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1. 3 Me 12 SIT B RIGITIB cs te 19 13 Shock absorber compression damping 15 Spring preload of the fork 14 Starter DUTTON 2 GS RON SG RON Scheme Es 11 SANE O E ee o Ev e e 18 Starting when the engine is cold 18 Starting when the engine is warm 18 MOCK vc 13 stopping and parking 19 S qula d Wehen ng d ern e AE eat dere oe ee 48 Technical Specifications Chassis 125 200 50 Technical Specifications Chassis 250 300 54 Technical Specifications Engine 125 200 52 Technical Specifications Engine 250 56 Technical Specifications Engine 300 58 Tires air pressure 37 What to do when the engine is flooded 18 What you should check before each start 17 Wiring diagramme 60 3211226en I N e A SZ N Se 1002 9 0103 702 75 MOTOREX IV Oil of Switzerland NI KTM Group Partner KTM Sportmotorcycle AG A 5230 Mattighofen www ktm com
2. 5 Electronic speedometer 6 Indicator lamps EXC 10 Short cire uit 9VILL0 s a a duo oet Pc C 10 Combination switch EXC 11 Headlamp switch XC W 11 I 2511CL 5M 6 0 zt uar EE dt 11 SLAM T HUOM 20m eto caet e deren 11 Emergency OFF switch Australia 11 SI C aD seine ee Gane Saas SENA ace 12 C 2 _ _ 12 Choke ses ELO E cam ERR Bc a e Eos 12 SIDE ICVCI Sn sado se se bs Ee dr putes ea 13 C Ier 13 Foot brake pedal 13 Silde 519009 PPP PON 13 Steering lock 13 Compression damping of fork 14 Rebound damping of fork 14 Spring preload of the fork 14 Shock absorber compression damping 15 Shock absorber rebound damping 15 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Ae deis dul Sud e Ton 16 Instructions for your first ride 16 o ate Ae e fer dic 16 DRIVING INSTRUCTIONS 17 What you should check before each start 17 Starting when the engine 15 cold 18 Starting when the engine is warm
3. 11 Foot brake pedal 13 6 a xac OR CREER ARP ENARRARE HU UR 12 Rx TUE e ote dr ed Ec 40 General information about KTM disc brakes 32 General tips and warnings for starting the motorcycle 16 Hand brake lever 5 Headlamp switch XC W 11 How to change the handlebar position 30 Indicator lamps EXC 10 Instructions for your first ride 16 nie sit ei RECON pes 13 Maintenance work on chassis and engine 24 Operation instruments 5 Periodic maintenance schedule 20 ICI 02689 ad Ne otk eee eate 24 Rebound damping of fork 14 Rebound damping of shock absorber 15 Refilling the front brake fluid reservoir 33 Refilling the rear brake fluid reservoir 34 Refilling Bleeding the cooling system 4 Refueling duel dense gc 19 Replacing fork springs 27 Replacing the battery of the digital speedometer 38 Replacing the front brake pads 34 Replacing the headlight lamp parking light lamp 38 Replacing the rear brake pads 35 33 32 lt _ _ 16 serial number locations 5 clock sux rd Rd REC 10 arate
4. 18 What to do when the engine is flooded 18 Starine OTI acutius sata ton Sot ics e Wa omen 18 801100806 noe RC oi ORC e cna 18 M ew Seales 19 stopping and parking 19 Refueling THO dd oS ca disct o Y d cometer 19 PERIODIC MAINTENANCE SCHEDULE 20 MAINTENANCE WORK ON CHASSIS AND ENGINE 24 Changing the spring preloading of the shock absorber 24 PIVOUDECONING ES ESS NT AN aside OP A Eon cio d ere a 24 Basic suspension setup for the weight of the driver 25 Checking the shock absorber and spring 2b Determining the static sag of the shock absorber 25 Determining the riding sag of the shock absorber 25 Changing the spring preload on the telescopic fork 26 Checking the basic setup of the telescopic fork 26 Breather plug front fork 26 Cleaning the dust sleeves of the telescopic fork 2 Checking and adjusting the steering head bearing AT Changing the fork offset caster XC EXC Six Days 28 How to change the handlebar position 29 Adapting chain guide to the rear sprocket 30 Check chain tension Correct chain tension Chain maintenance Chain wear General information about KTM disc brakes Changing basic position of the hand brake lever Checking the brake fluid level front brake Refilling th
5. E starter system horn flasher lights electronic speedometer The starter relay also contains a 10 amp spare fuse 3 Replace a blown fuse only with an equivalent one If a new fuse that has just been installed gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 10 Ampere CAUTION Under no circumstances is a stronger fuse allowed to be installed or a fuse allowed to be repaired An improper treatment could damage the whole elec trical installation Cooling system The water pump 1 in the engine circulates the cooling liquid 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 Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 2 a water temperature rising up to 120 C 248 F is admissible without fear of problems Some models are equipped with a thermostat so that the engine reaches its operating temperature more quickly When the engine is cold the liquid coolant circulates in the cylinder and the cylinder head As soon as the cooling liquid has reached a temperature of approximately 55 C the thermo Stat opens and the cooling liquid is also pumped through the two aluminum radiators Si WARNING If possible always check level of cooling liquid when engine is cold I
6. 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 1O 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 Disassemble and charge battery see chapter BATTERY 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 AFTER
7. Xx CV X U DI lt uojing doys LES uJou ignition coil NJO C N e eJ Jeusey Uo1Ms Guuiw pi Iu L 21 aw 9 a Joyoedeo pg L ZAY YoUMS Jeol ELE C BG1 3 C AJ1 3 EIE C CA A 00 CEO 6 8V9 SSOUIEU 09C 9 0 LL 87S SSeuleu UM LTE O LC IC Ix IN 6 dn yoid Lo E Ve SA 2 10129195 8AIN9 UOHIUBI e Q S C x T BG 3 2 li NI Z light 04 eS Brake light licence plate lamp GES 3 Fae BR JoynooJ JojejnBoJ Jeuse Ya Jeusej 1891 V29IIM MOI UBIU 7IL 1IVIIVI d D headlight multi func digital speedometer 5119 3 light switch stop switch handle bar switch optional regulator rectifier JH lt rear light brakelight generator ignition coil 200 250 300 XC USA 2008 200 XC W USA ZA 2008 wiring diagramm main harness 548 11 075 100 250 XC W ZA 2008 CDI harness 548 39 032 300 1 AIVI IVI 7 I headlight multi func digital speedometer OO speed sensor KE stop switch start button start relay battery handle bar switch light switch MN optional starter motor ji JE LE d LI pe L Tem L p
8. 33 Checking the oil level of the hydraulic clutch 42 Checking the rear brake fluid level 34 Checking the rear brake pads 35 Checking the shock absorber and spring 25 CHOKE 21605 eats OR Se a 12 Ceann e qeu 48 Cleaning the 41 Cleaning the dust sleeves of the telescopic fork 27 Clutch ever ood uaa e Gee f Tte dc 5 Combination switch EXC 11 Compression damping of fork 14 Compression damping of shock absorber 15 Conservation for winter operation 48 Coone SYSTEM De ou 40 Correct chain tension 31 Damping action during compression of shock wee weet M UR eee 15 Determining the riding sag of the shock absorber 25 Determining the static sag of the shock absorber 25 Dismounting and mounting the front wheel 36 Dismounting and mounting the rear wheel 34 Draining the float chamber of the carburetor 45 Driving instructions 17 Electronic speedometer 6 Emergency OFF switch Australia 11 Engine number engine type 5 EXHAUST SYSTEMI Ka NG eec o is 42 Page Willis dec M ETE 12 Flasher 5VVII CC e ac oii dote
9. Air pressure road driver only 1 5 bar 21 psi Rear tires 125 200 EXC EXC Six Days 120 90 18 65M Metzeler MCE 6 Days Extreme 200 XC XC W 100 100 18 59M Bridgestone M402 Air pressure offroad 1 0 bar 14 psi Fuel tank capacity 125 EXC EXC Six Days 200 EXC EU 9 5 liters 2 5 US gallons 2 liters 0 52 US gallone reserve 200 XC XC W EXC AUS 11 liters 2 9 US gallons 2 liters 0 52 US gallone reserve Final drive ratio 125 EXC EU 14 42 125 EXC Six Days 13 50 200 XC XC W 14 48 200 EXC 14 42 Chain 5 8 x 1 4 Available final sprockets 38t 401 42t 45t 48t 491 50t 511 521 Bulbs headlight 12V 35 35W Bilux base Ba20d parking light 12V 5W base W2 1x9 5d brake rear light LED flasher light 12V 10W base Bal5s Steering head angle Wheel base 1471 x 10 mm 57 9 in 0 4 in Seat height unloaded 925 mm 36 5 in Ground clearance unloaded 390 mm 15 3 in Weight without fuel 125 200 EXC EXC Six Days 97 kg 214 165 200 XC 94 4 kg 208 4 165 200 XC W 94 8 kg 209 3 Ibs further tire releases are available on the Internet at www ktm com JU XC X W EX JUC STANDARD ADJUSTMENT FORK 125 200 XC W EXC 125 EXC Six Days 200 XC Compression adjuster Rebound adjuster WP 4860 MXMA PA 14187002 22 clicks 22 clicks WP 4860 MXMA PA 14187D33 20 clicks 22 clicks WP 4860 MXMA CC 14187D27 20 clicks 21 clicks Spring 432 505 00 040W 432 505 00 042W 432 45
10. CAUTION Be careful not to turn the spring dolly 6 otherwise the engine characteris tic will deteriorate You can also change the engine characteristic through the interaction bet ween the ignition curve auxiliary spring 250 300 only and exhaust The fol lowing table shows examples of possible combinations Further combinations can be adjusted at random depending on the driving requirements 250 300 XC XC W EXC EXC Six Days EXC E EXC E Six Days Engine performance Standard Driveability Standard Ignition curve soft soft performance performance performance Auxiliary spring 250 300 green yellow gelb yellow red Exhaust EXC standard EXC standard EXC standard 250 SX 290 SXS Example of application extremely difficult difficult track average track good track conditions special track track conditions conditions conditions nonskid roadway well conditions very selective very selective not much prepared MX special deep sand very fast hard hardly any traction tiring stage track routing very well traction very tiring prepared track 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 when the motorcycle is in an upright position If necessary remove the plug 2 and top up with oil e
11. Loctite 243 10 Nm Shift lock M 6 Loctite 243 10 Nm Locking lever 5 Idler bolt M 6 M Loctite 243 6 Nm Loctite 2701 8 Nm Kickstarter release plate M 6 Loctite 243 10 Nm Spring hanger for kickstarter M 6 Loctite 243 10 Nm Loctite 243 10 Nm Spring hanger on kickstarter M 6 M 5 Other bolts M 6 M 8 20 Nm NIGA ATIONS ENGIN JU AG AG W EXG NW A UP JUC 300 XC W ENGINE 300 XC 300 EXC E 300 EXC E SIX DAYS Design Liquid cooled single cylinder two stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 293 ccm Bore stroke 72172 mm 2 84 2 84 in Fuel unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Motorex Cross Power 2T Oil gasoline ratio 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 Connecting rod bearing needle bearing Piston cast aluminium Dimensions X eae onde O 0 1 mm 0 0 004 in Spark plug NGK BR7 ES Electrode gap 0 60 mm Dimension 2 MEL me 47 5 mm 1 87 in TVC start open 5500 min TVC fully open 300 min red spring 7800 min yellow spring 8300 min green spring straight cut spur gears primary ratio 26 72 Clutch multiple disc cl
12. M 10 M 12x1 27 Nm 35 Nm 60 Nm Loctite 243 6 Nm Shift roller bearing retaining bracket Loctite 243 10 Nm Shift lock Loctite 243 10 Nm Locking lever Loctite 243 6 Nm Idler bolt Kickstarter release plate Loctite 243 10 Nm Spring hanger for kickstarter Spring hanger on kickstarter Oil drain plug with magnet Water pump wheel Drain plug on water pump cover Nut for primary sprocket LH thread Nut for inner clutch hub Crankcase Spark plug Kickstarter lever Shift lever Cover screws Ignition stator Ignition pick up Other bolts M 6 M 6 M 12x1 5 M 5 M 10X1 M 18x1 5 M 18x1 5 M 6 M 14x1 25 M 8 M 6 M 6 M 5 Loctite 2 01 8 Nm Loctite 243 10 Nm Loctite 243 10 Nm 20 Nm Loctite 243 6 Nm 15 Nm Loctite 2 01 150 Nm Loctite 2 01 100 Nm 10 Nm 25 Nm Loctite 243 25 Nm Loctite 243 14 Nm 6 Nm Loctite 243 8 Nm Loctite 243 6 Nm MALT FLAN WIRING DIAGKAIMIV multi func digital speedometer 0 driving light lamp 3 flasher control lamp q q front brake switch nd C CW 2 C CY 3 C DA A N Co C C25 Jeu C CW ce _AH1 2 1 Yal EH aJ Jeysey 1uoJj 1V6II ET nr MN 9 L Josues peeds E e 9e Iq e ara L jeuondo e NO C N x C gt
13. 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 O 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 ea 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 ODO no function no function next display mode next display mode X X SPEED TRI no function no function next display mode clears TRI S1 Al SPEED TR2 increases the TR2 figure
14. pibe ehe pud aree een CARBURETOR TABLE 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 the 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 TR2 M A2 91 52 1 020 010 SPEED WS Km h Mph Mies 000 MAX LAP CLK H A LI SPEED Km h rice LILI D ZI CI 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
15. reduces the TR2 figure next display mode clears TR2 SPEED A1 no function no function next display mode clears TR1 S1 A1 SPEED A2 no function no function next display mode next display mode SPEED S1 no function no function next display mode clears TR1 S1 A1 X SPEED S2 starts stops S2 no function next display mode clears S2 If the CLK LAP TRI TR2 A1 A2 SI 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 X X X X X X X X X X X gt lt tripmaster switch is available as accessory that lets you control the electronic speedometer functions from the handlebar Indicator lamps The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working ED The blue control lamp 2 lights up when the high beam is on Short circuit button XC XC W The short circuit button 3 turns off the engine When pressing this button the ignition circuit is short circuited Combination switch EXC EXC Six Days 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 the engine Leave the Switch pressed until the engin
16. tem looked over by a KTM dealer 6 CABLES Check correct adjustment and easy running of all control cables 7 COOLING FLUID Check the level of cooling fluid when the engine is cold 8 ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights turn indicators indicator lamps and horn while the engine is running 9 LUGGAGE If you are taking luggage with you check that it is securely fastened Starting when the engine is cold Open fuel tap Turn on 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 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 kickstart with too little momentum and an opened throttle increases the kicking back risk Check for power transmission at temperatures below 0 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 consciousness and death Always pro vide adequ
17. AND ENGIN Adjusting the engine characteristic via the auxiliary spring 250 300 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 smoother power application 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 auxiliary spring 1 and 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
18. Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in 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 5 in the direction of the chain wheel for the brake piston to reach its basic position Remove the safety device 6 knock out the guide pin 7 from the brake caliper with a drift towards the chain 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 7 in as far as it will go Mount the safety device 6 WARNING 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 one must always actuate the hand brake
19. Electrode gap 0 60 mm 0 023 in height of the control flap Dimension Z 43 5 mm 1 68 in 48 mm 1 9 in Primary drive straight cut spur gears primary ratio 23 73 Clutch multiple disc clutch in oil bath hydraulically operated Motorex hydraulic fluid 75 Transmission Gear ratio lst gear 2nd gear 3rd gear Ath gear 5th gear 6th gear 6 speed claw actuated 12 15 33 1633 31 2631 17 28 3S28H 19 26 4526 5521 21 25 55265 5617L 6620 20 20 6620 6G22H 13 45 99 31838 32681 17 28 3828H 19 26 4526 17 19339019H 22 20 6E20H LOZ loos 2930 28 352884 26 4S26H 294 5525 128 36528 joo L5 3517 4S19H eol 3517 AS19H 3517 4S19H 2521 6622 Gear lubrication 0 7 liter Motorex Top Speed 4T 15W50 Available chain sprockets 13t 141 for chain 5 8 x 1 4 Coolant 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system Generator output KOKUSAN 2K 3 12V 110W Carburetor Keihin PWK 365 flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert TECHNICAL SPECIFICATIONS ENGINE 125 EXC EXC SIX DAYS 200 XC XC W EXC 2008 BASIC CARBURETOR SETTING 125 EXC EU 4 4 KW Keihin PWK 36S AG FKO19 140 168 170 172 Carburetor
20. 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 DUE Changing the transmission oil 125 200 11 aset To change the gear oil warm up the engine and park the motorcycle on a hor EL udi 3 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 0 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 e 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 250 300 To change the transmission oil run the
21. 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 60 Fuel and engine oil should only be mixed immediately before use KTM recommends Motorex Cross Power 2T ART TAn Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refueling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately The tank cap s locking mechanism always has to snap into place when it is mounted CAUTION Only use premium grade gasoline ROZ 98 respectively 95 mixed with high grade two stroke engine oil Other types of gaso line 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 c
22. A PERIOD OF STORAGE Mount the charged battery regard polarity Set the time in the speedometer Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you 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 HSITINS me N A UP JU AU W EX JUG CHASSIS 125 200 XC XC W EXC EXC SIX DAYS Central chrome moly steel frame 125 200 XC W EXC EXC Six Days WP Suspension 4860 MXMA PA Open Cartridge WP Suspension 4860 MXMA CC Closed Cartridge Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension WP Suspension 5018 PDS DCC Front brake Disc brake with wave carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with wave 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 125 200 EXC EXC Six Days 90 90 21 54M Metzeler MCE 6 Days Extreme 200 XC XC W 80 100 21 51M Bridgestone M59 Air pressure offroad 1 0 bar 14 psi
23. Carburetor setting mark Main jet 125 EXC SIX DAYS Keihin PWK 36S AG FKOO70 38x38 45 48 50 85 R841 NOZE NOZF Idling jet Starting jet Jet needle 170 168 172 45 NOZE NOZF Needle position from top 5 4 Throttle valve Air adjustment srew open 2 5 1 Performance restrictor BASIC CARBURETOR SETTING 200 XC USA 200 XC W USA 200 EXC ZA 4 200 EXC AUS 200 EXC EU 6KW Carburetor Keihin PWK 365 AG Keihin PWK 365 AG Keihin PWK 36S AG Carburetor setting mark FK 020 FKO120 FKO21 Main jet 162 160 165 162 160 165 100 160 162 165 Idling jet 42 Starting jet 85 35 42 85 35X35 42 50 80 Jet needle NOZH NOZG R1475J NOZG NOZH N841 NOZG NOZH Needle position from top Throttle valve 3 7 4 7 Air adjustment open turn 1 5 turn 1 Performance restrictor slide stop 38 mm slide stop 36 mm TIGHTENING TORQUES ENGINE Nuts cylinder base Flywheel collar nut 12 1 60 Nut for primary sprocket M16x1 5 links Loctite 243 130 Nm Nut for inner clutch hub M18x1 5 Loctite 243 130 Nm Collar screws fur clutch springs M6 10 Nm Collar screw for clutch slave cylinder M6 Loctite 243 10 Nm Special screw for locating drum shifting M8 Loctite 243 25 Nm Oil drain plug M12x1 5 20 Nm Oil drain plug clutch cover 10 1 15 Dra
24. EXC E EU 250 300 EXC EXC E AUS 250 300 EXC Six Days EXC E Six Days Final drive ratio 250 300 XC 250 300 XC W EXC E Six Days 250 300 EXC EXC E 11 liters 2 9 US gallons 2 liters 0 52 US gallone reserve 9 5 liters 2 5 US gallons 2 liters 0 52 US gallone reserve 11 liters 2 9 US gallons 2 liters 0 52 US gallone reserve 9 5 liters 2 5 US gallons 2 liters 0 52 US gallone reserve 14 50 13 50 13 40 Chain 5 8 x 1 4 Available final sprockets 381 401 42t 451 48t 491 50t 51t 521 Bulbs headlight 12V 35 35W Bilux base 20 rer tight ED o flasher light 12V 10W base 88155 Battery electric starter models parking light 12V 5W base W2 1x9 5d brake rear light L Weight without fuel 250 EXC EXC Six Days 250 XC 250 XC W ZA 100 8 kg 222 5 Ibs 97 6 kg 215 5 Ibs 98 8 kg 218 Ibs 101 6 kg 224 3 Ibs 103 1 kg 227 6 Ibs 98 kg 216 3 Ibs 100 6 kg 220 Ibs 250 XC W USA 300 EXC E EXC E Six Days 300 XC 300 XC W further tire releases are available on the Internet at www ktm com STANDARD ADJUSTMENT FORK CE UE ICI WP 4860 PA WP 4860 MXMA WP 4860 MAMA CC ae DANK Spring 432 505 00 042W 432 505 00 044W 432 455 00 044W Preload Adjuster 2 turns 2 turns Air chamber length 110 mm 110 mm Fork oil SAE 5 SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER 250 300 XC W EXC EXC E 250 300 EXC E EXC E SIX DAYS 250 30
25. 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 display mode hold O button 3 secs changes to the next display mode SPEED TR1 display mode tripmaster 1 The TRI tripmaster is always active and counts to 999 9 It 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 Al and S1 figures are automatically cleared after passing 999 9 button no function button no function briefly press button changes to the next display mode hold button 3 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 c
26. 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 Explanation of table Example Compared to the needle NOZG the jet needle NOZI is two steps leaner in the range from the closed position of the throttle to 1 4 throttle Otherwise there are no differences CAUTION Pay attention to the correct needle designation when replacing the jet nee dle detailed information on the type of jet needle for the respective models can be found in the carburetor setting table AND ENGIN 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 float chamber leads to engine malfunction Make sure you do this while the engine is cold Close the fuel tap and place a cloth under the carburetor which is capable of absorbing the leaking fuel Unscrew the plug 1 and clean it wit
27. band 1 and remove the battery WARNING If electrolyte sulphuric acid leaks from the battery proceed with great care The electrolyte can cause severe burns In the case of skin contact rinse thoroughly with water In the case of contact with the eyes thoroughly rinse eyes with water for at least 15 minutes Immediately consult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defective batteries must be stored out of the reach of children Ensure proper disposal of discarded batteries CAUTION Never remove the closure 2 since it will be damaged STORAGE If the motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature O 35 C avoid direct sunlight Charge the battery every 3 months Charging the battery The battery discharges every day even if it is not used Always disconnect the battery when charging Charge the battery as described in the instructions 3 on the battery housing Do not exceed the amperage and charging time Quick charging at a high amperage has an adverse effect on the service life To charge the battery while mounted always use the KTM battery charger Item no 58429074000 to ensure that the electric system is not damaged by excess voltage Always remove the battery if using other battery chargers You can also use this charging device t
28. 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 indication that some thing is wrong with the brake system Don t ride your motorcy cle anymore without first having the brake system looked over by a KTM dealer Stopping and parking Apply the brakes fully and put the engine into neutral To turn off the engine push the short circuit button or the emergency OFF button with the engine at idling speed until the engine stops Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle Si 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 start ing 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 car buretor may get flooded and fuel will enter the engine Never park your motorcycle in places where there exist fire haz ards due to dry grass or other easily flammable materials The side stand is only designed for the weight of the motorcy cle If you get on your motorcycle and thus put additional
29. 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 P BLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO Bu D D 2 DE D D AE ARL Jh VERGASERREGULIERUNG CARBURETOR SETTING 200 XC XC W EXC 2008 KEIHIN PWK 36S AG MEERESHOHE TEMPERATUR 20 bis 7 C 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C ALTITUDE TEMPERATURE 2 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 3000 m 10000 ft NEEDLE 2301 m POS 7501 ft MJ 2300 m ASO 7500 ft IJ NEEDLE 1501 m POS 5001 ft 1500 m 5000 ft NEEDLE 751m POS 2501 ft MJ 750 ASO 2500 ft IJ NEEDLE 301 m POS 1001 ft 300 m 1000 ft NEEDLE Meeresniveau POS Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 RE IJ Idling jet POS Nadel Clip Position von oben ee 4 POS Needle clip position from top HD Hauptd se 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 PON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um
30. engine is hot use a rag to cover the cap and open slowly to release pressure Bleeding the cooling system By removing the screw 1 at the water pump cover you can drain the coolant To bleed the cooling system add coolant up to approx 10 mm above the radi ator fins when the engine Is cold After a short ride check the coolant level once more 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 2 tilt aside and remove the air filter 3 and filter support 4 from the filter box CAUTION Do not clean foam filter with fuel or petroleum since these damage the foam KTM recommends the products of the company Motorex for air fil ter maintenance Dirt Bio 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 filter is not mounted correctly Thoroughly wash the air filter in special cleaning fluid Motorex Twin Air Dirt Bio 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 Twin Air Liquid Bio Power Also clean the air filter box Check the
31. engine warm and set up the motorcy cle on a horizontal surface Remove the oil drain screw 7 and drain used oil 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 e 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 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 If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pres sure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear Before cleaning with water plug the exhaust pipe to prevent water ingress You should use normal brand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take
32. pin bearing Replace the crankshaft main bearings Replace the conrod bearings Check the entire transmission the shift mechanism and bearings Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Replace the sealing cup for the foot brake cylinder Replace the glass fiber yarn filling in the silencer Treat electric contacts and switches with contact grease Change break fluid C Change the hydraulic clutch oil C FOR COMPETITIVE OFFROAD RACING COMPETITION H FOR OFFROAD HOBBY USE Note lf the inspection establishes that permissible tolerances are exceeded the respective components must be replaced 125 EXC EXC SIX DAYS 200 XC XC W EXC 2008 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER after every cleaning for cross country use Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Check tires for pressure and wear Empty and clean float chamber Check all control elements for smooth operation Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check brake performance Treat blank metal parts with the exception of brake and exhaust s
33. 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 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 performs especially on wet surfaces f air pressure is too low abnormal wear and overheating of the tire can result Only mount tires approved by KTM on homologated models see Technical Data for Chassis No product liability will be assumed if other types of tires are used AND ENGIN Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety 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 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 Spokes can tear i
34. there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose Is free of kinks 3 CHAIN A loose chain was fall off the chain wheels an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of the chain and chain wheels 4 TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 5 BRAKES Check correct functioning of the braking system Verify that there is 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 WARNING ee 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 sys
35. 0 XC Typ WP 5018 PDS DCC WP 5018 PDS DCC WP 5018 PDS DCC 12 18 7D 04 12 18 7D 34 12 18 7D 28 Compression adjuster Low speed 15 clicks 15 clicks 15 clicks High speed 1 5 turn 1 5 turn 1 turn TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front M8 10 9 Loctite 243 25 Nm Brake disks M6 10 9 14 Nm Screw steering head M20x1 5 10 Nm Clamping screws upper fork bridge machined fork bridge M8 10 9 17 Nm Clamping screws lower fork bridge machined fork bridge M8 10 9 12 Nm Clamping screws upper steering stem M8 10 9 Loctite 243 17 Nm Clamping screws upper fork bridge forged fork bridge M8 10 9 20 Nm Clamping screws fork stubs M8 10 9 Collar nut rear wheel spindle M20x1 5 Hexagon nut swing arm bolt M16x1 5 Hexagon collar screw handlebar clamp M8 10 9 Shock absorber top M12 10 9 Loctite 243 80 Nm Shock absorber bottom M12 10 9 Loctite 243 80 Nm Flat head screws for subframe M8 10 9 Loctite 243 35 Nm Collared nuts for rear sprocket screws M8 10 9 Loctite 243 35 Nm Ball joint for push rod M6 10 9 Engine mounting bolt M10 10 9 Engine brace M8 10 9 Screw adjusting ring spring preload shock absorber M6 Spoke nipple M4 5 5 Other screws on chassis Other collar nuts on chassis Pm II ENGINE Design Piston displacement A UP 250 XC W ZA 250 EXC 250 EXC SIX
36. 08 KEIHIN PWK 36S AG 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 36 C 37 C bis 49 C ALTITUDE TEMPERATURE 2 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 3000 m 10000 ft NEEDLE 2301 m POS 7501 ft MJ 2300 m ASO 7500 ft IJ NEEDLE 1501 POS 5001 ft 1500 m 5000 ft NEEDLE 751m POS 2501 ft MJ 750 ASO 2500 ft IJ NEEDLE 301 m POS 1001 ft 300 m 1000 ft NEEDLE Meeresniveau POS Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top HD Hauptd se NN 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 PON 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 dethro
37. 2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK time display mode CLK displays the time in hours minutes and seconds no function no function changes to the next display mode set the clock menu 4 button button briefly press O button hold O button 3 secs To set 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 starts and stops the stop watch lap time is not reset to O button 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 briefly press O button hold O button 3 secs III I I ICI ILI 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
38. 3 Gear lubrication Available chain sprockets 0 7 liter Motorex Top Speed 4T 15W50 13t 14t for chain 5 8 x 1 4 Coolant 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system KOKUSAN E Generator output 12V 110W Starting aid kickstarter kickstarter kickstarter and electric starter Carburator Keihin PWK 36 flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert BASIC CARBURETOR SETTING Carburetor Carburetor setting mark 250 XC Keihin PWK 36S AG FKO22 250 XC W 250 EXC SIX DAYS Keihin PWK 365 AG FKO23 250 EXC AUS Keihin PWK 36S AG 3600B 250 EXC EU Keihin PWK 36S AG FKO25 Main jet Idling jet 168 170 39 165 162 35 160 162 165 39 1151162 165 38x38 35 starting jet 85 85 85 50 85 Jet needle N8RH N8RJ N3CJ N8RH N8RJ N8RW N2ZJ N2ZWG N84K N8RH N8RJ NOZG Needle position from top Throttle valve 1 3 4 7 Air adjustment screw open Su 1 Performance restrictor slide stop 38 mm slide stop 36 mm M 5 Exhaust control retaining bracket Loctite 243 7 Nm Exhaust control control flap M 6 Loctite 243 10 Nm Exhaust control lever for control segment M 5 Loctite 243 6 Nm Shift roller bearing retaining bracket M 6
39. 5 00 042W Preload Adjuster 2 turns 2 turns 110 mm 4 3 in SAE 5 110 mm 4 3 in SAE 5 Air chamber length Fork oil SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER 125 200 XC W EXC 125 EXC Six Days 200 XC WP 5018 PDS DCC WP 5018 PDS DCC WP 5018 PDS DCC 12187027 12187D02 12187D33 15 clicks 15 clicks 13 clicks 1 5 turns 1 75 turns 1 turn 24 clicks 24 clicks 23 clicks 66 250 66 250 63 250 7 mm 0 27 in mm 0 27 in 5 mm 0 2 in 35 mm 2 mm 35 mm 2 mm 33 mm 2 mm Compression adjuster Low Speed Compression adjuster High Speed Rebound adjuster Spring Spring preload Static sag Riding sag 105 mm 5 mm 105 mm 5 mm 112 mm x 5 mm TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle Brake caliper front Brake disks M6 10 9 14 Nm Screw steering head M20x1 5 10 Nm Clamping screws upper fork bridge machined fork bridge M8 10 9 17 Nm Clamping screws lower fork bridge machined fork bridge M8 10 9 12 Nm Clamping screws upper steering stem M8 10 9 Loctite 243 17 Nm Clamping screws upper fork bridge forged fork bridge M8 10 9 20 Nm Clamping screws fork stubs M8 10 9 Collar nut rear wheel spindle M20x1 5 Hexagon nut swing arm bolt M16x1 5 Hexagon collar screw handlebar clamp M8 10 9 Shock absorber top M12 10 9 Loctite 243 80 Nm Shock absorber bottom M12 10 9 Loctite 243 80 Nm Flat head screws for subframe M8 10 9 Loct
40. C ROADS KTM EXC and EXC E 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 OWNER S MANUAL 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 Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance A WARNING Ignoring these instructions can be dangerous to life and limb CAUTION ignoring these instructions may damage parts of the motorcycle or impair the motorcycle s traffic safety 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 15 an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it SERVICE Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultl
41. D 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 WP Suspension 14187D27 20 clicks WP Suspension 1418 7D28 20 clicks Rebound damping of fork XC Hydraulic rebound damping determines the reaction when the fork is rebound Remove the protecting cap 2 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 counter clockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far as It will go turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 14187D27 21 clicks Typ WP Suspension 14187D28 21 clicks Compression damping of fork XC W EXC EXC E 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 4 Turn the screw 5 clockwise to increase damping turn it counterclockwise to reduce damping during compression SIANDARD 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 WP Suspension 14187D02 22 clicks Typ WP Suspension 14187004 22 clicks Typ WP Suspensio
42. DAYS 250 XC W USA Liquid cooled single cylinder two stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber 249 ccm Bore stroke 66 4 72 mm 2 62 2 84 in Fuel Oil gasoline ratio Crankshaft bearing unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Motorex Cross Power 2T 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 1 deep groove ball bearing 1 cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing Piston needle bearing cast aluminium Piston ring 4 upper edge piston Dimension upper edge cylinder two plain compression rings O 0 1 mm 0 0 004 in Ignition timing 1 9 mm 0 074 in BTDC Spark plug NGK BR7 ES Electrode gap 0 60 mm Dimension Z 47 5 mm 1 87 in TVC start open 5500 min TVC fully open 300 min red spring 7800 min yellow spring 8300 min green spring Primary drive Clutch straight cut spur gears primary ratio 26 72 multiple disc clutch in oil bath hydraulically operated Brake fluid DOT 5 1 Transmission Gear ratio lst gear 2nd gear 3rd gear Ath gear 5th gear 5 speed claw actuated 14 30 14 30 14 30 16 26 17 26 17 26 18 24 12223 1923 21 24 20 20 20 20 22 21 29 23 293 2
43. GIN 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 BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701HHB sintered lining at the front and TOYO B 143 FF sintered lining at the back These linings provide an optimal combination of dosing brake performance and life cycle The lin ing type Is stated on the back of the brake pad and also recorded in the homolo gation papers 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 7N WARNING A brake disk worn down to 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
44. Nm Clamping screws a Gx dew 4 17 Nm Clamping screw 9 Loctite 243 17 Nm If the steering head bearing is not adjusted to be free of play the motorcy cle will exhibit unsteady driving characteristics and can get out of control Hold the clamp screw 6 9 in place with Loctite 243 CAUTION If you drive with play in the steering head bearing for longer periods the bear ings 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 Term 2000 C 1 wa m AND ENGIN Changing the fork offset caster XC EXC Six Days The fork offset A in the XC EXC Six Days models center fork legs center steering head angle can be set to either 18 or 20 mm This allows you to optimize the handling 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 stability 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 br
45. OWNER S MANUAL 2008 125 EXC EXC SIX DAYS 200 XC XC W EXC 290 XC XC W EXC EXC SIX DAYS 300 XC XC W EXC E EXC E SIX DAYS 3211226en INTRODUCTION gt 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 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 Sportmotorcycle 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 pre
46. SPRING RATE 65 70 75 80 89 90 98 Riders weight inclusive gears in kilogram 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 75 bis 85 kg wearing 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 accordingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring is suitable for your weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined Determining the static sag of the shock absorber The static sag setting should be as precise as possible 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 A Place the motorcycle on the ground again Ask a
47. X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty of water Residual used grease must be removed prior to lubri cation Motorex Chain Clean 611 After drying use a chain spray specially designed for X ring chains Motorex Chainlube 622 AN 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 do 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 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 EN
48. 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 FUR WIN X UPERALIUN In the event that the motorcycle is also used in winter and on 5 where one has to expect salt spraying you will have to take 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 gt Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well STORAGE A XA A
49. ake 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 Apply Loctite 243 to the thread of the collar screw 2 and turn all the way in WARNING OO Be sure to lock the thread on the collar screw 2 with Loctite 243 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 60 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages Adjust the steering head bearing with zero clearance see section on checking and adjusting the steering head support Hold the middle clamp screw A in place wit
50. ap To open it Press the release button 3 and turn the tank cap in a coun terclockwise direction To close it Put the tank cap back on and turn in a clockwise direction until the release button snaps into place Install tank breather hose 4 without kinks Fuel tap OFF In this position the fuel 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 tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Choke lever on the handlebar When you press the choke lever 5 a hole in the carburetor is opened through which the engine can take in additional fuel The result is a rich fuel air mixture of the type needed for cold starts Press the choke lever all the way up to close the hole in the carburetor again Choke knob When pulling the choke knob 6 fully towards the top a bore is opened in the carburetor Through this bore the engine can take in additional fuel This 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 T
51. as a number of display modes functions that you can also activate reveal see Activating and deactivating display modes IM M A2 Si 92 NI Km h Mph O00 SMA LAP CLK H LI ka CLK n nna CU ah SPEED Kmh LAP Activating and deactivating display modes 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 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 hold O button 3 secs 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 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 ODO SPEED TRI SPEED TR
52. ate ventilation while the engine is running CAUTION Do not ride your motorcycle with full load and do not rev up the engine when cold Since the piston warms up and expands faster than the water cooled cylinder this might cause engine damage Always let engine idle until warm or drive it warm at low r p m speeds DO RON NOTE The highly inflammable components in modern fuels volatilize if left stand ing for longer periods of time If the motorcycle has not been used for over 1 week the fuel should be drained from the float chamber The engine will Start up immediately if the float chamber is filled with fresh ignitable fuel Starting when the engine is warm Open fuel tap Turn on emergency OFF switch Swing up the side stand Put the gear in neutral Open throttle to 1 2 and kick down kickstarter vigorously 0 5 D 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 Once the engine is running open fuel tap again Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time 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 additionally secure the side sta
53. ause erosion of the pis ton when Using too much oil the engine may start smoking and foul the spark plug f your motorcycle is equipped with a catalytic converter always keep in mind that leaded fuel will destroy the catalytic converter Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig 125 EXC EXC SIX DAYS 200 XC XC W EXC 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY o gt o d o q Before each every 20 hours every 40 hours at least once Check gear box oil level Change gear box oil Check spark plugs adjust distance between electrodes ENGINE Renew spark plugs Clean the spark plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Check the carburetor connection boot and intake flange for cracks or 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 the fluid level in the master cylinder of the hydraulic clutch Clean air filter and filter box Check electric wires for damage and bends ADD ON PARTS Check headlamp setting Check function of electric systems low beam high beam break light indi
54. bearings will be subjected to unnec essary stress resulting in premature wear and even chain breakage Too much slack in the chain on the other hand can result in the chain Jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine In either case the operator is likely to lose control of the motorcycle CICICBCICS 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 WARNING m f you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle NOTE The large adjusting range of the chain adjusters 32mm 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 Maintenance of the
55. bricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Empty and clean float chamber Remove clean and oil the throttle slide Check all control elements for smooth operation Check brake performance e Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly Maintenance and adjusting work marked with an asterisk requires expert skills and technical know how For your own safety always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified skilled staff CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear 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 sho
56. can be adjusted for any hand size Models without front brake light switch When you push the hand brake lever forwards you must have at least 3 mm free travel Models with front brake light switch When you actuate the hand brake lever you must have at least 3 mm free travel CAUTION At the hand brake lever free travel must at least be 3 mm 0 1 in Only then REN RENS 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 with 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 EE 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 author ized 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
57. carburetor collar for damage and that it is filled correctly Place the air filter on the filter support and insert both in the center of the filter box Hold in place with the filter retaining clip AND ENGIN Exhaust system If the end cap 1 can be removed the silencer is filled with glass fiber yarn Have the filling checked regularly by an authorized KTM workshop see Lubrication and Service Chart The insulating material fibers escape through the holes in the perforated pipe with time causing the silencer to burn out In addition to causing a higher noise level it will also affect the power char acteristic The insulating material suitable for your exhaust is available from your authorized KTM workshop To replace the glass fiber yarn set 2 remove the end cap and pull off the outer pipe 3 Tape a new glass fiber yarn set to the inner tube and slide on the outer pipe Mount the end cap Make sure the caps are screwed on tightly Mount the muffler stress free before tightening the fixing screws WARNING Oe The exhaust system becomes very hot while the motorcycle is running Do not start work on the exhaust system until it has properly cooled down to avoid burns Changing the original position of the clutch lever The adjusting screw 4 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 The clutch leve
58. cator 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 the function smooth operation and free travel of the hand foot brake lever Check the screws and guide bolts on the brake system for a tight fit 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 Lubricate chain Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver 125 EXC EXC SIX DAYS 200 XC XC W EXC 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Check the wear on the clutch disks and length of the clutch springs C C H Check function of exhaust control Check piston
59. 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 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 connai
60. dkurve Z ndschloss linker vorderer Blinker linker hinterer Blinker Kennzeichenbeleuchtung Multifunktionsdigitaltacho Impulsgeber standlicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Starttaster Startrelais Startermotor Not Aus Schalter Vergaserpotentiometer KABELFARBEN bl schwarz ye gelb bu blau gn gr n re rot wh weif br braun or orange pi rosa gr grau pu violett ITALIANO Batteria Motorino ventola spia abbagliante spia lampeggiatori Rel indicatori Interruttore indicatori di direzione Interruttore luce ant di stop Generatore Interruttore sul manubrio per tachimetro multifunzione Faro anteriore Commutatore abbagliante anabbagliante Avvisatore acustico Interruttore avvisatore acustico Bobina d accensione Connettori curva d accensione Interruttore d accensione Indicatore ant sx Indicatore post sx Luce targa 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 Pulsante d avviamento Rel d avviamento Motorino d avviamento Interrutore di aresto d mergenza Potenziometro carburatore sensore TPS CAVO COLORATO bl nero ye giallo bu blu gn verde re rosso wh bianco br marrone or ara
61. e front brake fluid reservoir Checking the front brake pads Replacing the front brake pads Checking the rear brake fluid level Refilling the rear brake fluid reservoir Changing the basic position of the foot brake pedal Checking the rear brake pads Replacing the rear brake pads Dismounting and mounting the front wheel Dismounting and mounting the rear wheel Tires alr pressure Checking spoke tension Replacing the battery of the digital soeedometer Replacing the headlight lamp parking light lamp KEEN Scot Bice co Seca Charging the battery Fuse Cooling system Checking the coolant level Refilling Bleeding the cooling system Cleaning the air filter Checking the oil level of the hydraulic clutch Exhaust system Changing the original position of the clutch lever Bleeding the hydraulic clutch Carburetor adjustment Draining the float chamber of the carburetor Checking the float level Adjusting the engine characteristic via the ignition curve Adjusting the engine characteristic via the auxiliary spring Check transmission oil level Changing the transmission oil CLEANING CONSERVATION FOR WINTER OPERATION STORAGE su ede hee bU Epp qs TECHNICAL SPECIFICATIONS CHASSIS 125 200 TECHNICAL SPECIFICATIONS ENGINE 125 200 TECHNICAL SPECIFICATIONS CHASSIS 250 300 TECHNICAL SPECIFICATIONS ENGINE 250 TECHNICAL SPECIFICATIONS ENGINE 300 WIRING DIAGRAM
62. e stops Headlamp switch XC W 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 Starter button Pushing the black starter button 5 will actuate the E starter Emergency OFF switch Australia The emergency OFF switch 6 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 Emergency OFF switch EXC E Australia The red emergency OFF switch 1 is arranged adjacent to the throttle grip C m In this position the E starter is operational and the engine can be started X In this position the E starter and ignition circuits are interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter G Pushing the black starter button 2 will actuate the E starter Filler c
63. ect 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 addi tion the rear wheel will block so that the motorcycle can eas ily get out of control If the engine runs without throttle during longer downhill travel the engine should be accelerated occasionally to ensure that it is supplied with sufficient lubricant which is mixed in the fuel In the event that while riding on your motorcycle you notice any unusual operation related noise stop immediately turn the engine off and contact an authorized KTM dealer Braking Close the throttle and apply the hand and foot brake simultane ously Be especially careful when you apply the brakes on sandy wet or slick surfaces Always apply the brakes intuitively locked wheels can cause the bike to skid or crash Shift down to a lower gear to match your speed Always apply the brakes before you enter a curve Si WARNING Incase of rain after washing the motorcycle after rides through water and in case of rides on wet off road tracks humid or dirty brake discs can delay the braking effect The brakes must be pulled until they are dry or clean Rides on salt strewed or dirty roads can also delay the braking effect The brakes must be pulled until they are clean Dirty brake discs cause increased tear of brake pads and brake discs When you brake the brake discs brake pads
64. el 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 60 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 requirements 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 Only use premium grade gasoline ROZ 95 USA Premium 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 2T Not enough oil or low grade oil can cause erosion of the piston if you use too much oil the engine can start smoking and foul the spark plug and the exhaust control system In the case of a leaner adjustment of the carburetor proceed cautio
65. eload on the telescopic fork XC W EXC EXC Six Days EXC E EXC E Six Days The telescopic forks for these 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 in 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 Turn the adjusting screw all the way to the stop in a counterclockwise direc tion and 2 turns in a clockwise direction Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 2 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 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 hav ing the seals replaced VAIN NAN UN AND ENGIN Cleaning the dust sleeves of the telescopic fork The dust protection bellows 2 are to remove dust and coarse dirt particles fr
66. en 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 OFFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC EXC E models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the carburetor 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 EXC E 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 EXC E 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
67. eresniveau POS Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se IJ Idling jet POS Nadel Clip Position von oben BG POS Needle clip position from top HD Hauptd se 9 1 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 PON 91 EXC EXC E 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 MaBnahmen 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 EXC E models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the carburetor 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 EXC E Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratu
68. ess 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 use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle WARRANTY 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 No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle AUTOMOTIVE FLUIDS The fuels and lubricants specified in the Owner
69. f you have to open the radiator cap 2 when the engine is hot use a rag to cover the cap and open slowly to release pressure Caution scalding hazard Do not detach any radiator hoses while the engine is hot The escaping hot coolant and the steam may cause serious burns 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 Incase coolant is ingested consult a doctor immediately If coolant gets into your eyes rinse them out with water immediately and go see a doctor Use a mixture of 50 antifreeze and 50 distilled water for the cooling liquid The antifreeze should be designed for temperatures of at least 25 C This mixture offers frost protection as well as good corrosion protection and Should not be replaced by water alone 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 10 mm when engine ist cold AND ENGIN 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 WARNING If possible always check the level of cooling liquid when the engine is cold If you have to open the radiator cap when the
70. f you continue to ride with them loose This may lead to an unstable handling of your motorcycle Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 5 Nm Replacing the battery of the digital speedometer Remove the headlight mask and disassemble the electronic speedometer Remove the screw connection A insert the battery type Duracell CR 2430 with the writing facing up and reinstall the screw connection 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 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 Battery The battery is located under the seat and is maintenance free Maintenance free means you will not need to check the acid level Clean the battery terminals regularly and grease with acid free grease if necessary The charge condition and type of charge are very important for the battery s serv ice life TO REMOVE THE BATTERY First disconnect the negative pole then the positive pole from the battery Detach the rubber
71. g 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 lb STANDARD SETTING SPRING PRELOAD A Typ WP Suspension 12187D02 mm WP Suspension 12187 04 mm Typ WP Suspension 12187D27 5 mm Typ WP Suspension 12187D28 5 mm Typ WP Suspension 12187033 mm WP Suspension 12187034 8 mm Pivot bearing The pivot bearing 3 for PDS suspension struts at the swinging fork is Teflon coated and must not be lubricated 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 LLC LT D for example shock absorber 250 EXC 72 250 66 250
72. ground loaded dimension C 500 mm 100 mm Riding sag settings see above If the riding sag 15 too low the spring is too hard spring rate is too high If the riding sag is too high the spring is too soft spring rate too low The spring rate is written on the outside of the spring e g 76 250 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 Readjust the static sag after mounting a new Spring TYPE SOFTER STANDARD HARDER 12187002 12187004 12187027 12187 28 12187033 12187034 69 250 72 250 AND ENGIN According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for vari ous reasons Similar to the shock absorber smaller 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 Your KTM dealer will be happy to offer advice Changing the spring pr
73. h Loctite 243 Tighten the clamp screws on the upper triple clamp to 20 Nm in 3 stages CAUTION Hold the middle clamp screw A in place with Loctite 243 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 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 lbs 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 The screws 4 must be secured with loctite 243 Adapting the chain guide to the number of rear sprocket teeth XC EXC Six Days EXC E Six Days NOTE The position of the chain guide must be adjusted due to the large number of rear sproc
74. h compressed air Then mount the plug together with the gasket open the fuel tap and check the float chamber for leaks WARNING OOO Fuel is easily flammable and toxic When handling fuel be sure to exercise the utmost caution Never perform any work on the fuel system near open flames or burning cigarettes Always allow the engine to cool off first Immediately clean up any fuel which may have been spilled Materials satu rated 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 Adjusting the engine characteristic via the ignition curve 125 300 2 ignition curves PERFORMANCE and SOFT are stored in the digital box The PERFORMANCE ignition curve is activated in the condition at delivery The SOFT ignition curve can easily be activated by disconnecting the socket connector under the tank To change the ignition curve remove the seat and tank A PERFORMANCE higher engine performance socket connector connected B SOFT better driveability socket connector disconnected You can also change the ignition curve via the handlebar switch Power Parts while driving
75. he 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 means of the lock located on the steering head To lock it turn the handlebar all the way to the right insert the key turn it to the left press it in turn it to teh right and remove it CAUTION Never leave the key inserted in the steering lock If you turn the handlebar to the left the key could get damaged Compression damping of fork XC 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 Turn the screw 1 clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDAR
76. heel 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 15 Nm WARNING m If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the front wheel keep operating the hand brake until the pressure point returns t is very important to keep the brake disk free from oil and fatty matters otherwise the braking effect would be strongly reduced TIRES AIR PRESSURE Off road Road AND ENGIN Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Remove the collar nut 1 remove the chain tensioner 2 and pull out the wheel spindle 3 until you can push the rear wheel forwards Take the chain off the rear sprocket pull out the wheel spindle and carefully remove the rear wheel from the swing arm 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 col lar nut thoroughly and apply a new coat of grea
77. 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 B 565 mm icd E 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 Typ Static sag Riding sag 12187002 35 mm 2 105 mm 5 mm 12187004 35 mm 2 mm 105 mm 5 mm 12187D27 33 mm 2 mm 112 mm 5mm 1218 D28 33 mm 2 mm 112 mm 5mm 12187D33 35 mm 2 mm 105 mm 5 mm 1218 D34 35 mm 2 mm 105 mm 5 mm Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension 600 mm Motorcycle on
78. id Motorex Brake Fluid 5 1 CAUTION BREMBO clutch fittings are installed in the 250 300 models and filled with DOT 5 1 brake fluid To make sure the clutch operates smoothly never add hydraulic oil to these systems AND ENGIN Bleeding the hydraulic clutch The clutch control needs to be bled as soon as the resistance in the clutch lever starts to feel unresponsive You will need to use a bleeding syringe spe cial tool Please note that Motorex 75 clutch fluid must be used for the 125 200 models and Motorex DOT 5 1 brake fluid for the 250 300 models Both are available from your KTM dealer Turn the handlebar until the master cylinder is in a horizontal position remove the screws 1 the cover 2 and the rubber boot 3 Fill the bleeder syringe 4 with a suitable fluid see Technical Specifications Engine Remove the bleeder screw from the slave cylinder 5 and mount the bleeder syringe Press oil into the system until the fluid runs out of the hole 6 in the master cylinder without bubbles Occasionally extract the fluid from the master cylin der reservoir to keep it from overflowing After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the level in the reservoir and mount the cover see above 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 lev
79. in plug for water pump cover 10 1 15 Collar screw for water pump cover M6 Loctite 243 10 Nm Water pump wheel M5 Loctite 243 6 Nm Crankcase and clutch cover bolts M6 Collar screws for ignition cover M5 5 Collar screws for exhaust flange 6 Nm Spark plug M14x1 25 25 Nm Collar screws for ignition system M5 Loctite 243 6 Nm Collar screw for kickstarter lever M8 Loctite 243 25 Nm Collar screw f r shifting lever M6 10 9 Loctite 243 14 Nm Other screws ALIUNS LAA J 3U00 AU AU W EAL AV UP CHASSIS 250 XC XC W EXC EXC SIX DAYS 300 XC XC W EXC E EXC E SIX DAYS Central chrome moly steel frame Fork 250 300 XC 250 XC W EXC EXC Six Days 300 XC W EXC E EXC E Six Days WP Suspension 4860 MXMA CC Closed Cartridge WP Suspension 4860 MXMA PA Open Cartridge WP Suspension 4860 MXMA PA Closed Cartridge Front tires 250 300 XC XC W 250 300 EXC E EXC E Six Days 80 100 21 51M Bridgestone M59 90 90 21 54M Metzeler MCE 6 Days Extreme Air pressure offroad 1 0 bar 14 psi Air pressure road driver only 1 5 bar 21 psi Rear tires 250 300 XC XC W 250 300 EXC E EXC E Six Days 110 100 18 64M Bridgestone MAO2 140 80 18 7OM Metzeler MCE 6 Days Extreme Air pressure offroad 1 0 bar 14 psi Air pressure road driver only 2 0 bar 28 psi Fuel tank capacity 250 300 XC XC W 250 300 EXC
80. ing lot Or open space before going for a longer ride Also try to ride as Slowly as possible while standing upright to improve your feeling for the vehicle Do not drive along off road trails which go beyond your ability and experience Hold the handlebar with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system Is overheated 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 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 th
81. is reason during its first 500 kilometers 300 miles or 5 hours the engine must not be 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 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 drivers become aware of you as early as possible Do not drive after having consumed alcohol Only use accessory parts recommended by KTM For example front panelling can impair the driving characteristics of the motor cycle 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 30 minutes running time The spoke tension will decrease quickly on new wheels If you con tinue to drive with loose spokes the spokes may crack and lead to unstable handling see Checking the spoke tension Observe the traffic regulations drive defen
82. ite 243 35 Nm Collared nuts for rear sprocket screws M8 10 9 Loctite 243 35 Nm Ball joint for push rod M6 10 9 Engine mounting bolt M10 10 9 Engine brace M8 10 9 Screw adjusting ring spring preload shock absorber M6 Spoke nipple M4 5 5 Other screws on chassis 40 Nm Loctite 243 25 Nm M24x1 5 M8 10 9 Other collar nuts on chassis SF JN JU x QUE LNUIN A A UP ENGINE 125 EXC EXC SIX DAYS 200 XC W EXC 2200 XC Piston displacement Liquid cooled single cylinder two stroke engine with intake and exhaust control 124 8 ccm 193 ccm Bore stroke 54 54 5 mm 2 126 2 145 in 64 60 mm 2 52 2 362 in Fuel unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Oil gasoline ratio 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 Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston upper edge piston cast aluminum Piston ring 2 half keystone rings two plain compression rings Dimension X upper edge cylinder Ignition timing Spark plug 0 0 mm 0 10 mm 1 4 mm 0 055 in 16 5 BTDC NGK BR9 ECMVX 1 6 mm 0 063 in 17 BTDC NGK BR 8 EG
83. kets available Up to 44 teeth insert the retaining screw on the chain guide in the lower hole B from 45 teeth in the upper hole C Loosen the screw 5 and remove screw 6 Tilt the chain guide down and insert the collard bush 7 in the respective hole Tighten the screws to 10 Nm IS INT ESS NG NGANGKANG NGA NGA NGANG AND ENGIN Adapting the chain guide to the number of rear sprocket teeth XC W EXC EXC E NOTE The position of the chain guide must be adjusted due to the large number of rear sprockets available Up to 44 teeth insert the retaining screw on the chain guide in the lower hole B from 45 teeth in the upper hole C Loosen both screws on the chain guide and pull the chain guide off the swing arm Turn the chain guide over press out the retaining nut 1 and insert it in the other hole 2 turning the retaining nut around Remount the chain guide and tighten the screws 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 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 WARNING oa f the chain tension is too great parts within the secondary transmission chain chain wheels and rear wheel
84. lears the TR2 figure SPEED A1 display mode average 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 button changes to the next display mode hold button 3 secs clears the TRI 51 Al figures 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 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 rin ine 51 shows the traveling time based on TRI and continues to run whenever it Lt qa receives impulses from the wheel sensor The calculation of this figure is acti SPEED 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 3 secs clears the TRI 51 Al figures SPEED S2 display mode stop watch 2 S2 is a manual stop
85. 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 We recommend that you use Motorex DOT 5 1 brake fluid when you refill or change the brake fluid DOT 5 1 brake fluid has a wet boiling point of 180 C 356 F 25 C 45 F higher than DOT 4 and is safer for high performance applications Brake fluid DOT 5 1 is a polyethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motor cycle gaskets and brake hoses are not designed for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture from the air which lowers the boiling point The brake fluid should therefore be changed at the prescribed intervals A Have the brake fluid changed at least once annually If you wash your motor cycle often the brake fluid should be changed even more frequently Brake fluid tends to absorb water Therefore vapor pockets may form in old brake fluids even at low temperatures causing the brake system to fail AND ENGIN Changing the basic position of the hand brake lever You can change the basic position of the hand brake lever with the adjusting screw 1 The position of the pressure point the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disk
86. lever or foot brake lever respectively so as to ensure that the brake pads will lie against the brake disk and the pressure point is established VAIN AN UN AND ENGIN Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the collar screw 1 and the clamping screws 2 on both fork leg axle passages Unscrew the collar screw approx 8 turns press on the collar screw with your hand to push the wheel spindle out of the fork leg axle passage and remove the collar screw Hold the front wheel while you pull out the wheel spindle Lift the front wheel off the fork CAUTION Donotoperate 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 E x A NG 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 3 Mount the collar nut 1 tighten the clamping screws 2 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front w
87. lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING OOOO 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 tlet brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid taken from a tightly sealed container Checking the front brake pads The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thick 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 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 su
88. lockwise direction will increase the damping turning counter clockwise will decrease the damping STANDARD LOW SPEED SETTING Turn the adjusting screw 1 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 WP Suspension 12187D02 15 clicks WP Suspension 12187 04 15 clicks Typ WP Suspension 12187D27 15 clicks Typ WP Suspension 1218 7D28 15 clicks Typ WP Suspension 12187033 13 clicks Typ WP Suspension 12187034 15 clicks WARNING The damping unit of the shock absorber is filled with high compression nitro gen 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 STANDARD HIGH SPEED SETTING Turn the adjusting screw 3 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 WP Suspension 12187002 1 5 turn WP Suspension 12187004 1 5 turn Typ WP Suspension 12187D27 1 turn Typ WP Suspension 12187D28 1 turn Typ WP Suspension 12187D33 1 75 turn Typ WP Suspension 1218 D34 1 5 turn Rebound damping of shock absorber By using the adjusting screw 4 the degree of dampi
89. m s J regulator rectifier br 4 cooling fan eh br e re rear light brakelight br bu wh ignition coil generator 250 XC W USA 2008 300 XC W USA ZA 2008 main harness 594 11 075 100 wiring diagramm CDI harness 548 39 032 300 ENGLISH NANI 1 I HSITINS start relay battery high low beam switch 1n E starter motor horn switch stop button dE start button handle bar switc CY flasher Ara i 4 GE a AH 5 zi Terr EDT een gt C_BF1 1 TUN mam 3161415 2 C_BA1 1 F 3 1 4 2 C 9 aa S 5 horn 5 re CW 5 e faz SR regulator rectifier olo 5 1 ce cooling fan _ PUE EE 2 br C BS 2 2 1 1 bl 5 rear OO S brake switch speed sensor EXA A c 80 2 V 21 1 WW C_CA 4 multi func digital speedometer I HI flasher control lamp C_CW 2 bu right rear flasher b1la driving light lamp C_AJ1 3 C BG1 3 oe 1 CHE 8 eee EE 6 275 LE w I I LT 55 Lau S C 852 right front flasher C Bvi2 22 dea Te licence plate headlight ARE D TX IX left rear flasher ignition coil generator DH E C CW3 2 C CX3 2 left fr
90. 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 control screw open by 1 5 turns Then adjust to the normal idling speed by means of the air control screw Opening up B Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle setting the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking Part throttle range C Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main Jet in the upper 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
91. 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 wheel circumference of 21 with production tires Afterwards the display will return to the previous display mode SPEED display mode 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 h
92. n 14187D33 20 clicks Typ WP Suspension 14187D34 24 clicks Rebound damping of fork XC W EXC EXC E Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 6 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding SIANDARD 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 WP Suspension 14187002 22 clicks Typ WP Suspension 14187004 20 clicks Typ WP Suspension 14187D33 22 clicks Typ WP Suspension 14187D34 22 clicks Spring preload of the fork XC W EXC EXC E The fork s preload can be adjusted by means of the adjusting screws 7 Use a 24 mm fork wrench More information is provided in the chapter Adjusting the fork and shock absorber Compression damping of shock absorber The low speed and high speed compression damping can be adjusted sepa rately on the shock absorber 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 c
93. ncione pi rosa gr grigio pu violetto dH ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Flasher switch Front brake switch Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Horn button Ignition coil Ignition curve selector Ignition switch Left front flasher Left rear flasher Licence plate lamp Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button Throttle position sensor TPS CABLE COLOURS bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple 2T Rac0O8 JIAGRAIVIIVI FRANCAIS Batterie Ventilateur temoin feu route Relais de clignotants temoin de clignoteur buton de clignotants Contacteur de frein avant Alternateur Contacteur au guidon pour ordinateur de bord Phare Contacteur code phare Avertisseur sonore Bouton d avertisseur sonore Bobine d allumage Prise courbe d allumage Contacteur d allumage Clignotant avant gauche Clignotant arri re gauche Eclairage de plaque 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 d
94. nd with the rubber band on the air filter box JIN Le JRIVING IN Shifting Riding You are now in first gear referred to as the drive or uphill gear Depending on the conditions 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 go again and open the throttle If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of throttle the gas con sumption will increase When shifting down use the brakes if nec essary 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 CAUTION High rpm rates when the engine is cold have an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this resp
95. ng of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber Typ WP Suspension 12187002 24 clicks Typ WP Suspension 12187004 24 clicks Typ WP Suspension 12187D27 23 clicks Typ WP Suspension 12187D28 23 clicks Typ WP Suspension 12187D33 24 clicks Typ WP Suspension 12187D34 22 clicks WARNING OO The damping unit of the shock absorber is filled with high compression nitro gen 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 5 connection 15mm AND WARNING Instructions for your first ride Make sure the work for the pre delivery inspection was per formed by your authorized KTM workshop The DELIVERY CER TIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle 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 park
96. o test the off load voltage and startability of the battery and generator It is impossible to overcharge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the bat tery will run down and sulfatize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time CAUTION Never remove the closure 2 since it will be damaged To avoid damage to the on board electronic system always disconnect the minus pole before you charge the battery To charge connect the battery to the battery charger before you switch on the battery charger When the battery is charged switch off the battery charger before you disconnect the battery Provide adequate ventilation when charging the battery in a closed room the battery emits explosive gases when charging Electrolytes will escape through the safety valves if the battery is charged too long or at an excessive voltage or amperage This will reduce battery capacity Try to avoid quick charges T E we ns 4 Fuse The fuse 1 is located in the starter relay of the E starter 2 underneath the left side paneling Having removed the left side paneling the air box cover and the protection cover A you will be able to see the fuse The following loads are connected to it
97. om fully seated LD Leerlaufd se 31 IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top HD Hauptd se 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 PON 91 p gt rou p gt wu LA an D A VERGASERREGULIERUNG CARBURETOR SETTING 250 XC W EXC EXC SIX DAYS 2008 KEIHIN PWK 36S AG MEERESHOHE TEMPERATUR 20 C bis 7 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C ALTITUDE TEMPERATURE 2 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 3000 m 10000 ft NEEDLE 2301 POS 7501 ft 2300 m 7500 ft NEEDLE 1501 m POS 5001 ft 1500 m 5000 ft NEEDLE 751m POS 2501 ft 750 m 2500 ft NEEDLE 301m POS 1001 ft 300 m 1000 ft NEEDLE Meeresniveau POS Sea level LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 4 IJ Idling jet POS Nadel Clip Position von oben 4 POS Needle clip position from top HD Hauptd se 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 PON 91 EXC EXC E Modelle Die oben angef hrten Vergaserregulierung
98. om 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 Remove the screws 3 from the fork protector and allow the fork protector to hang down Pry the dust boot out of the outer tubes and push down Thoroughly clean the dust boots slide rings outer tubes and fork tubes and oil generously with Universal oil spray Motorex Joker 440 or engine oil Press the dust boots into the outer tubes by hand Position the fork protectors mount the screws and torque to 10 Nm WARNING OOOO No oil may reach the front tire or the brake disks since this would consider ably reduce the tire s road grip and the braking effect of the front brake Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcycle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust loosen the 5 clamping screws on the upper triple clamp and turn the end screw 5 8 until no play is left 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 Clamping screws 4 Clamping screws 4 20 Nm Clamping screw 6 Loctite 243 20
99. ont flasher main harness 594 11 075 150 CDI harness 548 39 032 300 300 EXC E EXC E Six Days EU AUS 2008 wiring diagram lamp MALT FLAN WIRING DIAGKAMIV light switch horn switch high low beam switch brake switch stop switch start switch cable Weg cable re ye bl br switch harness wh re 9 E D _ pushed _ TA PLAIN ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Flasher switch Front brake switch Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Horn button Ignition coil Ignition curve selector Ignition switch Left front flasher Left rear flasher Licence plate lamp Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button Throttle position sensor TPS CABLE COLOURS bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple 21 gt y JIAGRAMIVI DEUTSCH Batterie L ftermotor Fernlichtkontrolle Blinkerkontrolle Blinkerrelais Blinkerschalter vorderer Bremslichtschalter Generator Lenkerschalter f r Kombiinstrument Scheinwerfer Auf Abblendschalter Hupe Horntaster Z ndspule Stecker f r Z n
100. pport 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 It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correctly after working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established 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 WARNING Oe 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 author ized 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 5 Fill DOT5 1 brake fluid e g Motore
101. r moves closer to the handlebar if the adjusting screw is tur ned in a counterclockwise direction The clutch lever moves away from the handlebar if the adjusting screw is turned in a clockwise direction CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force Checking the oil level of the hydraulic clutch125 200 To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 5 and cover 6 together with the rubber boot 7 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 clutch fluid 75 available from your authorized KTM shop CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch in 125 200 models Do not mix this oil with any other hydraulic oil Always use original KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid Checking the oil level of the hydraulic clutch 250 300 To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 8 and cover together with the rubber boot 9 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add DOT 5 1 brake flu
102. ra 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 EXC E 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 DISPARAIT Modelos EXC EXC E 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 CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO Page Activating and deactivating display modes 7 Adjusting the engine characteristic via the auxiliary spring 45 Adjusting the engine characteristic via the ignition curve 44 Basic s
103. rake lining Check brake lines for damage and leaks BRAKES Check adjust the function smooth operation and free travel of the hand foot brake lever Check the screws and guide bolts on the brake system for a tight fit 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 Clean and lubricate chain clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver 250 300 XC XC W EXC EXC Six Days EXC E EXC E Six Days 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Every 100 Every 120 At least once Every 2 years Clean and adjust carburetor Replace the throttle slide jet needle float needle valve needle nozzle s gt Check the reed type intake valve for wear C C H C C H C C H Check the wear on the cl
104. roit Capteur de vitesse bouton de d marrage Relais de d marreur D marreur bouton d arr t d urgence Capteur d ouverture de carburateur COULEUR DE CABLE bl noir ye jaune bu bleu gn vert re rouge wh blanc br brun or orange pi rose gr gris pu violet ESPANOL Bateria Motor del ventilador lampara aviso luces largas Rel de la luz intermitente lampara aviso intermitentes Inerruptor de la luz intermitente Interruptor de luz del freno delantero Generador Interruptor de manillar para instrumento combinado Faro Interruptor de encender apagar la luz larga Claxon Interruptor del claxon Bobina de encendido Conexion de la curva de encendido Cerradura de encendido Luz intermitente izquierda delantera Luz intermitente izquierda trasera Luz de la matricula Veloc metro digital multifuncional Generador de impulsos luz de posicion Interruptor de luz del freno trasero Luces de parqueo traseras luces de freno Regulador rectificador Luz intermitente derecha delantera Luz intermitente derecha trasera sensor de velocidad bot n de arranque Rel del arranque Motor de arranque el ctrico interruptor de parada de emergencia Potenci metro del carburador COLOR DE CABLE bl negro ye amarillo bu azul gn verde re rojo wh blanco br marron or naranja pi rosado gr gris pu violeta D 2 DE AE ARE Jh AL VERGASERREGULIERUNG CARBURETOR SETTING 125 EXC EXC SIX DAYS 20
105. s Manual or automotive fluids with equivalent specifica tions must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES 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 TRANSPORT When transporting your motorcycle secure it with elastic straps or other mechanical devices in an upright position Be sure that the fuel tap is closed If the motorcycle topples over fuel can flow out of the car buretor or fuel tank ENVIRONMENT Offroad Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others Enjoy driving your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine Page SERIAL NUMBER LOCATIONS 5 Chassis AUMP ET Rc iC Et en C t 5 Engine number engine type 5 OPERATION INSTRUMENTS 5 5 Hand brake lever
106. se to prevent 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 m f you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the rear wheel keep operating the rear brake until the pres sure point returns t 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 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
107. sively and try to look ahead as far as possible so that you recognize any hazards as early as possible Adjust your driving speed to the conditions and your driving skills Drive carefully on unknown roads or in unknown territory When driving off road always have a friend on a second motor cycle to keep you company so that you can help each other should difficulties arise Replace the helmet visor or goggle glasses early enough When light shines directly on a scratched visor or goggles you will be practically blind Never leave your motorcycle without supervision as long as the engine is running The Above Models were designed and built for one person only no additional passenger allowed Neither do these models meet the applicable statutory regula tions and safety standards Using them on public roads high ways 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 2 FUEL Check that
108. 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 DISPARAIT Modelos EXC EXC E 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 CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEM S CADUCA LA PROTECCI N DEL SEGURO gt pu wu LA uy VERGASERREGULIERUNG CARBURETOR SETTING 300 XC XC W EXC EXC SIX DAYS 2008 KEIHIN PWK 36S AG 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C MEERESHOHE TEMPERATUR 20 C bis 7 6 C bis 5 C 6 C bis 15 C ALTITUDE TEMPERATURE 2 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 3000 m ASO 10000 ft IJ NEEDLE 2301 m POS 7501 ft 2300 m 7500 ft NEEDLE 1501 m POS 5001 ft 1500 m 5000 ft NEEDLE 751m POS 2501 ft MJ 750 m ASO 2500 ft IJ NEEDLE 301 m POS 1001 ft 300 m 1000 ft NEEDLE Me
109. ssent 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 ADEMAS CADUCA LA PROTECCI N DEL SEGURO ru ru p gt wu y Vu an LA VERGASERREGULIERUNG CARBURETOR SETTING 250 XC 2008 KEIHIN PWK 36S AG MEERESHOHE TEMPERATUR 20 C bis 7 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C ALTITUDE TEMPERATURE ZF 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 3000 m 10000 ft NEEDLE 2301 POS 7501 ft 2300 m 7500 ft NEEDLE 1501 m POS 5001 ft 1500 m 5000 ft NEEDLE 751 m POS 2501 ft 750 m 2500 ft NEEDLE 301 m POS 1001 ft 300 m 1000 ft NEEDLE Meeresniveau POS Sea level 175 172 LSO Luftregulierschraube offen 1 ASO Air screw open fr
110. ttled 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 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
111. uld 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 the 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 contam inates 1 000 000 liters of water Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting rin
112. usly 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 General information on carburetor wear Engine vibrations subject the throttle slide jet needle float needle valve and the needle jet to extreme wear Wear leads to malfunctio ning of the carburetor e g over enrichment These parts should be replaced after 100 operating hours The carburetor body main jet holder and the float support should be replaced after 200 operating hours e 99 9 6969 9 4M46 gt JET NEEDLE TYPE WSS lt td ft _ _ NAN UN OF main jet jet needle gt jet needle gt idle jet throttle valve MA D air control screw idle adjusting screw RANGE OF ACTION RICHER N8RG N8RH N8RW N8RJ JET NEEDLE TYPE RANGE OF ACTION RICHER NOZD NOZE NOZF NOZH NOZI A _ _ il Wo ieee __ E n AND ENGIN 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 1 and the air control screw 2 Only make adjust
113. uspension setup for the weight of the driver 25 BALLON ersten er re dos Gp 39 Bleeding the hydraulic clutch 43 BOKI see Ente nate we 19 Breather plug front fork 27 Carburetor adjustment 43 Carbutetor table ace us RE RD XC Des 67 Chain maintenance 31 CHAI WEL esed ot d de te eae om o o t 3l Changing the basic position of hand brake lever 39 Changing the basic position of the foot brake pedal 35 Changing the fork offset caster 28 Changing the original position of the clutch lever 41 Changing the spring preload on the telescopic fork 26 Changing the spring preloading of the shock absorber 24 Changing the transmission oll 47 Charging the battery 39 Chassis NUMDE o ded de e i gg d 5 Check chain tension 31 Check transmission oil level 47 Check set distance of the magnetic sensor 38 Checking and adjusting the steering head bearing 27 Checking spoke tension 38 Checking the basic setup of the telescopic fork 26 Checking the brake fluid level front brake 33 Checking the coolant level 41 Checking the float level 45 Checking the front brake pads
114. utch disks and length of the clutch springs C Check the cylinder and piston for wear Check function of exhaust control C C C Check piston pin bearing Replace the crankshaft main bearings Replace the conrod bearings Check the entire transmission the shift mechanism and bearings C C C C C H C H C H C H C H C H C C Complete maintenance of fork Complete maintenance of shock absorber C Clean and grease steering head bearings and gasket elements Replace the sealing cup for the foot brake cylinder C C Replace the glass fiber yarn filling in the silencer C CH C CH C C H C H C C C C C H Treat electric contacts and switches with contact grease C H Change break fluid Change clutch brake fluid C FOR COMPETITIVE OFFROAD RACING COMPETITION H FOR OFFROAD HOBBY USE C H C H C H C H Note If the inspection establishes that permissible tolerances are exceeded the respective components must be replaced 250 300 XC XC W EXC EXC Six Days EXC E EXC E Six Days 2008 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER before each after every cleaning for cross country use Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lu
115. utch in oil bath hydraulically operated Brake fluid DOT 5 1 Transmission 5 speed claw actuated Gear ratio lst gear 2nd gear 3rd gear Ath gear 5th gear Gear lubrication 0 7 liter Motorex Top Speed 4T 15W50 Available chain sprockets 13t 14t for chain 5 8 x 1 4 Coolant 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system KOKUSAN E Starting aid kickstarter kickstarter and electric starter Carburator Keihin PWK 36 flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert BASIC CARBURETOR SETTING 300 XC 300 XC W 300 EXC E SIX DAYS 300 EXC E AUS 300 EXC E EU Carburetor Keihin PWK 36S AG Keihin PWK 36S AG Keihin PWK 36S AG FKO24 165 162 Carburetor setting mark Main jet 3600B 160 162 165 FKO26 115 162 165 Idling jet Starting jet Jet needle N2ZJ N2ZW N3CJ N8RH N8RJ N8RW N2ZJ N2ZWG 38x38 35 50 85 N84K N2ZJ N2ZW NOZG Needle position from top Throttle valve Air adjustment screw open 35 III IV 1 75 1 Performance restrictor TIGHTENING TORQUES ENGINE Slide stop 38 mm Slide stop 36 mm Flange bolts cylinder head Nuts cylinder base Flywheel collar nut Exhaust control retaining bracket M5 Loctite 243 7 Nm Exhaust control control flap M 6 Loctite 243 10 Nm Exhaust control lever for control segment
116. vious 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 2007 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only TUV MANAGEMENT SERVICE In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality INTENDED PURPOSE 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 THE XC XC W MODELS ARE PROHIBITED ON PUBLIC ROADS The EXC and EXC E models are only allowed on public roads in the original homologated throttled ver sion Without this performance restriction i e dethrottled these models are only allowed to be driven off road but not on public roads The EXC and EXC E models are designed for off road sports endurance competitions enduro and not suitable for predominant motocross use 2 STROKE OFFROAD MOTORCYCLES ON PUBLI
117. 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 O 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 Al 51 TR2 and A2 figures E Will be cleared x 000 MAX LAP CLK H 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 M A2 91 52 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
118. x Brake Fluid 5 1 up to the mark B on the inside of the reservoir and remount the screw Spilled brake fluid must be rinsed off with water WARNING 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 tlet brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid taken from a tightly sealed container TUE 423 My ix gt f AND ENGIN Changing the basic position of the foot brake pedal To change the basic position of the foot brake lever loosen the counternut 1 and turn the stop screw 2 as needed Be sure to adjust the free travel of the foot brake lever Measured on the outside the foot brake lever should have 3 5 mm free travel before the piston rod moves the piston in the foot brake cylinder you will feel the stronger resistance of the foot brake lever Loosen the counternut 3 and turn the pushrod 4 as needed A The brake system will build up pressure if there is no free travel on the foot brake lever This will cause the brake pads to grind The brake system will overheat and can break down entirely in extreme cases
119. ystems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly 250 300 XC XC W EXC EXC Six Days EXC E EXC E Six Days 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY N x 5 N gt gt Before each 1st service after 10 hours every 40 hours at least once Check gear box oil level Change gear box oil Check spark plugs adjust distance between electrodes ENGINE Renew spark plugs Clean the spark plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Check the carburetor connection boot and intake flange for cracks or 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 the fluid level in the master cylinder of the hydraulic clutch Clean air filter and filter box Check electric wires for damage and bends ADD ON PARTS 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 b

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