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OWNER`S MANUAL 2007

1. 14 Check set distance of the magnetic sensor 38 Rebound damping OF TOM ue anh 14 Replacing the headlight lamp parking light lamp 38 Spring preload of the fork XC EXC Six Days 14 Cooling system 454 39 Compression damping of shock absorber XC W EXC 15 Checking the coolant level 39 Shock absorber compression damping XC W EXC 15 Refilling Bleeding the cooling system 40 SHOE EE AGA e 15 Cleaning the air 40 GENERAL TIPS AND WARNINGS FOR STARTING THE E m MOTORCYCLE set de car oon d Ro ph BI RE ode 16 OPE DE ek NE Instructions for your first ride 16 Changing ME pe SEENEN 16 Bleeding the hydraulic clutch 42 Carburetor adjustment 42 DRIVING INSTRUCTIONS 2 202000 0 17 Draining the float chamber of the carburetor 44 What you should check before each start 17 Checking the float level 44 Starting when engine is cold 18 Adjusting the engine characteristic via the ignition 44 Starting when the engine is warm ana 18 Adjusting the engine characteristic via the auxiliary spring 45 What to do when the engine is flooded 18 Check transmission oil level 125 200 46 EE
2. 4th gear 4519 19 26 4S26 AS19H 19 26 4826 4519 19 26 4526 5th gear 5521 210162518929 DG17H 17 19 5G19H Hoe 2192519920 6th gear 0G20 20 20 6G20 OG22H 22 20 6E20H 6622 22 23 6823 Available chain sprockets 13 14 for chain 5 8 1 4 Coolant 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system KOKUSAN 2K 3 EXC EXC Six Days KOKUSAN 2K 3 EXC Generator output 12V 110 W 12V 110 W Ignition system XC W KOKUSAN 2K 2 XC XC W Generator output 12V 40 W Carburetor 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 2007 Flange bolts cylinder head M7 Nuts cylinder base M8 Flywheel collar nut M12x1 Nut for primary sprocket LH thread 16 1 5 130 Nm Collar screw for clutch spring M6 10 Nm Oil drain plug M10x1 15 Nm Drain plug for water pump cover M10x1 15 Nm Collar screw for water pump cover M6 Loctite 243 10 Nm Water pump wheel M5 Loctite 243 6 Nm Collar screws for exhaust flange Mb 6 Nm Collar screws for ignition system Mb 6 Nm Other screws M6 M8 M 10 BASIC CARBURETOR SETTING 125 EXC EU 4 2 KW 125 EXC SIX DAYS 200 XC USA 200 EXC AUS 7 KW 200 XC W USA 200 EXC EU 7 KW 200 EXC ZA Carburetor Keihin PWK 365 AG Keihin PWK 365 AG Keihin PWK 365 AG Keihin
3. D D 2 DE D D AG ARE Jh VERGASERREGULIERUNG CARBURETOR SETTING 125 EXC SIX DAYS EXC 2007 KEIHIN PWK 36S AG mm 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 i 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 IJ NEEDLE 2301 POS 501 ft MJ 2300 m ASO 7500 ft IJ NEEDLE 1501 POS 5001 ft MJ 1500 m ASO 5000 ft IJ NEEDLE 751 m POS 2501 ft MJ 750 m ASO 2500 ft IJ NEEDLE 301 m POS 1001 ft MJ 300 m ASO 1000 ft IJ NEEDLE Meeresniveau POS Sea level LSO Luftregulierschraube offen j ASO Air screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben 4 POS Needle clip position from top HD Hauptd se SCH 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 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 AUSS
4. KTM EXC 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 AN WARNING Orr 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 is 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 faultless operation
5. Make sure you do not turn the dolly screw since this will impair the engine characteristic 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 Six Days EXC Engine performance Standard setting Driveability Standard setting 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 250 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
6. ing the screw counterclockwise produces a lower idling speed Create a round main jet 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 gt jet needle Opening up B Engine behavior when the throttle opens The idle jet and the shape of the D mm Bn MA jet needle mE throttle valve influences this range If despite good idling speed and part idle jet throttle setting the engine sputters and smokes when the throttle is fully opened 3 throttle valve and develops its full power not smoothly but suddenly at high engine speeds NNN 2 2 gt TT the mixture to the carburetor will be too rich the fuel level too high or the air control screw float needle is leaking idle adjusting screw Part throttle range C Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main Jet in the upper range If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at
7. push the rear wheel forwards so that the chain tensioners lie on the tension screws AN WARNING 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 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 o
8. 13 Stoppingandparking 19 ase Rare UH ROR dca pem eae 47 Technical Specifications Chassis 125 200 48 Technical Specifications Chassis 250 300 52 Technical Specifications Engine 125 200 50 Technical Specifications Engine 250 300 54 Tires air pressure 37 What to do when the engine is flooded 18 What you should check before each start 17 XIGN4ddV AIIGNAddV 9NVHNV O multi func digital speedometer flasher control lamp bu br driving light lamp front brake switch headlight CA f N left front flasher 1 e re k ccm dN br bl H s D SCH OTO DU high low beam switch horn switch stop button flasher switch flasher relay H Ex handle bar switch optional e C BT 3 2 4 3 2 1 2 horn 5 5 ala rear brake switch ye re br EN C BG1 3 C AJ1 3 SIS l i 2 lal C ignition curve selector ignition coil f regulator rectifier right rear flasher bl Ile x 9 CW 2 RS left rear flasher N C_CX1 2 C CW1 2 EXC 125 300 2007 wiring diagram main harness 548 11
9. 30 Nm 50 Nm NILA ALIUNS ENGIN A DE 20 XG XC W EX JU ENGINE 125 EXC EXC SIX DAYS 200 XC W EXC Design Liquid cooled single cylinder two stroke engine with intake and exhaust control Piston displacement 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 40 1 60 when using high grade two stroke oil Motorex Cross Power 2T When in doubt please contact your importer Crankshaft bearing deep groove ball bearing 1 cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston cast piston Piston ring two plain compression rings two plain compression rings Dimension a 0 0 mm Ignition timing 1 4 mm 0 055 in 16 5 BTDC 1 6 mm 0 063 in 17 BTDC Spark plug NGK BR9 EVX NGK BR 8 EG Electrode gap 0 60 mm Dimension 2 Feen fas 43 5 mm 1 68 in 47 mm 1 85 in Primary drive straight cut spur gears primary ratio 23 73 Clutch multiple disc clutch in oil bath hydraulically operated Motorex hydraulic fluid 75 Gear ratio lst gear 12533 01G953 13 33 10397 13 35 32 41932 2nd gear 25154 15 31 2G31 2515 72631 2515 5435029530 3rd gear 3517 17 28 3S28H 3517 17 28 3828H 3S17H 17 28 3S28H
10. 9 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 parking lot or open space before going for a longer ride Also try to ride as slowly as possible while standing upright to improve your feeling for the vehicle Do not drive along off road trails which go beyond your ability and experience Hold the handlebar with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated 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
11. 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 engine 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 Emergency OFF switch Australia The emergency OFF switch 5 is located next to the throttle grip Primarily designed as safety or emergency OFF switch it should normally not be in its activated state In this position the ignition circuit is shorted if the engine is running it will stall immediately if it is at standstill it will not start din this position the ignition circuit is enabled the engine should start Filler cap EXC EXC Six Days To open it turn filler cap counter clockwise To close it put filler cap back on and tighten it by turning it clockwise Filler cap XC XC W To open the filler cap Turn the filler cap 45 counter clockwise To close the filler cap Put the filler cap on and turn it 45 clockwis
12. LA Z LA lt gt lt Z LLJ lt co VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 2504 300 XC W USA 300 XC USA 250 300 EXC EU AUS 2504 300 EXC SIX DAYS 250 300 EXC ZA 2007 16 C bis 24 C 25 bis 36 C 37 C bis 49 C MEERESHOHE TEMPERATUR 20 C bis 7 C 6 C bis 5 C 6 C bis 15 C ALTITUDE TEMPERATURE P 4 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 EE MIL ET XION1ddV JIIGNIddv 9NVHNV 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1500 m 5000 ft t 751 m 2501 ft 750 m 2500 ft 301 m 1001 ft 300 m 1000 ft ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ ASO IJ 4 NEEDLE Meeresniveau POS 5 4 4 4 3 Sea level MJ 170 168 165 162 162 LSO Luftregulierschraube offen j 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 SCH 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 erhal
13. XC EXC Six Days 28 Changing the original position of the clutch lever 41 Changing the spring preload on the telescopic fork XC EXC Six Days models 26 Changing the spring preload on the telescopic fork XC W EXC models 26 Changing the spring preloading of the shock absorber 24 Changing the transmission oil 125 200 46 Changing the transmission oil 250 300 46 ChassIS aime SE weg kake 5 Check chain tension 30 Check transmission oil level 125 200 46 Check transmission oil level 250 300 46 Check set distance of the magnetic sensor 38 Checking and adjusting the steering head bearing 29 Checking spoke tension 37 Checking the basic setup of the telescopic fork 26 Checking the brake fluid level front brake 33 Checking the coolant level 39 Checking the float level 44 Checking the front brake pads 33 Checking the oil level of the hydraulic clutch 41 Checking the rear brake fluid level 34 Checking the rear brake pads 35 Checking the shock absorber and spring 2b CNOKE KN uet ee dad a ES E veis 12 Si RPM 47 Cleaning the air filter 40 Cleaning the dust sleeves of the telescopic fork 27 Ge NEN EX Lieu tung ud
14. see drawing If necessary correct the chain tension AN WARNING ee f the chain tension is too great parts within the secondary transmission chain chain wheels and rear wheel 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 EL IG II max 272 mm 16 17 18 AND ENGIN Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts Before tightening the collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm 60 ft Ib AM 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 combinat
15. 1 25 Umdrehungen offen Spring 4 2 N mm Rebound adjuster 24 Preload Adjuster 2 Umdrehungen offen Air chamber length 110 mm Fork oil SAE 5 Spring TIGHTENING TORQUES CHASSIS 72 250 Spring preload Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front M8 Brake disks Screw steering head M20x1 5 Loctite 243 25 Nm 10 Nm Lower Screw steering head M20x1 5 Loctite 243 60 Nm Clamping screws upper fork bridge 125 EXC SIX DAYS 200 XC M8 1 Nm Clamping screws lower fork bridge 125 EXC SIX DAYS 200 XC Clamping screws upper steering stem 125 EXC SIX DAYS 200 XC 8 Loctite 243 17 Nm Clamping screws upper fork bridge EXC XC W M8 20 Nm Clamping screws lower fork bridge EXC XC W M 8 Clamping screws fork stubs M8 Collar nut rear wheel spindle M20x1 5 15 Nm Hexagon nut swing arm bolt M16x1 5 Hexagon collar screw handlebar clamp M8 Allan head screw handlebar support Loctite 243 40 Nm Shock absorber top M12 Loctite 243 70 Nm Shock absorber bottom M12 Loctite 243 70 Nm Sprocket screws M8 Ball joint for push rod Engine mounting bolt Loctite 243 35 Nm 60 Nm Engine brace 33 Nm Screw adjusting ring spring preload shock abs Spoke nipple Other screws on chassis Other collar nuts on chassis M10 M8 M6 M6 M8 M1O M6 M8 M10 8 Nm 10 Nm 25 Nm 45 Nm 15 Nm
16. 30 Nm M10 50 Nm TI A JN ENGIN JU Ik Y JF JU ENGINE 250 XC 250 XC W EXC SIX DAYS EXC 300 XC 300 XC W EXC SIX DAYS EXC Design Liquid cooled single cylinder two stroke engine Piston displacement Bore stroke with KTM Twin Valve Control exhaust system and KTM Torque Chamber 249 ccm 293 15 ccm 66 4 72 mm 2 62 2 84 in 72172 mm 2 84 2 84 in Fuel Oil gasoline ratio Crankshaft bearing Connecting rod bearing unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Motorex Cross Power 2T 1 40 1 60 when using high grade two stroke oil When in doubt please contact your importer or use 1 40 mix ratio to be on the safe side deep groove ball bearing 1 cylinder roller bearing needle bearing Piston pin bearing Piston needle bearing cast piston Piston ring Dimension X upper edge cylinder Ignition timing two plain compression rings O 0 1 mm 0 0 004 1 9 mm 0 074 in BTDC Spark plug NGK BR7 ES Electrode gap 0 60 mm Dimension 2 708701 1 47 5 1 87 48 5 TVC start open 5500 min 5200 min TVC fully open 000 min red spring 7500 min yellow spring 7900 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 ge
17. PWK 365 AG Carburetor setting mark 8KTPC FK0070 FK 0130 8KTUD 145 168 170 172 170 168 172 162 160 165 162 160 165 Idling jet 35 45 48 4 42 35 42 Starting Jet 8 8 85 85 IV 7 1 5 5 IV 11 7 7 1 1 Needle position from top V 5 Throttle valve 7 1 5 Air adjustment srew open CHASSIS 250 300 XC XC W 250 300 EXC SIX DAYS 250 300 EXC EXC ZA Frame Central chrome moly steel frame Fork WP Suspension 4860 MXMA PA 250 300 XC EXC SIX DAYS Wheel travel front rear 300 335 mm 11 8 13 2 in WP Suspension 5018 PDS MCC Alu Hinterradschwinge Front brake Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Wear limit 2 50 mm 0 1 in front 3 50 mm 0 14 in rear Front tires 80 100 21 51M M59 Bridgestone 90 90 21 Pirelli MT 83 90 90 21 Pirelli MT 83 80 100 21 51M M59 Bridgestone Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 1 5 bar 21 psi 1 5 bar 21 psi Rear tires 110 100 18 64M M402 Bridgestone 140 80 18 Pirelli MT 83 140 80 18 Pirelli MT 83 110 100 18 51M M59 Bridgestone Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 2 0 bar 28 psi 2 0 bar 28 psi Fuel tank capacity 250 300 EX
18. Roa due SERO E att 5 Combination switch EXC 11 Compression damping of fork 14 Compression damping of shock absorber XC W EXC 15 Conservation for winter operation 47 Cooling a 39 Correct Cham TENSION wy raea V d Re ew cra 3l Damping action during compression of shock absorber XC EXC Six Days 14 Determining the riding sag of the shock absorber 25 Determining the static sag of the shock absorber 25 Dismounting and mounting the front wheel 35 Dismounting and mounting the rear wheel 36 Draining the float chamber of the carburetor 44 Driving Iastdctlonss a ex oH oec CERRO EE S 17 Electronic speedometer 6 Emergency OFF switch Australia 11 Page Engine characteristic 250 300 SX XC EXC 45 Engine number engine type 5 Exhaust system 41 We Hauer 12 Filler cap XC XC W 12 Flasher SWITCM a sia a nabe mana c aaa or p sua d 11 Foot brake pedal 13 STRENG 12 General information about KTM disc brakes 32 General tips and warnings for starting the motorcycle 16 Hand brake 5 Headlamp switch XC W 11 How to change the handlebar position 30 Indicator lamps EXC 10 Instructions for your first
19. 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 stand with the rubber band on the air filter box JN 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
20. adjust if necessary Clean air filter and filter box Check tires for pressure and wear e EN Check cooling liquid level e Check fuel lines for leaks e Empty and clean float chamber Remove clean and oil the throttle slide Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly VAIN NAN UN AND ENGIN AN 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 f 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 should fall over no fuel can leak from the carburetor or fuel tank Only use special screws with an appropriate thread lengt
21. 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 OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS 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 4 button button briefly press O button hold O button 3 secs time time changes to the next digit starts the SETUP menu stores the time and changes to the SPEED CLK dis play mode Motorcycle is driving display SPEED CLK briefly press button no function briefly press button SPEED H no function no function no function briefly press O button next display mode next display mode hold O button 3 secs displays the SETUP menu setting the clock menu SPEED LAP gt lt x X Motorcycle is standing SPEED MAX starts stops LAP without clearing LAP figure no function stops LAP stores LAP figure resets LAP to O LAP L
22. 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 SIANDARD SETTING Unscrew the adjusting screw to the limit and then back 2 turns Changing the spring preload on the telescopic fork XC W EXC models The telescopic forks for these models must be partly disassembled to adjust the spring preload see WP manual Pretension spacers are available in heights of 1 5 2 5 5 and 10 mm see spare parts catalog The fork springs may not be pretensioned by more than 20 mm The preload adjuster used in the XC EXC Six Days models can easily be retro fitted for the telescopic forks of the XC W EXC models NOTE WP precisely adjusts the spring pressure by inserting pretension spacers Fluctuations in production are compensated with pretension spacers in vari ous heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and pretension spacers should always stay together AND ENGIN Replacing fork springs for example front fork 250 EXC If you weigh less than 75 kg or more than 85 kg you should install the respec tive fork springs The correct spring rate is shown in the illustrations The stan dard spring is s
23. dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Check fuel lines for leaks e Check all control elements for smooth operation e Treat blank metal parts with the exception of brake and exhaust systems Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level e PERIUL VAIN NAN TEL 250 300 XC XC W EXC SIX DAYS EXC 2007 wm lt lt 2 5 g 2 2 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY o z o M r o Check gear box oil level e Change gear box oil e e ele Check spark plugs adjust distance between electrodes ttu Z Renew spark plugs e 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 e amp Check the carburetor connection boot and intake flange for cracks or leaks e Check idle speed setting Check that vent hoses are not damaged or bent s it Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Z Check cables for damage smooth operation bends adjust and lubricate lt Check the fluid level in the master cylinder of the hydraulic clutch Clean air filter and filter box e Check electric wires BI damage and bends LL Ge Check headlamp setting Check function of electric systems lo
24. figure button decreases the TR2 figure briefly press O button changes to the next display mode hold O button 3 secs clears the TR2 figure SPEED A1 display mode average speed 1 Al shows the average speed based on the TRI tripmaster 1 and S1 stop watch 1 figures The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TR1 51 Al figures SPEED 2 EP Km h MW Mhz AN AN d CITT VE I LILI ILI AC TRI TR M A2 9 92 ODO MAX LAP CLK H SPEED A2 display mode average speed 2 A2 shows the average speed based on the TR2 tripmaster 2 and S2 stop watch 2 figures The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip button no function button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode SPEED S1 display mode stop watch 1 S1 shows the traveling time based on TR1 and continues to run whenever it receives impulses from the wheel sensor The calculation of this figure is acti vated by the first impulse received from the wheel sensor and stops 3 sec onds after the last impulse i
25. hours minutes and seconds no function no function changes to the next display mode set the clock menu 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 Five 20 LILI LILI II LAP LAP LAP display mode to view lap times The LAP LAP display mode will only be shown If lap times have been stored and the front wheel has stopped It will display the lap number and the stopped lap time in hours minutes and seconds Press the button to access the next lap time To clear all of the
26. 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 d WARNING OO 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 tem looked over by a KTM dealer 6 CABLES Check correct adjustment and easy running of all control cables COOLING FLUID Check the level of cooling fluid when the engine is cold ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights turn indicators indicator lamps and horn while the engine is running LUGGAGE If you are taking luggage with you check that it is securely fastened Starting when the engine is cold Open fuel tap Turn on ignition or emergency OFF switch Swing up the side stand Put the gear in neutral Activate cold starting aid choke Leave throttle closed or open it no more than 1 3 and kick down kick starter vigorously all the way AE TT For starting always put on your motorcycle boots to avoid injuries You could slip off the kickstarter or the motor could kick back a
27. intake flange for cracks or leaks e Check idle speed setting Check that vent hoses are not damaged or bent s it Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment o Check cables for damage smooth operation bends adjust and lubricate lt Check the fluid level in the master cylinder of the hydraulic clutch Clean air filter and filter box e Check electric wires BI damage and bends LL Ge Check headlamp setting Check function of electric systems low beam high beam break light indicator e 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 ei 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 t it Check shock absorber and fork for leaks and function e Clean dust bellows e 2 Bleed fork legs e LR lt Check swing arm bearings e Check adjust steering head bearings e 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 e v Check tires and air pressure e ui Check chain rear sprockets and chain guides for wear fitment and tension gt Lubricate chain Clean and grease the
28. it has properly cooled down to avoid burns Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size The clutch lever 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 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex 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 2
29. on kickstarter M6 Loctite 243 10 Nm Oil drain plug with magnet M 12x1 5 20 Nm Kickstrteriever M Kickstarter lever Other bolts BASIC CARBURETOR SETTING 250 XC USA EU 250 300 EXC EU 300 EXC E EU 250 300 EXC AUS 250 300 XC W USA 300 XC USA 2504 300 EXC Six Days EU 250 300 EXC ZA Carburetor Keihin PWK 36S AG Keihin PWK 36S AG Keihin PWK 36S AG Carburetor setting mark FKO150 Main jet 168 170 3600B 160 162 165 FKO140 162 165 Idling jet 35 39 39 Starting jet Jet needle N8RG N8RH 85 N3CJ N8RH N8RW 85 N8RH N8RW Needle position from top IV Throttle valve Air adjustment screw open 7 7 Performance restrictor 3 5 1 slide stop 38 mm 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 Adjusting the free travel at the hand brake lever 33 Basic suspension setup for the weight of the driver 25 Bleeding the hydraulic clutch 42 BOKS etw oa Eet dua 19 Breather plug front fork 27 Carburetor adjustment 43 Chain maintenance 3l Chan WEE dereat 31 Changing the basic position of the foot brake pedal 34 Changing the fork offset caster
30. 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 MAX display mode maximum speed MAX displays the maximum speed traveled and is always active button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the MAX figure SPEED TR1 display mode tripmaster 1 The TR1 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 TR1 Al and S1 figures are automatically cleared after passing 999 9 button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TR1 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
31. 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 JET NEEDLE RANGE OF ACTION the main jet and the jet needle If the porcelain of the new spark plug is found TYPE RICHER LEANER 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 JET NEEDLE RANGE OF ACTION TYPE RICHER LEANER Explanation of table Example Compared to the needle NOZI the jet needle NOZG 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 t
32. 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 cautiously Always reduce the jet size in steps of one number to avoid overheating and piston seizure NOTE If the engine does not run properly despite a changed adjustment look for mechanical faults and check the ignition system 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 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 2 and the air control screw 3 Only make adjust ments when the engine is hot To this end slightly increase the idling speed of the engine by means of the air control screw Turning it clockwise produces a higher idling speed and turn
33. you assemble a rear sprocket with 14t the collar must be on the inside Secure the screws of the chain wheel by applying Loctite and fasten them in a crosswise order Tightening torque for nuts 35 Nm Tightening torque for screws 50 Nm AND ENGIN General information about KTM disc brakes BRAKE CALIPERS The brake calipers of this series use a floating mount This means that the brake calipers are not solidly attached to the caliper support which enables them to float for maximum braking contact Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm 19 ft Ib BRAKE PADS The brake pads are fitted with TOSHIBA TT 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 K
34. 075 350 1 6 rear light brakelight MALT FLAN VIKING DVIAGKAIMI P 4 4J10NdddV 9NVHNV gt mv mv rri Z gt lt gt mv rri Z O rri N light switch high low beam switch horn switch P LIGHT O brake switch flasher switch cable gn ye harness wh cable switch wee ele wwe stop switch cable ye Be harness bl cable ye br switch bl re eme NANI JJIGNJdV XIGN4ddV 39IaN3ddV 9NVHNV headlight multi func digital speedometer light switch handle bar switch optional ignition coil XC W 200 250 2007 stop switch ignition curve selector wiring diagramm regulator rectifier Ax CY pick up generator main harness 548 11 075 000 10 04 2006 rear light brakelight NANI multi func digital speedometer il K CX W 300 2007 ANHANG APPENDICE APPENDIX APENDICE handle bar switch optional lt T light switch 5 E gt ignition coil stop switch wiring diagramm ignition curve selector x 3 G CE generator main harness 548 11 075 100 regulator rectifier JH lt 10 04 2006 rear light brakelight re 1H LAN ENGLISH Capacitor CDI Driving light lamp Flasher relay Flasher switch Front brake switch Flasher control la
35. 1 liters 2 9 US gallons Final drive ratio 14 42 t 13 50 t EXC EU AUS 14 42 t 14 48 t XC XC W USA EXC ZA 14 48 t Chain 5 8 x 1 4 Available final sprockets 38t 401 421 45t 481 49t 50t 51t 521 Bulbs EXC EXC Six Days headlight 12V 35 35W Bilux base Ba20d parking light 12V 5W base W2 1x9 5d brake rear light 12V 21 5W base BaY15d flasher light 12V 10W base 155 Steering head angle 63 Wheel base 1471 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 98 6 kg 216 9 Ibs EXC EU AUS 99 8 kg 219 6 Ibs EXC ZA 98 4 kg 216 5 Ibs XC W USA 97 4 kg 214 3 Ibs XC USA 97 2 kg 213 8 Ibs STANDARD ADJUSTMENT FORK 125 200 EXC XC W A hi W EX STANDARD ADJUSTMENT SHOCK ABSORBER 125 200 EXC XC W WP 4860 MXMA WP 5018 PDS MCC 14187 02 12187 02 Compression adjuster 20 Compression adjuster 17 Rebound adjuster 20 Rebound adjuster 26 Spring 4 0 N mm Spring 110 mm SAE 5 STANDARD ADJUSTMENT FORK 125 EXC SIX DAYS 200 XC Air chamber length Fork oil Spring preload STANDARD ADJUSTMENT SHOCK ABSORBER 125 EXC SIX DAYS 200 XC WP 4860 MXMA PA WP 5018 PDS DCC 14187 27 12187 27 Compression adjuster Druckstufend mpfung Low Speed 15 Klicks Druckstufendampfung High Speed 18 Rebound adjuster 20
36. 18 Changing the transmission oil 125 200 46 Shifting Riding sca e aec eR cuo Cice 18 Check transmission oil level 250 300 46 Kiel 19 Changing the transmission oil 250 300 46 stopping and 19 DEENEN gaer e Or la eid 19 scq ca E 47 PERIODIC MAINTENANCE SCHEDULE 20 CONSERVATION FOR WINTER OPERATION 47 MAINTENANCE WORK ON CHASSIS AND ENGINE 24 STORAGE sro aw ard Eer T Er ow heehee 47 Changing the spring preloading of the shock absorber 24 Pivot Deae uires priest ses tay Mai serve 24 Basic suspension setup for the weight of the driver 25 V Checking the shock absorber and spring 25 Determining the static sag of the shock absorber 25 TEGANG AL SKEIE ENGINE week Determining the riding sag of the shock absorber 25 Changing the spring preload on the telescopic fork 26 TECHNICAL SPECIFICATIONS CHASSIS 250 300 52 Checking the basic setup of the telescopic fork 26 Replacing fork springs 27 TECHNICAL SPECIFICATIONS ENGINE 250 300 54 Breather plug front fork 27 Cleaning the dust sleeves of the telescopic fork 27 TE PET 56 Changing the fork offset caster XC 28 Checking and adjusting the steering head bearing 29 WIRING DIAGRAM CARBURETOR TABLE APPENDIX Chassis number The chassis number is stampe
37. 2007 125 EXC SIX DAYS EXC 200 XC XC W EXC 290 XC XC W EXC SIX DAYS EXC 300 XC XC W EXC SIX DAYS EXC ART NR 3 211 144EN IMPORTANT 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 with
38. 50 300 To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add DOT 5 1 brake fluid 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 rem
39. AP next figure no function no function next display mode clears all LAP figures next display mode next display mode next display mode clears MAX SPEED ODO no function no function next display mode next display mode SPEED TR1 X X X X SPEED A1 no function no function no function no function next display mode next display mode clears TRI S1 Al SPEED TR2 increases the TR2 figure reduces the TR2 figure next display mode clears TR2 clears TR1 S1 A1 SPEED A2 no function no function next display mode next display mode SPEED S1 SPEED S2 EIEIEIEIEIE X X X i no function no function next display mode clears TR1 S1 A1 starts stops S2 no function next display mode clears S2 If the CLK LAP MAX TRI TR2 Al A2 51 and S2 figures are suddenly cleared the battery in the electronic speedometer is empty and must be replaced see Replacing the battery in the electronic speedometer A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar Indicator lamps EXC 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 Combination switch EXC EXC Six Days The light switch has 2 respectively 3 switch positions
40. BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACION EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO P 4 ANHANG APPENDICE
41. C EU EXC Six Days 8 5 liters 2 2 US gallons Reserve page 12 250 300 EXC AUS 10 liters 2 6 US gallons 250 300 XC XC W 11 liters 2 9 US gallons Final drive ratio 13 50 t 13 50 t 13 40 t 13 50 250 300EXC EU AUS 13 50 t 250 300 EXC ZA Chain 5 8 x 1 4 Available final sprockets 38t 401 42t 45t 481 49t 51t 52t Bulbs headlight 12V 35 35W Bilux base Ba20d parking light 12V 5W base W2 1x9 5d brake rear light 12V 21 5W base BaY15d flasher light 12V 10W base Balbs Steering head angle 63 5 Wheel base 1475 10 mm 58 1 in 0 4 in Seat height unloaded 925 mm 36 5 in Weight without fuel 99 6 kg 250 XC EU 102 6 kg EXC Six Days EU 102 6 kg 250 300 EXC EU AUS 99 4 kg 250 XC USA 100 6 kg 250 300 EXC ZA 101 6 kg 250 XC W USA 99 8 kg 300 XC USA 100 4 kg 300 XC W USA 20 XC XC W EX A DE EA JU STANDARD ADJUSTMENT SHOCK ABSORBER 250 300 EXC XC W WP 5018 PDS MCC 12187C04 STANDARD ADJUSTMENT FORK 250 300 EXC XC W WP 4860 MXMA 14187C04 Rebound adjuster 20 Zugstufend mpfung 25 76 250 Spring preload 5 mm Spring 4 2 N mm Spring Luftkammerl nge 110 mm Gabel l SAE 5 STANDARD ADJUSTMENT FORK 250 300 XC EXC SIX DAYS WP 4860 MXMA PA 14187C28 Compression adjuster 18 Rebound adjuster 20 Spring 4 4 N mm Preload Adjuster 2 Umdrehungen offen Air chamber length 110 mm Fork oil SAE 5 STANDARD E
42. ECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACION EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO P u p gt rou p gt wu qu rw V v rw rw qu V v VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250 XC USA EU 2007 MEERESHOHE ALTITUDE I TEMPERATUR TEMPERATURE mac 2 20 C bis 7 C 2 F to 20 F 6 C bis 5 C 6 C bis 15 C 19 F to 41 F 42 F to 60 F 61 F to 78 F 79 F to 98 F 99 F to 120 F 16 bis 24 C 25 bis 36 C 37 C bis 49 C 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1500 m 5000 ft t 751 m 2501 ft 750 m 2500 ft 301 m 1001 ft 300 m 1000 ft t ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ ASO IJ NEEDLE Meeres
43. ERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v l
44. INSTELLUNG GABEL 250 300 XC EXC SIX DAYS WP 5018 PDS DCC 12187C28 Compression adjuster High Speed 1 0 Umdrehungen offen Rebound adjuster 24 Spring 76 250 Spring preload TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front Brake disks Steuerkopfschraube M8 M20x1 5 Loctite 243 25 Nm 10 Nm Steuerkopfschraube unten M20x1 5 Loctite 243 60 Nm Klemmschrauben Gabelbr cke oben XC EXC Six Days 8 Klemmschrauben Gabelbr cke unten XC EXC Six Days M8 Klemmschraube Gabelschaftrohr oben XC EXC Six Days M 17 Nm Loctite 243 17 Nm Clamping screws upper fork bridge EXC XC W M8 20 Nm Clamping screws lower fork bridge EXC XC W 8 Clamping screws fork stubs M8 Collar nut rear wheel spindle M M20x1 5 15 Nm Hexagon nut swing arm bolt M16x1 5 Hexagon collar screw handlebar clamp Allan head screw handlebar support Loctite 243 40 Nm Shock absorber top M8 M12 Loctite 243 70 Nm Shock absorber bottom M12 Loctite 243 70 Nm Sprocket screws Ball joint for push rod Engine mounting bolt M8 Loctite 243 35 Nm Engine brace Screw adjusting ring spring preload shock abs Spoke nipple Other screws on chassis Other collar nuts on chassis M10 60 Nm M8 33 Nm M6 8 Nm 6 10 Nm M8 25 Nm M10 45 Nm M6 15 Nm M8
45. K H 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 H service hours Only the SPEED H and SPEED ODO display modes are activated in the condition at delivery SPEED H is displayed whenever the display is activated and the front wheel is not turning It automatically changes to the SPEED ODO display mode as soon as the front wheel starts turning SPEED displays the speed H displays the engine s service hours The service hour counter starts to count as soon as you start the engine The displayed figure cannot be changed Service intervals are indicated in service hours for some KTM offroad motor cycles making the service hour counter a very practical function SPEED ODO display mode odometer The SPEED ODO mode displays the speed and the total distance traveled LILI n3 H The display automatically changes to the SPEED H display mode when the gt front wheel stops turning SPEED Km h 000 button no function button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode The electronic speedometer has a number of display modes functions that you can also activate reveal see Activating and deactivating di
46. POS 5001 ft MJ 1500 m ASO 5000 ft IJ NEEDLE 751 m POS 2501 ft MJ 750 m ASO 2500 ft IJ NEEDLE 301 m POS 1001 ft MJ 300 m ASO 1000 ft IJ NEEDLE NOZE NOZF NOZF NOZF NOZG Meeresniveau POS 4 4 4 4 3 Sea level 168 165 162 162 160 LSO Luftregulierschraube offen j ASO Air screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben 4 POS Needle clip position from top HD Hauptd se SCH 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 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 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
47. RIEB 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 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 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 ASSICURA
48. Remover and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Motorex liquid Bio Power Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Mount the air filter on the filter support Insert the air filter and filter support in the throttle cap and mount them in the filter box aligning in a central posi tion and fix with the filter retaining bracket AND ENGIN 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 AN WARNING om The exhaust system becomes very hot while the motorcycle is running Do not start work on the exhaust system until
49. TIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACION EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO P u p gt rou p gt wu qu rw V v rw rw qu V v VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 20 C bis C 6 C bis 5 C 6 C bis 15 C MEERESHOHE 16 bis 24 C 25 bis 36 C 37 C bis 49 C ALTITUDE TEMPERATUR TEMPERATURE ope 2 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 IJ NEEDLE 2301 m POS 501 ft MJ 2300 m ASO 7500 ft IJ NEEDLE 1501
50. TM dealer BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid DOT 5 1 brake fluid one of the best brake fluids is currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible with DOT 5 1 Never use brake fluid DOT 5 The color of this silicon oil based product is purple red The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid AN WARNING 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 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 In this way
51. Z gt o NX D e 545 EXAMPLE Motorcycle jacked up dimension 600 mm Motorcycle on ground unloaded dimension B 565 mm SAUC ML 35 mm If the static sag Is lower the spring preload of the shock absorber must be increased if the static sag is reduced the spring preload must be higher See chapter Changing the spring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C CN VD s N CN y my D ISS SSC SRC SKY SKY S SKY Motorcycle jacked up dimension 600 mm Motorcycle on ground loaded dimension C 500 mm Riding 100 mm for example shock absorber 250 EXC The riding sag should lie between 95 and 105 mm If the riding sag is less than 95 mm the spring is too hard the spring rate is too high If the riding sag is more than 105 mm the spring is too soft the spring rate is too low The spring rate is written on the outside of the sp
52. ace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING rm 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 i CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid taken from a tightly sealed container Checking the front brake pads The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thick AN WARNING OOOO At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc AND ENGIN Replacing the front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 Remove brake pads from the brake caliper Clean the brake caliper
53. adjusting screws on the chain tensioner eieiei Check clearance of wheel bearings e o 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 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER 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 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 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER country use before each start after every cleaning for cross Check gear box oil level Check brake fluid level Check brake pads for wear e Check lights for function e Check horn for function e Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean
54. 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 s Manual or au
55. and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the sliding metal sheet 3 in the caliper support and of the leaf spring 4 AN WARNING 00 It 15 very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correctly after working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw 5 The free play at the foot brake pedal must then be adjusted by means of the piston rod 6 Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylin der to be recognised from the resistance on the foot brake pedal AN WARNING m If this free play is not present then pressure can build up in the brake sys tem when driving causing the rear wheel to brake The braking syste
56. ar Ath gear bth gear 5 speed claw actuated 14 30 14 30 14 30 14 30 16 26 17 26 16 26 17126 18 24 19 23 18 24 19423 21 24 20 20 21 24 20 20 2212 29 23 22421 29523 Gear lubrication Available chain sprockets 0 7 liter Motorex Top Speed 4T 15W50 13t 14t for chain 5 8 x 1 4 Coolant Ignition system Generator output Ignition system XC W Generator output 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F KOKUSAN 2K 3 EXC EXC Six Days KOKUSAN 2K 3 EXC EXC Six Days 12V 110 W EXC EXC Six Days 12V 110 EXC EXC Six Days KOKUSAN 2K 2 XC XC W KOKUSAN 2K 2 XC XC W 12V 40 W XC XC W 12V 40 W XC XC W Carburator Air filter flat slide carburetor carburetor setting see table wet foam type air filter insert TIGHTENING TORQUES ENGINE Flange bolts cylinder head 2 Nm Nuts cylinder base 35 Nm Flywheel collar nut 60 Nm Exhaust control retaining bracket Loctite 243 7 Nm Exhaust control control flap Loctite 243 10 Nm Exhaust control lever for control segment M5 Loctite 243 6 Nm Shift roller bearing retaining bracket M 6 Loctite 243 10 Nm Shift lock M 6 Loctite 243 10 Nm Locking lever Loctite 243 6 Nm Idler bolt M6 Loctite 270 10 Nm Kickstarter release plate M6 Loctite 243 10 Nm Spring hanger for kickstarter M6 Loctite 243 10 Nm Spring hanger
57. ber plate Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the blind screw 1 from the upper triple clamp loosen the clamp screw and upper triple clamp on the seat Remove the O ring 3 and the pro tection ring 4 Tap gently on the lower triple clamp with a rubber hammer to loosen the steer ing stem 5 out of the bearing seat Take the lower triple clamp with the steer ing stem out of the steering head Remove the collar screw from the lower triple clamp and pull out the steer ing stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp Apply Loctite 243 to the thread of the collar screw 2 and turn all the way in Y WARNING ee 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 middl
58. d 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 OPERATION INSTRUMENTS 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 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 LI The O button is used to change between display modes SPEED amp 5 The and buttons are used to control various functions TEST All of the display segments briefly light up for the display function test C D TR 4 To AN SPEED WS Km h Mph Miles 000 MAX LAP CL
59. d with a soft water Jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all the gliding bearing parts Treat the chain with a chain spray To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch the short circuit button the light switch and the socket connectors with contact spray JNSERVATIUN FUR WINTER UFERA HUN In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent WW ARN emm ere aee paenan ag aa aa a ana ag a Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly w
60. dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them downward Clean the dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with Universal oil spray Motorex Joker 440 or engine oil Then push the dust protection bellows into the outer tubes by hand Si WARNING rom 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 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 num
61. e Install tank breather hose 1 without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carbure tor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES Ihe reserve tank cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Reserve of the 8 5 10 tank 1 3 0 34 US gallons Reserve of the 11 2 I tank 1 7 1 0 45 US gallons Choke knob When pulling the choke knob 2 fully towards the top a bore is opened in the carburetor Through this bore the engine can take in additional fuel This results in a rich fuel air mixture that is needed for a cold start When pressing the choke knob downward in the carburetor the bore is closed again Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled Foot brake pedal The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to
62. e 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 defensively and try to look ahead as far as possible so that you recognize any hazards as early as possible Adjust your driving speed to the conditions and your driving skills Drive carefully on unknown roads or in unknown territory When driving off road always have a friend on a second 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
63. e clamp screw A in place with Loctite 243 Tighten the clamp screws on the upper triple clamp to 20 Nm in 3 stages i 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 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 the 5 clamping screws 1 and 3 loosen the upper triple clamp and turn the end screw 2 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 XC EXC Six 17 Nm clamp screw 1 XC EXC Six Days Loctite 243 17 Nm clamp screw 3 XC W EXC 20 Nm clamp screw 1 3 AEO 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 XC EXC Six Days hold the clamp screw 3 in place with Loctite 243 CAUTION If you drive with play in the steering head bearing for longer
64. ed 31 OPERATION INSTRUMENTS 5 een SCH Clutch lever 6 nn General information about KTM disc brakes 32 Hand brake SE Adjusting the free travel at the hand brake lever 33 Eec Ome SE era utin A d 6 Checking the brake fluid level front brake 33 mec aor NEN A ANAN onec iav spi er s Refilling the front brake fluid reservoir 33 Combination switch EXC 11 Stek hetont EE 33 Headlamp switch XC W 11 KARE MOOD C NU Flasher SWITCH DEENEN 11 REPIACINE ME ironi aus Eer Ende 34 Emergency OFF switch Australia 11 Changing the basic position of the foot brake pedal 34 SEENEN 12 Checking the rear brake fluid level 34 Filler cap XC XC W aaa 12 Refilling the rear brake fluid reservoir 34 EVS E E gt NEQOE TENET 12 Checking the rear brake pads 35 CR 12 Replacing the rear Drake pads 35 sd TP 12 Dismounting and mounting the front wheel 35 Kickstarter 25 ose 6 0 200620032 en 13 Dismounting and mounting the rear wheel 36 Foot brake pedal 13 Tires air pressure 37 Sde stand Vo osa No eos Pte 13 Checking spoke tension 37 SPRENG OCK se SE 13 Replacing the battery of the digital speedometer 37 Compression damping of fork
65. eeze and 50 distilled water for the cooling liq uid 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 Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 2 a water temperature of up to 120 C 248 F is admissible without having to expect any trouble 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 Y 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 engine is hot use a rag to cover the cap and open slowly to release pressure CAUTION The cooling system must be bled after draining the cooling liquid or after adding more than 0 25 0 06 US gallons cooling liquid AND ENGIN Refilling Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0 25 0 06 US gallons cooling lig uid Make sure that the drain screw 1 is fas
66. el carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARA T Modelos EXC Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACI N EN CARRETERAS LA CIRCULACION EN V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO P 4 APPENDIX APENDICE Lid lt c5 T zZ St KTM Group Partner 9002 7 YANVEYALLIW 0103
67. ensure that the brake pads will lie against the brake disk and the pressure point is established Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 4 on the left side of the fork fists Loosen and remove the collar nut 5 loosen the clamping screews 6 on the right side of the fork fist Hold the front wheel pull out the wheel spindle 7 Carefully remove the front wheel from the fork CAUTION 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 AND ENGIN Before remounting the front wheel clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushing To install the front wheel lift it into the fork position and mount the axle shaft 1 Mount the collar nut 2 tighten the clamping screws 3 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 wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp scre
68. er 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 weight on the motorcycle the side stand or the frame can be damaged or the motorcycle may fall on the side Refueling fuel 125 300 Unleaded premium gasoline RON 95 mixed with high grade two stroke oil Mixture ratio 1 40 1 60 Fuel and engine oil should only be mixed immediately before use KTM recommends Motorex Cross Power 2T AN WARNING Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motor cycle 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 CAUTION Only use premium grade gasoline ROZ 98 respectively 95 mixed with high
69. es and exhaust to rust USE AFTER A PERIOD OF STORAGE Fill up the tank with fresh fuel Check the motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season e ALIUNS LHA A DE JO XC X W EX JU CHASSIS 125 EXC SIX DAYS EXC 200 XC XC W EXC Frame Central chrome moly steel frame Fork WP Suspension 4860 MAMA WP 4860 MXMA PA 200 XC EXC 125 Six Days Front tires 90 90 21 MT 83 Pirelli 200 XC XC W USA XC W ZA 80 100 21 51M M59 Bridgestone 200 EXC EU AUS 90 90 21 Pirelli MT 83 Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 1 5 bar 21 psi 1 5 bar 21 psi Rear tires 120 90 18 Pirelli MT83 200 XC XC W USA XC W ZA 100 100 18 59M M402 Bridgestone 200 EXC EU AUS 120 90 18 Pirelli MT83 Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 2 0 bar 28 psi 2 0 bar 28 psi Fuel tank capacity 8 5 liters 2 2 US gallons EXC EU 8 5 liters 2 2 US gallons Reserve page 12 EXC AUS 10 liters 2 6 US gallons XC XC W 1
70. g the transmission oil 250 300 To change the transmission oil run the engine warm and set up the motorcy cle on a horizontal surface Remove the oil drain screw 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 h h Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION 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 rinse
71. 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 cause 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 PERIUL VAIN NAN TEL 125 EXC EXC SIX DAYS 200 XC XC W EXC 2007 S c G o v 8 CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY pg SES 2 5 oi H E 8 Smeg SI ejm Check gear box oil level e Change gear box oil e e ele Check spark plugs adjust distance between electrodes ttu Z Renew spark plugs e 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 e amp Check the carburetor connection boot and
72. h 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 f 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 absorher The spring preload can be changed by turning the adjusting ring 1 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the sp
73. he carburetor which is capable of absorbing the leaking fuel Unscrew the plug 1 and clean it with compressed air Then mount the plug together with the gasket open the fuel tap and check the float chamber for leaks AN WARNING 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 disconnec
74. he cooling system is therefore required a after adding more than 0 25 cooling liquid and b after refilling the entire cooling system see Bleeding the cooling system Some models are equipped with a thermostat 1 so that the engine reaches Its operating temperature more quickly When the engine is cold the liquid coolant circulates in the cylinder and the cylinder head As soon as the cooling liquid has reached a temperature of approximately 55 C the thermo stat opens and the cooling liquid is also pumped through the two aluminum radiators The cooling liquid is cooled by the air stream This means that the cooling effect decreases with the traveling speed Dirty radiators additionally reduce the cooling effect AN WARNING f possible always check level of cooling liquid when engine is cold If 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 haz ard 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 n case coolant is ingested consult a doctor immediately f coolant gets into your eyes rinse them out with water immediately and go see a doctor Use a mixture of 50 antifr
75. hown in bold print The type number of the telescopic fork is embossed on the inside of the fork leg axle passage If you are uncertain which spring to use contact your KTM workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring SPRING RATE 65 70 75 80 85 90 95 Riders weight inclusive gears in kilogram MODELL SOFTER STANDARD 14187C02 125 200 XC W EXC 3 8 N mm 4 0 N mm 4 2 N mm 14187 27 125 EXC Six Days 200 XC 4 0 N mm 4 2 N mm 14187C04 250 300 XC W EXC 4 0 N mm 4 2 N mm 14187C28 250 300 XC EXC Six Days 4 2 N mm 4 4 Nimm Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on the road it will suffice to have this job performed in the course of 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 Cleaning the dust sleeves of the telescopic fork The dust protection bellows 2 are to remove dust and coarse
76. idos 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 V AS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO P 4 ANHANG APPENDICE APPENDIX APENDICE m XIGN4ddV 3J9IdN3ddV 9NVHNV P u p gt rou p gt wu qu rw V v rw rw qu V v VERGASERREGULIERUNG CARBURETOR SETTING 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 IJ NEEDLE 2301 POS 501 ft MJ 2300 m ASO 7500 ft IJ NEEDLE 1501 POS 5001 ft MJ 1500 m ASO 5000 ft IJ NEEDLE 751 m POS 2501 ft MJ 750 m ASO 2500 ft IJ NEEDLE 301 m POS 1001 ft MJ 300 m ASO 1000 ft IJ NEEDLE Meeresniveau POS Sea level LSO Luftregulierschraube offen j ASO Air screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben 4 POS Needle clip position from top HD Hauptd se SCH MJ Main jet NICHT F R STRASSENBET
77. ines the reaction when the fork is rebound By turning the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it 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 14187C02 20 clicks WP Suspension 14187C04 20 clicks Typ WP Suspension 14187C27 20 clicks Typ WP Suspension 14187C28 20 clicks Spring preload of the fork XC EXC Six Days The fork s preload can be adjusted by means of the adjusting screws 4 Use a 24 mm fork wrench More information is provided in the chapter Adjusting the fork and shock absorber Damping action during compression of shock absorber XC EXC Six Days The shock absorber on the XC EXC Six Days models can synchronize the com pression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during com pression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning coun terclockwise will decrea
78. ing when the motorcycle is in an upright position If necessary remove the plug 2 and top up with oil e g Motorex Top Speed 4T 15W50 i CAUTION Transmission and clutch will be subjected to excessive wear and tear if you use too little or low grade oil Use only high grade oil e g Motorex Top Speed 4T 15W50 Changing the transmission oil 125 200 To change the gear oil warm up the engine and park the motorcycle on a hor izontal surface Remove oil drain plugs 3 and 4 and drain the used oil into an appropriate container Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets Fill in 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 Changin
79. ion with the same chain length The chain adjusters 4 can be rotated by 180 CAUTION Always mount the chain tensioner equally aligned Chain maintenance For long chain life good maintenance is very important X ring chains require only modest maintenance The best way is to use lots of water but never use brushes or solvents After letting the chain dry you can use a special X ring chain spray Motorex Chainlube 622 Y 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 When
80. ith cold water and let it dry well STORAGE gt 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 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 valv
81. l overloading The spokes must be tensioned to 5 Nm AND ENGIN 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 Check set distance of the magnetic sensor The distance between the magnet 2 and the sensor 1 must be 2 4 mm otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing the sensor 1 in or off Replacing the headlight lamp parking light lamp Loosen both rubber bands and tilt the headlight mask to the front Pull the parking light lamp with holder 3 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 UDO UNI 10 mm when engine ist cold AND ENGIN Cooling system The water pump in the engine circulates the cooling liquid However the cool ing liquid can only circulate properly if the cooling circuit contains no air bubbles Bleeding of t
82. m over heats and may even fail completely in extreme cases Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motor cycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked in a vertical position Y 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 rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 7 Fill DOT5 1 brake fluid e g Motorex Brake Fluid 5 1 up to the mark B on the inside of the reservoir and remount the screw Spilled brake fluid must be rinsed off with water AN 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 AND ENGIN Checking the rear brake pads The brake pads can be ins
83. mp Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Horn switch Ignition coil Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Stop switch CABLE COLOURS bl black ye yellow bu blue gr green re red wh white br brown or orange pi pink gr grey pu purple J AGKAIMIV DEUTSCH Kondensator CDI Fernlichtkontrolle Blinkerrelais Blinkerschalter vorderer Bremslichtschalter Blinkerkontrolle Generator Lenkerschalter f r Kombiinstrument Scheinwerfer Auf Abblendschalter Hupe Hornschalter Z ndspule linker vorderer Blinker linker hinterer Blinker Multifunktionsdigitaltacho Impulsgeber Standlicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Stop schalter KABELFARBEN bl schwarz ye gelb bu blau gr gr n re rot wh wei br braun or orange pi rosa gr grau pu violett ITALIANO Condensatore CDI Spia abbagliante Rel indicatori Deviatore indicatori di direzione Interruttore luce ant di stop spia lampeggiatori Generatore Interruttore sul manubrio per tachimetro multifunzione Faro anteriore Commutatore abbagliante anabbagliante Avvi
84. nd fling your foot upwards Forcefully kick the kickstarter down the whole way and do not open the throttle A kickstart with too little momentum and an opened throttle increases the kicking back risk Check for power transmission at temperatures below O C 32 F before you actuate the kickstarter If you depress the kickstarter without feeling any resistance power is not being transmitted This could cause injuries Do not start the engine and allow it to idle in a closed area Exhaust fumes are poisonous and can cause loss of consciousness and death Always pro vide adequate 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 OO Co N Mm 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 ignition or emergency OFF switch Swing up the side stand Put the gear in neutral Open throttle to 1 2 and kick down kickstarter vigorously 01 N rn
85. niveau POS 5 4 4 4 3 Sea level 175 172 170 168 168 LSO Luftregulierschraube offen j ASO Air screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben 4 POS Needle clip position from top HD Hauptd se SCH 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 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 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 d
86. out previous announcement and without giving reasons KTM may stop manufactur ing certain models without previous notice KTM shall not be held liable for any deviations of availabil ity and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2006 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only MAMELEMTNT SATANGE wm In accordance with the international quality management ISO 9001 standard KTM uses ___ 7 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 models are only allowed on public roads in the original homologated throttled version Without this performance restriction i e dethrottled these models are only allowed to be driven off road but not on public roads The EXC models are designed for off road sports endurance competitions enduro and not suitable for predominant motocross use 2 STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS
87. ove 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 level and the ambient temperature of approx 20 C 68 F mainly for off road use and central European premium grade fuel 95 ROZ Mixing ratio 2 stroke motor oil super fuel 1 40 1 60 depends on oil quality Basic information on changing the carburetor setting Always start with the original carburetor setting the provided factory setting is meant for break in operation after the break in period the carburetor needs to be adjusted according to the carburetor datasheet see appendix Essential 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 AN WARNING 000000000000 Only use premium grade gasoline ROZ 95 USA z Premium PON 91 mixed with high grade two stroke engine oil Other types of gasoline can cause engine failure and will void your
88. pected from the rear The thickness of the linings may not be less than 1 mm 0 04 in Y WARNING At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc Replacing the rear brake pads Press the brake caliper 1 in the direction of the chain wheel for the brake piston to reach its basic position Remove the safety device 2 knock out the guide pin 3 from the brake caliper with a drift towards the chain wheel and remove the brake pads Carefully clean the brake caliper with compressed air and check the sleeves of the guide pins for damage Slide the left brake pad into the brake caliper and fix it with the pin Slide in the right brake pad and knock the bolt 3 in as far as it will go Mount the safety device 2 AN 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 lever or foot brake lever respectively so as to
89. 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 AND ENGIN How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 2 are offset from the cen ter by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar support and tighten screws 4 to 40 Nm 30 ft Ibs Mount the handlebar and handlebar clamps and tighten screws 3 to 20 Nm 15 ft Ibs The gap between the handlebar sup port and the handlebar clamps should be the same size in the front and in the rear AN WARNING The screws 4 must be secured with loctite 243 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Press the chain upward at the 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
90. ptimum driving comfort and extends the life of your tires 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 Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer AN WARNING Oe Spokes can tear if you continue to ride with them loose This may lead to an unstable handling of your motorcycle Excessively tensioned spokes may rupture due to loca
91. ride 16 Kickstarter acscacicauwaceadg I3 Maintenance work on chassis and engine 24 Operation instruments 5 Periodic maintenance schedule 20 Pivot DEU S ss kde Xo ao M CM EC 24 Radiator cover for the cold 39 Rebound damping of fork 5 sees 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 40 Refueling fuel 022 frata 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 e vadesteder R 16 Serial number locations 5 Sens The CIOCK seach Seeders eI EE 10 SIME EN 2 xk arduerak nea eae Maa de b Ma 12 deg CR 19 SIGE STANG TATT 13 Shock absorber compression damping XC W EXC 15 Spring preload of the fork XC EXC Six Days 14 STAT M 2201 esce gru L aub V RD a EEN 18 Starting when the engine is cold 18 Starting when the engine is warm 18 SEGONE TOC K et ie card D ace en ag RE a
92. ring 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 65 70 75 80 85 90 95 After installing a different spring readjust the static sag to 35 mm 2 mm Riders weight inclusive gears in kilogram SPRING RATE MODELL SOFTER STANDARD HARDER 12187 02 125 200 EXC XC W 12187 27 125 EXC Six Days 200 XC 69 250 12187604 250 300 EXC XC W 12187628 250 300 XC EXC Six Days 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 Changing the spring preload on the telescopic fork XC EXC Six Days The telescopic forks on the XC EXC Six Days models are equipped with a pre load adjuster You can easily adjust the spring preload by 10 mm
93. ring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 1 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm 6 ft Ib ADJUSTMENT VALUES SPRING PRELOAD A Typ WP Suspension 12187C02 4 mm Typ WP Suspension 12187627 5 mm Typ WP Suspension 1218 C28 5 mm WP Suspension 1218 C04 5 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 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 d
94. river 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 V a lt Checking the shock absorber and spring DNE d You can establish whether or not the shock absorber spring is suitable for your aP weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined 2 P Z 2 Z r stad X XXX XY A lt A X YY Py X SRF OGIO O d 2 ES N Determining the static sag of the shock absorber The static sag should be as close as possible to 35 mm Deviations of more than 2 mm can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the 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 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 AY Basa ea E AN 6924 d C7 XXX Vv eon
95. rottle slide jet needle float needle valve needle nozzle C H Check the wear on the clutch disks and length of the clutch springs C CH C CH GH Check the cylinder and piston for wear C C C CH Check function of exhaust control C H C C C H C H C H C H C H Check piston pin bearing H C CH C C C H C C H Replace the conrod bearings C C Check the entire transmission the shift mechanism and bearings Complete maintenance of fork C C C C CH Complete maintenance of shock absorber C C H Replace the sealing cup for the foot brake cylinder CH CH GH Replace the glass fiber yarn filling in the silencer C CH C CH GH Change break fluid C CH CH CH Change clutch brake fluid C H C FOR COMPETITIVE OFFROAD RACING COMPETITION H FOR OFFROAD HOBBY USE Note If the inspection establishes that permissible tolerances are exceeded the respective components must be replaced 250 300 XC XC W EXC SIX DAYS EXC 2007 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 e Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain check tension and
96. s received button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TR1 51 Al figures SPEED S2 display mode stop watch 2 52 is a manual stop watch Start the stop watch by pressing the button press again to hold Press again to continue timing Press the O button to change to the next mode The S2 display will blink in the other modes if S2 continues to run in the background To stop S2 return to the SPEED S2 mode and press the button button starts and stops the stop watch button no function briefly press O button changes to the next display mode hold 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 TR1 1 51 TR2 and A2 figures Will be cleared To select the unit select the SPEED H mode and hold the O button for 3 sec onds to access the SETUP menu Press the O button until the KMH MPH function blinks Press the button briefly to move to the options Press the button for KMH or the button for MPH To set briefly press the O button 1 x and hold for 3 seconds until the dis play returns to the SPEED H mode If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode button to access the menu to activate the KMH display
97. satore acustico Interruttore avvisatore acustico Bobina d accensione Indicatore ant sx Indicatore post sx Tachimetro digitale multifunzione Pick up luce di posizione Interruttore luce post di stop Luce post di posizione stop Regolatore raddrizzatore Indicatore ant dx Indicatore post dx sensore velocit Interruttore d emergenza CAVO COLORATO bl nero ye giallo bu blu gr verde re rosso wh bianco br marrone or arancione pi rosa gr grigio pu violetto ANHANG APPENDICE LA Z LA ct gt lt LA ct OT 4 4J10NdddV INVHNV gt mv mv rri Z gt lt gt mv rri Z O rri o ENGLISH Capacitor CDI Driving light lamp Flasher relay Flasher switch Front brake switch Flasher control lamp Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Horn switch Ignition coil Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Stop switch CABLE COLOURS bl black ye yellow bu blue gr green re red wh white br brown or orange pi pink gr grey pu purple rw JIAGKAIVI V FRANCAIS Condensateur CDI Temion feu route Relais de clignotants Bouton de clignotants Contacte
98. se the damping SIANDARD LOW SPEED SETTING Turn the adjusting screw 5 to the limit in a clockwise direction using a screwdriver Unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ WP Suspension 14187C27 15 clicks Typ WP Suspension 14187C28 15 clicks AN 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 6 connection 24mm STANDARD HIGH SPEED SETTING Turn the adjusting screw 1 to the limit in a counterclockwise direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber in a clockwise direction Typ WP Suspension 14187C27 1 turns Typ WP Suspension 14187C28 1 25 turns Compression damping of shock absorber XC W EXC The compression damping during compression can be adjusted for the XC W and EXC shock absorbers Mono Compression Control The degree of damping can be adjusted by turning adjusting screw 2 with a screwdriver Turning in a clockwise direction will increase the damping turn ing in a counterclockwise direction will decrease the damping SIANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise coun
99. so change down to lower gears depend ing on your speed AN 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 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 f 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 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 AN WARNING Motorcycle engines produce a great amount of heat while running The engine exhaust pipe muffl
100. splay modes IM M A2 SI 92 I Km h Mph 000 gt MAN LAP CLK H 1 2 1 164 LI ILL 11101 1 1 CLK Wc rice uw LL paha 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 TR2 tripmaster 2 A1 average speed 1 A2 average speed 2 51 stop watch 1 52 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH MPH display in kilometers or miles see Kilometers or miles If you have activated all of the display modes they will be displayed in the following order SPEED H SPEED CLK SPEED LAP LAP LAP SPEED MAX SPEED ODO SPEED TR1 SPEED TR2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK time display mode CLK displays the time in
101. ted You can also change the ignition curve via the handlebar switch Power Parts while driving 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 even 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
102. ten 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 models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure vostro concessionario KTM sar sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Mod les EXC Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFF
103. tened Pour approx 0 5 litres 0 13 US gallons coolant into the system Remove screw 2 at the cylinder head Reinstall it as soon as the cooling liq uid emerges free of air bubbles only for 125 200 engines Remove the screw 3 on the right radiator Now add cooling liquid until it emerges free of bubbles at the right radiator Then immediately mount the screw so that no more air can enter the right radiator Top up the left radiator until the coolant can be seen approx 10 mm 0 4 in above the radiator fins Check the coolant level again after a short ride Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accu mulated To clean lift the filter box cover see illustration and pull off towards the front Detach the bottom of the filter retaining bracket 4 tilt aside and remove the throttle cap 5 and the air filter 6 and filter support 7 from the filter box 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 Bio Dirt Remover and Liquid Bio Power Never start your motorcycle without any air filters otherwise dust and dirt may penetrate and cause damage and increased wear Dust and dirt can accumulate and damage the engine if the air filter is not mounted correctly Thoroughly wash the air filter in special cleaning fluid Motorex Bio Dirt
104. 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 respect need to be taken Never have the throttle wide open when changing down to a lower gear The engine will overrev damaging the valves In 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 Turn off the gas and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Al
105. the front and the rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet Pay attention to running in procedure Running in Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be broken in For this reason during its first 500 kilometers 300 miles or 5 hours the engine must not be 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 AR TING MULUR WARNING 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 exampl
106. the position of the point of pressure i e the resis tance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary CAUTION At the hand brake lever free travel must at least be 3 mm 0 1 in Only then may the piston in the hand brake cylinder be moved to be recognized by the greater resistance of the hand brake lever If this free travel is not provided pressure will build up in the braking system and the front wheel brake may fail due to overheating Checking the brake fluid level front brake The brake fluid reservoir is linked 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 AN WARNING 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 Repl
107. ting the number of clicks that corresponds to the respective type of shock absorber Typ WP Suspension 14187C02 17 clicks WP Suspension 14187CO04 15 clicks WP Suspension 14187C27 15 clicks Typ WP Suspension 14187C28 15 clicks Y WARNING Oe 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 3 connection 24mm Rebound damping of shock absorber By using the adjusting screw 4 the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber WP Suspension 14187C02 26 clicks WP Suspension 14187CO04 25 clicks WP Suspension 14187C27 24 clicks Typ WP Suspension 14187C28 24 clicks AN 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 5 connection 15mm
108. tomotive 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 Page SERIAL NUMBER LOCATIONS 5 How to change the handlebar position 30 Chassis RE D Check chain tension oe 30 Engine number engine Type ar 5 Correct ehai tensio vadere 31 Chain maintenance 3 42 e ROSEO E s
109. ur de frein avant Temion de clignoteur Genrateur Contacteur au guidon pour ordinateur de bord Phare Contacteur code phare Avertisseur sonore Bouton d avertisseur sonore Bobine d allumage Clignotant avant gauche Clignotant arri re gauche Ordinateur de bord Capteur d allumage Feu de position Contacteur de frein arri re Feu rouge stop R gulateur redresseur Clignotant avant droit Clignotant arri re droit Capteur de vitesse Contacteur stop COULEUR DE CABLE bl noir ye Jaune bu bleu gr vert re rouge wh blanc br brun or orange pi rose gr gris pu violet ESPANOL Condensador CDI Lampara aviso luces largas Rel de la luz intermitente Interruptor de la luz intermitente Interruptor de luz del freno delantero Lampara aviso intermitentes Generador Interruptor de manillar para instrumento combinado Faro Interruptor de encender apagar la luz larga Cl xon Interruptor del cl xon Bobina de encendido Luz intermitente izquierda delantera Luz intermitente izquierda trasera 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 Interruptor parada COLOR DE CABLE bl negro ye amarillo bu azul gr verde re rojo wh blanco br marron or naranja pi rosado gr gris pu violeta
110. w beam high beam break light indicator e indicator lamps speedometer illumination horn emergency OFF switch or button HAHA Check brake fluid level lining thickness brake lining 1 Check brake lines for damage and leaks 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 e Clean dust bellows e 221 44 2 Bleed fork legs lt Check swing arm bearings e 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 e v Check tires and air pressure e ui Check chain rear sprockets and chain guides for wear fitment and tension Pili o Lubricate chain Clean and grease the adjusting screws on the chain tensioner eieiei Check clearance of wheel bearings e o 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 SIX DAYS EXC 2007 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 C H Replace the th
111. 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 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks CHAIN A loose chain was fall off the chain wheels an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of the chain and chain wheels TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance BRAKES Check correct functioning of the braking system Verify that there 15 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
112. ws on both fork legs with 15 Nm 7 ft Ibs A 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 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 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 4 remove the chain tensioner 5 and pull out the wheel spindle 6 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 f the axle is dismounted clean the thread of the wheel spindle and col lar nut thoroughly and apply a new coat of grease to prevent the thread from jamming TIRES AIR PRESSURE front rear Off road 1 0 bar 1 0 bar AND ENGIN The rear wheel is remounted in the reverse order Before tightening the col lar nut to 80 Nm 60 ft Ib
113. 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 Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap 1 Turn the screw 2 clockwise to increase damping turn it counterclockwise to reduce damping during compression 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 1418 6002 20 clicks WP Suspension 14187C04 20 clicks Typ WP Suspension 14187C27 18 clicks Typ WP Suspension 14187C28 18 clicks Rebound damping of fork Hydraulic rebound damping determ

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