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1. Check the reed type intake valve for wear C C CH Check the wear on the clutch disks and length of the clutch springs C CH C CA C CH Check the cylinder and piston for wear C CH C C H C C H C CH C CH C CH C H H C C C H C C C H Check piston pin bearing Replace the crankshaft main bearings Replace the conrod bearings Check the entire transmission the shift mechanism and bearings Complete maintenance of fork C C H C Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Replace the sealing cup for the foot brake cylinder Replace the glass fiber yarn filling in the silencer Treat electric contacts and switches with contact grease Change break fluid Change clutch brake fluid 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 EXC Six Days 2009 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check gear box oil level Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear e e Check cooling liquid level
2. 2 3 Q 2 re g 8 E ge Sl al E 8 C la fi D als re regulator rectifier gt LD o a us br 1 2 1 yere efe cooling fan ee E les E JE 2 pS Sl 2 w C BS 2 o L 22 2 1 2 Li bl E 2 B i rear brake E speed sensor EA 14 a c Bor E V JE E IR c o PU E LI I II TI c Ki bijojo 8 HD IH H ID es I D Sot TI IT sine br br 1 UU 14 1 1 l wv ech 95 fa RS a E PS ee ee ee ee eea 52 ira LI LL y O zz CHR a IE 7 58 5c TEMEN I Ta EE D IS III LL JL om ER EEE 5 amp e a 1 d gt o c a i JS TUR RSR right front flasher 22 oO E to aa 2 bu o WS o E I 2 I pel 2 d OS PS E CN e Islela u 8 O ole 2 T JE i1 J L LI EH ignition curve selector Ka 2 s 8 2 D al S 5 15 SX S KE i x E left rear flasher OA ignition coil generator 3 left front flasher 300 EXC Six Days EU 2009 250 300 EXC AUS 2009 wiring diagram main harness 594 11 075 150 250 300 EXC AUS CDI harness 548 39 032 300 300 EXC EU 2009 light switch stop button handle bar switch optional M regulator rectifier JH lt multi func digital speedometer IN rear light brake light li 1 21 5 ignition curve selector D c KQ es Kn S Folk Kal amp er pick up generator ignition coil 200 XC USA 2009 wird nicht verwendet Lifter Licht Tacho Start Sw 200 XC W USA 2009 main harness 548 11 075 100 2
3. Before starting for an off road tour itis recommended to additionally secure the side stand with the rubber band on the air filter box JN Jh 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 shiftto 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 rewing of throttle the gas con sumption will increase When shifting down use the brakes if nec essary and turn down at the same time Pull the clutch lever and shift down to the next lower gear Let the clutch lever go slowly and open the throttle or shift down again A 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 wa
4. CO k POS Needle clip position from top HD Hauptd se 3 MJ Main jet NICHT F R STRASSENBETRIEB NICHT F R SANDSTRECKEN Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE AND SAND TRACKS Fuel unleaded fuel with at least RON 95 USA Premium PON 91 EXC EXC E Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM H ndler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC EXC E models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the carburetor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC EXC E Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure Il vostro concessionario KTM sara sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCI
5. 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 voirto 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water y 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 Useonly clean brake fluid taken from a tightly sealed container Checking the front brake pads The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thick A 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 bra
6. 12 Nm Clamping screws upper steering stem Loctite 243 17 Nm Clamping screws upper fork bridge forged fork bridge M8 10 9 20 Nm Clamping screws lower fork bridge forged fork bridge M8 10 9 15 Nm Clamping screws fork stubs M8 10 9 M8 10 9 Collar nut rear wheel spindle M20x1 5 Hexagon nut swing arm bolt M16x1 5 Hexagon collar screw handlebar clamp Allan head screw handlebar support Shock absorber top M8 10 9 M10 10 9 M12 10 9 Loctite 243 40 Nm Loctite 243 80 Nm Shock absorber bottom M12 10 9 Loctite 243 80 Nm Flat head screws for subframe 10 9 Loctite 243 35 Nm Collared nuts for rear sprocket screws Flat head screw for side stand Ball joint for push rod foot brake cylinder M8 M8 10 9 M8 Loctite 243 35 Nm 10 9 Loctite 243 40 Nm M6 10 9 Engine mounting bolt M10 10 9 Engine brace M8 10 9 Screw adjusting ring spring preload shock absorber M6 Spoke nipple M4 5 M5 5 Nm Other screws on chassis Other collar nuts on chassis l l s p 8 N i A AL V A A A JP JUS 250 EXC EU 250 XC W ENGINE 250 X 2 SE 250 EXC SIX DAYS 250 EXC AUS Design Liquid cooled single cylinder two stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement Bore stroke Fuel 249 ccm 66 4 72 mm 2 62 2 84 in unleaded
7. 125 200 EXC EXC Six Days WP Suspension 5018 PDS DCC Double Compression Control Disc brake with wave carbon steel brake disc 260 mm 10 2 in brake caliper floated Disc brake with wave carbon steel brake disc 220 mm 8 7 in brake caliper floated Wear limit 2 50 mm 0 1 in front 3 50 mm 0 14 in rear 90 90 21 54M Metzeler MCE 6 Days Extreme 200 XC XC W Air pressure offroad Air pressure road driver only Rear tires 125 200 EXC EXC Six Days 120 90 18 65M Metzeler MCE 6 Days Extreme 200 XC XC W 100 100 18 59M Bridgestone M402 Air pressure offroad 1 0 bar 14 psi Fuel tank capacity 125 EXC EXC Six Days 200 EXC EU 9 5 liters 2 5 US gallons 2 liters 0 52 US gallone reserve 200 XC XC W EXC AUS 11 liters 2 9 US gallons 2 liters 0 52 US gallone reserve Final drive ratio 125 EXC EXC Six Days 200 XC XC W 200 EXC 5 8 x 1 4 Available final sprockets 38t 40t 42t 45t 48t 49t 50t 51t 52t headlight 12V 35 35W Bilux base Ba20d parking light 12V 5W base W2 1x9 5d brake rear light LED flasher light 12V 10W base Ba15s Steering head angle 63 Wheel base 1471 10 mm 57 9 in 0 4 in Seat height unloaded 985 mm 38 70 in Ground clearance unloaded 390 mm 15 30 in Weight without fuel 125 200 EXC EXC Six Days 97 kg 214 Ibs 200 XC 94 4 kg 208 4 Ibs 200 XC W 94 8 kg 209 3 Ibs 80 100 21 51M Bridgestone M59 1 0 bar 14 psi 1 5 bar 21 psi
8. Check fuel lines for leaks Empty and clean float chamber Remove clean and oil the throttle slide Check all control elements for smooth operation e Check brake performance e Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly MAIN NAN WURK UN CHA AND ENGIN A Maintenance and adjusting work marked with an asterisk requires expert skills and technical know how For your own safety always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified skilled staff CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear When transporting your KTM ensure that it is held upright with restraining straps or other mechanical fastening devices and that the fuel tap is in the OFF position if the motorcycle should fall over no fuel can leak from the carburetor or fuel tank Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank Using other screws or longer screws can cause leaks in the tank through which fuel
9. Clamping screws lower fork bridge forged fork bridge Clamping screws fork stubs M8 10 9 Loctite 243 17 Nm M8 10 9 20 Nm M8 10 9 15 Nm M8 10 9 Collar nut rear wheel spindle M20x1 5 Hexagon nut swing arm bolt M16x1 5 Hexagon collar screw handlebar clamp Allan head screw handlebar support Shock absorber top M8 10 9 M10 10 9 M12 10 9 Loctite 243 40 Nm Loctite 243 80 Nm Shock absorber bottom M12 10 9 Loctite 243 80 Nm Flat head screws for subframe 10 9 Loctite 243 35 Nm Collared nuts for rear sprocket screws Flat head screw for side stand Ball joint for push rod foot brake cylinder M8 M8 10 9 Loctite 243 35 Nm M8 10 9 Loctite 243 40 Nm M6 10 9 Engine mounting bolt M10 10 9 Engine brace M8 10 9 Screw adjusting ring spring preload shock absorber M6 Spoke nipple M4 5 M5 5 Nm Other screws on chassis Other collar nuts on chassis NIL e ATIONS ENGIN AL EAL SIA DA QUE ENGINE 125 EXC EXC SIX DAYS 200 XC W EXC 200 XC Design Piston displacement Liquid cooled single cylinder two stroke engine with intake and exhaust control 124 8 ccm 193 ccm Bore stroke 54 54 5 mm 2 126 2 145 in 64 60 mm 2 52 2 362 in Fuel unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Oil gasoline ratio 1 60 when using high
10. Y WARNING The brake system will build up pressure if there is no free travel on the foot brake lever This will cause the brake pads to grind The brake system will overheat and can break down entirely in extreme cases Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in KIT At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc Replacing the rear brake pads Press the brake caliper 5 in the direction of the chain wheel for the brake piston to reach its basic position Remove the safety device 6 knock out the guide pin 7 from the brake caliper with a drift towards the chain wheel and remove the brake pads Carefully clean the brake caliper with compressed air and check the sleeves of the guide pins for damage Slide the left brake pad into the brake caliper and fix it with the pin Slide in the right brake pad and knock the bolt 7 in as far as it will go Mount the Safety device 6 AL MEN Itis very important to keep the brake disk free from oil and fatty matte
11. Coolant 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system Generator output KOKUSAN 2K 3 12V 110 W Carburetor Keihin PWK 36S AG flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert TECHNICAL SPECIFICATIONS ENGINE 125 EXC EX 125 EXC EXC SIX DAYS 5 KW Carburetor Keihin PWK 36S AG Main jet 140 168 170 172 Idling jet 38x38 45 48 Starting jet 50 85 Jet needle R841 NOZE NOZF IX DAYS 200 XC XC W EXC 2005 Needle position from top 5 4 Throttle valve 7 Air adjustment srew open 2 5 1 Performance restrictor BASIC CARBURETOR SETTING 200 XC 200 XC W 200 EXC AUS 200 EXCEU 7KW arburetor Keihin PWK 365 AG Keihin PWK 365 AG Keihin PWK 365 AG Carburetor setting mark FK 0200 FK0121 FK0211 Main jet 162 160 165 162 160 165 100 160 162 165 Idling jet Starting jet 85 35 42 85 35X35 42 50 85 Jet needle NOZH NOZG R1475J NOZG NOZH N841I NOZG NOZH Needle position from top Throttle valve 3 1 4 7 Air adjustment srew open 1 turn 1 5 turn 1 Performance restrictor TIGHTENING TORQUES ENGINE Flange bolts cylinder head Nuts cylinder base Flywheel collar nut slide stop 36 mm M12x1 slide stop 36 mm 60 Nm Nut for primary sprocket M16x1 5 links Loctite 243 130 Nm Nut for
12. F 42 F to 60 F 61 F to 78 F 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C 79 F to 98 F 99 F to 120 F 3000 m ASO 10000 ft IJ A NEEDLE 2301 m 7501 ft 2300 m 7500 ft IJ NEEDLE 1501 m 5001 ft MJ 1 3 95 N8RW 1 75 35 N8RW 162 1500 m 5000 ft IJ NEEDLE 751m 2501 ft 750m 2500 ft IJ NEEDLE 301 m 1001 ft MJ 300 m 1000 ft IJ NEEDLE Meeresniveau Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 jp 2 IJ Idling jet POS Nadel Clip Position von oben um 7C POS Needle clip position from top HD Hauptd se ew MJ Main jet NICHT F R STRASSENBETRIEB NICHT F R SANDSTRECKEN Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE AND SAND TRACKS Fuel unleaded fuel with at least RON 95 USA Premium PON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM H ndler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF OFFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will
13. at least 25 C 13 F Ignition system KOKUSAN E Starting aid kickstarter and electric starter Carburator Keihin PWK 36 flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert BASIC CARBURETOR SETTING 300 XC 300 EXC EU 300 XC W en 300 EXC SIX DAYS Carburetor Keihin PWK 365 AG Keihin PWK 365 AG Keihin PWK 365 AG Carburetor setting mark FK0240 3600C FK0261 Main jet 165 162 160 162 165 115 162 165 Idling jet 38x38 35 35 35 Starting jet 85 85 50 85 J et needle N27 N2ZW N3CJ N8RH N8RJ N8RW N27 N2ZW N84K N2ZJ N2ZW Needle position from top 1 Throttle valve 7 7 Air adjustment screw open 3 5 turns 1 75 1 turns Performance restrictor slide stop 36 mm slide stop 36 mm TIGHTENING TORQUES ENGINE Flange bolts cylinder head M 8 27 Nm Nuts cylinder base M 10 35 Nm Flywheel collar nut M 12x1 60 Nm Exhaust control retaining bracket M 5 Loctite 243 7 Nm Exhaust control control flap M 6 Loctite 243 10 Nm Exhaust control lever for control segment M 5 Loctite 243 6 Nm M 6 Kickstarter release plate Loctite 243 10 Nm Spring hanger for kickstarter M 6 Loctite 243 10 Nm M 6 Loctite 243 10 Nm Oil drain plug with magnet M 12x1 5 20 Nm M 5 Other bolts Spring hanger on kickstarter M 6 M 8 high low beam switch horn button stop button flasher switch handle bar
14. further tire releases are available on the Internet at www ktm com STANDARD ADJUSTMENT FORK 125 200 XC W EXC EXC Six Days 200 XC WP 4860 MXMA PA 14187E02 Compression adjuster 22 clicks Rebound adjuster 22 clicks WP 4860 MXMA CC 14187E27 15 clicks 21 clicks Spring 432 505 00 040W 432 485 00 042W Preload Adjuster 2 turns Air chamber length 110 mm 4 3 in Fork oil SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER 125 200 XC W EXC EXC Six Days 200 XC WP 5018 PDS DCC 12187E02 Compression adjuster Low Speed 15 clicks Compression adjuster High Speed 1 5 turns WP 5018 PDS DCC 12187E27 15 clicks 1 turn Rebound adjuster 24 clicks 25 clicks Spring 66 250 66 250 Spring preload 7 mm 0 27 in 5 mm 0 20 in Static sag 35 mm 2 mm 1 38 in 0 08 38 mm 2 mm 1 50 in x 0 08 Riding sag 105 mm 5 mm 4 13 in 0 20 TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle 112 mm 5 mm 4 40 in x 0 20 M24x1 5 45 Nm Brake caliper front M8 10 9 Loctite 243 25 Nm Brake disks M6 10 9 14 Nm Screw steering head Lower Screw steering head Clamping screws upper fork bridge machined fork bridge M20x1 5 10 Nm Loctite 243 60 Nm M8 10 9 17 Nm Clamping screws lower fork bridge machined fork bridge M8 10 9 12 Nm Clamping screws upper steering stem Clamping screws upper fork bridge forged fork bridge
15. 1 kg 221 6 Ibs 222 lbs 222 lbs 227 6 Ibs 222 5 lbs 221 6 Ibs 222 lbs 227 6 Ibs further tire releases are available on the Internet at www ktm com STANDARD ADJUSTMENT FORK 250 300 XC W EXC EXC SIXDAYS NENNEN WP 4860 MXMA PA Spring 432 505 00 042W 250 300 XC WP 4860 MXMA CC 14 18 7E 28 21 clicks 432 485 00 044W Preload Adjuster 2 turns Air chamber length 110 mm 4 3 in Fork oil SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER 250 300 XC W EXC EXC SIXDAYS 250 300 XC Typ WP 5018 PDS DCC 12 18 7E 04 WP 5018 PDS DCC 12 18 7E 28 Compression adjuster Low speed High speed 15 clicks 1 5 turn 15 clicks l turn Rebound adjuster 24 clicks 25 clicks 69 250 69 250 Spring Spring preload Static sag 9 mm 0 35 in 35 mm 2 mm 1 38 in 0 08 Riding sag 105 mm 5 mm 4 13 in 0 20 TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle 5 mm 0 2 in 38 mm 2 mm 1 50 in 0 08 112 mm 5 mm 4 40 in 0 20 M24x1 5 45 Nm Brake caliper front M8 10 9 Loctite 243 25 Nm Brake disks M6 10 9 14 Nm Screw steering head Lower Screw steering head Clamping screws upper fork bridge machined fork bridge M20x1 5 M8 10 9 10 Nm Loctite 243 60 Nm 17 Nm Clamping screws lower fork bridge machined fork bridge M8 10 9
16. 50 mm 0 1 in front 3 50 mm 0 14 in rear Front tires 250 300 XC XC W 80 100 21 51M Bridgestone M59 250 300 EXC EXC Six Days 90 90 21 54M Metzeler MCE 6 Days Extreme Air pressure offroad 1 0 bar 14 psi Air pressure road driver only 1 5 bar 21 psi Rear tires 250 300 XC XC W 110 100 18 64M Bridgestone M402 250 300 EXC EXC Six Days 140 80 18 70M Metzeler MCE 6 Days Extreme Air pressure offroad 1 0 bar 14 psi Air pressure road driver only 2 0 bar 28 psi Fuel tank capacity 250 300 XC XC W 11 liters 2 9 US gallons 2 liters 0 52 US gallone reserve 250 300 EXC EU 9 5 liters 2 5 US gallons 2 liters 0 52 US gallone reserve 250 300 EXC AUS 11 liters 2 9 US gallons 2 liters 0 52 US gallone reserve 250 300 EXC Six Days 9 5 liters 2 5 US gallons 2 liters 0 52 US gallone reserve Final drive ratio 250 300 XC 14 50 250 XC W 13 50 300 XC W 14 50 250 300 EXC EXC Six Days 13 40 Chain 5 8 x 1 4 Available final sprockets 38t 40t 42t 45t 48t 49t 50t 51t 52t Bulbs headlight 12V 35 35W Bilux base Ba20d parking light 12V 5W base W2 1x9 5d HEN brake rear light LED flasher light 12V 10W base Bal5s Battery electric starter models 1475 10 mm 58 in 0 4 in 985 mm 38 70 in 385 mm 15 15 in Weight without fuel 250 XC 100 4 kg 250 XC W ZA 100 6 kg 250 XC W USA 101 6 kg 250 EXC AUS 103 1 kg 250 EXC EU EXC Six Days 100 8 kg 300 XC 100 4 kg 300 XC W 100 6 kg 300 EXC EXC Six Days 103
17. ath di ate t 19 Breather plug front fork 27 Carburetor adjustment 43 cCarDuretor table Ee WE ee ee Ie Se ea 67 Chain maintenance o de d RC d ins c 31 CHa WEeal x at LD Re ERO tots ded wee SNC 31 Changing the basic position of hand brake lever 3 3 Changing the basic position of the foot brake pedal 35 Changing the fork offset caster XC 28 Changing the original position of the clutch lever 41 Changing the spring preload on the telescopic fork 26 Changing the spring preloading of the shock absorber 24 Changing the transmission oil 47 Charging the battery 39 Chassis number 4 xce amp x wine au wi are Ae eR ae ws ee 5 Check chain tension 31 Check transmission oil level 47 Check set distance of the magnetic sensor 38 Checking and adjusting the steering head bearing 27 Checking spoke tension 38 Checking the basic setup of the telescopic fork 26 Checking the brake fluid level front brake 33 Checking the coolant level 41 Checking the float level 45 Checking the front brake pads 33 Checking the oil level of the hydraulic clutch 42 Checking the rear brake fluid level 34 Checking the rear brake pads 35 Checking the sho
18. brake system to fail AND ENGIN Changing the basic position of the hand brake lever You can change the basic position of the hand brake lever with the adjusting screw 1 The position of the pressure point the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disk can be adjusted for any hand size Models without front brake light switch When you push the hand brake lever forwards you must have at least 3 mm free travel Models with front brake light switch When you actuate the hand brake lever you must have at least 3 mm free travel CAUTION At the hand brake lever free travel must at least be 3 mm 0 1 in Only then 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 Y WARNING OOO 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
19. closes the SETUP menu 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 0 12 will show the time in the 12 hour mode 0 24 in the 24 hour mode Press and hold the O button for 3 seconds to store the settings If no button is pressed for 20 seconds the settings will be stored automati cally and the display will return to the SPEED CLK mode button time button time briefly press O button changes to the next digit hold O button 3 secs starts the SETUP menu stores the time and changes to the SPEED CLK dis play mode display SPEED H OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS briefly press button briefly press button no function no function briefly press O button next display mode hold O button 3 secs displays the SETUP menu SPEED CLK no function no function next display mode setting the clock menu SPEED LAP starts stops LAP without clearing LAP figure stops LAP stores LAP figure resets LAP to 0 next display mode clears all LAP figures LAP LAP next figure no function next display mode next display mode SPEED ODO SPEED TR2 no function increases the TR2 figure no function X X SPEED TR1 no function no function reduces the TR2
20. 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 clockwise direction The clutch lever moves away from the handle bar if the adjusting screw is turned in a counterclockwise direction CAUTION Adjustment of the clutch lever position is only possible within certain limits Only tum the adjusting screw manually and never apply excessive force Changing the original position of the clutch lever 250 300 The adjusting screw 5 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 tum the adjusting screw manually and never apply excessive force Checking the oil level of the hydraulic clutch 125 200 To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 6 and cover 7 together with the rubber boot 8 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 Mo
21. crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARAIT Modelos EXC 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 tambien otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACION EN CARRETERAS LA CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO KAHNPWK365 AG MEERESH HE 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 A NEEDLE 2301 m 7501 ft MJ 2300 m 7500 ft IJ NEEDLE 1501 m 5001 ft 1500 m 5000 ft IJ NEEDLE 751m 2501 ft 750m 2500 ft IJ NEEDLE 301 m 1001 ft 300 m 1000 ft IJ A NEEDLE Meeresniveau Sea level
22. digital speedometer Pick up Position light Rear brake light switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button CABLE COLOURS bl black br brown bu blue gn green gr grey or orange pi pink pu purple re red wh white ye yellow 2T Rac09 DEUTSCH Batterie Kondensator Luftermotor Fernlichtkontrolle Blinkerkontrolle Blinkerrelais Blinkerschalter vorderer Bremslichtschalter Generator Lenkerschalter fur Kombiinstrument Scheinwerfer Auf Abblendschalter Hupe Horntaster Zundspule Stecker f r Z ndkurve Z ndschloss linker vorderer Blinker linker hinterer Blinker Kennzeichenbeleuchtung Lichtschalter Multifunktionsdigitaltacho Impulsgeber Standlicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Starttaster Startrelais Startermotor Not Aus Schalter KABELFARBEN bl schwarz br braun bu blau gn gr n gr grau or orange pi rosa pu violett re rot wh wei ye gelb ITALIANO Batteria Condensatore Motorino ventola spia abbagliante spia lampeggiatori Rel indicatori Interruttore indicatori di direzione Interruttore luce ant di stop Generatore Interruttore sul manubrio per tachimetro multifunzione Faro anteriore Commutatore abbagliante anabb
23. figure next display mode next display mode next display mode clears TR1 S1 A1 next display mode clears TR2 SPEED A1 no function no function next display mode clears TR1 S1 A1 X X X SPEED A2 X no function no function next display mode next display mode next display mode SPEED S1 no function no function next display mode clears TR1 S1 A1 X SPEED S2 starts stops S2 no function clears S2 If the CLK LAP TR1 TR2 Al A2 S1 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 The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working ED The blue control lamp 2 lights up when the high beam is on Short circuit button XC XC W The short circuit button 3 turns off the engine When pressing this but ton the ignition circuit is short circuited Combination switch EXC EXC Six Days The light switch has 2 respectively 3 switch positions A Light off this function is not available in all models B Low beam on C High beam on You may use button 2 to actuate the horn The red short circuit button 3 serves to switch off t
24. for the suspension components accordingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring is suitable for your weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined Ka I LIT EI LESS Pg RU FBP IS P AN L LCL LT SAD SL Determining the static sag of the shock absorber The static sag setting should be as precise as possible Deviations of more than 2 mm can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm SIE et Le et cta eU sid nah Ded ques USA Ee S EROS ee ee a 35 mm If the static sag is lower the spring preload of the shock absorber must be increased if the s
25. fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Motorex Cross Power 2T Oil gasoline ratio 1 60 when using high grade two stroke oil When in doubt please contact your importer or use 1 40 mix ratio to be on the safe side Crankshaft bearing Connecting rod bearing Piston pin bearing 1 deep groove ball bearing 1 cylinder roller bearing needle bearing needle bearing Piston Piston ring cast aluminium two plain compression rings upper edge piston Dimension n upper edge cylinder Ignition timing 0 0 1 mm 0 0 004 in 1 9 mm 0 074 in BTDC Spark plug NGK BR7 ES Electrode gap 0 60 mm Dimension Z tet 47 5 mm 1 87 in TVC start open 5500 min TVC fully open Primary drive 7300 min red spring 7800 min yellow spring 8300 min green spring straight cut spur gears primary ratio 26 72 Clutch multiple disc clutch in oil bath hydraulically operated Brake fluid DOT 5 1 Transmission 5 speed claw actuated Gear ratio lst gear 14 30 14 30 14 30 2nd gear 16 26 17 26 17 26 3rd gear 18 24 19 23 19 23 4th gear 21 24 20 20 20 20 5th gear 22 21 29 23 29 23 Gear lubrication 0 7 liter Motorex Top Speed 4T 15W50 Available chain sprockets Coolant 13t 14t for chain 5 8 x 1 4 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system Generator output KOKUSAN E 12V
26. grade two stroke oil Motorex Cross Power 2T When in doubt please contact your importer Crankshaft bearing 1 deep groove ball bearing 1 cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston upper edge piston cast aluminum Piston ring 2 half keystone rings two plain compression rings Dimension X Ignition timing upper edge cylinder 0 0 mm 40 10 mm 1 4 mm 0 055 in 16 5 BTDC 1 6 mm 0 063 in 17 BTDC Spark plug NGK BR9 ECMVX NGK BR 8 EG Electrode gap 0 60 mm 0 023 in height of the control flap Dimension Z 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 Transmission Gear ratio lst gear 2nd gear 3rd gear 4th gear 5th gear 6th gear 6 speed claw actuated 093401935 312631 28 3528H 26 4S26 wood ig 2 9920 2617H 6G20 20 6G20 6G22H 33 1633 L 28 3528H 26 4S26 19 5619H 20 6E 20H 92 19932 30 2830 28 3828H 26 4526H 025 49949 23 0523 52515 3S17H AS19H 529197 3917H AS19H 2915 39 LA AS19H 2921 6622 Gear lubrication 0 7 liter Motorex Top Speed 4T 15W50 Available chain sprockets 13t 14t for chain 5 8 x 1 4
27. grade filter oil Motorex Twin Air Liquid Bio Power Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Place the air filter on the filter support and insert both in the center of the filter box Hold in place with the filter retaining clip AND ENGIN Exhaust system If the end cap 1 can be removed the silencer is filled with glass fiber yarn Have the filling checked regularly by an authorized KTM workshop see Lubrication and Service Chart The insulating material fibers escape through the holes in the perforated pipe with time causing the silencer to burn out In addition to causing a higher noise level it will also affect the power char acteristic The insulating material suitable for your exhaust is available from your authorized KTM workshop To replace the glass fiber yarn set 2 remove the end cap and pull off the outer pipe 3 Tape a new glass fiber yarn set to the inner tube and slide on the outer pipe Mount the end cap Make sure the caps are screwed on tightly Mount the muffler stress free before tightening the fixing screws AN WARNING er The exhaust system becomes very hot while the motorcycle is running Do not start work on the exhaust system until it has properly cooled down to avoid burns Changing the original position of the clutch lever 125 200 The adjusting screw 4 can be used for individual adjustment of the original position of the
28. inner clutch hub M18x1 5 Loctite 243 130 Nm Collar screws f r clutch springs M6 10 Nm Collar screw for clutch slave cylinder M6 Loctite 243 10 Nm Special screw for locating drum shifting M8 Loctite 243 25 Nm Oil drain plug M12x1 5 20 Nm Oil drain plug clutch cover M10x1 15 Nm Drain plug for water pump cover M10x1 15 Nm Collar screw for water pump cover Water pump wheel Crankcase and clutch cover bolts Collar screws for ignition cover Collar screws for exhaust flange M6 M5 Loctite 243 10 Nm Loctite 243 6 Nm 6 Nm Spark plug M14x1 25 25 Nm Collar screws for ignition system M5 Loctite 243 6 Nm Collar screw for kickstarter lever Collar screw f r shifting lever Other screws M8 Loctite 243 25 Nm Loctite 243 14 Nm TUN s JN s LHD JU A AVV A A A JP JUS CHASSIS 250 300 XC XC W EXC EXC SIX DAYS Central chrome moly steel frame Fork 250 300 XC WP Suspension 4860 MXMA CC Closed Cartridge 250 300 XC W EXC EXC Six Days WP Suspension 4860 MXMA PA Open Cartridge Preload Adjuster Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension WP Suspension 5018 PDS DCC Double Compression Control Front brake Disc brake with wave carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with wave carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake discs Wear limit 2
29. least once a year e g Motorex Long Term 2000 AND ENGIN Changing the fork offset caster XC The fork offset A in the XC models center fork legs center steering head 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 13 mm This setting will deliver more directional stability on fast race courses If the mark B is in the rear as illustrated the offset is 20 mm This setting will deliver better handling in curves The offset is set to 20 mm in the condition at delivery To adjust the offset dismount the front wheel and remove the front wheel fender Remove the screw on the starting number plate Remove the clamp screws on the hand 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 ste
30. 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 2008 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only il oo 1 ed 8 E a dd E F k i TUV MANAGEMENT EDDACE In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading interna tional motorcycle associations THE XC XC W MODELS ARE PROHIBITED ON PUBLIC ROADS The EXC models are only allowed on public roads in the original homologated throttled version Without this performance restriction i e dethrottled these models are only allowed to be driven off road but not on public roads The EXC models are designed for off road sports endurance competitions enduro and not suitable for predominant motocross use 2 STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS KTM EX
31. switch optional flasher relay C_BG 3 1 EEE BF1 1 M 1 E ae AE U 3161415 2 2 re 2 S sl 2 5 1 _BA1 1 3 DA 4 regulator rectifier br 1 O C C_DB 4 C C_CZ 3 C_CY 3 C_CA 4 multi func digital speedometer br e re CZ ak u 1 bl Se rear brake OO o E light switch speed sensor Er c V C 8072 S E 2 cam Ce 1 DU 2 Y D ET C_CW 2 bl ES 5 flasher control lamp Q E D bu right rear flasher D br gt M E 25 S 1 e g5 ow em sq l r i Oo LL ow CT SE EJ 2 i v u N Lech z Io C_AJ1 3 N a _ C_BG1 3 C B9 2 right front flasher IC BV 2 22 2 2 bu S Si l E o S LL UX 8 D N E e Isiela 4 8 Q a a W Oo o o le crt ignition curve selector bw 2 aje Cc sis e me ES left rear flasher Q V g position light ER 3 RZ SY ignition coil left front flasher pick up generator 125 200 250 EXC EU 2009 125 250 EXC EU EXC Six Days 2009 200 EXC AUS 2009 main harness 548 11 075 350 wiring diagram CDI harness 548 39 032 300 lamp high low beam switch starter motor start relay battery horn button stop button start button GET L F E g handle bar switch flasher switch start button stop switch 1 CR eo Gem SH asher rela y IC ara 4 bl HEI C_BF1 1 iL B Es C_BA1 1 SUP
32. the clutch springs Check the cylinder and piston for wear Check function of exhaust control Check piston pin bearing Replace the crankshaft main bearings Replace the conrod bearings Check the entire transmission the shift mechanism and bearings Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Replace the sealing cup for the foot brake cylinder Replace the glass fiber yarn filling in the silencer Treat electric contacts and switches with contact grease Change break fluid Change the hydraulic clutch oil C 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 2009 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Check tires for pressure and wear e Empty and clean float chamber Check all control elements for smooth operation e Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check brake performance Treat b
33. warm at low r p m speeds Using the electric starter start continuously for no more than five sec onds Wait five seconds before making another attempt to start the engine HOI BR UJ NF NOTE The highly inflammable components in modern fuels volatilize if left stand ing for longer periods of time If the motorcycle has not been used for over 1 week the fuel should be drained from the float chamber The engine will start up immediately if the float chamber is filled with fresh ignitable fuel Starting when the engine is warm Open fuel tap Turn on emergency OFF switch Swing up the side stand Put the gear in neutral Open the throttle approx 1 2 of the way While doing so depress the kick starter vigorously all the way down or press the start button for the elec tric starter Ln amp LUJ KJ IP 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 Open the throttle approx 12 of the way While doing so depress the kick Starter vigorously all the way down or press the start button for the elec tric starter Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time y 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
34. 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 SERIAL NUMBER LOCATIONS 5 Check chain tension 31 Chassis NUMDEN resume inte 5 Correct chain tension 31 Engine number engine type 5 Chain maintenance 31 CVI WOON ES ee heey hac die es Hb
35. 0 2 ignition curves PERFORMANCE and SOFT are stored in the digital box The PERFORMANCE ignition curve is activated in the condition at delivery The SOFT ignition curve can easily be activated by disconnecting the socket connector under the tank To change the ignition curve remove the seat and tank A PERFORMANCE higher engine performance socket connector connected B SOFT better driveability socket connector disconnected You can also change the ignition curve via the handlebar switch Power Parts while driving 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
36. 00 XC USA wiring diagramm 200 XGW USA 200 XC W ZA 2009 g g CDI harness 548 39 032 300 stop button start button handle bar switch light switch start Ms i optional M U U starter motor 5 Fe eq Es wh re regulator rectifier EX 4 O re p br L Ai O O speed sensor RE an fan multi func digital speedometer i e bl wh e re br h e re br rear light brake light br bu wh X il position light P ignition coil generator 250 300 XC W USA 2009 wird nicht verwendet L fter Licht Tacho Start Sw 250 300 XC W ZA 2009 wiring diag ramm main harness 594 11 075 100 asorsooxc wusal X 250 300 xc usa X X 250 300 XC USA 2009 CDI harness 548 39 032 300 light switch horn button high low beam switch brake light switch flasher switch cable gn ye harness wh cable switch me ei Tome TT stop switch start button cable ye cable re ye bl br switch harness wh re cus Ole unpushed ETC ETS ENGLISH Battery Capacitor Cooling fan Driving light lamp Flasher control lamp Flasher relay Flasher switch Front brake switch Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Horn button Ignition coil Ignition curve selector Ignition switch Left front flasher Left rear flasher Licence plate lamp Light switch Multi func
37. 110 W Starting aid kickstarter and electric starter kickstarter kickstarter and electric starter Carburator Keihin PWK 36 flat slide carburetor carburetor setting see table Air filter wet foam type air filter insert BASIC CARBURETOR SETTING 250 EXC EU 250 XC 250 XC W 250 EXC AUS 250 EXC SIX DAYS Carburetor Keihin PWK 36S AG Keihin PWK 36S AG Keihin PWK 36S AG Keihin PWK 36S AG Carburetor setting mark FK0220 FK0230 3600C FK0251 Main jet 168 170 165 162 160 162 165 115 162 165 Idling jet 35 35 38x38 35 Starting jet 85 85 50 85 J et needle N8RW N3C N8RH N8RJ N84K N8RH N8RJ N8RW N2ZJ N2ZW N8RH N8RJ N8RW Needle position from top 1 3 4 Throttle valve 7 7 Air adjustment screw open 1 turn 3 5 turns 1 75 turns Performance restrictor Slide stop 36 mm slide stop 36 mm M5 Exhaust control retaining bracket Loctite 243 7 Nm Exhaust control control flap M 6 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 M Loctite 243 6 Nm 5 IK Loctite 2701 8 Nm Spring hanger on kickstarter M 6 Loctite 243 10 Nm M5 Other bolts 57 M 6 M 8 PL i A JN JU A VI A A A UP JU 300 XC W ENGINE 300 XC 300 EXC 300 EXC SIX DAYS Design Liquid cooled single cyli
38. 4187E02 22 clicks Typ WP Suspension 14187E04 22 clicks Rebound damping of fork XC W EXC EXC Six Days Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 6 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding STANDARD AD USTMENT 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 14187E02 22 clicks Typ WP Suspension 14187E04 22 clicks Spring preload of the fork XC W EXC EXC Six Days The fork s preload can be adjusted by means of the adjusting screws 7 Use a 24 mm fork wrench More information is provided in the chapter Adjusting the fork and shock absorber Compression damping of shock absorber The low speed and high speed compression damping can be adjusted sepa rately on the shock absorber Dual Compression Control Low and high speed refers to the movement of the shock absorber during com pression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counter clockwise will decr
39. 67 How to change the handlebar position 29 Adapting chain guide to the rear sprocket 30 M plo AE EE 72 Chassis number The chassis number is stamped on the right side of the steering head tube Enter this number in the field on page no 1 Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 Clutch lever The clutch lever 1 is located on the left side of the handlebars The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebars on the right and actu ates the front wheel brake The adjusting screw B can be used to change the basic position of the hand brake lever see maintenance work on chassis and engine LAP n TR2 Al A2 S1 2 a CD De WW m g OG OG O0 SPEED SPEED WS Km h ph Miles ODO MAX LAP CLK H T H L L Km h 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
40. AP LAP SPEED ODO SPEED TRI SPEED TR2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK time display mode CLK displays the time in hours minutes and seconds no function no function changes to the next display mode set the clock menu 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 0 button Stops the stop watch stores the lap time and restarts the stop watch again The time Is reset to 0 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 If 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 SPEED aS Km h MT DO LILI LIULI 3 7I 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 I
41. C 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 Si WARNING Ignoring these instructions can be dangerous to life and limb CAUTION ignoring these instructions may damage parts of the motorcycle or impair the motorcycle s traffic safety At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual 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 and the avoidance
42. CE x 31 OPERATION INSTRUMENTS Near 5 General information about KTM disc brakes 32 SI eH ENEE goan dnc Mies dea Na bd dee B ER CE eS 2 Changing basic position of the hand brake lever 33 Hand Ka EE ee 2 Checking the brake fluid level front brake 33 Electronic speedometer qi ed a cif rene e act 6 Refilling the front brake fluid reservoir 33 Indicator lamps EXC zu cp et nn Sawa ae 10 Checking the front brake pads 33 Sort G HG DUTTON ses Bee doti eio nt 10 Replacing the front brake pads 34 Combination switch EXC EXC Six Days 11 Checking the rear brake fluid level 34 Headlamp switch XC W 11 Refilling the rear brake fluid reservoir 34 a EXC EXC Six Days i Changing the basic position of the foot brake pedal 35 tarter button Checking the rear brake pads 35 Emergency OFF switch Australia AMNEM 11 amd the rear E MR Min ar EN 35 Filler cap 12 Dismounting and mounting the front wheel 36 Fuel tap 22 12 Dismounting and mounting the rear wheel 37 Choke knob 12 Tires aif Pressure na vnd debt TP EE 37 Shift lever isses enne 13 Checking spoke tension 38 Kickstarter 13 Replacing the battery of
43. CLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA E VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Modeles EXC EXC E Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLOGATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARAIT Modelos EXC EXC E Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACION EN CARRETERAS LA CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE jADEMAS CADUCA LA PROTECCION DEL SEGURO Activating and deactivating display modes 7 Adjusting the engine characteristic via the auxiliary spring 45 Adjusting the engine characteristic via the ignition curve 44 Basic suspension setup for the weight of the driver 25 SI e EEN 39 Bleeding the hydraulic clutch 43 Dial He ade one ede AE Pb
44. GATION N EST PLUS VALABLE L UTILISATION SUR LA VOIE PUBLI QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI DE PLUS LA COUVERTURE D ASSURANCE DISPARAIT Modelos EXC EXC E Los reglajes del carburador arriba indicados son v lidos solamente para motocicletas sin reducci n Para alcanzar la potencia plena del motor adem s de la regulaci n del carburador son necesarias tambi n otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACION EN CARRETERAS LA CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCION DEL SEGURO pw p u Le uu VERGAGERREGLLIERUNG CARBURETOR SETTING KHHNPAK365 G KIM MEERESH HE TEMPERATUR 20 C bis 7 C 6 C bis 5 C ALTITUDE TEMPERATURE 2 F to 20 F 19 F to 41 F 3000 m 10000 ft IJ NEEDLE 2301 m 7501 ft MJ 6 C bis 15 C 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C 42 F to 60 F 61 F to 78 F 79 F to 98 F 99 F to 120 F 2300 m 7500 ft IJ NEEDLE 1501 m 5001 ft 1500 m 5000 ft IJ NEEDLE 751m 2501 ft MJ 750 m 2500 ft IJ NEEDLE 301 m 1001 ft 300 m 1000 ft IJ NEEDLE MJ Meeresniveau Sea level M 165 LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se a Ei IJ Idling jet POS Nadel Clip Position von oben at
45. JUS 125 EXC EXC SIX DAYS 200 XC XC W EXC 250 XC XC W EXC EXC SIX DAYS 300 XC XC W EXC EXC SIX DAYS 3211353en We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inopera tive by any person All information contained is without obligation KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM
46. LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se o 2 IJ Idling jet POS Nadel Clip Position von oben nl C POS Needle clip position from top HD Hauptd se E MJ Main jet NICHT F R STRASSENBETRIEB NOT FOR HIGHWAY USE AND SAND TRACKS NICHT F R SANDSTRECKEN Fuel unleaded fuel with at least RON 95 Kraftstoff Super Bleifrei ROZ 95 USA Premium PON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM H ndler 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 tara
47. TTING Turn the adjusting screw all the way to the stop in a counterclockwise direc tion and 2 turns in a clockwise direction Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 2 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on the road it will suffice to have this job performed in the course of the periodical maintenance service CAUTION Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leaking it is recommended to open the breather plugs before hav ing the seals replaced MAIN NAN VONA UN CHA AND ENGIN Cleaning the dust sleeves of the telescopic fork The dust protection bellows 2 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Remove the screws 3 from the fork protector and allow the fork protector to hang down Pry the dust boot out of the outer tubes and push down Thoroughly clean the dust boots slide rings outer tubes and fork tubes and oil generously with Universal oil spray Motorex oker 440 or engine oil Press the dust boots into the outer tubes by hand Position the fork prot
48. 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 EN ARNING E Si Ave eee eet ws en A Only use premium grade gasoline ROZ 95 USA Premium PON 91 mixed with high grade two stroke engine oil Other types of gasoline can cause engine failure and will void your warranty Only use high grade 2 stroke engine oil of known brands e g Motorex Cross Power 2T Not enough oil or low grade oil can cause erosion of the piston if you use too much oil the engine can start smoking and foul the spark plug and the exhaust control system In the case of a leaner adjustment of the carburetor proceed 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 SS EE D JET NEEDLE TYPE I V WS MZ main jet jet needle y jet need
49. agliante Awisatore acustico Interruttore avvisatore acustico Bobina d accensione Connettori curva d accensione Interruttore d accensione Indicatore ant sx Indicatore post sx Luce targa Interruttore luci Tachimetro digitale multifunzione Pick up Luce di posizione Interruttore luce post di stop Luce post di posizione stop Regolatore raddrizzatore Indicatore ant dx Indicatore post dx Sensore velocit Pulsante d avviamento Rel d awiamento Motorino d avviamento Interrutore di aresto d mergenza CAVO COLORATO bl nero br marrone bu blu gn verde gr grigio or arancione pi rosa pu violetto re rosso wh bianco ye giallo ENGLISH Battery Capacitor Cooling fan Driving light lamp Flasher relay Flasher control lamp Flasher switch Front brake light switch Generator FRANCAIS Batterie Condensateur Ventilateur temoin feu route Relais de clignotants temoin de clignoteur buton de clignotants Contacteur de frein avant Alternateur ESPANOL Bateria Condensador Motor del ventilador lampara aviso luces largas Rel de la luz intermitente lampara aviso intermitentes Inerruptor de la luz intermitente Interruptor de luz del freno delantero Generador Handle bar switch for multi func digital soeedometer Contacteur au guidon pour ordinateur de bord Interruptor de manillar para instrumento combinado Headlight High low beam switch Horn Horn button Ignition coi
50. artly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the engine pings adjust the idling range richer Full throttle range D Operation with the throttle fully open flat out This range is influenced by the main jet and the jet needle If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings after a short dis tance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one Explanation of table Example Compared to the needle NOZG the jet needle NOZI is two steps leaner in the range from the closed position of the throttle to 1 4 throttle Otherwise there are no differences CAUTION Pay attention to the correct needle designation when replacing the jet nee dle detailed information on the type of jet needle f
51. as medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACION EN CARRETERAS LA CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO AL AHRDURE IUK IAD KIND 2P A 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 gt 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 1 5 1 5 10000 ft IJ 35 35 NEEDLE N8RJ NER 2301m 7501 ft 160 2300 m 7500 ft IJ NEEDLE 1501 m 5001 ft 1500 m 5000 ft IJ NEEDLE 751 m 2501 ft 750 m 2500 ft IJ NEEDLE 301 m 1001 ft 300 m 1000 ft I NEEDLE Meeresniveau Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se o 2 IJ Idling jet POS Nadel Clip Position von oben ns 4 7C POS Needle clip position from top HD Hauptd se ERE MJ Main jet NICHT F R STRASSENBETRIEB NOT FOR HIGHWAY USE AND SAND TRACKS NICHT FUR SANDSTRECKEN Fuel unleaded fuel with at least RON 95 Kraftstoff Super Bleifrei ROZ 95 USA Premium PON 91 EXC EXC E Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma na
52. bber boot 3 Fill the bleeder syringe 4 with a suitable fluid see Technical Specifications Engine Remove the bleeder screw from the slave cylinder 5 and mount the bleeder syringe Press oil into the system until the fluid runs out of the hole 6 in the master cylinder without bubbles Occasionally extract the fluid from the master cylin der reservoir to keep it from overflowing After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the level in the reservoir and mount the cover see above Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx 500 meters 1600 ft above sea 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 60 Basic information on changing the carburetor setting Always start with the original carburetor setting the provided factory setting is meant for break in operation after the break in period the carburetor needs to be adjusted according to the carburetor datasheet see appendix Essential requirements are a clean air fil ter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly
53. 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 I 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 E VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Modeles 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 DISPARAIT 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 tambien otr
54. can flow out Do not use toothed washers or spring rings with the engine fastening screws as these work into the frame parts and keep working loose Instead use self locking nuts If you unscrewed any screwed connections with self locking nuts they must be replaced when mounting If no self locking nuts are available apply Loctite 243 to the thread The screws and nuts must be replaced if the thread is damaged All screws and nuts must be tightened to the specified torque figures using a torque wrench If screws or nuts are not adequately tightened they can become loose and cause the motorcycle to go out of control while you drive Tightening the screws and nuts too tightly can damage the thread and components Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned Dispose of oils fatty matters filters fuels washing detergents etc properly Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter of used oil contam inates 1 000 000 liters of water Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring 1 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 1 cha
55. ck absorber and spring 25 CROKE NOD se sa tee iur Ae bea ones hl C ACA OL Aa e a 12 GIEANINO see ap oA de hae op fed ee 48 Cleaning the air filter 41 Cleaning the dust sleeves of the telescopic fork 27 KEE ENER aod stica dr NOE ei rit ati tee 5 Combination switch EXC EXC Six Days 11 Compression damping of fork 14 Compression damping of shock absorber 15 Conservation for winter operation 48 Beie le SYSTEM ue ac s ac EUR ace eM A E 40 Correct chain TENSION sc cde duse ov e dint doe s 31 Damping action during compression of shock AD ODEN oes caso ot ug Deed aeu d odas ea 15 Determining the riding sag of the shock absorber 25 Determining the static sag of the shock absorber 25 Dismounting and mounting the front wheel 36 Dismounting and mounting the rear wheel 37 Draining the float chamber of the carburetor 45 Driving instructions 17 Electronic speedometer 6 Emergency OFF switch Australia 11 Engine number engine type 5 EXNAUSE SYSTEM 2 aer ea ore a T 42 Page FINGER CAD een tee Ae eee da E 12 Flasher SMIC NES ds nee N E a a RT e 11 Foot brake pedal 23 94 9e ede Sa au 13 gc i E LM 12 FUSO Loops AE d ub iue arguta o qo MUS bas 40 General information about KTM disc brakes 32 General tips and warnings f
56. crease damping turn it counterclockwise to reduce damping during compression STANDARD AD USTMENT 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 14187E27 15 clicks Typ WP Suspension 14187E28 15 clicks Rebound damping of fork XC Hydraulic rebound damping determines the reaction when the fork is rebound Remove the protecting cap 2 By turning the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding STANDARD AD USTMENT 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 14187E27 21 clicks Typ WP Suspension 14187E28 21 clicks Compression damping of fork XC W EXC EXC Six Days Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap 4 Turn the screw 5 clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD AD USTMENT 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 1
57. ease the damping STANDARD LOW SPEED SETTING Turn the adjusting screw 1 to the limit in a clockwise direction using a screwdriver Unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ WP Suspension 12187E02 15 clicks Typ WP Suspension 12187E04 15 clicks Typ WP Suspension 12187E27 15 clicks Typ WP Suspension 12187E28 15 clicks si WARNING The damping unit of the shock absorber is filled with high compression nitro gen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the black screw 2 connection 24mm STANDARD HIGH SPEED SETTING Turn the adjusting screw 3 to the limit in a counterclockwise direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber in a clockwise direction Typ WP Suspension 12187E02 1 5 turn Typ WP Suspension 12187E04 1 5 turn Typ WP Suspension 12187E27 1 turn Typ WP Suspension 12187E28 1 turn 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 ADJ USTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise co
58. ectors mount the screws and torque to 10 Nm AY WARNING OOOO No oil may reach the front tire or the brake disks since this would consider ably reduce the tire s road grip and the braking effect of the front brake Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcycle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust loosen the 5 clamping screws on the upper triple clamp and turn the end screw 5 8 until no play is left Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly tap on the triple clamp to release tension Retighten the five pinch bolts Clamping screws 4 Clamping screws 4 uuu r a0 6 20Nm Clamping screw 6 Loctite 243 20 Nm Clamping screws 71 17 Nm Clamping screw 9 Loctite 243 17 Nm A WARNINp If the steering head bearing is not adjusted to be free of play the motorcy cle will exhibit unsteady driving charactenstics and can get out of control Hold the clamp screw 6 9 in place with Loctite 243 CAUTION If you drive with play in the steering head bearing for longer periods the bear ings and subsequently the bearing seats in the frame will be destroyed The steering head bearings should be regreased at
59. ed If 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 The rear wheel is remounted in the reverse order Before tightening the col lar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws Si WARNING ee If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the rear wheel keep operating the rear brake until the pres sure point returns Itis 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 speci
60. ed by excess voltage Always remove the battery if using other battery chargers You can also use this charging device to test the off load voltage and startability of the battery and generator It is impossible to overcharge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the bat tery will run down and sulfatize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time CAUTION Never remove the closure 2 since it will be damaged Toavoid damage to the on board electronic system always disconnect the minus pole before you charge the battery Tocharge connect the battery to the battery charger before you switch on the battery charger When the battery is charged switch off the battery charger before you disconnect the battery Provide adequate ventilation when charging the battery in a closed room the battery emits explosive gases when charging Electrolytes will escape through the safety valves if the battery is charged too long or at an excessive voltage or amperage This will reduce battery capacity Try to avoid quick charges me jc AND ENGIN Fuse models with electric starter The fuse 1 is located in the starter relay of the E starter 2 underneath the left side paneling Having removed the left side paneling t
61. elective 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 coveristo beremoved Oil should just barely escape from the inspection open ing when the motorcycle is in an upright position If necessary remove the plug 2 and top up with oil e 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 AT 15W50 HI N 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 M12x1 5 20 Nm M10xl 15 Nm Fill in 0 7 I 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
62. electric components plugs cables bearings carburetor etc The high pres sure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear Before cleaning with water plug the exhaust pipe to prevent water ingress You should use normal brand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take 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 UNS ERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean the motorc
63. er when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other man ufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you it should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and the rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver with protective clothing and helmet Pay attention to running in procedure Running in Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be broken in For this reason during its first 500 kilometers 300 miles or 5 hours the engine must not be rewed 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 Lil dE MUIUR AN WARNING Wear suitable clothing when driving a motorcycle smart KTM drivers always wear a hel
64. ering 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 AN WARNING Oe Be sure to lock the thread on the collar screw 2 with Loctite 243 AND ENGIN Mount the lower triple clamp upper steering head bearing protection ring O ring upper triple clamp and the blind screw Tighten the collar screw on the lower triple clamp to 60 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages Adjust the steering head bearing with zero clearance See section on checking and adjusting the steering head support Hold the middle clamp screw A in place with Loctite 243 Tighten the clamp screws on the upper triple clamp to 20 Nm in 3 stages CAUTION Hold the middle clamp screw A in place with Loctite 243 Mount the front wheel fender and tighten the screws to 10 Nm Mount the hand brake cylinder and tighten the screws to 10 Nm Mount the staring number plate Mount the front wheel see Dismounting and mounting the front wheel How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper triple clamp 1 includes 2 bores arranged at a dis
65. evel in the master cylinder of the hydraulic clutch e RARE 6 Clean air filter and filter box e Check electric wires for damage and bends e Check headlamp setting e 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 e LL Check brake lines for damage and leaks e e ei Check adjust the function smooth operation and free travel of the hand foot brake lever e Check the screws and guide bolts on the brake system for a tight fit e HMM Check shock absorber and fork for leaks and function e Clean dust bellows e tuii V Bleed fork legs e jeje Check swing arm bearings e Check adjust steering head bearings e EHE Check tightness of all chassis screws triple clamps fork leg axle passage e axle nuts and screws swing arm bearings shock absorber t Check spoke tension and rim joint e Check tires and air pressure e Til o i Check chain rear sprockets and chain guides for wear fitment and tension e Clean and lubricate chain clean and grease the adjusting screws on the chain tensioner e Pili o Check clearance of wheel bearings e ei 250 300 XC XC W EXC EXC Six Days 2009 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide jet needle float needle valve needle nozzle
66. f the chain adjusters 32mm 1 25 in allows you to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 CAUTION Always mount the chain tensioner equally aligned Chain maintenance Maintenance of the X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty of water Residual used grease must be removed prior to lubri cation Motorex Chain Clean 611 After drying use a chain spray specially designed for X ring chains Motorex Chainlube 622 Y WARNING eee 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 s
67. fic regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pres sure ensures optimum driving comfort and extends the life of your tires Si 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 Wom tires can have a negative effect on how your motorcycle performs especially on wet surfaces If air pressure is too low abnormal wear and overheating of the tire can result Only mounttires approved by KTM on homologated models see Technical Data for Chassis No product liability will be assumed if other types of tires are used AND ENGIN Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especiallyon 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
68. from the wheel sensor The O button is used to change between display modes The and buttons are used to control various functions TEST All of the display segments briefly light up for the display function test WS wheel size The display changes and the circumference of the front wheel is briefly dis played in millimeters 2205 mm corresponds to a front wheel circumference of 21 with production tires Afterwards the display will return to the previous display mode SPEED display mode H service hours Only the SPEED H and SPEED ODO display modes are activated in the condition at delivery SPEED H is displayed whenever the display is activated and the front wheel is not turning It automatically changes to the SPEED ODO display mode as soon as the front wheel starts turning SPEED displays the speed H displays the engine s service hours The service hour counter starts to count as soon as you start the engine The displayed figure cannot be changed Service intervals are indicated in service hours for some KTM offroad motor cycles making the service hour counter a very practical function SPEED ODO display mode odometer The SPEED ODO mode displays the speed and the total distance traveled The display automatically changes to the SPEED H display mode when the front wheel stops turning button no function button no function briefly press O button changes to the next display mode hold O button 3 secs cha
69. gital multifuncional Generador de impulsos luz de posicion Interruptor de luz del freno trasero Luces de parqueo traseras luces de freno Regulador rectificador Luz intermitente derecha delantera Luz intermitente derecha trasera Sensor de velocidad bot n de arranque Rel del arranque Motor de arranque el ctrico interruptor de parada de emergencia COLOR DE CABLE bl negro br marron bu azul gn verde gr gris or naranja pi rosado pu violeta re rojo wh blanco ye amarillo VERGASERTABELLE 125 EXC EXC SIX DAYS 2009 KEHNPVK365G MEERESH HE 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 1 5 1 5 10000 ft IJ 45 42 NEEDLE NOZE NOZF 2301 m 7501 ft 165 2300 m 7500 ft IJ t NEEDLE 1501 m 5001 ft 1500 m 5000 ft IJ NEEDLE 751m 2501 ft 750m 2500 ft IJ t NEEDLE 301m 1001 ft 300 m 1000 ft I NEEDLE Meeresniveau Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 2 IJ Idling jet POS Nadel Clip Position von oben c lt POS Needle clip position from top HD Hauptd se 2 MJ Main jet NICHT F R STRASSENBETRIEB NOT FOR HIGHWAY USE AND SAND TRACKS NICHT FUR SANDSTRECKEN Fuel unleaded fuel
70. he air box cover and the protection cover A you will be able to see the fuse The following loads are connected to it E starter system horn flasher lights electronic speedometer The starter relay also contains a 10 amp spare fuse 3 Replace a blown fuse only with an equivalent one If a new fuse that has just been installed gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 10 Ampere CAUTION Under no circumstances is a stronger fuse allowed to be installed or a fuse allowed to be repaired An improper treatment could damage the whole elec trical installation Cooling system The water pump 1 in the engine circulates the cooling liquid The cooling liquid is cooled by the air stream This means that the cooling effect decreases with the traveling speed Dirty radiators additionally reduce the cooling effect Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 2 a water temperature rising up to 120 C 248 F is admissible without fear of problems Some models are equipped with a thermostat so that the engine reaches its operating temperature more quickly When the engine is cold the liquid coolant circulates in the cylinder and the cylinder head As soon as the cooling liquid has reached a temperature of approximately 55 C the thermo stat opens and the cooling liquid is also pumped through the two alumi
71. he 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 EXC EXC Six Days The flasher switch is a separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dismount the entire turn indicator system without affecting the function of the remaining electrical system a Flasher left gt Flasher right Starter button 3 Pushing the black starter button 5 will actuate the E starter Emergency OFF switch Australia The emergency OFF switch 6 is located next to the throttle grip Primarily designed as safety or emergency OFF switch it should normally not be in its activated state In this position the ignition circuit is shorted if the engine is running it will stall immediately if it is at standstill it will not start C in this position the ignition circuit is enabled the engine should start Emergency OFF switch EXC E Australia The red emergency OFF switch 1 is arranged adjacent to the throttle grip C m In this position the E starter is operational and the engine can be started X In this position the E starter and ignition circuits are interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter 3 P
72. heck 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 Bleeding the cooling system By removing the screw 1 at the water pump cover you can drain the coolant To bleed the cooling system add coolant up to approx 10 mm above the radi ator fins when the engine is cold After a short ride check the coolant level once more Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accu mulated To clean lift the filter box cover see illustration and pull off towards the front Detach the bottom of the filter retaining bracket 2 tilt aside and remove the air filter 3 and filter support 4 from the filter box CAUTION Do not clean foam filter with fuel or petroleum since these damage the foam KTM recommends the products of the company Motorex for air fil ter maintenance Dirt Bio Remover and Liquid Bio Power Never start your motorcycle without any air filters otherwise dust and dirt may penetrate and cause damage and increased wear Dust and dirt can accumulate and damage the engine if the air filter is not mounted correctly Thoroughly wash the air filter in special cleaning fluid Motorex Twin Air Dirt Bio Remover and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high
73. hmen erforderlich Ihr KTM H ndler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF FFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC EXC E models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the carburetor adjustment for full engine performance Your KTM dealer will be pleased to assist you CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON PUBLIC ROADS YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED Modelli EXC EXC E Le tarature suindicate del carburatore valgono solo per motociclette potenziate Per ottenere la piena potenza del motore sono richieste oltre alla taratura del carburatore anche altre misure I vostro concessionario KTM sara sempre disposto ad aiutarvi MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL OMOLOGAZIONE STRADALE L IMPIEGO SU STRADE PUBBLI CHE DI CONSEGUENZA E VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Modeles EXC EXC E Les r glages de carburateur d crits ci dessus valent seulement pour des machines d brid es Pour obtenir la pleine puissance d autres mesures sont n cessaires en plus de ces r glages Les agents KTM connaissent ces mesures QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO L HOMOLO
74. iculties arise Replace the helmet visor or goggle glasses early enough When light shines directly on a scratched visor or goggles you will be practically blind Never leave your motorcycle without supervision as long as the engine is running The Above Models were designed and built for one person only no additional passenger allowed Neither do these models meet the applicable statutory regula tions and safety standards Using them on public roads high ways freeways etc is against the law When riding your motorcycle please bear in mind that other people may feel molested by excessive noise What you should check before each start When you start off the motorcycle must be in a perfect technical condition For safety reasons you should make it a habit to perform an overall check of your motorcycle before each start The following checks should be performed x 1 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism d sy 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks 3 CHAIN A loose chain was fall off the chain wheels an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of the chain and chain wheels 4 TIRES Check for damaged tires Tires showing cuts or dents mu
75. ife TO REMOVE THE BATTERY First disconnect the negative pole then the positive pole from the battery Detach the rubber band 1 and remove the battery Si WARNING Oe f electrolyte sulphuric acid leaks from the battery proceed with great care The electrolyte can cause severe burns n the case of skin contact rinse thoroughly with water n the case of contact with the eyes thoroughly rinse eyes with water for at least 15 minutes Immediately consult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defective batteries must be stored out of the reach of children Ensure proper disposal of discarded batteries CAUTION Never remove the closure 2 since it will be damaged STORAGE If the motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature 0 35 C avoid direct sunlight Charge the battery every 3 months Charging the battery The battery discharges every day even if it is not used Always disconnect the battery when charging Charge the battery as described in the instructions 3 on the battery housing Do not exceed the amperage and charging time Quick charging at a high amperage has an adverse effect on the service life To charge the battery while mounted always use the KTM battery charger Item no 58429074000 to ensure that the electric system is not damag
76. ing preload of the fork 14 Stater OU EO ce ora d deu eO RC deo E di er CC n 11 SAINI OIT ed ve ee enr 18 Starting when the engine is cold 18 Starting when the engine is warm 18 STEEING IOCK 7 ar Na EE bee sr eds ee 13 Stopping and parking 19 SONG re MR sie Ree SB ee Ar EEE ees 48 Technical Specifications Chassis 125 200 50 Technical Specifications Chassis 250 300 54 Technical Specifications Engine 125 200 52 Technical Specifications Engine 250 56 Technical Specifications Engine 300 58 Tires air pressure ee Du id e de Pau En 37 What to do when the engine is flooded 18 What you should check before each start 17 Wiring diagramme 60 3211353en 8002 S uanvayuaLLiN 0104 spens on 4 MOTOREX IV Oil of Switzerland J KTM Group Partner KTM Sportmotorcycle AG A 5230 Mattighofen Www kim Com
77. ke disc AND ENGIN Replacing the front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the sliding metal sheet 3 in the caliper support and of the leaf spring 4 A WARNING MEM It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correctly after working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motor cycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked in a vertical position A MEN If the brake fluid level drops below the minimum either the brake system has a leak or the b
78. l Ignition curve selector Ignition switch Left front flasher Left rear flasher Licence plate lamp Light switch Multi func digital speedometer Pick up Position light Rear brake light switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button CABLE COLOURS bl black br brown bu blue gn green gr grey or orange pi pink pu purple re red wh white ye yellow 2T Rac09 Phare Contacteur code phare Avertisseur sonore Bouton d avertisseur sonore Bobine d allumage Prise courbe d allumage Contacteur d allumage Clignotant avant gauche Clignotant arriere gauche Eclairage de plaque Contacteur d electrique Ordinateur de bord Capteur d allumage feu de position Contacteur de frein arriere Feu rouge stop Regulateur redresseur Clignotant avant droit Clignotant arriere droit Capteur de vitesse bouton de d marrage Relais de d marreur Demarreur bouton d arr amp t d urgence COULEUR DE CABLE bl noir br brun bu bleu gn vert gr gris or orange pi rose pu violet re rouge wh blanc ye jaune Faro Interruptor de encender apagar la luz larga Cl xon Interruptor del claxon Bobina de encendido Conexi n de la curva de encendido Cerradura de encendido Luz intermitente izquierda delantera Luz intermitente izquierda trasera Luz de la matricula Interruptor de luces Veloc metro di
79. lank 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 250 300 XC XC W EXC EXC Six Days 2009 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Check gear box oil level every 20 hours 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 dt Al Se Change gear box oil e NEM Check spark plugs adjust distance between electrodes d Renew spark plugs e d Clean the spark plug connector and check for a tight fit e Check the screws on the kick starter and shift lever for a tight fit e Clean and lubricate the starter drive and the bearing bush of the starter drive Check the starter drive for play and adjust if necessary check that the bearing bushes are firmly seated e e e Check the carburetor connection boot and intake flange for cracks or leaks e Check idle speed setting e e qui Check that vent hoses are not damaged or bent e Check cooling system for leaks check quantity of antifreeze e RER Check exhaust system for leaks and fitment e ee Check cables for damage smooth operation bends adjust and lubricate e Check the fluid l
80. ld O button 3 secs clears the TR2 figure SPEED A1 display mode average speed 1 Al shows the average speed based on the TR1 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 S1 Al figures SPEED A2 display mode average speed 2 A2 shows the average speed based on the TR2 tripmaster 2 and S2 stop watch 2 figures The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip button no function button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode am s SPEED S1 display mode stop watch 1 f riis EA zi S1 shows the traveling time based on TR1 and continues to run whenever it i LII CT u receives impulses from the wheel sensor The calculation of this figure is acti eeng ss vated by the first impulse received from the wheel sensor and stops 3 sec Km h onds 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 S1 Al figures SPEED S2 display mode s
81. le gt idle jet throttle valve air control Screw idle adjusting screw D RANGE OF ACTION N8RG N8RH N8RW NER JET NEEDLE TYPE NOZD NOZE NOZF NOZG NOZH NOZI AND EN Definitions Mixture too rich Too much fuel in proportion to air Mixture too lean Not enough fuel in proportion to air Idling range A Operation with closed throttle valve This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 Only make adjust ments when the engine is hot To this end slightly increase the idling speed of the engine by means of the idle adjusting screw Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed Create a round and stable engine speed using the air control screw basic position of the air control screw see technical data engine Then adjust to the normal idling speed by means of the idle adjusting screw Opening up B Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle setting the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking Part throttle range C Operation with p
82. lean air filter and filter box e tit Check electric wires for damage and bends e Check headlamp setting 8 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 e Check brake lines for damage and leaks e HEHE Check adjust the function smooth operation and free travel of the hand foot brake lever e Check the screws and guide bolts on the brake system for a tight fit e Check shock absorber and fork for leaks and function e Clean dust bellows e V Bleed fork legs e MM Check swing arm bearings e Check adjust steering head bearings e Check tightness of all chassis screws triple clamps fork leg axle passage e axle nuts and screws swing arm bearings shock absorber Check spoke tension and rim joint e Check tires and air pressure e eieiei i Check chain rear sprockets and chain guides for wear fitment and tension e Lubricate chain Clean and grease the adjusting screws on the chain tensioner e HHHE Check clearance of wheel bearings e ei 125 EXC EXC SIX DAYS 200 XC XC W EXC 2009 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide jet needle float needle valve needle nozzle Check the reed type intake valve for wear Check the wear on the clutch disks and length of
83. met boots gloves and a jacket regardless of whether driving all day or just go for a short ride The protective clothing should be brightly colored so that other users of the roads can see you as early as possible Of course your passenger will also need suitable protective clothing Always turn on the light to make sure that other drivers become aware of you as early as possible Do not drive after having consumed alcohol Only use accessory parts recommended by KTM For example front panelling can impair the driving characteristics of the motor cycle Cases extra tanks etc can alter the weight distribution and thus also impair the vehicle s driving characteristics The front and rear wheel are allowed to be fitted only with tires that have the same profile type Be sure to check the spoke tension after 30 minutes running time The spoke tension will decrease quickly on new wheels If you con tinue to drive with loose spokes the spokes may crack and lead to unstable handling see Checking the spoke tension Observe the traffic regulations drive 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 diff
84. nd 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 60 Fuel and engine oil should only be mixed immediately before use KTM recommends Motorex Cross Power 2T AN WARNING a Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refueling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately The tank cap s locking mechanism always has to snap into place when it is mounted CAUTION Only use premium grade gasoline ROZ 98 respectively 95 mixed with high grade two stroke engine oil Other types of gaso line can cause engine failure Do not use premixed two stroke oils oils for outboard engines or normal engine oil to prepare the mixture Do not use gasoline and oil mixtures that are older than one week The lubrication properties of some two stroke oils can deteriorate very rapidly Only use known brands of high grade 2 stroke engine oil i e Motorex Cross Power 2T Never mix synthetic oils and mineral oils Not enough oil or low grade
85. nder two stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber Piston displacement 293 ccm Bore stroke 72 72 mm 2 84 2 84 in Fuel unleaded fuel with at least RON 95 USA Premium RON 91 mixed with high grade two stroke oil Motorex Cross Power 2T Oil gasoline ratio 1 60 when using high grade two stroke oil When in doubt please contact your importer or use 1 40 mix ratio to be on the safe side Crankshaft bearing 1 deep groove ball bearing 1 cylinder roller bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston cast aluminium Piston ring two plain compression rings Dimension X per edge E 0 0 1 mm 0 0 004 in Ignition timing 1 9 mm 0 074 in BTDC Electrode gap 0 60 mm Dimension Z tan 47 5 mm 1 87 in TVC start open 5500 min 7300 min red spring 7800 min yellow spring 8300 min green spring Primary drive o Primary drive o straight cut spur gears primary ratio 28 72 cut spur gears primary straight cut spur gears primary ratio 28 72 26 72 Clutch multiple disc clutch in oil bath hydraulically operated Brake fluid DOT 5 1 5 speed claw actuated Gear ratio lst gear 2nd gear 3rd gear 4th gear 5th gear Gear lubrication 0 7 liter Motorex Top Speed 4T 15W50 Available chain sprockets 13t 14t for chain 5 8 x 1 4 Coolant 1 2 litres 50 anti freeze 50 distilled water
86. ng and tighten the collar nut to 45 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 screws on both fork legs with 15 Nm Si WARNING ee 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 retums It is very important to keep the brake disk free from oil and fatty matters otherwise the braking effect would be strongly reduced TIRES AIR PRESSURE Off road Road AND ENGIN Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Remove the collar nut 1 remove the chain tensioner 2 and pull out the wheel spindle 3 until you can push the rear wheel forwards Take the chain off the rear sprocket pull out the wheel spindle and carefully remove the rear wheel from the swing arm CAUTION Do not operate the rear brake when the rear wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be damag
87. nges the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm 6 ft lb STANDARD SETTING SPRING PRELOAD A Typ WP Suspension 12187E02 7mm Typ WP Suspension 12187E04 9mm Typ WP Suspension 12187E27 5 mm Typ WP Suspension 12187E28 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 driver weighing 75 bis 85 kg wearing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup
88. nges 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 display modes IM TR2 M A2 Si 2 MZ Km h Mph 000 SMA LAP CLK H III IC UU N CLK I e WG 30 CBC LESC EU Lia C I SPEED Kmh LAP Activating and deactivating display modes In the display mode SPEED H press and hold the O button for 3 seconds to access the SETUP menu The active functions will be displayed The blink ing function can be activated by pressing the button and deactivated by pressing the button Press and hold the O button 3 seconds to store the settings If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode button button briefly press O button activates the blinking display deactivates the blinking display changes to the next display without changing any settings starts the SETUP stores the settings and changes to the SPEED H mode hold button 3 secs The following display modes can be activated TR1 tripmaster 1 TR2 tripmaster 2 Al average speed 1 A2 average speed 2 S1 stop watch 1 S2 stop watch 2 CLK clock LAP lap time KMH MPH display in kilometers or miles see Kilometers or miles If you have activated all of the display modes they will be displayed in the following order SPEED H SPEED CLK SPEED LAP L
89. ngine is flooded 18 Check transmission oil level gee toe u Oey te ee ee A Starting off rn 18 Changing the transmission oil 47 SNILUNG RIAMG Sag ap e D dz EECHER 18 SICUT ae PCENA 19 CEEANING ue erre dtes dre ue da ere Ene 49 Stopping and parking 19 Refueling fuel 19 CONSERVATION FOR WINTER OPERATION 48 PERIODIC MAINTENANCE SCHEDULE 20 STORAGE isse nn nn nnn nnn 48 MAINTENANCE WORK ON CHASSIS AND ENGINE 24 TECHNICAL SPECIFICATIONS CHASSIS 125 200 50 Changing the spring preloading of the shock absorber 24 Pivot Hagen rn anna 24 TECHNICAL SPECIFICATIONS ENGINE 125 200 52 Basic suspension setup for the weight of the driver 25 Checking the shock absorber and spring GOD PLE 25 TECHNICAL SPECIFICATIONS CHASSIS 250 300 54 Determining the static sag of the shock absorber 25 Determining the riding sag of the shock absorber 25 TECHNICAL SPECIFICATIONS ENGINE 250 56 Changing the spring preload on the telescopic fork 26 Checking the basic setup of the telescopic fork 26 TECHNICAL SPECIFICATIONS ENGINE 300 58 Breather plug front fork 26 Cleaning the dust sleeves of the telescopic fork 27 WIRING DIAGRAM Gas 24322 Maar Re 60 Checking and adjusting the steering head bearing 27 Changing the fork offset caster XC 28 CARBURETOR TABLE sica 3 2 3m Beso Ren RE Y
90. ns Cover the motorcycle with an air permeated tarp or blanket Do not use non airtight materials as a possible humidity might not be able to escape and thereby cause corrosion CAUTION It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust USE AFTER A PERIOD OF STORAGE Mount the charged battery regard polarity Set the time in the speedometer Fill up tank with fresh fuel Check motorcycle as before each start See driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season N P d k JN aft A A UP JU A A VI A JU CHASSIS 125 200 XC XC W EXC EXC SIX DAYS Central chrome moly steel frame 125 200 XC W EXC EXC Six Days WP Suspension 4860 MAMA PA Open Cartridge Preload Adjuster WP Suspension 4860 MXMA CC Closed Cartridge Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension Front brake Rear brake Brake discs Front tires
91. num radiators Si 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 hazard Do not detach any radiator hoses while the engine is hot The escaping hot coolant and the steam may cause serious burns n case you get burnt hold the affected part of your body under running cold water right away Coolant is toxic Keep the coolant out of the reach of children 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 antifreeze and 50 distilled water for the cooling liquid The antifreeze should be designed for temperatures of at least 25 C This mixture offers frost protection as well as good corrosion protection and should not be replaced by water alone CAUTION For the cooling system use only with high grade antifreeze e g Motorex Anti Freeze Using lower grade antifreeze agents can cause corrosion and coolant foaming DULL LLLA 10 mm when engine ist cold AND ENGIN Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system si WARNING OOO If possible always c
92. 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 automotive fluids
93. oil can cause erosion of the pis ton when Using too much oil the engine may start smoking and foul the spark plug If your motorcycle is equipped with a catalytic converter always keep in mind that leaded fuel will destroy the catalytic converter Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig 125 EXC EXC SIX DAYS 200 XC XC W EXC 2009 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Check gear box oil level 40 at least once a year 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 b FE HEIE Change gear box oil e NEM d Check spark plugs adjust distance between electrodes 2 Renew spark plugs e Clean the spark plug connector and check for a tight fit e Check the screws on the kick starter and shift lever for a tight fit e Check the carburetor connection boot and intake flange for cracks or leaks e ti Check idle speed setting e ei ele Check that vent hoses are not damaged or bent e Check cooling system for leaks check quantity of antifreeze e HEHH Check exhaust system for leaks and fitment e Check cables for damage smooth operation bends adjust and lubricate e RARE Check the fluid level in the master cylinder of the hydraulic clutch e eieiei 5 C
94. or starting the motorcycle 16 Hand brake lever 5 Headlamp switch XC W 11 How to change the handlebar position 30 Indicator lamps EXC EXC Six Days 10 Instructions for your first ride 16 KICKS tAE rasen et ERR ee whe Go E 13 Maintenance work on chassis and engine 24 Operation instruments 5 Periodic maintenance schedule 20 PIVOEDCONAO 2c dro sir eg d qase edo d acts 24 Rebound damping of fork 14 Rebound damping of shock absorber 15 Refilling the front brake fluid reservoir 33 Refilling the rear brake fluid reservoir 34 Refilling Bleeding the cooling system 41 Refueling fuel Sach com dub Sea as due dean d pode dcs 19 Replacingforksprings 27 Replacing the battery of the digital speedometer 28 Replacing the front brake pads 34 Replacing the headlight lamp parking light lamp 38 Replacing the rear brake pads 35 RUNNING TERI o a oo cae Nol o e oae eet He 16 Serial number locations 5 Setting the clock aca a bacs X ee CY E b CY ER S 10 SALLE ts Seat eebe qe dup icit ae de i UNE aes s 12 SHITUNSRIANG Sa tng cto Ga D Ene p Oeo Je tes 19 SIGE SLANG ours doe see S ard a 13 Shock absorber compression damping 15 Spr
95. or 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 underthe 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 Y WARNING OOOO 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 30
96. ou brake the brake discs brake pads brake caliper and brake fluid heat up The hotter these parts get the weaker the breaking effect In extreme cases the entire braking system can fail If the resistance in the hand brake lever or foot brake pedal feels spongy too much give this is an indication that some thing is wrong with the brake system Don t ride your motorcy cle anymore without first having the brake system looked over by a KTM dealer Stopping and parking Apply the brakes fully and put the engine into neutral To turn off the engine push the short circuit button or the emergency OFF button with the engine at idling speed until the engine stops Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle ART Motorcycle engines produce a great amount of heat while running The engine exhaust pipe muffler brake rotors and shock absorbers can become very hot Do not touch any of these parts after start ing the motorcycle and take care to park it where pedestrians are not likely to touch it and get bumed 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 a
97. ox 8 10 mm 0 31 0 39 in In the course of this procedure the upper chain portion A must be taut see drawing If necessary correct the chain tension Si WARNING Ifthe 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 n either case the operator is likely to lose control of the motorcycle CICIECBCICS 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 Si WARNING eee 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 o
98. prockets should also be replaced New chains wear faster if used on old used sprockets CAUTION Secure the screws of the chain wheel by applying Loctite and fasten them in a crosswise order Tightening torque for nuts 35 Nm Tightening torque for screws 50 Nm AND 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 BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701HHB Six Days models TOYO B153 sintered lining at the front and TOYO B 143 FF sintered lining at the back These linings provide an optimal combination of dosing brake perform ance and life cycle The lining type is stated on the back of the brake pad and also recorded in the homologation 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 Si 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 repai
99. rake pads are completely worn In this case consult an author ized KTM dealer immediately Refilling the rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 5 Fill DOT5 1 brake fluid e g 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 7N WARNING MM 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 Useonly clean brake fluid taken from a tightly sealed container AND ENGIN Changing the basic position of the foot brake pedal To change the basic position of the foot brake lever loosen the counternut 1 and turn the stop screw 2 as needed Be sure to adjust the free travel of the foot brake lever Measured on the outside the foot brake lever should have 3 5 mm free travel before the piston rod moves the piston in the foot brake cylinder you will feel the stronger resistance of the foot brake lever Loosen the counternut 3 and turn the pushrod 4 as needed
100. rd in the carburetor the bore is closed again Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled Foot brake pedal The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to your seat position See maintenance work a 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 usethe rubber band 1 to additionally secure the center stand in its folded up position Steering lock EXC EXC Six Days 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 tum the handlebar to the left the key could get damaged Compression damping of fork XC Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the top of the fork legs Turn the screw 1 clockwise to in
101. re taking luggage with you check that it is securely fastened Starting when the engine is cold Open fuel tap Turn on emergency OFF switch Swing up the side stand Put the gear in neutral Activate cold starting aid choke Do not open the throttle at all or open it no more than 1 3 of the way While doing so depress the kickstarter vigorously all the way down or press the start button for the electric starter Si WARNING Forstarting always put on your motorcycle boots to avoid injuries You could slip off the kickstarter or the motor could kick back and fling your foot upwards Forcefully kick the kickstarter down the whole way and do not open the throttle A kickstart with too little momentum and an opened throttle increases the kicking back risk Check for power transmission at temperatures below 0 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 Donotstart the engine and allow itto 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
102. retightened and the wheel centered by a KTM dealer AN WARNING Spokes can tear if you continue to ride with them loose This may lead to an unstable handling of your motorcycle Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 5 Nm Replacing the battery of the digital speedometer Remove the headlight mask and disassemble the electronic speedometer Remove the screw connection A insert the battery type Duracell CR 2430 with the writing facing up and reinstall the screw connection Replacing the headlight lamp parking light lamp Loosen both rubber bands and tilt the headlight mask to the front Pull the parking light lamp with holder 3 carefully out of the reflector Pull connector 4 off the headlamp and remove rubber cap 5 Disengage retain ing clip and take the bulb out of the reflector When changing the parking light lamp simply pull it out of the holder Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above AND ENGIN Battery models with electric starter The battery is located under the seat and is maintenance free Maintenance free means you will not need to check the acid level Clean the battery terminals regularly and grease with acid free grease if necessary The charge condition and type of charge are very important for the battery s serv ice l
103. rm 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 Ifthe engine runs without throttle during longer downhill travel the engine should be accelerated occasionally to ensure that it is supplied with sufficient lubricant which is mixed in the fuel In the event that while riding on your motorcycle you notice any unusual operation related noise stop immediately turn the engine off and contact an authorized KTM dealer Braking Close the throttle and apply the hand and foot brake simultane ously Be especially careful when you apply the brakes on sandy wet or slick surfaces Always apply the brakes intuitively locked wheels can cause the bike to skid or crash Shift down to a lower gear to match your speed Always apply the brakes before you enter a curve 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 y
104. rs Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correctly After working on the braking system one must always actuate the hand brake lever or foot brake lever respectively so as to ensure that the brake pads will lie against the brake disk and the pressure point is established AND ENGIN Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the collar screw 1 and the clamping screws 2 on both fork leg axle passages Unscrew the collar screw approx 8 turns press on the collar screw with your hand to push the wheel spindle out of the fork leg axle passage and remove the collar screw Hold the front wheel while you pull out the wheel spindle Lift the front wheel off the fork CAUTION Donot operate the hand brake when the front wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be damaged Before remounting the front wheel clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushing To install the front wheel lift it into the fork position and mount the axle Shaft 3 Mount the collar nut 1 tighten the clamping screws 2 on the right fork leg axle passage to prevent the axle shaft from turni
105. rs on the brake system be performed by a KTM dealer BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID We recommend that you use Motorex DOT 5 1 brake fluid when you refill or change the brake fluid DOT 5 1 brake fluid has a wet boiling point of 180 C 356 F 25 C 45 F higher than DOT 4 and is safer for high performance applications Brake fluid DOT 5 1 is a polyethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motor cycle gaskets and brake hoses are not designed for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture from the air which lowers the boiling point The brake fluid should therefore be changed at the prescribed intervals Y 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
106. screws 2 lift off the closing cover 3 and remove the springs including the spring insert 4 from the clutch cover Pull both springs off the spring insert mount the auxiliary spring 1 and control spring 5 and slide both into the clutch cover until the recess in the spring insert 4 engages in the rocker arm Check the O ring in the closing cover mount the closing cover ensuring that the dolly screw 6 engages in the auxiliary spring Make sure you do not turn the dolly screw since this will impair the engine characteristic CAUTION Be careful not to turn the spring dolly 6 otherwise the engine characteris tic will deteriorate You can also change the engine characteristic through the interaction bet ween the ignition curve auxiliary spring 250 300 only and exhaust The fol lowing table shows examples of possible combinations Further combinations can be adjusted at random depending on the driving requirements 250 300 XC XC W EXC EXC Six Days Engine performance Standard Driveability Standard Ignition curve soft soft performance performance performance Auxiliary spring 250 300 green yellow gelb yellow red Exhaust EXC standard EXC standard EXC standard 250 SX 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 s
107. st be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 5 BRAKES Check correct functioning of the braking system Verify that there is suf ficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by an author ized KTM dealer as complete failure of the braking system can be expected Also check the state of the brake hose and the thickness of the brake linings Check free travel of the hand brake lever and foot brake lever A If the resistance in the hand brake lever or foot brake pedal feels spongy too much give this is an indication that something is wrong with the brake system Don t ride your motorcycle anymore without first having the brake sys tem looked over by a KTM dealer 6 CABLES Check correct adjustment and easy running of all control cables 7 COOLING FLUID Check the level of cooling fluid when the engine is cold 8 ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights turn indicators indicator lamps and horn while the engine is running 9 LUGGAGE If you a
108. t will display the lap number and the stopped lap time in hours minutes and seconds Press the button to access the next lap time To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode button changes to the next lap time button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode 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 TR1 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 S1 Al figures SPEED TR2 display mode tripmaster 2 The tripmaster 2 is always active and counts to 999 9 Contrary to TR1 the displayed figure can be changed using the and buttons This is a very use ful function for trips taken according to a roadbook button increases the TR2 figure button decreases the TR2 figure briefly press O button changes to the next display mode ho
109. tance of 15 mm 0 6 in from one another The bores at the handlebar support 2 are offset from the cen ter by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar support and tighten screws 4 to 40 Nm 30 ft lbs Mount the handlebar and handlebar clamps and tighten screws 3 to 20 Nm 15 ft lbs The gap between the handlebar sup port and the handlebar clamps should be the same size in the front and in the rear ZN WARNING Oe The screws 4 must be secured with loctite 243 AND ENGIN Adapting the chain guide to the number of rear sprocket teeth NOTE The position of the chain guide must be adjusted due to the large number of rear sprockets available Up to 44 teeth insert the retaining screw on the chain guide in the lower hole B from 45 teeth in the upper hole C Loosen both screws on the chain guide and pull the chain guide off the swing arm Turn the chain guide over press out the retaining nut 1 and insert it in the other hole 2 turning the retaining nut around Remount the chain guide and tighten the screws Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Press the chain upward at the end of the chain sliding component The dis tance between the chain and the swing arm should be appr
110. tatic sag is reduced the spring preload must be higher See chapter Changing the spring preload of the shock absorber Typ Static sag Riding sag 12187E02 35 mm 2 mm 105 mm 5 mm 12187E04 38 mm 2 mm 105 mm 5 mm 12187E27 38 mm 2 mm 112 mm 5 mm 12187E28 33 mm 2 mm 112 mm 5 mm Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE for example shock absorber 250 EXC Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 500 mm RIGING SAG e a ta ho me or cer io 100 mm Riding sag settings see above G If the riding sag is too low the spring is too hard spring rate is too high If the riding sag is too high the spring is too soft spring rate too low The spring rate is written on the outside of the spring e g 66 250 The type o number of the shock absorber is embossed on the front of the shock absorber The 65 70 75 80 85 90 95 illustrations show which spring should be installed The standard spring is Shown in bold print Readjust
111. the control screw 5 on the clutch Cover is to be removed Oil should just barely escape from the inspection open ing when the motorcycle is in an upright position If necessary remove the plug 6 and top up with oil e g Motorex Top Speed 4T 15W50 CAUTION Transmission and clutch will be subjected to excessive wear and tear if you use too little or low grade oil Use only high grade oil e g Motorex Top Speed 4T 15W50 Changing the transmission oil 250 300 To change the transmission oil run the 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 M12x1 5 20 Nm Pour in 0 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 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
112. the digital speedometer 38 Ge SE pedal e Replacing the headlight lamp parking light lamp 28 OA E EE SE ege EE 39 Steering lock 13 an the battery SN nee ee 39 Compression damping of fork 14 SEN EN Et Ae eg 40 Rebound damping of fork 14 Cooling system 40 Spring preload of the fork XC W EXC 14 Checking the coolant level 41 EE ENG er Refilling Bleeding the cooling system 41 Shock absorber rebound damping 15 Cleaning the air filter sss 41 GENERAL TIPS AND WARNINGS FOR STARTING THE Checking the oil level of the hydraulic clutch 42 MOTORCYCLE LLL LLL 16 Exhaust system LIA ee K 42 EE Changing the original position of the clutch lever 42 Instructions for your first ride 16 Dunnen 16 Bleeding the hydraulic ElUICHE Er tty senatu as ee 43 Carburetor adjustment 43 DRIVING INSTRUCTIONS 0 0000002 17 Draining the float chamber of the carburetor 45 What you should check before each start 17 Checking the float level De eg hs ud ui 45 Starting when the engine is cold 18 Adjusting the engine characteristic via the ignition curve 45 Starting when the engine is warm 18 Adjusting the engine characteristic via the auxiliary spring Ap What to do when the e
113. the static sag after mounting a new spring Riders weight inclusive gears in kilogram 12187E02 SOFTER STANDARD HARDER 12187E04 12187E27 12187E28 AND ENGIN According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for vari ous reasons Similar to the shock absorber smaller deviations in your weight can be compensated by adjusting the spring preload However if your tele scopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Your KTM dealer will be happy to offer advice Changing the spring preload on the telescopic fork XC W EXC EXC Six Days The telescopic forks for these models are equipped with a preload adjuster You can easily adjust the spring preload by 10 mm by turning the adjusting screw 1 Turning in a clockwise direction will increase the prestress turning in a coun terclockwise direction will decrease the prestress Changing the spring preload will not affect the rebound damping adjustment Generally if the spring preload is higher the rebound damping should also be set higher STANDARD SE
114. top watch 2 S2 is a manual stop watch Start the stop watch by pressing the button press again to hold Press again to continue timing Press the 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 A1 S1 TR2 and A2 figures e will be cleared ODO MAX LAP CLK H To select the unit select the SPEED H mode and hold the O button for 3 sec onds to access the SETUP menu Press the O button until the KMH MPH function blinks Press the button briefly to move to the options Press the button for KMH or the button for MPH To set briefly press the O button 1 x and hold for 3 seconds until the dis play returns to the SPEED H mode If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode TRI TR2 M A2 St 52 button to access the menu to activate the KMH display button to activate the MPH display briefly press O button changes to the next mode changes from the menu to the SETUP menu hold O button 3 secs stores and
115. torex clutch fluid 75 available from your authorized KTM shop CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch in 125 200 models Do not mix this oil with any other hydraulic oil Always use original KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid Checking the oil level of the hydraulic clutch 250 300 To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 9 and cover together with the rubber boot 10 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 forthe 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 ru
116. tura del carburatore anche altre misure Il 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 E VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Modeles 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 DISPARAIT 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 tambien otras medidas Su distribuidor KTM le ayudar con todo gusto SI EFECTUA CAMBIOS EN LA MOTOCICLETA SE PIERDE EL PERMISO DE CIRCULACION EN CARRETERAS LA CIRCULACION EN VIAS PUBLICAS QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE ADEMAS CADUCA LA PROTECCI N DEL SEGURO VERG SERREGULIERUNG CARBURETOR SETTING KIND 365 AG MEERESH HE TEMPERATUR ALTITUDE TEMPERATURE L 250 XC 2009 20 C bis 7 C 6 C bis 5 C 6 C bis 15 C 2 F to 20 F 19 F to 41
117. unting the number of clicks that corresponds to the respective type of shock absorber Typ WP Suspension 12187E02 24 clicks Typ WP Suspension 12187E04 24 clicks Typ WP Suspension 12187E27 25 clicks Typ WP Suspension 12187E28 25 clicks A 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 A gt NER ND WARNIN J 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 lev
118. ushing the black starter button 2 will actuate the E starter Filler cap To open it Press the release button 3 and turn the tank cap in a coun terclockwise direction To close it Putthetank cap back on and turn in a clockwise direction until the release button snaps into place Install tank breather hose 4 without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carbure tor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Choke lever on the handlebar When you press the choke lever 5 a hole in the carburetor is opened through which the engine can take in additional fuel The result is a rich fuel air mixture of the type needed for cold starts Press the choke lever all the way up to close the hole in the carburetor again Choke knob When pulling the choke knob 6 fully towards the top a bore is opened in the carburetor Through this bore the engine can take in additional fuel This results in a rich fuel air mixture that is needed for a cold start When pressing the choke knob downwa
119. with at least RON 95 Kraftstoff Super Bleifrei ROZ 95 USA Premium PON 91 EXC Modelle Die oben angef hrten Vergaserregulierungen gelten nur f r entdrosselte Motorr der Um die volle Motorleistung zu erhalten sind neben der Vergaserregulierung auch noch andere Ma nahmen erforderlich Ihr KTM H ndler hilft Ihnen gerne WENN SIE ANDERUNGEN AM MOTORRAD VORNEHMEN GEHT DIE STRASSENZULASSUNG VERLOREN DER BETRIEB AUF OFFENTLICHEN STRAS SEN IST DANN VERBOTEN UND STRAFBAR AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ EXC 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 Il 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 E VIETATO E PASSIBILE DI PENA INOLTRE DECADE LA COPERTURA ASSICURATIVA Modeles EXC Les r glages de carburateur d
120. ycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent A Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well _ STORAGE gt 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 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate bearing points of the control levers footrests etc as well as the chain Disassemble and charge battery see chapter BATTERY The storage place should be dry and not be subjected to too big temperature fluctuatio

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