons 8 5 10 5 liters 2 2 2 8 US gallons Final drive ratio 13 48 t 8 13 40 t Final drive ratio USA 13 48 t 13 50 t 13 50 t Chain 5 8 x 1 4 Available final sprockets 38t 40t 42t 45t 48t 491 5Ot 51t 521 headlight 12V 35 35W Bilux base Ba20d parking light 12V 5W base W2 1x9 5d brake rear light 12V 21 5W base BaY15d flasher light 1
5. F gt JE 4 D AND ENGIN Before remounting the front wheel clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushing To install the front wheel lift it into the fork position and mount the axle shaft Mount the collar nut 5 tighten the clamping screws 6 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm 30ft 1b 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 WARNING IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS 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 touches the ground Loosen the collar nut 1 remove chain tensioner 2 h
6. S2 display mode stop watch 2 S2 is a manual stop watch Start the stop watch by pressing the button press again to hold Press again to continue timing Press the O button to change to the next mode The S2 display will blink in the other modes if S2 continues to run in the background To stop S2 return to the SPEED S2 mode and press the button button Starts and stops the stop watch button no function briefly press O button changes to the next display mode hold button 3 secs clears the S2 figure Kilometers or miles The unit kilometers or miles can also be changed The ODO figure will be retained and converted accordingly The TRI Al 51 TR2 and A2 figures Will be cleared To select the unit select the SPEED H mode and hold the O button for 3 sec onds to access the SETUP menu Press the O button until the KMH MPH function blinks Press the button briefly to move to the options Press the button for KMH or the button for MPH To set briefly press the O button 1 x and hold for 3 seconds until the dis play returns to the SPEED H mode 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 to access the menu to activate the KMH display button to activate the MPH display briefly press O button changes to the next mode changes from the menu to the SETUP menu hold O button 3 secs stores and closes the SETUP menu
7. Setting the clock To set the clock switch the ignition off and select the SPEED CLK mode Press and hold the O button for 3 seconds The blinking digits can be changed using the and buttons Press the button to move to the next digit O 12 will show the time in the 12 hour mode 0 24 in the 24 hour mode Press and hold the O button for 3 seconds to store the settings 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 briefly press O button changes to the next digit hold O button 3 secs starts the SETUP menu stores the time and changes to the SPEED CLK dis play mode OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS display briefly press button briefly press button briefly press O button hold O button 3 secs SPEED H no function no function next display mode displays the SETUP menu Motorcycle is driving SPEED CLK no function no function next display mode setting the clock menu starts stops LAP without stops LAP stores LAP SPEED LAP clearing LAP figure figure resets LAP to O next display mode clears all LAP figures LAP LAP next figure no function next display mode next display mode SPEED MAX no function no function next display mode clears MAX X X SPEED ODO no function no function next display mode next display mode X SPEED TRI no function no functi
8. driving light lamp front brake switch KF right front flasher headlight left front flasher Kina 125 300 2005 wiring diagramm main harness 948 11 075 250 29 right rear flasher left rear flasher 20 02 2004 rear light brakelight KA At 212 multi func digital speedometer headlight EXC USA 200 250 O5 ANHANG APPENDICE APPENDIX APENDICE handle bar switch optional N light switch ignition coil stop switch wiring diagramm regulator rectifier main harness 948 11 075 000 20 02 2004 rear light brakelight KA At 212 JIIONJdY XIGN4iddV JJIAN3ddV INVHNV headlight light switch handle bar switch optional multi func digital speedometer ignition coil EXC USA 300 2005 stop switch y e bl br wiring diagramm main harness regulator rectifier JH lt 548 11 075 100 20 02 2004 rear light brakelight TC At 212 ANHANG APPENDICE APPENDIX APENDICE stop button black brown Ai ignition coil 125 250 2005 generator pick up ellow black Eg 5 lt 5 CH CH D CH DI 2 ei blue white 548 39 032 000 19 05 2003 gt y D 18 AN ENGLISH Capacitor CDI Driving light lamp Flasher relay Flasher switch Front brake switch Flasher control lamp Generator Handle bar switch for multi fun
9. 23 23 24 24 24 24 25 25 26 26 26 27 m Page Check cham tension a ice Qe ESO ERAS 29 Correct chain tension 30 Chain maintenance 30 Chan Wear cod vous iow DE vorax 30 General information about KTM disc brakes 31 Adjusting the free travel at the hand brake lever DZ Checking the brake fluid level front brake 32 Refilling the front brake fluid reservoir 32 Checking the front brake pads 32 Replacing the front brake pads 33 Changing the basic position of the foot brake pedal 33 Checking the rear brake fluid level 33 Refilling the rear brake fluid reservoir 33 Checking the rear brake pads 34 Replacing the rear brake pads 34 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 Tires air pressure 36 Checking spoke tension 36 Replacing the battery of the digital speedometer 36 Check set distance of the magnetic sensor 37 Replacing the headlight lamp parking light lamp OL Cooling system 38 Radiator cover for the cold season 38 Checking the coolant level 38 Refilling Bleeding the cooling system 39 Cleanin
10. 25 C 13 F Coolant Ignition system Generator output Ignition system USA KOKUSAN 2 1 no generator KOKUSAN 2 1 no generator KOKUSAN 2K 3 12V 110W KOKUSAN 2K 2 12V 40 W KOKUSAN 2K 3 12V 110W KOKUSAN 2K 2 12V 40W TIGHTENING TORQUES ENGINE Flange bolts cylinder head Nuts cylinder base 12 1 Flywheel collar nut Nut for primary sprocket LH thread Nut for inner clutch hub M16x1 5 M18x1 5 Crankcase and clutch cover bolts M6 Spark plug Swingarm pivot 14X1 25 M16x1 5 Other screws BASIC CARBURETOR SETTING M 6 M 8 M 10 125 EXC EU 4 2 KW 125 EXC SIX DAYS 200 EXC USA 200 EXC AUS 200 EXC EU 7 KW Carburetor Keihin PWK 39 Keihin PWK 38 AG Keihin 38 AG Keihin 38 AG Keihin PWK 38 AG 98SA0 141102 Carburetor setting mark Carburetor setting number 85SA01 080202 SKTPB 070202 855 1 160202 SKTUB Main jet 188 185 190 Idling jet 45 48 Starting jet 85 148 180 185 180 185 178 180 35 45 48 45 48 45 48 85 85 85 100202 180 178 35 45 48 R1469D R1468D Needle position from top I I Jet needle R1472N NOZE NOZF NOZE V IV H1 NOZE NOZF 85 R1475J NOZE NOZF Throttle valve 5 5 1 5 Air adjustment screw open Performance restrictor 6 5 6 5 6 5 1 5 119 1 5 11 CL H JNS
11. LAR SCREW IS SELF LOCKING Grease the steering head bearing and sealing elements AND ENGIN Mount the lower triple clamp upper steering head bearing protection ring O ring upper triple clamp and the blind screw Tighten the collar screw on the lower triple clamp to 80 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 stages Adjust the steering head bearing without clearance see Checking and adjust ing the steering head support and tighten the clamp screws on the upper triple clamp to 15 Nm in 3 stages Mount the front wheel fender and tighten the screws to 10 Nm Mount the hand brake cylinder and tighten the screws to 10 Nm Mount the staring number plate Mount the front wheel see Dismounting and mounting the front wheel Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcy cle 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 1 of the top triple clamp and turn steering stem bolt 2 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 15 Nm SX 20 Nm EXC MXC WARNING eee IF THE STEERING HEA
12. 300 9 2 KW Carburetor Keihin PWK 38 S AG Keihin PWK 36 S AG Keihin PWK 36 S AG Carburetor setting number 191102 171102 Main jet 168 165 170 160 162 160 162 Idling jet 42 40 3 5 35 Starting jet 85 85 85 Jet needle NOZF NOZG NOZE N3EH N3EW N3CJ N3bEW N3EH Throttle valve 6 5 7 Performance restrictor slide stop 38 Activating and deactivating display modes 7 Adjusting the free travel at the hand brake lever 32 Basic suspension setup for the weight of the driver 24 Eil 19 Breather plug front fork 26 Carburetor adjustment 41 Chain maintenance 30 ET 30 Changing the basic position of the foot brake pedal 33 Changing the fork offset caster SX 27 Changing the original position of the clutch lever A0 Changing the spring preload on the telescopic fork 25 Changing the spring preload on the telescopic fork 25 Changing the spring preloading of the shock absorber 23 Changing the transmission oil 125 200 44 Changing the transmission oil 250 300 44 Chassis HU mIDGl aue esca mem ca abe REO RORIS ares 5 Check chain tension 29 Check transmission oil level 125 200 44 Check transmission oil level 250 300 44 Check set distance of the magnetic sensor 37 Checking and adjusting the stee
13. 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 125 SX 125 EXC 200 EXC CHASSIS Frame Fork Central chrome moly steel frame White Power Upside down 48 MA Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension Front brake WP PDS 5018 Progressive Damping System shock absorber aluminium swingarm Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Front tires Front tires USA Air pressure offroad Air pressure road driver only Rear tires Rear tires USA Air pressure offroad Air pressure road driver only Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Wear limit 2 50 mm 0 1 in front 3 50 mm 0 14 in rear 80 100 21 51M M59 80 100 21 51M M59 1 0 bar 14 psi 100 90 19 57M M70 100 90 19 57M M70 1 0 bar 14 psi 90 90 21 MT 83 1 0 bar 14 psi 1 5 bar 21 psi 120 90 1
14. ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWAL LOWED OR SPLASHED IN THE EYES SEEK 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 MOTOREX CROSS POWER 2T NEVER MIX SYNTHETIC OILS AND MINERAL OILS NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON WHEN USING TOO MUCH OIL THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG IF YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CON VERTER ALWAYS KEEP IN MIND THAT LEADED FUEL WILL DESTROY THE CATALYTIC CONVERTER FUEL EXPANDS WHEN ITS TEMPERATURE RISES THEREFORE DO NOT FILL THE TANK TO THE TOP SEE FIG PERIODIC MAINTENANCE SCHEDULE A CLEAN MOTORCYCLE CAN BE CHECKED 125 200 SX EXC st service after 20 hours after 40 hours or 250 300 SX MXC EXC after 10 hours or or 2000 kilo 4000 kilometers MORE QUICKLY WHICH SAVES MONEY a a Check gear box oil level e Change gear box oil e Engine Check spark
15. IN THE FUEL IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMME DIATELY 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 depend ing on your speed 23 WARNING __ 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 BRAK ING 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 WEAKER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICA TION 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 Stopping and parking Brake motorcycle
16. REAR FERODO 4424 organic better controllability shorter service life for dry terrain TOSHIBA H38 Sinter longer service life than FERODO 4424 higher braking performance BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases The brake disk must be at least 2 50 mm front 3 50 mm rear thick at the thinnest point A Check the thickness of the brake disk at several points WARNING Oe ABRAKE DISK WORN DOWN LESS THAN 2 50 MM FRONT 3 50 MM REAR IS A SAFETY RISK HAVE THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE 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 are 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 completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid 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 re
17. 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 1 25 in allows you to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 CAUTION ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED 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 Motorex Chainlube 622 WARNING 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 OF THE SAFETY DEVICE MUST POINT IN 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 lat est when a space of 272 mm 10 70 in is measured Chains d
18. Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM H ndler hilft Ihnen gerne WENN SIE NDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KT
19. 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 position of the air control screw 2 and the air control screw 3 Only make adjust ments 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 turn ing 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 main jet control screw open by 1 5 turns Then adjust to the normal idling speed by means of the air control screw jet needle 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 idle jet the mixture to the carburetor will be too rich the fuel level too high or the throttle valve float needle is leaking air control screw idle adjusting screw main jet EDEN d c idle jet throttle valve SN EE air control screw idle adjusting screw JET NEEDL
20. 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 AN WARNING 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 FLAMMA BLE 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 Motorex Cross Power 2T VAN WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAU TION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING BE CAREFUL NOT TO SPILL GASOLINE ON THE
21. based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly 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 60 90 hours hours 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 NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK REQUIRES EXPERT SKILLS AND TECHNICAL KNOW HOW FOR Y
22. end of the chain sliding component The dis tance between the chain and the swing arm should be approx 8 10 mm 0 31 0 39 in In the course of this procedure the upper chain portion A must be taut see drawing If necessary correct the chain tension AN WARNING OOO IF THE CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY TRANS MISSION CHAIN CHAIN WHEELS AND REAR WHEEL BEARINGS WILL BE SUB JECTED 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 MOTOR CYCLE max 272 mm 16 17 18 AND ENGIN Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts Before tightening the collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm 60 ft Ib WARNING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE TIGHTEN
23. 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 each race or whenever dust has accu mulated To clean lift the filter box cover see illustration and pull off towards the front Detach the bottom of the filter retaining bracket 4 tilt aside and remove the throttle cap 5 and the air filter 6 and filter support 7 from the filter box The SX models do not have a throttle cap CAUTION DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM AGE THE FOAM KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE BIO DIRT REMOVER AND LIQUID BIO POWER NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS OTHERWISE DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL TER IS NOT MOUNTED CORRECTLY Thoroughly wash the air filter in special cleaning fluid Motorex Bio Dirt Remover 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 Motorex liquid Bio Power 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 Insert the air fil
24. ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1 5 45 NOZE 180 2 29 38 NOZF 1500 m 5000 ft t 751 m 2501 ft 750 m 2500 ft t 301 m 1001 ft ASO lJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 300 m 1000 ft Meeresniveau Sea level ASO lJ NEEDLE POS LSO Luftregulierschraube offen 1 4 ASO Air screw open from fully seated LD Leerlaufd se E em IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top HD Hauptd se 9 T MJ Main jet NICHT F R STRASSENBETRIEB NOT FOR HIGHWAY USE Kraftstoff Super Bleifrei ROZ 95 Fuel unleaded fuel with at least RON 95 USA Premium RON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM Handler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be ple
25. 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 Typ White Power 12187A01 22 clicks Typ White Power 12187A02 22 clicks Typ White Power 12187A03 22 clicks Typ White Power 12187A04 22 clicks WARNING eee THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION 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 4 CONNECTION 15MM 9 AND WARNING 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 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 f
26. 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 HAN DLEBAR TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap 1 Turn the screw 2 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 Typ White Power 14187A01 20 clicks Typ White Power 14187A02 22 clicks Typ White Power 14187A03 22 clicks Typ White Power 14187A04 20 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 3 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 ty
27. 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 the maintenance schedule has been reached THE SX SXS AND MXC MODELS ARE PROHIBITED ON PUBLIC ROADS The EXC models are only allowed on 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 2 STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS KTM EXC and MXC models were designed for offroad use only and are only suitable for longer rides on public roads to a certain extent The engine is subjected to completely different performance demands on public roads and must be adapted to these operating conditions Ask your KTM dealer for more information In accordance with the international quality management ISO 9001 standard KTM uses REG NO 12 100 6061 quality assurance processes that lead to the highest possible product quality SERIAL NUMBER LOCATIONS Chassis number Engine number engine type OPERATION INSTRUMENTS Clutch lever Hand brake lever Electronic speedometer Indicator lamps
28. the clock see Setting the clock SPEED LAP lap time display mode You can use the manual stop watch to stop and store up to 10 lap times which you can view in the LAP LAP display mode see below LAP displays the lap times in hours minutes and seconds button button briefly press O button hold O button 3 secs Starts and stops the stop watch lap time is not reset to O Stops the stop watch stores the lap time and restarts the stop watch again The time is reset to O A total of 10 lap times can be stored If the lap time con tinues to run after you press the button all 10 mem ory locations are occupied To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode Up to 10 lap times can be stored in this way Changes to the next display mode lf no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped Clears all LAP figures rC 20 LILI LILI II LAP LAP LAP display mode to view lap times The LAP LAP display mode will only be shown if lap times have been stored and the front wheel has stopped It will display the lap number and the stopped lap time in hours minutes and seconds Press the button to access the next lap time To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode button changes to the next lap time button no function briefly press O button changes to the next
29. 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 7 and drain used oll into a container Clean the magnet of the oil drain screw and reinstall oil drain screw with seal Pour in O 7 litres engine oil g Motorex Top Speed 4T 15W50 replace plug 6 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 E G MOTOREX TOP SPEED 4T 15W50 CLEANING gt o h Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS 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
30. wheel and remove the brake pads Carefully clean the brake caliper with compressed 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 3 in as far as it will go Mount the safety device 2 WARNING 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 AGAINST THE BRAKE DISK AND THE PRES SURE 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 4 on the left side of the fork fists Loosen and remove the collar nut 5 loosen the clamping screews 6 on the right side of the fork fist Hold the front wheel pull out the wheel spindle 7 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 TR E ge 4 4 1 T d
31. wheel circumference of 21 with production tires Afterwards the display will return to the previous display mode SPEED display mode H service hours Only the SPEED H and SPEED ODO display modes are activated in the condition at delivery SPEED H is displayed whenever the display is activated and the front wheel is not turning It automatically changes to the SPEED ODO display mode as soon as the front wheel starts turning SPEED displays the speed H displays the engine s service hours The service hour counter starts to count as soon as you start the engine The displayed figure cannot be changed Service intervals are indicated in service hours for some KTM offroad motor cycles making the service hour counter a very practical function SPEED ODO display mode odometer The SPEED ODO mode displays the speed and the total distance traveled The display automatically changes to the SPEED H display mode when the front wheel stops turning no function no function changes to the next display mode changes to the next display mode button button briefly press O button hold O button 3 secs The electronic speedometer has a number of display modes functions that you can also activate reveal see Activating and deactivating display modes IM TR M A2 Si 2 Km h Mph o MAN LAP CLK H 10041 ka CLK n MAO 2o LL SPEED Kmh LAP Activating and deactivating display mo
32. you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throt tle 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 shifting 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 AN WARNING AFTER FALLING WITH THE MOTORCYCLE CHECK ALL ITS FUNCTIONS THOR OUGHLY BEFORE USING IT AGAIN A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED DO NOT ADJUST THE HANDLEBAR IT WILL LOSE STABILITY JR NG INS IK JN 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 GIV ING IT ACHANCE TO WARM UP AFTER THAT NO FURTHER PRE CAUTIONS 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 MOTORCYCLE CAN EASILY GET OUT OF CONTROL IF THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL TRAVEL THE ENGINE SHOULD BE ACCELERATED OCCA SIONALLY TO ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS MIXED
33. 01 m 1001 ft ASO lJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 300 m 1000 ft ASO IJ NEEDLE Meeresniveau POS Sea level LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 gt IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top b HD Hauptd se MJ Main jet NICHT F R STRASSENBETRIEB Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE Fuel unleaded fuel with at least RON 95 USA Premium RON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM Handler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburator
34. 2 Driving instructions 17 Electronic speedometer 6 Emergency OFF switch Australia 11 Engine characteristic 250 300 SX MXC EXC 43 Page Engine number engine type 5 Exhaust E NEE 40 BUI el M CD PX EE 12 Flasher 55 112 a aim dedos e doe m de e node 11 Foot brake pedal 13 AA ee fak 12 General information about KTM disc brakes 31 General tips and warnings for starting the motorcycle 16 Hand Drake lever audae 44 dada eddies 5 Headlamp switch EXC USA 11 How to change the handlebar position 29 Indicator lamps EXC 10 Instructions for your first ride 16 KICKSIAM E sa at audi di tie ati 13 Maintenance work on chassis and engine 22 Operation instruments 5 Periodic maintenance schedule 20 Pivot Deanne TIRE 23 Radiator cover for the cold season 38 Rebound damping of fork 14 Rebound damping of shock absorber SX MXC EXC 15 Refilling the front brake fluid reservoir 32 Refilling the rear brake fluid reservoir 38 Refilling Bleeding the cooling system 39 Refueling fuel 19 Replacing fork 5 26 Replacing the batt
35. 2005 125 SX EXC 200 EXC 290 SX EXC 300 MXC EXC OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 38 AM IMPORTANT gt 12 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 interest please pay particular attention to notices that are marked as follows AN WARNING IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB CAUTION GNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR CYCLE S TRAFFIC SAFETY Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance 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 inopera tive by any person All information contained is without obligation KTM Sport
36. 2V 10W base 155 license plate illumination 12V 1 2W base 1x4 6d Steering head angle 63 Wheel base 1475 10 mm 58 1 in 0 4 in Seat height unloaded 925 mm 36 5 in Ground clearance unloaded 385 mm 15 2 in STANDARD ADJUSTMENT FORK STANDARD ADJUSTMENT SHOCK ABSORBER 250 SX 250 300 MXC EXC 250 SX 250 300 MXC EXC WP 4860 MA PA WP 4860 MA WP PDS 5018 DCC WP PDS 5018 MCC 14187A03 14187A04 12187A03 12187A04 Compression adjuster Compression adjuster 15 LS low speed 15 O 20 Rebound adjuster 2 2 HS high speed Spring 4 4 N mm 4 0 N mm Rebound adjuster 22 22 Spring preload 5 mm 5 mm Spring 76 N mm linear 76 N mm linear Air chamber length 100 mm 110 mm Spring preload mm mm CL H JNS A A JU A TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front M8 Loctite 243 25 Nm Brake disks M6 Loctite 243 10 Nm Clamping screws upper fork bridge EXC M8 20 Nm Clamping screws lower fork bridge EXC Clamping screws upper fork bridge SX Clamping screws lower fork bridge SX Clamping screws fork stubs MB 10 Nm Collar nut rear wheel spindle M20x1 5 80 Nm Hexagon nut swing arm bolt M16x1 5 100 Nm Hexagon collar screw handlebar clamp MB Loctite 243 20 Nm Allan head screw handlebar support M10 Loctite 243 40 Nm Shock absorber top M12 80 Nm Bal
37. 8 MT 83 1 0 bar 14 psi 2 0 bar 28 psi 90 90 21 MT 83 80 100 21 51M M59 1 0 bar 14 psi 1 5 bar 21 psi 120 90 18 MT 83 100 100 18 59M M402 1 0 bar 14 psi 2 0 bar 28 psi Fuel tank capacity 7 5 liters 2 US gallons 8 5 liters 2 2 US gallons 8 5 10 5 liters 2 2 2 8 US gallons Final drive ratio Final drive ratio USA 13 50 t 13 50 t 14 42 t 13 50 t 14 42 t 14 48 t Chain Available final sprockets 5 8 x 1 4 38t 40t 42t 45t 48t 49t 50t 51t 52t Bulbs headlight parking light 12V 35 35W Bilux base Ba20d 12V 5W base W2 1x9 5d 12V 21 5W base BaY15d 12V 10W base Bal53 license plate illumination 12 1 2W base 1x4 6d Steering head angle 63 Seat height unloaded 925 mm 36 5 in STANDARD ADJUSTMENT FORK 125 SX 125 200 EXC WP 4860 MA PA WP 4860 MA D 2 Rebound adjuster 2 Spring 4 2 N mm Spring preload 5mm Air chamber length 100 mm brake rear light flasher light STANDARD ADJUSTMENT SHOCK ABSORBER 125 SX 125 200 EXC WP PDS 5018 DCC WP PDS 5018 MCC 12187A01 12187A02 15 LS low speed 15 1 5 HS high speed 22 72 N mm linear Compression adjuster 22 72 N mm linear Rebound adjuster Spring Spring preload 7 mm 7 mm TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front M8 Loctite 243 25 Nm Brake
38. 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 GOG GLES YOU WILL BE PRACTICALLY BLIND NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PER SON ONLY NO ADDITIONAL PASSENGER ALLOWED NEITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY REGULATIONS AND SAFETY STANDARDS USING THEM ON PUB LIC 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 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 The following checks should be performed 1 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kink
39. ASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA C
40. D BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI ODS 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 Motorex Long Therm 2000 AND ENGIN 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 triple clamp 1 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 2 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 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar support and tighten screws 4 to 40 Nm 30 ft Ibs Mount the handlebar and handlebar clamps and tighten screws 3 to 20 Nm 15 ft Ibs The gap between the handlebar sup port and the handlebar clamps should be the same size in the front and in the rear WARNING OOOO THE SCREWS 4 MUST BE SECURED WITH LOCTITE 243 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Press the chain upward at the
41. E EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACI N EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEM S CADUCA LA PROTECCI N DEL SEGURO Fou pr mu pr VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 38 AG MEERESH HE ALTIDUDE TEMPERATUR TEMPERATURE 20 C bis 7 C 2 F to 20 F gt y gt y gt y 200 2005 6 C bis 5 C 6 C bis 15 19 F to 41 F 42 F to 60 F 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C 61 F to 78 F 79 F to 98 F 99 F to 120 F 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1 75 45 NOZE 178 1500 m 5000 ft t 751 m 2501 ft 750 m 2500 ft t 301 m 1001 ft ASO lJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 300 m 1000 ft Meeresniveau Sea level ASO lJ NEEDLE FOS LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 gt IJ Idling jet POS Nadel Clip Position von oben 5 4 POS Needle clip position from top HD Hauptd se NICHT F R STRASSENBETRIEB Kraftstoff Super Bleifrei ROZ 95 MJ Main jet NOT FOR HIGHWAY USE Fuel unleaded fuel with at least RON 95 USA Premium RON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der
42. E RANGE OF ACTION TYPE LEANER NOZD NOZE NOZF NOZG NOZH AND ENGIN Part throttle range C Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer Full throttle range D 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 dis tance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one Draining the float chamber of the carburetor Following every wet cleaning procedure the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it Water in the f
43. GHLY WITH COLD WATER AND LET IT DRY WELL ___ 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 pre vented from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate 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 GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST USE
44. HE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS 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 Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring 1 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 1 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm 6 ft Ib ADJUSTMENT VALUES SPRING PRELOAD A minimum preload 4 mm 0 15 in SIANDARD PRELOAD mm 0 28 in maximum preload 10 mm 0 4 in Pivot bearing The pivot bearing 3 for PDS suspension struts at the swinging fork is Teflon coated and must not be lubri
45. IERUNG CARBURETOR SETTING KEIHIN PWK 36 AG E MEERESHOHE TEMPERATUR 20 C bis 7 C 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C ALTIDUDE TEMPERATURE F to 20 19 F to 41 F 42 F to 60 F 61 F to 78 F 79 F to 98 F 99 F to 120 F 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1 5 29 N3EW 1500 m 5000 ft t 751 m 2501 ft 750 m 2500 ft t 301 m 1001 ft ASO lJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 300 m 1000 ft ASO IJ ANHANG APPENDICE APPENDIX APENDICE mmh NEEDLE Meeresniveau POS Sea level LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se E em IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top HD Hauptd se 9 T MJ Main jet NICHT F R STRASSENBETRIEB Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE Fuel unleaded fuel with at least RON 95 USA Premium RON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM Handler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STR
46. ING FLUID Check the level of cooling fluid when the engine is cold ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights turn indicators indicator lamps and horn while the engine is running LUGGAGE If you are taking luggage with you check that it is securely fastened Starting when the engine is cold Open fuel tap Turn on ignition or emergency OFF switch Swing up the side stand Put the gear in neutral Activate cold starting aid choke Leave throttle closed or open it no more than 1 3 and kick down kick Starter vigorously all the way WARNING ee 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 CHECK FOR POWER TRANSMISSION AT TEMPERATURES BELOW O C 32 F BEFORE YOU ACTUATE THE KICKSTARTER IF YOU DEPRESS THE KICKSTARTER WITHOUT FEELING ANY RESISTANCE POWER IS NOT BEING TRANSMITTED THIS COULD CAUSE INJURIES DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS NESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING CAUTION DO NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP
47. LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACI N EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEM S CADUCA LA PROTECCI N DEL SEGURO JJIGN3dV XIGN4ddV 39IdN3ddV INVHNV P u P u ee gt y gt y a LA VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 38 AG 125 EXC 2005 MEERESHOHE ALTIDUDE I TEMPERATUR TEMPERATURE mmm 20 C bis 7 C 2 F to 20 F 6 C bis 5 C 6 C bis 15 C 19 F to 41 F 42 F to 60 F 16 bis 24 C 61 F to 78 F 25 C bis 38 C 37 C bis 49 C 79 F to 98 F 99 F to 120 F 3000 m 10000
48. M connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECT A CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACI N EN V AS P BLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEM S CADUCA LA PROTECCI N DEL SEGURO E ANHANG APPENDICE APPENDIX APENDICE P u P u ee gt y gt y Tan gt y a LA VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 5 38 AG 250 SX 2005 MEERESHOHE TEMPERATUR 20 C bis 7 C 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C ALTIDUDE TEMPERATURE 2 og F to 20 F 19 F to 41 F 42 F to 60 F 61 F to 78 F 79 F to 98 F 99 F to 120 F EEUU ET JIIMGNAddv 9NVHNV 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1500 m 5000 ft t 751 m 2501 ft 750 m 2500 ft t 3
49. OUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERV ICED 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 CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION IF THE MOTORCYCLE SHOULD FALL OVER NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS IF YOU UNSCREWED ANY SCREWED CONNECTIONS WITH SELF LOCKING NUTS THEY MUST BE REPLACED WHEN MOUNTING IF NO SELF LOCKING NUTS ARE AVAILABLE APPLY LOCTITE 243 TO THE THREAD THE SCREWS AND NUTS MUST BE REPLACED IF THE THREAD IS DAMAGED ALL SCREWS AND NUTS MUST BE TIGHTENED TO THE SPECIFIED TORQUE FIGURES USING A TORQUE WRENCH IF SCREWS OR NUTS ARE NOT ADEQUATELY TIGHTENED THEY CAN BECOME LOOSE AND CAUSE THE MOTORCYCLE TO GO OUT OF CONTROL WHILE YOU DRIVE TIGHTENING T
50. OUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACI N EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEM S CADUCA LA PROTECCI N DEL SEGURO Oil of Switzerland SUSPension 2 GA LT amp KTM Group Partner
51. T F R STRASSENBETRIEB Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE Fuel unleaded fuel with at least RON 95 USA Premium RON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM Handler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE
52. T THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTAB LISHED 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 5 The free play at the foot brake pedal must then be adjusted by means of the piston rod 6 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 cylin der to be recognised from the resistance on the foot brake pedal 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 reservoir for the rear brake disk is located on the right side of the motor cycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked in a vertical position IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 7 Fill DOT5 1 brake fluid e g Motorex Brake Fluid 5 1 up to the mark B on the inside of the reservoir and remount t
53. TEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN NING DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN TO AVOID BURNS AND ENGIN Cleaning the spark arrestor EXC USA With these models the spark arrestor is part of the exhaust silencer Clean it every 4000 km 2500 miles to guarantee proper functioning Also clean the spark arrestor when replacing the glassfiber yarn filling After assembling the silencer remove the plug 1 and start the motorcycle Close the opening of the muffler with a rag and press the accelerator approx imately 20 times The carbon deposits will be blown out through the open ing 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 setting Always start with the original carburetor setting the provided factory setting is meant for break in operation after the break in period the carburetor needs to be adjusted according to the carburetor datasheet see appendix Essential requireme
54. 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 NN rn Starting when the engine is warm Open fuel tap Turn on ignition or emergency OFF switch Swing up the side stand Put the gear in neutral Open throttle to 1 2 and kick down kickstarter vigorously O1 BR oO Mm 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 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 WARNING BEFORE YOU START OFF CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG RIGHT UP TO THE TOP IF THE STAND DRAGS ON THE FLOOR YOU MAY LOSE CONTROL OF YOUR MOTORCYCLE BEFORE STARTING FOR AN OFF ROAD TOUR IT IS RECOMMENDED TO ADDI TIONALLY 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 g0 again and open the throttle If you turned on the choke make sure
55. U HAVE TO OPEN THE RADIATOR CAP 2 WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRES SURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS 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 IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDI ATELY AND GO SEE A DOCTOR A mixture of 50 antifreeze liquid and 50 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 E G MOTOREX ANTI FREEZE USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 2 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 tem peratures the radiator cover 3 must be mounted For this purpose detach the left rad
56. apped 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 8 5 I tank 1 3 0 32 US gallons Reserve of the 10 5 I tank 1 7 0 45 US gallons Choke knob When pulling the choke knob 2 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 between 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 maintenance work Side stand Push the side stand to the ground with your foot and load it with the motor cycle Make sure that you put your bike on solid ground and in a secure posi tion For off road riding you can use the rubber band 1 to additionally secure the center stand in its folded up position Steering lock The handlebar can be locked by
57. ased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERD
58. c digital speedometer Headlight High low beam switch Horn Horn switch Ignition coil Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Stop switch CABLE COLOURS bl black ye yellow bu blue gr green re red wh white br brown or orange pi pink gr grey pu purple AGKAIMIV DEUTSCH Kondensator CDI Fernlichtkontrolle Blinkerrelais Blinkerschalter vorderer Bremslichtschalter Blinkerkontrolle Generator Lenkerschalter f r Kombiinstrument Scheinwerfer Auf Abblendschalter Hupe Hornschalter Z ndspule linker vorderer Blinker linker hinterer Blinker Multifunktionsdigitaltacho Impulsgeber Standlicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Stop schalter KABELFARBEN bl blau ye gelb bu blau gr grun re rot wh wei br braun or orange pi rosa gr grau pu violett ITALIANO Condensatore CDI Spia abbagliante Rel indicator Deviatore indicatori di direzione Interruttore luce ant di stop spia lampeggiatori Generatore Interruttore sul manubrio per tachimetro multifunzione Faro anteriore Commutatore abbagliante anabbagliante Avvisatore acustico Interruttore avvisatore acustico Bob
59. carefully out of the reflector Pull connector 4 off the headlamp and remove rubber cap 5 Disengage retain ing clip and take the bulb out of the reflector When changing the parking light lamp simply pull it out of the holder Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps Indicated above 10 mm when engine ist cold AND ENGIN Cooling system The water pump in the engine circulates the cooling liquid However the cool ing 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 1 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 thermo Stat opens and the cooling liquid is also pumped through the two aluminum radiators The cooling liquid is cooled by the air stream This means that the cooling effect decreases with the traveling speed Dirty radiators additionally reduce the cooling effect WARNING eee IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YO
60. cated with either grease or other lubricants 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 ce AOO 066000000094 V dl H Q A KE ry r x gt D TAN for example Shock absorber 76 250 72 250 69 250 50 55 60 65 70 75 80 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE AND ENGIN 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 KTM s offroad motorcycles are set to accommodate a driver weighing 60 70 kg wear ing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accord ingly 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 sh
61. ck WARNING OOOO 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 AND ENGIN Replacing the front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 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 sheet 3 in the caliper support and of the leaf spring 41 WARNING eee T 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 THA
62. des In the display mode SPEED H press and hold the O button for 3 seconds to access the SETUP menu The active functions will be displayed The blink ing function can be activated by pressing the button and deactivated by pressing the button Press and hold the O button 3 seconds to store the settings 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 button briefly press O button hold O button 3 secs activates the blinking display deactivates the blinking display changes to the next display without changing any settings starts the SETUP stores the settings and changes to the SPEED H mode The following display modes can be activated TRI tripmaster 1 2 tripmaster 2 AI average speed 1 A2 average speed 2 Sl stop watch 1 S2 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH MPH display in kilometers or miles see Kilometers or miles If you have activated all of the display modes they will be displayed in the following order SPEED H SPEED CLK SPEED LAP LAP LAP SPEED MAX SPEED ODO SPEED TR1 SPEED TR2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK time display mode CLK displays the time in hours minutes and seconds button button briefly press O button hold O button 3 secs no function no function changes to the next display mode set the clock menu To set
63. deviations in your weight can be compensated by adjusting the spring preload However if your tele scopic 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 on the SX models are equipped with a preload adjuster You can easily adjust the spring preload by 10 mm by turning the adjusting screw 1 Turning in a clockwise direction will increase the prestress turning a coun terclockwise 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 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 space
64. disks M6 Loctite 243 10 Nm Clamping screws upper fork bridge EXC M8 20 Nm Clamping screws lower fork bridge EXC Clamping screws upper fork bridge SX Clamping screws lower fork bridge SX Clamping screws fork stubs MB 10 Nm Collar nut rear wheel spindle M20x1 5 80 Nm Hexagon nut swing arm bolt M16x1 5 100 Nm Hexagon collar screw handlebar clamp MB Loctite 243 20 Nm Allan head screw handlebar support M10 Loctite 243 40 Nm Shock absorber top M12 80 Nm Ball joint for push rod M6 Loctite 243 10 Nm Engine mounting bolt M10 60 Nm Engine brace MB Screw adjusting ring spring preload shock abs M6 Spoke nipple M4 5 M5 Other screws on chassis Other collar nuts on chassis TECHNICAL SPECIFICATIONS ENGINE 125 SX EXC 200 EXC 125 SX 125 EXC 200 EXC ENGINE Design Piston displacement Liquid cooled single cylinder two stroke engine with intake and exhaust control 124 8 ccm 124 8 ccm 193 ccm Bore stroke 54 54 5 mm 2 126 2 145 in 54 54 5 mm 2 126 2 145 in 64 60 mm 2 52 2 362 in Fuel Oil gasoline ratio unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil 1 40 1 60 when using high grade two stroke oil Motorex Cross Power 2T When in doubt please contact your importer Crankshaft bearing 1 deep groove ball bearing 1 cylinder roller bearing Connectin
65. display mode hold O button 3 secs changes to the next display mode SPEED MAX display mode maximum speed MAX displays the maximum speed traveled and is always active button no function button no function briefly press O button changes to the next display mode hold button 3 secs clears the MAX figure SPEED TR1 display mode tripmaster 1 The TRI tripmaster is always active and counts to 999 9 t is used to meas ure the length of a trip or the distance between 2 refueling stops TRI is linked to Al average speed 1 The calculation of these figures is acti vated 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 TRI A1 and S1 figures are automatically cleared after passing 999 9 button no function button no function briefly press O button changes to the next display mode hold button secs clears the TRI 51 Al figures SPEED TR2 display mode tripmaster 2 The tripmaster 2 is always active and counts to 999 9 Contrary to TRI the displayed figure can be changed using the and buttons This is a very use ful function for trips taken according to a roadbook button increases the TR2 figure button decreases the TR2 figure briefly press O button changes to the next display mode hold O button 3 secs clears the TR2 figure SPEED A1 display mode av
66. e 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 4 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 a Flasher left gt Flasher right Emergency OFF switch Australia The emergency OFF switch 5 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 15 enabled the engine should start Filler cap To open it turn filler cap counter clockwise To close it put filler cap back on and tighten it by turning it clockwise Install tank breather hose 1 without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carbure tor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES The reserve tank cannot be t
67. e valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACI N EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEM S CADUCA LA PROTECCI N DEL SEGURO P u P u ee PS gt y gt y Tan gt y VERGASERREGUL
68. erage speed 1 Al shows the average speed based on the TRI tripmaster 1 and SI stop watch 1 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 briefly press O button changes to the next display mode hold button secs clears the TRI 51 Al figures SPEED Km h SKmh Mhz AAN d DC 2 CT AC TRI TR2 M A2 9 52 00 MAX LAP CLK H SPEED A2 display mode average speed 2 A2 shows the average speed based on the TR2 tripmaster 2 and S2 stop watch 2 figures The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip button no function button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode SPEED S1 display mode stop watch 1 S1 shows the traveling time based on TRI and continues to run whenever it receives impulses from the wheel sensor The calculation of this figure is acti vated by the first impulse received from the wheel sensor and stops 3 sec onds after the last impulse is received button no function button no function briefly press O button changes to the next display mode hold button secs clears the TRI 51 Al figures SPEED
69. ery of the digital speedometer 36 Replacing the front brake pads 33 Replacing the headlight lamp parking light lamp 37 Replacing the rear brake pads 34 edo e Hw a RESCUE E eh CR Wet wd 16 Serial number locations 5 6468 22 ae INA 12 Shifting Riding 18 Short circuit button SX 11 STO SANTE a TNS TT 13 OTT sr SE 18 Starting when the engine is cold 18 Starting when the engine is warm 18 SAMLER adu MU nier neue 13 stopping and parking 19 wi wet tb eee ue Sr 45 Technical Specifications Chassis 125 SX EXC 200 EXC 46 Technical Specifications Chassis 250 SX EXC 300 MXC EXC 50 Technical Specifications Engine 125 SX EXC 200 EXC 48 Technical Specifications Engine 250 SX EXC 300 MXC EXC 52 Tires air pressure 36 What to do when the engine is flooded 18 What you should check before each start 17 JIIONJdY XIGN4iddV AIIGNAddV SNVHNV high low beam switch horn switch stop button flasher switch Le flasher relay H handle bar switch optional To or horn regulator rectifier capacitor rear brake switch NAMI JIE multi func digital speedometer flasher control lamp
70. esides 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 upgrades of these motorcycles This manual is an important part of your motor bike and should be 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 chas sis and engine must be performed by a KTM workshop If maintenance 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 intervals Heeding these guidelines will significantly increase the life of your motorcycle Have services carried out by a KTM dealer so that your warranty claim remains intact 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
71. g rod bearing needle bearing Piston pin bearing needle bearing Piston cast piston Piston ring one plain compression ring two plain compression rings two plain compression rings upper edge piston Dimension X upper edge cylinder 0 0 mm Ignition timing 1 4 mm 0 055 in 16 5 BTDC NGK BR9 EVX 1 4 mm 0 055 in 16 5 BTDC NGK BR9 EVX 1 6 mm 0 063 in 17 BTDC NGK BR 8 EG Spark plug Electrode gap 0 60 mm straight cut spur gears primary ratio 23 73 43 mm 1 67 in 43 mm 1 67 in 47 mm 1 85 in Primary drive Clutch Transmission multiple disc clutch in oil bath hydraulically operated Motorex Kupplungs Fluid 75 5 speed claw actuated 6 speed claw actuated 6 speed claw actuated Gear ratio lst gear 2nd gear 3rd gear Ath gear 5th gear 6th gear 133 12919 45 3517 17 28 3S28H AS19H 19 26 4526 50921 21 294552b 32 1532 30 42530 I2 gece 15 3517 17 28 3S28H 4S19H 19 26 48526 21525 5825 6G20 20 20 6G20 EE E ST 220941 12 15 17 19 143 225 33 4160937 Pole Gol 28 3S28H 26 4820 19 5G19H 20 6E20H AH 3517 4S19H 0G1 H OG22H Gear lubrication 0 7 liter Motorex Top Speed 4T 15W50 Available chain sprockets 13t 14t for chain 5 8 x 1 4 1 2 litres 50 anti freeze 50 water at least
72. g the air filter 39 Changing the original position of the clutch lever 40 Checking the oil level of the hydraulic clutch 40 Bleeding of the hydraulic clutch 40 E EE 40 Cleaning the spark arrestor EXC USA 41 Carburetor adjustment 41 Draining the float chamber of the carburetor 42 Checking the float level 42 Engine characteristic 250 300 SX MXC EXC 43 Check transmission oil level 125 200 44 Changing the transmission oil 125 200 44 Check transmission oil level 250 300 44 Changing the transmission oil 250 300 44 CLEANING Men teen a on dica 45 CONSERVATION FOR WINTER OPERATION 45 STORAGE scade edt TGS oct GE EST REN 45 USE AFTER A PERIOD OF STORAGE 45 TECHNICAL SPECIFICATIONS CHASSIS 125 200 46 TECHNICAL DATA ENGINE 125 200 48 TECHNICAL SPECIFICATIONS CHASSIS 250 300 50 TECHNICAL DATA ENGINE 250 300 52 INDEX RG May th pice XR Eu Dai Oden 54 WIRING DIAGRAM CARBURETOR TABLE APPENDIX 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 The engine number and the engine type are stamped into the left side of the engine below t
73. h the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reser voir in a horizontal position the brake fluid level should not drop below the middle of the glass WARNING eee IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reser voir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING 0208 NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the front brake pads The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thi
74. he engine sprocket Enter this number on page 1 Clutch lever The clutch lever 1 is located on the left side of the handlebars The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebars on the right and actu ates the front wheel brake The adjusting screw B can be used to change the basic position of the hand brake lever see maintenance work on chassis and engine L SPEED Km TR2 Al A2 51 82 DO Mo SPEED Ws Km h Mph Mies 000 MAX LAP CLK H LI SPEED Km h LILI 222 000 Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sen sor The display lights up when the engine is running The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor The O button is used to change between display modes The and buttons are used to control various functions TEST All of the display segments briefly light up for the display function test WS wheel size The display changes and the circumference of the front wheel is briefly dis played in millimeters 2205 mm corresponds to a front
75. he screw Spilled brake fluid must be rinsed off with water AO TT NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER AND ENGIN Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in AJ WARNING 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 1 in the direction of the chain wheel for the brake piston to reach its basic position Remove the safety device 2 knock out the guide pin 3 from the brake caliper with a drift towards the chain
76. iator protec tion 4 and mount the cover in front of the left radi ator as illustrated Remount the radiator protection NOTE The radiator shutter can be obtained from your KTM dealer Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system AN WARNING eee 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 AND ENGIN 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 liq uid Make sure that the drain screw 1 is fastened Pour approx 0 5 litres 0 13 US gallons coolant into the system Remove screw 2 at the cylinder head Reinstall it as soon as the cooling liq uid emerges free of air bubbles only for 125 200 engines Remove the screw 3 on the right radiator Now add cooling liquid until it emerges free of bubbles at the right radiator Then immediately mount the screw so that no more air can
77. ina d accensione Indicatore ant sx Indicatore post sx Tachimetro digitale multifunzione Pick up luce di posizione Interruttore luce post di stop Luce post di posizione stop Regolatore raddrizzatore Indicatore ant dx Indicatore post dx sensore velocit Interruttore d emergenza CAVO COLORATO bl nero ye giallo bu blu gr verde re rosso wh bianco br marrone or arancione pi rosa gr grigio pu violetto LA ANHANG APPENDICE LA LA ct gt lt LA ER A Ol P 4 EMI LET INVHNV J gt ne ne rni I C rn o ENGLISH Capacitor CDI Driving light lamp Flasher relay Flasher switch Front brake switch Flasher control lamp Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Horn switch Ignition coil Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Stop switch CABLE COLOURS bl black ye yellow bu blue gr green re red wh white br brown or orange pi pink gr grey pu purple gt y HEI CA FRANCAIS Condensateur CDI Temion feu route Relais de clignotants Bouton de clignotants Contacteur de frein avant Temion de clignoteur Genrateur Co
78. ing TVC fully open Primary drive straight cut spur gears primary ratio 26 72 Clutch multiple disc clutch in oil bath hydraulically operated Motorex Kupplungs Fluid 75 Transmission 5 speed claw actuated Gear ratio 250 300 EXC 300 MXC lst gear 14 30 14 28 2nd gear l 17 26 16 26 3rd gear 19 23 18 24 Ath gear 20 20 21 24 5th gear 29 23 22 21 Gear lubrication 7 liter Motorex Top Speed 4T 15W50 Coolant 1 2 litres 50 anti freeze 50 water at least 25 C 13 F KOKUSAN 2K 1 KOKUSAN 2K 3 KOKUSAN 2K 3 Ignition system no generator 12V 110W 12V 110W Generator output Ignition system USA KOKUSAN 2K 1 KOKUSAN 2K 2 KOKUSAN 2K 2 Generator output no generator 12V 40W 12V 40W Vergaser flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert A A JU WIA A pr ep p am TIGHTENING TORQUES ENGINE Flange bolts cylinder head Nuts cylinder base Flywheel collar nut 60 Nm Flange bolt pump part kickstarter Loctite 243 10 Nm Nut for primary sprocket LH thread M18x1 5 Loctite 243 150 Nm Nut for inner clutch hub M18x1 5 Loctite 243 100 Nm Crankcase and cover bolts M6 10 Nm Spark plug M 14X1 25 Swingarm pivot M16x1 5 Other screws BASIC CARBURETOR SETTING 250 EXC USA 250 300 EXC EU 300 MXC EXC USA 250 300 EXC AUS 250 EXC SIX DAYS 300 EXC SIX DAYS 250 6 6 KW
79. l joint for push rod M6 Loctite 243 10 Nm Engine mounting bolt M10 60 Nm Engine brace MB Screw adjusting ring spring preload shock abs M6 Spoke nipple M4 5 M5 Other screws on chassis Other collar nuts on chassis JNS ENGIN J SA EA JU MA A 250 EXC 300 MXC EXC ENGINE Design Liquid cooled single cylinder two stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber 249 ccm 249 ccm 293 15 ccm Piston displacement Bore stroke 66 4 72 mm 2 62 2 84 in 66 4 72 mm 2 62 2 84 72 72 mm 2 84 2 84 in unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Motorex Cross Power 2T 1 40 1 60 when using high grade two stroke oil When in doubt please contact your importer or use 1 40 mix ratio to be on the safe side Crankshaft bearing 1 deep groove ball bearing 1 cylinder roller bearing Piston pin bearing needle bearing Piston cast piston Piston ring two plain compression rings two plain compression rings two plain compression rings Dimension X rer edes Dinde O 0 1 mm 0 0 004 in Ignition timing 1 9 mm 0 074 in BTDC Spark plug NGK BR8 ECM NGK BR7 ES NGK BR 7 ES Electrode gap 0 60 mm Dimension Z height of the control flap 48 5 mm 1 9 in 0 2 mm 0 008 in TVC start open 5200 min 7000 min red spring 7500 min yellow spring 7900 min green spr
80. lity on fast race courses If the mark B is in the rear as illustrated the offset is 20 mm This setting will deliver better handling in curves The offset is set to 20 mm in the condition at delivery To adjust the offset dismount the front wheel and remove the front wheel fender Remove the screw on the starting number plate Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the blind screw 1 from the upper triple clamp loosen the clamp screw and upper triple clamp on the seat Remove the O ring 3 and the pro tection ring 4 Tap gently on the lower triple clamp with a rubber hammer to loosen the steer ing stem 5 out of the bearing seat Take the lower triple clamp with the steer ing stem out of the steering head Remove the collar screw from the lower triple clamp and pull out the steer ing stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp tighten the collar screw all the way to the stop WARNING PLASTIC INSERT IN THE COLLAR SCREW THREAD MAKES THE COLLAR SCREW SELF LOCKING REPLACE IF THE COLLAR SCREW CAN BE SCREWED IN BY HAND DO NOT CONFUSE THE COLLAR SCREW WITH THE BLIND SCREW THE COL
81. loat 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 1 and clean it with compressed air Then mount the plug together with the gasket open the fuel tap and check the float chamber for leaks WARNING OO FUEL IS EASILY FLAMMABLE AND TOXIC WHEN HANDLING FUEL BE SURE TO EXERCISE THE UTMOST CAUTION NEVER PERFORM ANY WORK ON THE FUEL SYS TEM 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 SATURATED 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 AND ENGIN Engine characteristic 250 300 SX MXC EXC The engine characteristic can be modified through various thicknesses of the auxiliary spring 1 An auxiliary spring designed for good driveability smooth power application is mounted in the condition at delivery One of the auxiliary springs can be mounted if you prefer an even smoother power applica
82. motorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM may stop manufactur ing certain models without previous notice KTM shall not be held liable for any deviations of availabil ity and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2004 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics even if this means that you 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 B
83. n the motorcycle is in an upright position If necessary remove the plug 2 and top up with oil g Motorex Top Speed 4T 15W50 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 E G MOTOREX TOP SPEED 4T 15W50 Changing the transmission oil 125 200 To change the gear oil warm up the engine and park the motorcycle on a hor izontal surface Remove oil drain plugs 3 and 4 and drain the used oil into an appropriate container Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets Fill in O 7 oil e g Motorex Top Speed 4T 15W50 mount the plug 2 and check the engine for leaks 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 E G MOTOREX TOP SPEED 4T 15W50 Check transmission oil level 250 300 In order to check the transmission oil level the control screw 5 on the clutch cover is to be removed Oil should just barely escape from the inspection open ing when the motorcycle Is in an upright position If necessary remove the plug 6 and top up with oil g Motorex Top Speed 4T 15W50 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 E G MOTOREX TOP SPEED 4T 15W50 Changing the
84. ng sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension 600 mm Motorcycle on ground loaded dimension 510 mm 10111 2 242 Pe 90 mm 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 72 250 The type number of the shock absorber is embossed on the front of the shock absorber The illustrations show which spring should be installed The standard spring is shown in bold print After installing a different spring readjust the static sag to 35 mm 2 mm According to our experience the damping rate of the compression stage can MODELL SOFTER STANDARD HARDER remain unchanged The damping rate of the rebound stage can be reduced ae by a few clicks for a softer spring or increased by a few clicks for a harder 125 SX 69 250 72 250 76 250 spring 12187A02 125 200 EXC 69 250 72 250 76 250 12187A03 250 MX 12187A04 250 300 MXC EXC VAIN NAN UN AND ENGIN 72 250 76 250 72 250 76 250 Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for vari ous reasons Similar to the shock absorber smaller
85. ntacteur au guidon pour ordinateur de bord Phare Contacteur code phare Avertisseur sonore Bouton d avertisseur sonore Bobine d allumage Clignotant avant gauche Clignotant arri re gauche Ordinateur de bord Capteur d allumage Feu de position Contacteur de frein arri re Feu rouge stop R gulateur redresseur Clignotant avant droit Clignotant arri re droit Capteur de vitesse Contacteur stop COULEUR DE CABLE bl noir ye jaune bu bleu vert re rouge wh blanc br brun Or orange pi rose gr gris pu violet ESPANOL Condensador CDI Lampara aviso luces largas Rel de la luz intermitente Interruptor de la luz intermitente Interruptor de luz del freno delantero Lampara aviso intermitentes Generador Interruptor de manillar para instrumento combinado Faro Interruptor de encender apagar la luz larga Claxon Interruptor del claxon Bobina de encendido Luz intermitente izquierda delantera Luz intermitente izquierda trasera Velocimetro digital multifuncional Generador de impulsos Luz de posicion Interruptor de luz del freno trasero Luces de parqueo traseras de freno Regulador rectificador Luz intermitente derecha delantera Luz intermitente derecha trasera Sensor de velocidad Interruptor parada COLOR DE CABLE bl negro ye amarillo bu azul gr verde re rojo wh blanco br marron or naranja pi rosado gr gris pu violeta P u P u ee gt y g
86. nts are a clean air fil ter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance RULE OF THUMB high altitude or high temperatures gt choose leaner carburetor adjustment low altitude or low temperatures gt choose richer carburetor adjustment ZS ONLY USE PREMIUM GRADE GASOLINE ROZ 95 USA PREMIUM RON 91 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 MOTOREX CROSS POWER 21 NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON IF YOU USE TOO MUCH OIL THE ENGINE CAN START SMOK ING 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 retor malfunction e g overly rich mixture Therefore these parts should be replaced
87. o not always wear off evenly therefore repeat the measurement at different places on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets CAUTION WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14T THE COLLAR MUST BE ON THE INSIDE 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 AND ENGIN 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 caliper support with Loctite 243 and tighten to 25 Nm 19 ft Ib BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front and TOSHIBA H 38 sintered lining at the back These linings provide an opti mal 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 homologation 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
88. ock 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 ground 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 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 600 mm Motorcycle on ground unloaded dimension 565 mm SE EE 35 mm If the static sag is lower the spring preload 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 ridi
89. old the rear wheel and pull out the wheel spindle 3 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 PRE VENT THE THREAD FROM JAMMING The rear wheel is remounted in the reverse order Before tightening the col lar nut to 80 Nm 60 ft Ib push the rear wheel forwards so that the chain tensioners lie on the tension screws WARNING eee IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS 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
90. on next display mode clears TRI S1 Al SPEED TR2 increases the TR2 figure reduces the TR2 figure next display mode clears TR2 SPEED A2 no function no function next display mode next display mode SPEED 51 no function no function next display mode clears TR1 S1 A1 X SPEED S2 starts stops S2 no function next display mode clears S2 X X SPEED A1 no function no function next display mode clears TRI S1 Al X X If the CLK LAP MAX TRI TR2 Al A2 51 and S2 figures are suddenly cleared the battery in the electronic speedometer is empty and must be replaced see Replacing the battery in the electronic speedometer A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar Indicator lamps EXC flashing indicator when the indicator is working L on ST ED The blue control lamp 2 lights up when the high beam is on D The green control lamp 1 flashes in the same rhythm as the CCR Short circuit button SX The short circuit button 1 turns off the engine When pressing this button the ignition circuit is short circuited Combination switch EXC The light switch has 2 respectively 3 switch positions A Light off this function is not available in all models B Low beam on C High beam on You may use button 2 to actuate the horn The red short circuit button 3 serves to switch off th
91. oot 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 fit ted and registered for such purposes During the ride the pas senger 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 man ufacturers 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 distribute 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 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
92. 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 failures in the electric system you should treat the ignition lock the emergency OFF switch the short circuit button the light switch and the socket connectors with contact spray KVALIUN FUR WIN X UPERALIUN 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 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 THOROU
93. pe of fork Typ White Power 14187A01 20 clicks Typ White Power 14187A02 21 clicks Typ White Power 14187A03 20 clicks Typ White Power 14187A04 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 com pression 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 coun terclockwise will decrease the damping STANDARD LOW SPEED SETTING Turn the adjusting screw 4 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 Typ White Power 12187A01 15 clicks Typ White Power 12187A03 15 clicks STANDARD HIGH SPEED SETTING Turn the adjusting screw 5 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 Typ White Power 12187A01 1 5 turns Typ White Power 12187A03
94. place it as soon as possible with DOT 5 1 Never use brake fluid DOT 5 The color of this silicon oil based product 15 purple red The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid WARNING Oe HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE QUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCK ETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUS ING THE BRAKE SYSTEM TO FAIL AND ENGIN Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 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 size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary 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 PROVIDED 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 wit
95. plugs adjust distance between electrodes Renew spark plugs Check the carburetor connection boot for cracks and leaks Check idle speed setting Carburetor Check that vent hoses are not damaged or bent 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 Add on parts 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 Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks Brakes 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 Chassis 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 Check spoke tension and rim joint Check tires and air pressure Check chain rear sprockets and chain guides for wear fitment and tension Wheels Lub
96. revved up to its perform ance 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 Be Pu P m WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE SMART KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A 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 DRIV ERS 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 CHARACTER ISTICS 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 RUN NING TIME THE SPOKE TENSION 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 RECOG NIZE ANY HAZARDS AS EARLY
97. ricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE WORK 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 5 HOURS OR 500 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 for cross each country 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 Clean air filter and filter box heck tires for pressure and wear Check cooling liquid level Check fuel 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
98. ring head bearing 28 Checking spoke tension 36 Checking the basic setup of the telescopic fork 25 Checking the brake fluid level front brake 32 Checking the coolant level 38 Checking the float level 42 Checking the front brake pads 32 Checking the oil level of the hydraulic clutch 40 Checking the rear brake fluid level 33 Checking the rear brake pads 34 Checking the shock absorber and spring 24 CROKE Knob d nod e dio e IOS eo au 12 SI LEE 45 Cleaning the air filter 39 Cleaning the dust sleeves of the telescopic fork 26 Cleaning the spark arrestor EXC USA 41 Cutet DANA te aed acd ete 5 Combination switch EXC 11 Compression damping of fork 14 Compression damping of shock absorber MXC EXC 15 Conservation for winter operation 45 Cooling ue e ce e a 38 Correct chain 5 30 Damping action during compression of shock absorber SX 14 Determining the riding sag of the shock absorber 24 Determining the static sag of the shock absorber 24 Dismounting and mounting the rear whell 35 Dismounting and mounting the front wheel 34 Draining the float chamber of the carburetor 4
99. rs in vari ous heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and pretension spacers should always stay together AND ENGIN Replacing fork springs for example 125 SX If you weigh less than 60 kg or more than 70 kg you should install the respec Front fork tive fork springs The correct spring rate is shown in the illustrations The stan dard spring is shown in bold print The type number of the telescopic fork is embossed on the inside of the fork leg axle passage 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 for a harder spring SPRING RATE 50 55 60 65 70 75 80 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM MODELL SOFTER STANDARD HARDER 14187A01 125 SX 14187A02 125 200 EXC 14187A03 250 SX 14187A04 3 8 4 0 250 300 MXC EXC N mm N mm Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 1 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 job performed in the course of
100. s 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 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 BRAKES Check correct functioning of the braking system Verify that there is suf ficient 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 author ized 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 AN WARNING eee IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER 6 CABLES Check correct adjustment and easy running of all control cables COOL
101. t y Tan gt y a LA VERGASERREGULIERUNG CARBURETOR SETTING 1 25 SX 2005 KEIHIN PWK 39 su a lt MEERESHOHE TEMPERATUR 20 C bis 7 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 38 C 37 C bis 49 C ALTIDUDE TEMPERATURE SA 2F to 20 19 F to 41 F 42 F to 60 F 61 F to 78 F 79 F to 98 F 99 F to 120 F gt o A 3000 m ASO 1 5 1 75 2 2 25 2 5 lt 10000 ft IJ 45 42 40 38 38 7 NEEDLE R1469D R1470D R1470D R1470D R1471D 2301 POS 2 3 2 1 7501 ft MJ 185 182 180 175 2300 m ASO 1 25 1 5 1 75 2 25 2 5 7500 ft LI 48 45 42 38 38 NEEDLE R1469D R1469D R1470D R1470D R1470D R1471D 1501 m POS 2 3 2 1 5001 ft MJ 185 182 180 175 1500 m ASO 1 25 1 5 1 79 2 25 5000 ft J 48 45 42 38 NEEDLE R1468D R1469D R1469D R1470D R1470D R1470D 751m POS 3 2 2 2 2501 ft MJ 190 185 182 180 750 m ASO 0 75 1 25 1 5 1 75 2500 ft J 52 48 45 42 NEEDLE R1468D R1468D R1469D R1469D R1470D R1470D 301m POS 4 3 2 2 5 1001 ft MJ 192 190 188 182 180 300m ASO 0 5 0 75 1 25 1 5 1 75 1000 ft J 55 52 48 45 42 NEEDLE R1468D R1468D R1469D R1469D R1469D R1470D Meeresniveau POS 5 4 3 3 2 2 Sea level MJ 195 185 182 LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 2 IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top b HD Hauptd se MJ Main jet NICH
102. t 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 WARNING eee 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 OVERLOAD ING 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 1 insert the battery type Duracell CR 2430 with the writing facing up and reinstall the screw connection AND ENGIN Check set distance of the magnetic sensor The distance between the magnet 2 and the sensor 1 must be 2 4 mm otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing the sensor 1 in or off 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 3
103. tch lever starts to feel unresponsive the clutch control system needs to be bled You will need a bleeder syringe special tool and biodegradable hydraulic oil Both are available from your KTM dealer Turn the handlebar until the master cylinder is in a horizontal position remove the screws 2 the cover 3 and the rubber boot 4 Fill the bleeder syringe 5 with biodegradable hydraulic oil Motorex Kupplungs fluid 75 Remove the bleeder screw 6 from the slave cylinder and mount the bleeder syringe Press oil into the system until the oil runs out of the hole 7 in the master cylinder without bubbles Occasionally extract the oil from the master cylinder reservoir to keep it from overflowing After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the oil level in the reservoir and mount the cover see above Exhaust system Silencers whose cap 8 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 silencer s silencing effect To replace the glass fiber yarn packing 9 remove the silencer cap and pull off the outer tube 10 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 AN WARNING Oe THE EXHAUST SYS
104. ter and filter support in the throttle cap and mount them in the filter box aligning in a central posi tion and fix with the filter retaining bracket AND ENGIN Changing the original position of the clutch lever The adjusting screw 1 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 counterclockwise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER TAIN 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 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex Kupplungs fluid 75 available from your authorized KTM workshop CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON TROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Bleeding the hydraulic clutch If the clu
105. 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 pr mu pr 9 P 1 pp gt pr CD P ANI WARRAN ANL 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 interna tional 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 specifica tions 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
106. the periodical maintenance 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 2 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 Universal oil spray Motorex Joker 440 or engine oil Then push the dust protection bellows into the outer tubes by hand WARNING NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE AND ENGIN Changing the fork offset caster SX The fork offset AI in the SX models center fork legs center steering head angle can be set to either 18 or 20 mm This allows you to optimize the han dling to match the race course Remove the blind screw 1 to see which offset is set If the mark B is in front the offset is 18 mm This setting will deliver more directional stabi
107. tion or an aggressive engine characteristic Auxiliary spring for good driveability mounted in condition at delivery Spare part number 546 37 072 300 YELLOW color mark Auxiliary spring for an even smoother power application included in scope of supply Spare part number 548 37 072 100 GREEN color mark Auxiliary spring for aggressive engine characteristic included in scope of sup ply Spare part number 548 37 072 000 RED color mark To mount tilt the motorcycle approx 45 to the left remove both screws 2 lift off the closing cover 3 and remove the springs including the spring insert 4 from the clutch cover Pull both springs off the spring insert mount the red or the green auxiliary spring and the control spring 5 and slide both into the clutch cover until the recess in the spring insert 4 engages in the rocker arm Check the O ring in the closing cover mount the closing cover ensuring that the dolly screw 6 engages in the auxiliary spring Make sure you do not turn the dolly screw since this will impair the engine characteristic If you prefer a smoother engine power application you can mount a different ignition rotor and a different exhaust Ask your KTM dealer for more information AND ENGIN Check transmission oil level 125 200 In order to check the transmission oil level the control screw 1 on the clutch cover is to be removed Oil should just barely escape from the inspection open ing whe

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