KTM Motorcycle 300SX User Manual

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IMPORTANT

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY

BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT

DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU

USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTE-

REST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT

ARE MARKED AS FOLLOWS:

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.

Please insert the serial numbers of your motorcycle in the boxes below

Chassis 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 mainte-

nance, repair or replacement, of any device or element of design incorporated into any new

vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser

or while it is in use; and

(b) the use of the vehicle after such device or element of design has been removed or rendered

inoperative by any person.

KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS,

MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT

^{PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS}, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT

^{SUBSTITUTING THEM WITH OTHERS}. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT

^{PRIOR NOTICE}. IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION.

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Introduction

We would like to congratulate you on your purchase of a KTM motorcycle.

You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring

you lots of fun and enjoyment, provided that you clean and maintain it appropriately.

Before you go for your first ride, be sure to read this manual carefully and thoroughly in

order to familiarize yourself with how to operate your new motorcycle and with its cha-

racteristics, even if this means that you will have to dedicate some of your valuable

time to this task. Only by doing so will you learn how to tune your motorbike to your

specific needs and how to protect yourself against injury. Besides, this manual contains

important information on motorcycle maintenance. At the time this manual was typeset,

it was up-to-date with the latest state of this production series. It cannot be completely

ruled out, however, that minor discrepancies may exist resulting from further design upg-

rades of these motorcycles.This manual is an important part of your motorbike and

should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance

work on the chassis and engine" must be performed by a KTM workshop. If mainten-

ance work should become necessary during a competition, it must be performed by a

trained mechanic.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable

for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance inter-

vals. Heeding these guidelines will significantly increase the life of your motorcycle. Have

services carried out by a KTM dealer so that your warranty claim remains intact.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to

enjoy it to the full. It may, however, involve potential problems for the environment or

lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle

is used responsibly. To safeguard the future of motorcycle sports, make sure that you use

the motorcycle in accordance with the law, show that you are environmentally conscious

and respect the rights of others.

We wish you a lot of fun when driving !

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

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IMPORTANT WARRANTY AND

GUARANTEE INFORMATION

KTM sports motorcycles are designed and constructed to resist the usual

wear and tear of normal use in competitions.

The motorcycles comply with the regulations and categories currently in

effect with the leading international motorcycle associations.

Observance of the service, maintenance and tuning instructions for the

engine and chassis specified in the Owner's Manual is a prerequisite for

faultless operation and the avoidance of premature wear. An improperly

tuned chassis can lead to damage and breakage of the chassis components

(see chapter on checking the basic chassis setting).

The service work specified in the "Lubrication and Maintenance Schedule"

must be performed by a KTM workshop and recorded in the service manual

otherwise claims under the warranty shall become void.

The fuels and lubricants specified in the Owner's Manual or automotive

fluids with equivalent specifications must be used in accordance with the

maintenance schedule.

No claims can be filed under the warranty for damage or consequential

damage caused by manipulations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely

muddy and wet terrain, can lead to higher than average wear on

components such as the drive train or the brakes. In this case it may become

necessary to service or replace wear parts before the service limit specified in

the maintenance schedule has been reached.

THE SX/SXS AND MXC MODELS ARE PROHIBITED ON PUBLIC ROADS.

The EXC models are only allowed on public roads in the original

homologated (throttled) version. Without this performance restriction (i.e.

dethrottled), these models are only allowed to be driven off-road but not on

public roads. The EXC models are designed for off-road sports endurance

competitions(enduro) and not suitable for predominant motocross use.

In accordance with the international quality management

ISO 9001 standard, KTM uses quality assurance processes

that lead to the highest possible product quality.

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TABLE OF CONTENTS

Page

SERIAL NUMBER LOCATIONS .............................................5

Chassis number................................................................5

Engine number, engine type (125/200)............................5

Engine number, engine type (250/300)............................5

Changing the spring preload on the telescopic fork (MXC/EXC models).27

Replacing fork springs ....................................................27

Adjusting the spring preload on the fork (SX).................28

Changing the spring preloading of the shock absorber...28

Pivot bearing..................................................................28

Checking the chain tension ............................................29

Correct the chain tension ...............................................29

Chain maintenance ........................................................30

Chain wear.....................................................................30

General information about KTM disc brakes...................31

Adjusting the free travel at the hand brake lever ............32

Checking the brake fluid level - front brake....................32

Refilling the front brake fluid reservoir............................32

Checking the front brake pads .......................................32

Replacing the front brake pads.......................................33

Changing the basic position of the foot brake pedal.......33

Checking the rear brake fluid level .................................33

Refilling the rear brake fluid reservoir .............................33

Checking the rear brake pads.........................................34

Replacing the rear brake pads ........................................34

Dismounting and mounting the front wheel...................34

Dismounting and mounting the rear wheel ....................35

Tires, air pressure ...........................................................36

Checking the spoke tension............................................36

Replacing the battery of the electronic speedometer ......36

Setting the clock of the electronic speedometer..............37

Checking/setting the distance of the magnetic sensor....38

Replacing the headlight lamp .........................................38

Cooling system...............................................................39

Radiator cover for the cold season..................................39

Checking the coolant level .............................................39

Refilling / Bleeding the cooling system ...........................40

Cleaning the air filter......................................................40

Changing the original position of the clutch lever ..............41

Checking the oil level of the hydraulic clutch..................41

Bleeding of the hydraulic clutch......................................41

Exhaust system...............................................................41

Cleaning the spark arrestor (EXC USA)...........................42

Carburetor adjustment ...................................................42

Draining the float chamber of the carburetor .................43

Checking the float level..................................................43

Checking the transmission oil level (125/200) ................44

Changing the transmission oil (125/200)........................44

Checking the transmission oil level (250/300) ................44

Changing the transmission oil (250/300)........................44

OPERATION INSTRUMENTS ...............................................5

Clutch lever .....................................................................5

Hand brake lever..............................................................5

Electronic speedometer, indicator lamp (EXC)...................6

Electronic speedometer ....................................................6

Tripmaster switch.............................................................7

Short circuit button (SX).................................................11

Combination switch (EXC)..............................................11

Headlamp switch (EXC USA)..........................................11

Flasher switch.................................................................11

Emergency OFF switch (Australia)..................................11

Filler cap.........................................................................12

Fuel tap..........................................................................12

Choke knob ...................................................................12

Shift lever.......................................................................12

Kickstarter......................................................................13

Foot brake pedal ............................................................13

Side stand ......................................................................13

Steering lock ..................................................................13

Compression damping of fork ........................................14

Rebound damping of fork ..............................................14

Compression damping of shock absorber (SX)................14

Compression damping of shock absorber (MXC, EXC) ...15

Rebound damping of shock absorber (SX, MXC, EXC) ...15

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE...................................................................16

Instructions for your first ride .........................................16

Running in .....................................................................16

DRIVING INSTRUCTIONS ..................................................17

What you should check before each start.......................17

Starting when the engine is cold.....................................18

Starting when the engine is warm ..................................18

What to do when the engine is “flooded“ .....................18

Starting off.....................................................................18

Shifting, Riding...............................................................18

Braking...........................................................................19

Stopping, Parking...........................................................19

Refueling, fuel................................................................19

CLEANING..........................................................................45

CONSERVATION FOR WINTER OPERATION ....................45

STORAGE...........................................................................45

Using RE Iniation............................................................45

PERIODIC LUBRICATION - AND MAINTENANCE-SCHEDULE ....20

MAINTENANCE WORK ON CHASSIS AND ENGINE ..........24

Checking and adjusting the steering head bearing..........24

How to change the handlebar position...........................25

Breather plug front fork..................................................25

Cleaning the dust sleeves of the telescopic fork..............25

Basic suspension setup for the weight of the driver ........26

Checking the shock absorber and spring ........................26

Determining the static sag of the shock absorber ...........26

Determining the riding sag of the shock absorber...........26

Checking the basic setup of the telescopic fork ..............27

Changing the spring preload on the telescopic fork (SX models)27

TECHNICAL SPECIFICATIONS - CHASSIS (125/200)..........46

TECHNICAL SPECIFICATIONS - ENGINE (125/200)...........48

TECHNICAL SPECIFICATIONS - CHASSIS (250/300) ............50

TECHNICAL SPECIFICATIONS - ENGINE (250/300)...........52

INDEX.................................................................................54

WIRING DIAGRAM, CARBURETOR SETTING............Appendix

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SERIAL NUMBER LOCATIONS

Chassis number

The chassis number is stamped on the right side of the steering head tube.

Enter this number in the field on page no 1.

Engine number, engine type (125/200)

The engine number and the engine type are stamped into the left side of

the engine below the engine sprocket. Enter this number on page 1.

Engine number, engine type (250/300)

Engine number and engine type are stamped on the right hand side of the

engine in front of the kickstarter. Enter this number in the relevant field on

page 1.

OPERATION INSTRUMENTS

Clutch lever

The clutch lever 1is 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).

Hand brake lever

The hand brake lever is mounted on the handlebars on the right and actu-

ates the front wheel brake.

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Electronic speedometer, indicator lamp (EXC)

The green control lamp 1flashes in the same rhythm as the

flashing indicator when the indicator is working.

The blue control lamp 2lights up when the high beam is on.

Electronic speedometer

The electronic speedometer display is activated as soon as the engine is

switched on and the motorcycle starts to move.

The engine must be started in order for the speedometer to be supplied

with electricity from the generator. An impulse must be received from the

wheel sensor to activate the display; the front wheel must turn at least one

time.

TEST

All of the display elements will light up for 1 second for the function test.

WS (wheel size)

The display will change and briefly show the diameter of the front wheel in

millimeters.

If the front wheel does not turn, the display will automatically change to the

SPEED/H mode.

If the front wheel turns, the display will automatically change to the

SPEED /ODO mode.

SPEED/H (hours) display mode

When you stop driving and no impulses are sent from the wheel sensor, the

display mode will automatically change from SPEED/ODO to SPEED/H. H

shows the operating hours. The operating hour counter starts to count as

soon as you start the engine. The displayed figure cannot be cleared.

Service intervals are indicated in operating hours for some KTM offroad

motorcycles, making the operating hour counter a very practical function.

Anzeigemodus SPEED/ODO

The SPEED/ODO mode shows the speed and the total kilometers traveled.

When the front wheel stops turning, the display will automatically change

to the SPEED/H mode.

The information will disappear in the display when the front wheel stops

turning for 1 minute.

NOTE:

A Tripmaster switch is available as an accessory and enhances the electronic

speedometer by providing the following functions:

2x Tripmaster

2x chronometer for the lap time

Average speed

Maximum speed

Clock

Display in miles

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Tripmaster switch

The switch has three buttons: MODE, + (plus) and – (minus).

WARNING

–

MODE

DO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR

ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN

ACCIDENT.

Electronic speedometer functions provided by the Tripmaster

switch

The display modes on the electronic speedometer will change in the follo-

wing order. If not, please read the chapter "ACTIVATING AND DEACTIVA-

TING THE DISPLAY MODE."

SPEED/ODO display mode

SPEED displays the speed in KPH or MPH. The displayed figure cannot be

cleared.

ODO displays the kilometers or miles traveled. The displayed figure cannot

be cleared.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the next mode

SPEED/MAX display mode

MAX displays the maximum speed. It is always active.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the MAX figure to 0

SPEED/LAP display mode

LAP displays the stopped lap time in hours, minutes and seconds.

+ BUTTON Starts and stops the stop watch. The lap time is not reset to 0.

– BUTTON Stops the running stop watch, stores the lap time and restarts

the stop watch. The time is reset to 0. A total of 10 lap times

can be stored and read in the SPEED/LAP display mode. To

clear all of the stored lap times, hold the MODE button for 3

seconds in the SPEED/LAP mode.

press the MODE BUTTON to change to the next mode

If no lap time is stored or the motorcycle is driving, the LAP/LAP

mode will be skipped.

press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all

stored lap times to 0

LAP/LAP display mode

The lap number is shown at the top and the lap time in hours, minutes and

seconds at the bottom of the display.

If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will

be skipped.

Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the

stored lap times.

+ BUTTON changes to the next lap time.

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the next mode

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SPEED/CLK (clock) display mode

CLK will display time in hours, minutes and seconds.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode.

press and hold the MODE BUTTON 3 SECONDS to set the time in the menu

(see SETTING THE CLOCK)

SPEED/H (hours) display mode

When you stop driving and no impulses are sent from the wheel sensor, the

display mode will automatically change from SPEED/ODO to SPEED/H. H

shows the operating hours. The operating hour counter starts to count as

soon as you start the engine. The displayed figure cannot be cleared.

Service intervals are indicated in operating hours for some KTM offroad

motorcycles, making the operating hour counter a very practical function.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the SETUP mode

(see REVEALING/CONCEALING functions).

SPEED/TRP1 (trip 1) display mode

The TRP1 trip meter is always active and counts to 999.9. It is used to mea-

sure the length of a trip or the distance between 2 refueling stops.

TRP1 is linked to AVS1 and STP1. The calculation of these figures is activa-

ted by the first impulse received from the wheel sensor (when the front

wheel starts to turn) and stops 3 seconds after the last impulse is received

(when the front wheel has stopped).

The TRP1, AVS1 and STP1 figures are automatically reset to 0 after passing

999.9.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode.

press and hold the MODE BUTTON 3 SECONDS to automatically reset the

TRP1, AVS1 and STP1 figures to 0.

SPEED/AVS1 (average speed 1) display mode

AVS1 is always active and shows the average speed based on the TRP1 and

STP1 figures. The calculation of this figure is activated by the first impulse

received from the wheel sensor and stops 3 seconds after the last impulse is

received.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and

STP1 figures to 0.

SPEED/STP1 (stop 1) display mode

STP1 shows the traveling time based on TRP1 and continues to count whe-

never it receives impulses from the wheel sensor. The calculation of this

figure is activated by the first impulse received from the wheel sensor and

stops 3 seconds after the last impulse is received.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and

STP1 figures to 0.

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SPEED/TRP2 (trip 2) display mode

The TRP2 trip meter is always active and counts to 999.9. Contrary to

TRP1, the displayed figure can be changed using the + and – buttons. This

is a very useful function for trips taken according to a roadbook.

TRP2 is activated by the first impulse received from the wheel sensor and

stops automatically 3 seconds after the last impulse is received.

+ BUTTON increases the TRP2 figure

– BUTTON decreases the TRP2 figure

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset TRP2 to 0

SPEED/AVS2 (average speed 2) display mode

AVS2 shows the average speed based on the TRP2 and STP2 figures. The

calculation of this figure is activated by the first impulse received from the

wheel sensor and stops 3 seconds after the last impulse is received.

The displayed figure will deviate from the actual average speed if TRP2 was

changed manually or if STP2 was not stopped after the trip.

+ BUTTON no function

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to change to the next mode

SPEED/STP2 (stop 2) display mode

STP2 is a manual stop watch. Start the stop watch by pressing the + but-

ton, press again to hold. Press again to continue timing.

Press the MODE button to change to the next mode. The STP2 display will

blink in the other modes if STP2 continues to run in the background. To

stop STP2, return to the SPEED/STP2 mode and press the + button.

+ BUTTON starts and stops the stop watch

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset STP2 figures to 0

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OVERVIEW OF TRIPMASTER FUNCTIONS

Display

Press +

Press –

Press MODE

Hold MODE for 3 sec

no function

SPEED / ODO

no function

next display mode

no function

resets MAX to 0

SPEED / MAX

SPEED / LAP

no function

next display mode

starts / stops LAP

figure LAP remains

clears all LAP figures

stops LAP, stores LAP

figure, resets LAP to 0

next figure

no function

next display mode

set clock menu

LAP / LAP

SPEED / CLK

SPEED / H

no function

next display mode

display setup menu

resets TRP1, STP1 and

AVS1 to 0

SPEED / TRP1

no function

resets TRP1, STP1 and

AVS1 to 0

SPEED / AVS1

SPEED / STP1

no function

next display mode

resets TRP1, STP1 and

AVS1 to 0

increases TRP2 figure

no function

resets TRP2 to 0

next display mode

sets STP2 to 0

SPEED / TRP2

SPEED / AVS2

SPEED / STP2

decreases TRP2 figure

no function

next display mode

starts / stops STP2

no function

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Short circuit button (SX)

The short circuit button 1turns off the engine. When pressing this button,

the ignition circuit is short-circuited.

Combination switch (EXC)

The light switch has 2, respectively 3 switch positions.

A= Light off (this function is not available in all models)

B= Low beam on

C= High beam on

You may use button 2to actuate the horn.

The red short circuit button 3 serves to switch off the engine. Leave the

switch pressed until the engine stops.

Headlamp switch (EXC USA)

In this model the headlamp is switched on with the pull switch 4.

Flasher switch

The flasher switch is a separate unit and is mounted on the left portion of

the handlebar.

The wire harness is designed in a way that whenever you want to use your

bike off-road, you can dismount the entire turn indicator system without

affecting the function of the remaining electrical system.

Flasher left

Flasher right

Emergency OFF switch (Australia)

The emergency OFF switch 5is located next to the throttle grip. Primarily

designed as safety or emergency OFF switch, it should normally not be in its

activated state.

In this position, the ignition circuit is shorted; if the engine is running,

it will stall immediately, if it is at standstill, it will not start.

In this position, the ignition circuit is enabled; the engine should start.

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Filler cap

To open it: turn filler cap counter-clockwise.

To close it: put filler cap back on and tighten it by turning it clockwise.

Install tank breather hose 1without kinks.

Fuel tap

OFF In this position the fuel tap is closed. No fuel can flow to the carburetor.

ON During operation the twist grip must be turned to ON. This means

that the fuel can flow to the carburetor. With the twist grip in this

position the tank will be emptied until only the reserve is left.

RES The reserve tank cannot be tapped until the rotating handle is turned

to the RES position. Fill the tank as soon as possible and remember to

turn the rotating handle back to the ON position so that you will have

backup fuel next time, too.

Reserve of the 9 l tank . . . . . . 1.3 l (0.32 US gallons)

Reserve of the 11 l tank . . . . . . . 1.7 l (0.45 US gallons)

OFF

RES

MXC

EXC

Choke knob

When pulling the choke knob 2fully towards the top, a bore is opened in

the carburetor. Through this bore the engine can take in additional fuel.

This results in a rich fuel-air mixture, that is needed for a cold start.

When pressing the choke knob downward in the carburetor, the bore is

closed again.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the

gears is shown in the illustration. Neutral, or the idle speed, is located bet-

ween first and second gear.

2,3,4,5 (6)

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Kickstarter

The kickstarter is mounted on the left side of the engine. Its upper part can

be swivelled.

Foot brake pedal

The foot brake pedal is disposed in front of the right foot rest. Its basic posi-

tion can be adjusted to your seat position (see maintenance work).

Side stand

Push the side stand to the ground with your foot and load it with the

motorcycle. Make sure that you put your bike on solid ground and in a

secure position. For off-road riding, you can use the rubber band 1 to

additionally secure the center stand in its folded-up position.

Steering lock

The handlebar can be locked by means of the lock located on the steering

head. To lock it, turn the handlebar all the way to the right, insert the key,

turn it to the left, press it in, turn it to teh right, and remove it.

CAUTION

NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK. IF YOU TURN THE HANDLEBAR

TO THE LEFT THE KEY COULD GET DAMAGED.

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Compression damping of fork

Hydraulic compression damping determines the reaction when the fork is

compressed. The degree of compression can be adjusted with adjusting

screws at the bottom of the fork legs.Remove the protecting cap 1.

Turn the knob 2clockwise to increase damping, turn it counterclockwise to

reduce damping during compression.

STANDARD ADJUSTMENT

– turn adjusting screw clockwise as far as it will go

– turn it back by as many clicks as are specified for the relevant type of fork

Type White Power 1418X725 ..............20 clicks

Type White Power 1418X735 ..............22 clicks

Type White Power 1418X736 ..............20 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is

rebound. By turning the adjusting screw 3(REB), the degree of damping of

the rebound can be adjusted. Turn the knob clockwise to increase damping,

turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT

– turn adjusting screw clockwise as far as it will go

– turn it back by as many clicks as are specified for the relevant type of fork

Type White Power 1418X725 ..............20 clicks

Type White Power 1418X735 ..............20 clicks

Type White Power 1418X736 ..............20 clicks

Damping action during compression of shock absorber (SX)

The shock absorber on the SX models can synchronize the compression

damping in the low and high-speed range separately (Dual Compression

Control).

Low and high speed refers to the movement of the shock absorber during

compression and not to the speed of the motorcycle.

The low and high-speed technology overlaps.

The low-speed setting is primarily for slow to normal shock absorber

compression rates.The high-speed setting is effective at fast compression

rates.Turning in a clockwise direction will increase the damping, turning

counterclockwise will decrease the damping.

STANDARD LOW-SPEED SETTING:

– Turn the adjusting screw 4 to the limit in a clockwise direction using a

screwdriver .

– Unscrew the respective number of clicks for the specific type of shock

absorber in a counterclockwise direction.

Type White Power 1218X756..............17 clicks

STANDARD HIGH-SPEED SETTING:

– Turn the adjusting screw 5 to the limit in a counterclockwise direction

using a box wrench.

– Unscrew the respective number of turns for the specific type of shock

absorber in a clockwise direction.

Type White Power 1218X756.............. 2 turns

WARNING

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY

MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW 6CONNECTION (24MM).

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Compression damping of shock absorber (MXC, EXC)

The compression damping (during compression) can be adjusted for the

MXC and EXC shock absorbers (Mono Compression Control).

The degree of damping can be adjusted by turning adjusting screw 1with

a screwdriver. Turning in a clockwise direction will increase the damping,

turning in a counterclockwise direction will decrease the damping.

STANDARD ADJUSTMENT:

– Turn the adjusting screw clockwise to the stop.

– Then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

Type White Power 1218X757 ..............17 clicks

Type White Power 1218X759 ..............17 clicks

WARNING

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN-

ANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW 2CONNECTION (24MM).

Rebound damping of shock absorber (SX, MXC, EXC)

By using the adjusting screw 3, the degree of damping of the rebound can

be adjusted. Turn the knob to the right side to increase damping, turn it to

the left side to reduce damping during rebounding.

STANDARD ADJUSTMENT:

– Turn the adjusting screw clockwise to the stop.

– Then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

Type White Power 1218X756 ..............28 clicks

Type White Power 1218X757 ..............28 clicks

Type White Power 1218X759 ..............26 clicks

WARNING

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTE-

NANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW 4CONNECTION (15MM).

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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for your first ride

WARNING

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Thoroughly read the whole instruction manual before

starting for your first tour.

– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. SMART

KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES, AND A

JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR

SHORT RIDE. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY

– Familiarize yourself with the controls.

– Adjust the clutch lever, the hand brake lever and the foot

brake pedal to the most comfortable position.

– Get used to handling the motorcycle on an empty parking

lot or open space, before going for a longer ride. Also try to

ride as slowly as possible while standing upright, to improve

your feeling for the vehicle.

– Do not drive along off-road trails which go beyond your

ability and experience.

– Hold the handlebar with both hands and leave your feet on

the foot rests while driving.

– Remove your foot from the foot brake lever when you are

not braking. If the foot brake lever is not released the

brake pads rub continuously and the braking system is

overheated.

– You may only take a passenger along if your motorcycle is

fitted and registered for such purposes. During the ride, the

passenger must hold on to the straps or to the driver, with

his feet on the passenger footrests.

COLORED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS

EARLY AS POSSIBLE. OF COURSE YOUR PASSENGER WILL ALSO NEED

SUITABLE PROTECTIVE CLOTHING.

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

– DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

– ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM. FOR EXAM-

PLE, FRONT PANELLING CAN IMPAIR THE DRIVING CHARACTERISTICS OF

THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT

DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’S DRIVING

CHARACTERISTICS.

– THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH

TIRES THAT HAVE THE SAME PROFILE TYPE.

– BE SURE TO CHECK THE SPOKE TENSION AFTER 30 MINUTES' RUNNING

TIME. THE SPOKE TENSION WILL DECREASE QUICKLY ON NEW WHEELS.

I^{F YOU CONTINUE TO DRIVE WITH LOOSE SPOKES}, THE SPOKES MAY

^{CRACK AND LEAD TO UNSTABLE HANDLING}(SEE "CHECKING THE SPOKE

TENSION").

– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRY TO

LOOK AHEAD AS FAR AS POSSIBLE SO THAT YOU RECOGNIZE ANY

HAZARDS AS EARLY AS POSSIBLE.

– ADJUST YOUR DRIVING SPEED TO THE CONDITIONS AND YOUR

DRIVING SKILLS.

– DRIVE CAREFULLY ON UNKNOWN ROADS OR IN UNKNOWN

TERRITORY.

– WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE.

– Do not make any alterations to the motorcycle and always

use ORIGINAL KTM SPARE PARTS. Spare parts from other

manufacturers can impair the safety of the motorcycle.

– Motorcycles are sensitive to alterations in the distribution of

weight. If you are taking luggage with you, it should be

secured as close as possible to the middle of the vehicle; dis-

tribute the weight evenly between the front and the rear

wheel. Never exceed the maximum permissible laden

weight and the axle weights. The maximum permissible

laden weight is made up of the following components:

– Motorcycle ready for operation and tank full

– 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.

– Luggage

– Driver and passenger with protective clothing and helmet.

– Pay attention to running-in procedure.

WARNING

– THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON

ONLY - NO ADDITIONAL PASSENGER ALLOWED!

– NEITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY

REGULATIONS AND SAFETY STANDARDS. USING THEM ON PUBLIC

ROADS, HIGHWAYS, FREEWAYS, ETC. IS AGAINST THE LAW.

– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT

OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.

Running in

Even very precisely machined sections of engine components

have rougher surfaces than components which have been

sliding across one another for quite some time. Therefore,

every engine needs to be broken in. For this reason, during its

first 500 kilometers (300 miles) or 5 hours the engine must not

be revved up to its performance limits.

Apply low but changing loads for running-in.

CAUTION

DO NOT DRIVE AT FULL LOAD FOR THE FIRST 500 KILOMETERS

(300 MILES) OR 5 HOURS!

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DRIVING INSTRUCTIONS

What you should check before each start

When you start off, the motorcycle must be in a perfect technical condition.

For safety reasons, you should make it a habit to perform an overall check

of your motorcycle before each start.

The following checks should be performed:

1 CHECK TRANSMISSION OIL LEVEL

Too little transmission oil leads to premature wear and will ultimately

destroy gear wheels and parts of the shift mechanism.

2 FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap,

check that the tank venting hose is free of kinks.

3 CHAIN

A loose chain was fall off the chain wheels; an extremely worn chain

may tear, and insufficient lubrication may result in unnecessary wear of

the chain and chain wheels.

4 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced.

The tread depth must comply with the legal regulations. Also check the

air pressure. Insufficient tread and incorrect air pressure deteriorate the

driving performance.

5 BRAKES

Check correct functioning of the braking system. Verify that there is

sufficient brake fluid in the reservoir. The reservoirs have been designed

in such a way that brake fluid does not need to be refilled even when the

brake pads are worn. If the level of brake fluid falls below the minimum

value, this indicates a leak in the braking system or completely worn out

brake pads. Arrange for the braking system to be checked by an

authorized KTM dealer, as complete failure of the braking system can be

expected.

Also check the state of the brake hose and the thickness of the brake

linings.

Check free travel of the hand brake lever and foot brake lever.

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS

“SPONGY” (TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG

WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT

FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

6 CABLES

Check correct adjustment and easy running of all control cables.

7 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

8 ELECTRICAL SYSTEM

Check correct functioning of headlamps, tail-lights, brake lights, turn

indicators, indicator lamps and horn while the engine is running.

9 LUGGAGE

If you are taking luggage with you, check that it is securely fastened.

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Starting when the engine is cold

1 Open fuel tap

2 Turn on ignition or emergency OFF switch

3 Put the gear in neutral

4 Activate cold-starting aid (choke)

5 Leave throttle closed or open it no more than ¹/ and kick down kickstar-

ter vigorously all the way.

WARNING

– FOR STARTING ALWAYS PUT ON YOUR MOTORCYCLE BOOTS TO AVOID INJURIES.

YOU COULD SLIP OFF THE KICKSTARTER OR THE MOTOR COULD KICK BACK AND

FLING YOUR FOOT UPWARDS.

– FORCEFULLY KICK THE KICKSTARTER DOWN THE WHOLE WAY AND DO NOT OPEN THE

THROTTLE. A KICKSTART WITH TOO LITTLE MOMENTUM AND AN OPENED THROTTLE

INCREASES THE KICKING BACK RISK.

– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.

ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

CAUTION

DO NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP THE ENGINE

WHEN COLD. SINCE THE PISTON WARMS UP AND EXPANDS FASTER THAN THE WATER

COOLED CYLINDER, THIS MIGHT CAUSE ENGINE DAMAGE. ALWAYS LET ENGINE IDLE UNTIL

WARM OR DRIVE IT WARM AT LOW R.P.M. SPEEDS.

Starting when the engine is warm

1 Open fuel tap

2 Turn on ignition or emergency OFF switch

3 Put the gear in neutral

4 Open throttle to ¹/

and kick down kickstarter vigorously

What to do when the engine is “flooded”

1 Close fuel tap

Start engine with full throttle. If necessary, unscrew spark plug and dry it.

3 Once the engine is running, open fuel tap again.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch

lever and accelerate at the same time.

WARNING

– BEFORE YOU START OFF, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG

RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE FLOOR, YOU MAY LOSE CON-

TROL OF YOUR MOTORCYCLE.

– BEFORE STARTING FOR AN OFF-ROAD TOUR, IT IS RECOMMENDED TO ADDITIONALLY

SECURE THE SIDE STAND WITH THE RUBBER BAND ON THE AIR FILTER BOX.

Shifting/Riding

You are now in first gear, referred to as the drive or uphill gear. Depending

on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Turn

down the throttle, at the same time pull the clutch lever in and shift to the

next higher gear. Let the clutch lever 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 / ; the speed hardly decreases although the engine will use

less gas. Only give as much gas as the engine can handle. Through quick

and high revving of throttle, the gas consumption will increase. When shif-

ting down, use the brakes if necessary and turn down at the same time. Pull

the clutch lever and shift down to the next lower gear. Let the clutch lever

go slowly and open the throttle or shift down again.

WARNING

– AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS THOROUGHLY

BEFORE USING IT AGAIN.

– A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DO NOT ADJUST THE HAND-

LEBAR, IT WILL LOSE STABILITY.

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Refueling, fuel

CAUTION

125-300: Unleaded premium gasoline RON 95 mixed with

high grade two stroke oil. Mixture ratio 1:40 - 1:60

Fuel and engine oil should only be mixed immediately before

use. KTM recommends SHELL ADVANCE RACING X.

– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT

A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED TO BE TAKEN.

WARNING

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.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

A LOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE VALVES.

IN ADDITION, THE REAR WHEEL WILL BLOCK SO THAT THE MOTORCY-

CLE CAN EASILY GET OUT OF CONTROL.

– IF THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL

TRAVEL, THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO

ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS

MIXED IN THE FUEL.

– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIA-

TELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM

DEALER.

CAUTION

– ONLY USE PREMIUM-GRADE GASOLINE ROZ 98 RESPECTIVELY 95

MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF

GASOLINE CAN CAUSE ENGINE FAILURE.

– DO NOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD

ENGINES OR NORMAL ENGINE OIL TO PREPARE THE MIXTURE.

– DO NOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN

ONE WEEK. THE LUBRICATION PROPERTIES OF SOME TWO-STROKE

OILS CAN DETERIORATE VERY RAPIDLY.

– ONLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL

(i.e. SHELL ADVANCE RACING X).

– NEVER MIX SYNTHETIC OILS AND MINERAL OILS.

– NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE

PISTON. WHEN USING TOO MUCH OIL, THE ENGINE MAY START SMO-

KING AND FOUL THE SPARK PLUG.

– IF YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER,

ALWAYS KEEP IN MIND THAT LEADED FUEL WILL DESTROY THE CATALY-

TIC CONVERTER.

Braking

Turn off the gas and apply the hand and foot brakes at the

same time. When driving on sandy, wet or slippery ground,

use mainly the rear wheel brake. Always brake with feeling,

blocking wheels can cause you to skid or fall. Also change

down to lower gears depending on your speed.

WARNING

– IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES

THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD TRACKS,

HUMID OR DIRTY BRAKE DISCS CAN DELAY THE 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.

– FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT

FILL THE TANK TO THE TOP. (SEE FIG.)

– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER

AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEA-

KER THE BREAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING

SYSTEM CAN FAIL.

– IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL

FEELS “SPONGY” (TOO MUCH GIVE), THIS IS AN INDICATION THAT

SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR

MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM

LOOKED OVER BY A KTM DEALER.

35 mm

Stopping and parking

Brake motorcycle and shift gears to idling. To switch off the

engine, depress short circuit switch until the engine stops or

switch off ignition. Close fuel tap.

WARNING

MOTORCYCLE ENGINES PRODUCE

GREAT AMOUNT OF HEAT WHILE

RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND

SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF

THESE PARTS AFTER STARTING THE MOTORCYCLE, AND TAKE CARE TO

^{PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED}.

CAUTION

– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE

CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE

HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE

MATERIALS.

– THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE

MOTORCYCLE. IF YOU GET ON YOUR MOTORCYCLE AND THUS PUT

ADDITIONAL WEIGHT ON THE MOTORCYCLE, THE SIDE STAND OR THE

FRAME CAN BE DAMAGED OR THE MOTORCYCLE MAY FALL ON THE

SIDE.

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125/200 SX/MXC/EXC

250/300 SX/MXC/EXC

PERIODIC MAINTENANCE SCHEDULE

1st service

after

4000 kilometer

after

20 hours

after 10 hours

A clean motorcycle can be checked more quickly which saves money!

1000 kilometers

once a year

2000 kilometers

Check gear box oil level

●

Change gear box oil

●

Check spark plugs, adjust distance between electrodes

Renew spark plugs

●

Check the carburetor connection boot for cracks and leaks

Check idle speed setting

●

Check that vent hoses are not damaged or bent

Check cooling system for leaks, check quantity of antifreeze

Check exhaust system for leaks and fitment

Check cables for damage, smooth operation, bends; adjust and lubricate

Check oil level of the clutch master cylinder

Clean air filter and filter box

●

Check electric wires for damage and bends

Check headlamp setting

Check function of electric systems (low beam, high beam, break light, indicator,

indicator lamps, speedometer illumination, horn, emergency OFF switch or button

Check brake fluid level, lining thickness, brake lining

Check brake lines for damage and leaks

●

Check/adjust smooth operation and free travel of handbrake/foot brake lever

Check tightness of brake system screws

Check shock absorber and fork for leaks and function

Clean dust bellows

Bleed fork legs

Check swing arm bearings

Check/adjust steering head bearings

●

Check tightness of all chassis screws (triple clamps, fork leg axle passage

axle nuts and screws, swing arm bearings, shock absorber)

Check spoke tension and rim joint

●

Check tires and air pressure

●

Check chain, rear sprockets and chain guides for wear, fitment and tension

Lubricate chain

Check clearance of wheel bearings

IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER

every 2 years

or 20000 km

at least

once a year

Check function of exhaust control

●

Complete maintenance of shock absorber

Complete maintenance of fork

●

Clean and grease steering head bearings and gasket elements

Clean and adjust carburetor

●

Replace glass fibre- yarn filling of the exhaust main silencer

Treat electric contacts and switches with contact grease

Change hydraulic clutch fluid

Change break fluid

IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!

SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN

HOURS OR 500 KM!

MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!

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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

Clean and lubricate chain, check tension and adjust if necessary

Clean air filter and filter box

Check tires for pressure and wear

●

Check cooling liquid level

Check fuel lines for leaks

Empty and clean float chamber

●

Check all control elements for smooth operation

Check brake performance

●

Treat blank metal parts (with the exception of brake and exhaust systems)

with wax-based anti corrosion agent

Treat ignition and steering locks and light switches with contact spray

Check tightness of screws, nuts and hose clamps regularly

●

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RECOMMENDED INSPECTION OF THE 125/200/250/300 SX AND EXC ENGINE

USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP

(ADDITIONAL ORDER FOR THE KTM WORKSHOP)

120

hours

135

hours

Check the reed-type intake valve for wear

●

Check the clutch shoes for wear

Check the length of the clutch springs

Check the cylinder and piston for wear

Check the exhaust control for proper functioning and smooth running

Check the eccentricity of the crankshaft journal

Check the radial clearance of the conrod bearings

Check the radial clearance of the piston pin main bearing

Check the crankshaft main bearing for wear

Replace the crankshaft bearings and conrod bearings

Check the entire transmission including roller and bearings for wear

●

RECOMMENDED INSPECTION OF THE 125/200/250/300 EXC ENGINE

USED FOR HOBBY- ENDURO BY YOUR KTM WORKSHOP

(

ADDITIONAL ORDER FOR THE KTM WORKSHOP

)

120

240

hours

270

hours

180

hours

Check the reed-type intake valve for wear

●

Check the clutch shoes for wear

Check the length of the clutch springs

Check the cylinder and piston for wear

Check the exhaust control for proper functioning and smooth running

Check the eccentricity of the crankshaft journal

Check the radial clearance of the conrod bearings

Check the radial clearance of the piston pin main bearing

Check the crankshaft main bearing for wear

Replace the crankshaft bearings and conrod bearings

Check the entire transmission including roller and bearings for wear

●

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS

MUST BE REPLACED.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

WARNING

MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND

TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED

KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED,

SKILLED STAFF.

CAUTION

– WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-

BURETOR, ELECTRIC CONNECTORS, ETC.

– WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT

THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK

– ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR

LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.

– DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING

LOOSE. INSTEAD, USE SELF-LOCKING NUTS.

– LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

– DISPOSE OF OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS, ETC. PROPERLY.

– UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER OF USED OIL CONTAMINATES

1,000,000 LITERS OF WATER.

Checking and adjusting the steering head bearing *

Check steering head bearing for play periodically. To check, put the

motorcycle on a stand so that the front wheel is off the ground. Now try to

move the fork forward and backward. For readjusting, loosen the five pinch

bolts 1of the top triple clamp and turn steering stem bolt clockwise 2until

there is no more play. Don’t tighten the steering stem bolt all the way,

otherwise the bearings will be damaged. With a plastic hammer, lightly tap

on the triple clamp to release tension. Retighten the five pinch bolts to 20 Nm

(15 ft.lb).

WARNING

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE

WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.

CAUTION

IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE

BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.

The steering head bearings should be regreased at least once a year

(e.g. Shell Advance Grease).

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How to change the handlebar position

The handlebar position can be readjusted by 22 mm. Thus, you can put the

handlebar in the position that is the most convenient for you. The upper tri-

ple clamp 1includes 2 bores arranged at a distance of 15 mm (0.6 in) from

one another. The bores at the handlebar support 2are 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 scr-

ews 4 to 40 Nm (30 ft.lbs). Mount the handlebar and handlebar clamps,

and tighten screws 3to 20 Nm (15 ft.lbs). The gap between the handlebar

support and the handlebar clamps should be the same size in the front and

in the rear.

WARNING

THE SCREWS 4MUST BE SECURED WITH LOCTITE 243.

3,5 mm

Breather plug front fork

After every 5 hours of use for competitive racing, slacken the breather

plugs 5 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 mainte-

nance service.

CAUTION

EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF

YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE

HAVING THE SEALS REPLACED.

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows 6 are to remove dust and coarse dirt particles

from the fork tube. However, after some time, dirt may also get in behind

the dust-protection bellows. If this dirt is not removed, the oil sealing rings

located behind it may start to leak.

Use a screwdriver to lift the dust-protection bellows out of the outer tubes

and slide them downward.

Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly,

and oil them thoroughly with silicone spray or engine oil. Then, push the

dust-protection bellows into the outer tubes by hand.

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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 70 -

80 kg (wearing full protective clothing). If your weight exceeds or falls short

of this range, you will need to adjust the basic setup for the suspension

components accordingly. Minor deviations in weight can be compensated

by adjusting the spring preload. Different springs must be installed for larger

deviations.

Checking the shock absorber and spring

You can establish whether or not the shock absorber spring is suitable for

your weight by checking the riding sag. The static slag must be correctly

adjusted before the riding sag can be determined.

Determining the static sag of the shock absorber

The static sag should be as close as possible to 35 mm. Deviations of more

than 2 mm can strongly influence the motorcycle's performance.

Procedure:

– Jack up the motorcycle until the rear wheel no longer touches the gro-

und.

– Measure the vertical distance between the rear wheel axle and a fixed

point (e.g. a mark on the side cover) and write it down as dimension A.

– Place the motorcycle on the ground again.

– Ask a helper to hold the motorcycle in vertical position.

– Measure the distance between the rear axle and the fixed point again to

establish dimension B.

– The static sag is the difference between dimensions A and B.

EXAMPLE:

Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . . . . .600 mm

Motorcycle on ground, unloaded (dimension B) . . . . . . . . . . . . . .– 565 mm

Static sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 mm

If the static sag is lower, the spring preload of the shock absorber must be

increased, if the static sag is reduced, the spring preload must be higher. See

chapter "Changing the spring preload of the shock absorber."

Determining the riding sag of the shock absorber

– Have a helper hold the motorcycle while you sit on the bike in a normal

seating position (feet on the footrests) wearing full protective clothing

and bounce up and down a few times to allow the rear wheel suspension

to become level.

– Stay on the bike and have another person measure the distance between

the same two points and write it down as dimension C.

– The riding sag is the difference between dimensions A and C.

EXAMPLE:

Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . . . . .600 mm

Motorcycle on ground, loaded (dimension C) . . . . . . . . . . . . . . . .– 510 mm

Riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 mm

PDS 1218X756

125 SX

PDS 1218X759 250/300 MXC/EXC

The riding sag should lie between 90 and 105 mm.

If the riding sag is less than 90 mm, the spring is too hard (the spring rate is

too high). If the riding sag is more than 105 mm, the spring is too soft (the

spring rate is too low).

76-95/260

71-90/260

The spring rate is written on the outside of the spring (e.g. 71-90/260). The

type number of the shock absorber is embossed on the bottom of the tank.

The illustrations show which spring should be installed. The standard spring

is shown in bold print (e.g. 1218X756).

66-86/260

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

After installing a different spring, readjust the static sag to 35 mm ( 2 mm).

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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.

PDS 1218X757

125 EXC

200 SX/MXC/EXC

71-90/260

66-86/260

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

Checking the basic setup of the telescopic fork

The precise riding sag of the telescopic fork cannot be determined for

various reasons. Similar to the shock absorber, smaller deviations in your

weight can be compensated by adjusting the spring preload. However, if

your telescopic fork bumps frequently (hard end stop during compression),

you should install harder fork springs to avoid damaging the telescopic fork

and frame.

Changing the spring preload on the telescopic fork (SX models)

The telescopic forks of the SX models come with a preload adjuster for easy

adjustment of the spring preload. You can adjust the spring preload 9 mm

by turning the adjusting screws (basic position = middle position).

NOTE:

Always turn the adjusting screws the same distance on both fork legs. Diffe-

rent spring preloads on the fork legs will reduce the telescopic fork's res-

ponse.

Changing the spring preload on the telescopic fork

(MXC/EXC models)

The telescopic forks for these models must be partly disassembled to adjust

the spring preload (see WP manual). Pretension spacers are available in

heights of 1.5, 2.5 and 5 mm (see spare parts catalog). The fork springs

may not be pretensioned by more than 20 mm.

The preload adjuster used in the SX models can easily be retrofitted for the

telescopic forks of the MXC/EXC models.

NOTE:

1418X725

1418X736

125 SX

250/300 MXC/EXC

WP precisely adjusts the spring pressure by inserting pretension spacers.

Fluctuations in production are compensated with pretension spacers in

various heights. This can cause the fork springs in the fork legs to have dif-

ferent degrees of pretension. Fork springs and pretension spacers should

always stay together.

4,2 N/mm

4,0 N/mm

3,8 N/mm

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

Replacing fork springs

1418X735

125 EXC

If you weigh less than 70 kg or more than 80 kg, you should install the res-

pective fork springs. The correct spring rate is shown in the illustrations. The

standard spring is shown in bold print. The type number of the telescopic

fork is embossed on the caps on the top of the telescopic fork.

200 SX/MXC/EXC

If you are uncertain which spring to use, contact your KTM workshop.

4,0 N/mm

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.

3,8 N/mm

3,6 N/mm

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

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Adjusting the spring preload on the fork (SX)

The spring preload on the SX models can be adjusted (changed) by 10 mm

by turning adjusting screw 1.

Turning in a clockwise direction will increase the prestress, turning in a

counterclockwise direction will decrease the prestress.

Changing the spring preload will not affect the rebound damping

adjustment.

Generally, if the spring preload is higher, the rebound damping should also

be set higher.

STANDARD SETTING:

Unscrew the adjusting screw to the limit and then back 2 turns.

Changing the spring preloading of the shock absorber

The spring preload can be changed by turning the adjusting ring 2. 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 2 changes the spring pretension by

approximately 1.75 mm (0.07 in).

Loosen the clamping screw 3 and use the hook wrench contained in the

vehicle tool set to turn the adjusting ring as desired. Turning it counter-

clockwise will reduce the preload, turning it clockwise will increase the

preload.

After readjusting the clamping screw 3, tighten it to 8 Nm (6 ft.lb)

ADJUSTMENT VALUES - SPRING PRELOAD A

minimum preload . . . . . . . . . . . . . . . . . 4 mm (0.15 in)

STANDARD PRELOAD . . . . . . . . . . . . . 6 mm (0.24 in)

maximum preload. . . . . . . . . . . . . . . . . 10 mm (0.4 in)

Pivot bearing

The pivot bearing 4 for PDS suspension struts at the swinging fork is

Teflon-coated and must not be lubricated with either grease or other lubri-

cants. Grease and other lubricants cause the Teflon coat to dissolve,

whereby the bearing’s lifecycle will be reduced dramatically.

When cleaning your bike with a high-pressure cleaner, do not aim the high-

pressure spray directly at the pivot bearing.

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Check chain tension

To check the chain tension, park the motorcycle.

Press the chain upward at the end of the chain sliding component. The

distance between the chain and the swing arm should be approx. 15 mm

(0.6 in). In the course of this procedure, the upper chain portion A must be

taut (see drawing). If necessary, correct the chain tension.

WARNING

– IF THE CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY TRANSMISSION

(CHAIN, CHAIN WHEELS AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO

UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE.

– TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

Correct chain tension

Loosen collar nut 1, loosen lock nuts 2, and turn right and left adjusting

screws 3equally 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 1to 80 Nm (60 ft.lb).

WARNING

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS

POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF

YOUR MOTORCYCLE.

– TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

NOTE:

The large adjusting range of the chain adjusters (32mm) allows you to use

different secondary ratios in combination with the same chain length. The

chain adjusters 4can be rotated by 180°.

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Chain maintenance

For long chain life, good maintenance is very important. X-ring chains

require only modest maintenance. The best way is to use lots of water, but

never use brushes or solvents. After letting the chain dry, you can use a

special X-ring chain spray (Shell Advance Bio Chain).

WARNING

NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK, EITHERWISE

THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY

REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL.

CAUTION

WHEN MOUNTING THE CHAIN JOINT, THE CLOSED SIDE OF THE SAFETY DEVICE MUST

POINT IN RUNNING DIRECTION.

●

Also check sprockets and chain guides for wear, and replace if necessary.

Chain wear

To check the chain wear, observe the following indications:

Shift the gear into idling and pull the upper chain strand with approx. 10-15

kilograms (33 lb) upwards (see figure). Now one can measure a space of 18

chain reels at the lower chain strand. The chain should be replaced at the

latest when a space of 272 mm (10.70 in) is measured. Chains do not

always wear off evenly, therefore repeat the measurement at different pla-

ces on the chain.

15 KG

33 lbs

NOTE:

If you mount a new chain, the sprockets should also be replaced. New

chains wear faster if used on old used sprockets.

CAUTION

WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14T, THE COLLAR MUST BE ON THE INSIDE

SECURE THE SCREWS OF THE CHAIN WHEEL BY APPLYING LOCTITE AND FASTEN THEM IN A

CROSSWISE ORDER.

TIGHTENING TORQUE FOR NUTS: 35 NM

TIGHTENING TORQUE FOR SCREWS: 50 NM

max. 272 mm

16 17 18

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General information about KTM disc brakes

BRAKE CALIPERS:

The brake calipers of this series use a ”floating” mount. This means that the

brake calipers are not solidly attached to the caliper support, which enables

them to ”float” for maximum braking contact.Secure the screws of the cali-

per support with Loctite 243 and tighten to 25 Nm (19 ft.lb).

BRAKE PADS:

The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front

and TOSHIBA H 38 sintered lining at the back. These linings provide an

optimal combination of dosing, brake performance and life cycle. The lining

type is stated on the back of the brake pad and also recorded in the homo-

logation papers.

Other brake pads are available for competition sports.

FRONT: TOSHIBA H 38 (SINTERED) – harder to dose, good brake perfor-

mance, long life, for wet slippery terrain.

FERODO ID 450 (ORGANIC) – easy to dose, good brake perfor-

mance, short life, for dry terrain, low price.

REAR: FERRIT 222 (ORGANIC) – can be dosed better, short life cycle, for

dry terrain.

FERODO ID 450 (ORGANIC) – easy to dose, good brake perfor-

mance, short life, for dry terrain, low price.

BRAKE DISCS:

Due to wear, the thickness of the brake disc in the area of the contact

face 1 of the brake pads decreases. At their thinnest point A, the brake

discs must not be more than 0.40 mm (0.016 in) thinner than the pad's

nominal thickness. Measure the nominal thickness in a location B outside

the contact face. Check wear at several locations.

WARNING

– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.4 MM (0.016 IN) CONSTI-

TUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS

THEY REACH THE WEAR LIMIT.

– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER

BRAKE FLUID RESERVOIRS:

The brake fluid reservoirs on the front and rear wheel brakes have been

designed in such a way that even if the brake pads 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 comple-

tely worn.

In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:

KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake

fluid, one of the best brake fluids is currently available. We recommend that

you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of

an amber color. If you do not have any DOT 5.1 for refilling, you may use

DOT 4 brake fluid. However, you should replace it as soon as

possible with DOT 5.1.

Never use brake fluid DOT 5. The color of this silicon oil-based product is

purple red. The gaskets and brake hoses of KTM motorcycles are not

designed for DOT 5 brake fluid.

DOT

5.1

DOT

WARNING

●

HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR

MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY.

BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCKETS MAY FORM IN

"OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING THE BRAKE SYSTEM TO

FAIL.

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Adjusting the free travel at the hand brake lever

Free travel at the hand brake lever may be readjusted by using adjustment

screw 1. In this way, the position of the point of pressure (i.e. the resis-

tance you feel on the hand brake lever when the brake pads are pressed

against the brake disc) can be adjusted for any hand size.

CAUTION

AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN). ONLY

THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY

THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF THIS FREE TRAVEL IS NOT PRO-

VIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE

MAY FAIL DUE TO OVERHEATING.

min. 3 mm

Checking the brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the

handlebar and the reservoir is provided with an inspection glass. With the

reservoir in a horizontal position, the brake fluid level should not drop below

the middle of the glass.

WARNING

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN

AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws 2and remove lid 3and membrane 4.

Place hand brake cylinder in a horizontal position and fill the brake fluid

reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1

(e.g. Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten scr-

ews. Rinse off spilled or overflowing brake fluid with water.

WARNING

– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF

YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A

DOCTOR

CAUTION

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

5 mm

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.

min.

1 mm

WARNING

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,

OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT

OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,

THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

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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 3in the caliper support and of the leaf spring 4.

WARNING

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

–

AFTER WORKING ON THE BRAKING SYSTEM, ALWAYS ACTUATE THE HAND BRAKE LEVER

^{OR FOOT BRAKE LEVER}, RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE

^{AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED}.

Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop

screw 5. The free play at the foot brake pedal must then be adjusted by

means of the piston rod 6.

Measured on the outside, the foot brake pedal must have 3-5 mm

(0.12–0.20 in) of free play before the piston rod can move the piston in the

brake cylinder (to be recognised from the resistance on the foot brake

pedal).

CAUTION

IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM

WHEN DRIVING, CAUSING THE REAR WHEEL TO BRAKE.THE BRAKING SYSTEM OVERHEATS

AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES.

3-5mm

Checking the rear brake fluid level

The brake fluid reservoir of the rear disc brake is located on the right side of

the motorcycle next to the kickstarter. The brake fluid level must not drop

below the ”MlN” marking when the vehicle is in an upright position.

WARNING

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHO-

RIZED KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

For this purpose, it is recommended to remove screw 7 and to pull the

brake fluid reservoir outwards. Now the screw cap 8 and the rubber boot

9 can be removed. Add brake fluid DOT 5.1 (Shell Advance Brake DOT

5.1) until the brake fluid level reaches the ”MAX” mark, then mount the

screw cap together with the rubber boot. Return the brake fluid reservoir to

its original position and fix it with the screw. The connecting hose between

the reservoir and the foot brake cylinder must be carefully positioned, pre-

venting kinks and keeping a safe distance between the hose and the

exhaust pipe. Spilled brake fluid must be rinsed off with water.

WARNING

– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF

YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A

DOCTOR.

CAUTION

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT

REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

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Checking the rear brake pads

min.

1 mm

The brake pads can be inspected from the rear. The thickness of the linings

may not be less than 1 mm (0.04 in).

WARNING

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,

OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT

OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,

THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing the rear brake pads *

Press the brake caliper 1 in the direction of the chain wheel for the brake

piston to reach its basic position. Remove the safety device 2, knock out

the guide pin 3from the brake caliper with a drift towards the chain wheel

and remove the brake pads. Carefully clean the brake caliper with compres-

sed air and check the sleeves of the guide pins for damage.

Slide the left brake pad into the brake caliper and fix it with the pin. Slide in

the right brake pad and knock the bolt 3in as far as it will go. Mount the

safety device 2.

WARNING

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

– AFTER WORKING ON THE BRAKING SYSTEM, ONE MUST ALWAYS ACTUATE THE HAND

^{BRAKE LEVER OR FOOT BRAKE LEVER}, RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE

^{PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED}.

Dismounting and mounting the front wheel

To remove the front wheel, jack the motorcycle up on its frame so that the

front wheel no longer touches the ground.

Loosen the 2 clamping screws 4on the left side of the fork fists.

Loosen and remove the collar nut 5, loosen the clamping screews 6 on

the right side of the fork fist.

Hold the front wheel, pull out the wheel spindle 7.

NOTE: The wheel spindle can be easily removed if you slightly revolve it

with a ring spanner (SW 21 mm).

Carefully remove the front wheel from the fork.

CAUTION

– DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN

DISMOUNTED.

– MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,

OTHERWISE THE BRAKE DISC CAN BE DAMAGED.

To install the front wheel, lift it into the fork, position and mount the axle

shaft. Mount the collar nut 5, tighten the clamping screws 6 on the right

fork leg axle passage to prevent the axle shaft from turning and tighten the

collar nut to 40 Nm (30ft.lb).

Loosen the clamp screws on the right fork leg. Take the motorcycle down

from its stand. Press the front wheel brakes and push down on the fork a

few times vigorously so that the fork legs come into alignment.

Only after this has been accomplished, tighten the clamp screws on both

fork legs with 10 Nm(7 ft. lbs).

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WARNING

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS

POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE.

– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

Dismounting and mounting the rear wheel

Jack the motorcycle up on its frame so that the rear wheel no longer tou-

ches the ground.

Loosen the collar nut 1, remove chain tensioner 2, hold the rear wheel

and pull out the wheel spindle 3 until the rear wheel is free but the brake

caliper support is still held.

Push the rear wheel as far forward as possible, take the chain from the

chain wheel and carefully take the rear wheel out of the swingarm.

CAUTION

–

DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.

– MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,

OTHERWISE THE BRAKE DISC CAN BE DAMAGED.

– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND

COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE

THREAD FROM JAMMING.

The rear wheel is remounted in the reverse order. Before tightening the

collar nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the

chain tensioners lie on the tension screws.

WARNING

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSI-

BLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE.

– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL THE

PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

OTHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

– TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

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Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motorcy-

cle rides and must therefore be checked whenever you are getting ready to

go anywhere on your motorcycle.

– Tire size can be found in the technical specifications and in the homolo-

gation certificate

– Tire condition has to be checked every time you want to ride your

motorcycle. Before leaving, check tires for punctures and nails or other

sharp objects that might have become embedded in them.

Refer to the specific regulations in your country for minimum tire tread

requirements. We recommend you replace the tires at the latest when

the tread is down to 2 mm (0.08 in).

– Tire pressure should be checked regularly on a “cold” tire. Proper pres-

sure ensures optimum driving comfort and extends the life of your tires.

WARNING

– DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES

COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.

TIRES-AIR PRESSURE

–

FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD

front

rear

LAYOUT. USE HOMOLOGATED TIRES

– FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.

– WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PER-

FORMS, ESPECIALLY ON WET SURFACES

– IF AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN

RESULT

Off road

Road

1,0 bar

1,5 bar

1,0 bar

2,0 bar

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels

and thus for riding safety. A loose spoke causes the wheel to become

unbalanced and before long other spokes will have come loose. Check

spoke tension, especially on a new motorcycle, at regular intervals. For

checking, tap on each spoke with the blade of a screwdriver (see photo). A

clear tone must be the result. Dull tones are indicators of loose spokes. If

necessary, have the spokes retightened and the wheel centered by a KTM

dealer.

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 1, insert the battery (type Duracell CR 2430)

with the writing facing up and reinstall the screw connection.

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Setting the clock

To set the clock, switch the ignition off and select the SPEED/CLK mode.

Press and hold the MODE button for 3 seconds. The blinking digits can be

changed using the + and – buttons. Press the MODE button to move to the

next digit.

If no button is pressed for 20 seconds, the settings will be stored automati-

cally and the display will return to the SPEED/CLK mode.

+ BUTTON time +

– BUTTON time –

press the MODE BUTTON to change to the next digit

press and hold the MODE BUTTON 3 SECONDS to store the time and return to

the SPEED/CLK mode

Activating/deactivating the display modes

It may not be necessary to display all of the display modes (functions) at the

same time. It is possible to conceal any information not currently required.

By deactivating certain functions, the MODE button will only allow you to

select from the activated modes.

In the SPEED/H mode, press and hold the MODE button for 3 seconds to

access the SETUP menu. The blinking function can be activated by pressing

the + button and deactivated by pressing the – button.

If no button is pressed for 20 seconds, the setting will be stored automati-

cally and the display will return to the SPEED/H mode.

+ BUTTON activates the blinking display

– BUTTON deactivates the blinking display

press the MODE BUTTON to change to the next display without changing

any settings

press and hold the MODE BUTTON 3 SECONDS to store the settings and

change to the SPEED/H mode

Kilometers or miles

The unit (kilometers or miles) can also be changed. The ODO figure will be

retained and converted accordingly. The TRP1, AVS1, STP1, TRP2 and

AVS2 figures will be cleared.

To select the unit, select the SPEED/H mode and hold the MODE button for

3 seconds to access the SETUP menu. Press the MODE button 10 times

until the KMH/MPH function blinks. Press the + button to move to the

options. Press the + button for KMH or the – button for MPH. If no button

is pressed for 20 seconds, the setting will be stored automatically and the

display will return to the SPEED/H mode.

The setting can be stored immediately by holding the MODE button for a

few seconds until the display returns to the SPEED/H mode.

+ BUTTON to access the menu

to activate the KMH setting

– BUTTON to activate the MPH setting

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to store the setting and return

to the SETUP menu

NOTE:

If you retrofit this Tripmaster on another motorcycle, the power can also be

supplied by the 12 V vehicle electric system. You will need an additional

cable harness, spare part no. 583.14.069.210, which you can order from

your KTM dealer.

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Check/set distance of the magnetic sensor

The distance between the magnet 2 and the sensor 1 must be 2-4 mm,

otherwise malfunctions on the speedometer might occur.

This distance can be corrected by screwing the sensor 1 in or off.

KMH:

WS = mm x 3.14

mm x 3,14

MPH:

WS = (mm x 3.14) : 1.61

Wheel circumference with standard tires = 2205 mm

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 4off the headlamp and remove rubber cap 5. Disengage retai-

ning clip and take the bulb out of the reflector. When changing the par-

king-light lamp, simply pull it out of the holder.

Insert a new lamp such that the noses 6 engage in the recesses 7 .When

doing so, do not touch the glass body of the lamp so that it remains free

from fat. Engage retaining clip, mount rubber cap and connector. If the par-

king-light lamp is to be replaced, simply insert it in the holder. Reinsert par-

king-light lamp together with the holder.

Engage the bottom end of the headlamp mask at the retaining pins and fix

the mask by means of the rubber bands.

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Cooling system

The water pump in the engine circulates the cooling liquid. However, the

cooling liquid can only circulate properly if the cooling circuit contains no air

bubbles.

Bleeding of the cooling system is therefore required

a) after adding more than 0.25 l cooling liquid and

b) after refilling the entire cooling system.

(see Bleeding the cooling system).

Some models are equipped with a thermostat 1so that the engine reaches

its operating temperature more quickly. When the engine is cold, the liquid

coolant circulates in the cylinder and the cylinder head. As soon as the

cooling liquid has reached a temperature of approximately 55°C, the ther-

mostat opens and the cooling liquid is also pumped through the two alumi-

num radiators.

The cooling liquid is cooled by the air stream. This means that the cooling

effect decreases with the traveling speed. Dirty radiators additionally reduce

the cooling effect.

WARNING

–

IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT, USE A RAG TO COVER

THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE. CAUTION SCALDING HAZARD.

– DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE ESCAPING

HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS.

– IN CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING

COLD WATER RIGHT AWAY.

– COOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN.

– IN CASE COOLANT IS INGESTED, CONSULT A DOCTOR IMMEDIATELY.

– IF COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDIATELY

AND GO SEE A DOCTOR.

A mixture of 40% antifreeze liquid and 60% water is used as coolant.

However, the antifreeze protection must be at least -25° C (-13° F). This

mixture offers antifreeze protection but also good corrosion protection and

should therefore not be replaced by pure water.

CAUTION

FOR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (E.G. SHELL

ADVANCE COOLANT). USING LOWER-GRADE ANTIFREEZE AGENTS CAN CAUSE CORRO-

SION AND COOLANT FOAMING.

Pressure induced by heating of the coolant in the system is controlled by a

valve in the radiator cap 2; a water temperature of up to 120° C (248° F) is

admissible without, having to expect any trouble.

Radiator cover for the cold season

To ensure that the engine reaches its operative temperature also at low

temperatures, the radiator cover 3must be mounted.

For this purpose, detach the left radiator protection 4and mount the cover

in front of the left radiator as illustrated.

Remount the radiator protection.

NOTE: The radiator shutter can be obtained

from your KTM dealer

Checking the coolant level

The coolant should be 10 mm (0.4 in) above the radiator fins when the

engine is cold (see diagram). In the event of the coolant being drained,

always fill and bleed the system.

WARNING

10 mm

IF POSSIBLE, ALWAYS CHECK THE LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD.

IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT, USE A RAG TO

COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE.

when engine is cold

CAUTION

THE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQUID OR AFTER

ADDING MORE THAN 0.25 L (0.06 US GALLONS) COOLING LIQUID.

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Refilling/Bleeding the cooling system

The cooling system must be bled as described below after draining the

cooling liquid or after adding more than 0.25 l (0.06 US gallons) cooling

liquid.

Make sure that the drain screw 1is fastened.

Pour approx. 0.5 litres (0.13 US gallons) coolant into the system.

Remove screw 2 at the cylinder head. Reinstall it as soon as the cooling

liquid emerges free of air bubbles (only for 125/200 engines).

Remove the screw 3on the right radiator.

Now add cooling liquid until it emerges free of bubbles at the right radia-

tor. Then immediately mount the screw so that no more air can enter the

right radiator.

Top up the left radiator until the coolant can be seen approx. 10 mm

(0.4 in) above the radiator fins.

Check the coolant level again after a short ride.

Cleaning the air filter *

The air filter must be cleaned prior to every race or whenever the motorcycle

has been exposed to great quantities of dust.

For this purpose, rotate the two quick-release fasteners 4counter-clockwise

and pull them outward up to the stop, pull the filter box cover forward and

remove it. Unhook the filter holding brackets 6at the bottom, swing them

sideways and take the air filter 5 together with the filter support 7 out of

the filter box.

CAUTION

DO NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE

THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER

MAINTENANCE. FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER.

Thoroughly wash the air filter in special cleaning fluid and allow it to dry

well. Only press out the filter, do not wring it out under any circumstances.

Oil the dry air filter with a high-grade filter oil. Also clean the air filter box.

Check the carburetor collar for damage and that it is filled correctly.

Mount the air filter on the filter support. Mount the filter together with the

filter support in the filter box, making sure to center them, and fix them

properly with the filter holding bracket.

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Changing the original position of the clutch lever

The adjusting screw 1can be used for individual adjustment of the original

position of the clutch lever, thus allowing adjustment to an optimal position

for every hand size.

Turning the adjusting screw clockwise reduces the distance between the

clutch lever and the handlebar. Turning the adjusting screw counterclock-

wise increases the distance between the clutch lever and the handlebar.

CAUTION

ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS.

ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE.

Checking the oil level of the hydraulic clutch

To check the oil level in the master cylinder of the clutch remove the

cover. For this purpose, remove screws 2 and cover 3 together with

the rubber boot 4. The oil level in the horizontaly positioned master

cylinder should be 4 mm below the upper edge.

If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Shell

Naturelle HF-E15).Biodegradable hydraulic oil is available from your

KTM dealer (50ml).

CAUTION

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL.

NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.

ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLIN-

DER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

Bleeding of the hydraulic clutch

To bleed, the cover of the master cylinder of the clutch needs to be

removed. For this purpose, remove screws 2and take off cover 3together

with rubber bellows 4. At the slave cylinder of the clutch, remove the

bleeder nipple 5. In its place, mount the bleeder syringe 6 which is filled

with SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore 7

of the master cylinder in a bubble-free state. Make sure that the oil does

not overflow. The bleeder syringe can be purchased at your KTM

dealer.Having completed the bleeding procedure, you have to verify that

the oil level in the master cylinder is correct.If necessary, fill up with biode-

gradable hydraulic oil SAE 10 (e.g. Shell Naturelle HF-E15).Biodegrada-

ble hydraulic oil is available from your KTM dealer (50ml).

CAUTION

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL.

NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.

ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLIN-

DER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

Exhaust system *

EXC

Silencers whose cap 8is detachable are filled with glass-fiber yarn. Let this

package be ckecked at least after 4000 km or at once a year. Glass-fiber

yarn that is too loose may cause a drop in performance and curtail the silen-

cer’s silencing effect.

To replace the glass-fiber yarn packing 9, remove the silencer cap and pull

off the outer tube bk. Use adhesive tape to attach the new glass-fiber yarn

packing to the inner tube, and slide on outer tube. Mount silencer cap.

Glass-fiber yarn packings are available at your authorized KTM dealer.

WARNING

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.

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Cleaning the spark arrestor (EXC USA) *

With these models, the spark arrestor is part of the exhaust silencer. Clean it

every 4000 km (2500 miles) to guarantee proper functioning. Also clean the

spark arrestor when replacing the glassfiber yarn filling.

After assembling the silencer, remove the plug 1and start the motorcycle.

Close the opening of the muffler with a rag and press the accelerator

approximately 20 times. The carbon deposits will be blown out through the

opening. Then turn off the engine and let the exhaust system cool down.

Grease the plug with molycote grease and mount the plug.

Carburetor adjustment *

Basic information on the original carburetor setting

The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient

temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ).

Mixing ratio (2-stroke motor oil : super fuel)

1:40 – 1:60 (depends on oil quality)

Basic information on changing the carburetor 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 filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and

the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance.

RULE OF THUMB: high altitude or high temperatures

low altitude or low temperatures

●

choose leaner carburetor adjustment

choose richer carburetor adjustment

WARNING

– ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE

FAILURE, AND WILL VOID YOUR WARRANTY.

– ONLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS (e. g. Shell Advance Racing X).

– NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. IF YOU USE TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL

THE SPARK PLUG AND THE EXHAUST CONTROL SYSTEM.

– IN THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR, PROCEED CAUTIOUSLY. ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID

OVERHEATING AND PISTON SEIZURE.

NOTE:

If the engine does not run properly despite a changed adjustment, look for mechanical faults and check the ignition system.

Basic information on carburetor wear

As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carbu-

retor malfunction (e.g. overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles).

Definitions

Mixture too rich:

Too much fuel in proportion to air.

Mixture too lean:

Not enough fuel in proportion to air.

Idling range A

Operation with closed throttle valve. This range is influenced by the posi-

tion of the air control screw 2 and the air control screw 3. Only make

adjustments when the engine is hot.

To this end, slightly increase the idling speed of the engine by means of the

air control screw. Turning it clockwise produces a higher idling speed and

turning the screw counterclockwise produces a lower idling speed. Create a

round and stable engine speed using the air control screw (basic position of

the air control screw = open by 1.5 turns). Then adjust to the normal idling

speed by means of the air control screw.

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Opening up B

main jet

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.

jet needle

Part-throttle range C

idle jet

Operation with partly open throttle valve. This range is only influenced by

the jet needle (shape and position). The optimum part-throttle setting is

controlled by the idling setting in the lower range and by the main jet in the

upper range. If the engine runs on a four-stroke cycle or with reduced

power when it is accelerated with the throttle partly open, the jet needle

must be lowered by one notch. If then the engine pings, especially when

accelerating under full power at maximum engine revs, the jet needle

should be raised.

throttle valve

air control screw

idle adjusting screw

JET NEEDLE

TYPE

RANGE OF ACTION

RICHER

LEANER

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.

NOZD

NOZE

NOZF

NOZG

NOZH

Full throttle range D

Operation with the throttle fully open (flat out). This range is influenced by

the main jet and the jet needle. If the porcelain of the new spark plug is

found to have a very bright or white coating or if the engine rings, after a

short distance of riding flat out, a larger main jet is required. If the porce-

lain is dark brown or black with soot the main jet must be replaced by a

smaller one.

Draining the float chamber of the carburetor

Following every wet-cleaning procedure, the float chamber of the carbure-

tor should be drained in order to remove any water that may have penetra-

ted into it. Water in the float chamber leads to engine malfunction.

Make sure you do this while the engine is cold. Close the fuel tap, and place

a cloth under the carburetor, which is capable of absorbing the leaking fuel.

Unscrew the plug 1 and clean it with compressed air. Then, mount the

plug together with the gasket, open the fuel tap, and check the float

chamber for leaks.

WARNING

FUEL IS EASILY FLAMMABLE AND TOXIC. WHEN HANDLING FUEL, BE SURE TO EXERCISE

THE UTMOST CAUTION. NEVER PERFORM ANY WORK ON THE FUEL SYSTEM NEAR OPEN

FLAMES OR BURNING CIGARETTES. ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST.

IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED. MATERIALS SATURA-

TED WITH FUEL ARE ALSO EASILY FLAMMABLE. IN CASE YOU INGESTED FUEL OR FUEL

SPLASHED INTO YOUR EYES, CONSULT A DOCTOR IMMEDIATELY.

DISPOSE OF THE FUEL PROPERLY.

Checking the float level *

Arrange the carburetor diagonally at about 60° so that the spring in the

float needle valve is not pressed together. In this position, the edge of

the float should be parallel with the float chamber sealing surface (see

illustration).

60°

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Check transmission oil level (125/200)

In order to check the transmission oil level the control screw 1on the clutch

cover is to be removed. Oil should just barely escape from the inspection

opening when the motorcycle is in an upright position. If necessary, remove

the plug 2and top up with oil (see technical data engine).

CAUTION

TRANSMISSION AND CLUTCH WILL BE SUBJECTED TO EXCESSIVE WEAR AND TEAR IF YOU USE

TOO LITTLE OR LOW GRADE OIL. USE ONLY HIGH-GRADE OIL.

Changing the transmission oil (125/200) *

To change the gear oil warm up the engine and park the motorcycle on a

horizontal surface. Remove oil drain plugs 3 and 4 and drain the used oil

into an appropriate container. Clean the magnets of the oil drain plugs and

mount them together with the appropriate gaskets. Fill in 0.7 l oil (see tech-

nical data- engine), mount the plug 2and 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.

Check transmission oil level (250/300)

In order to check the transmission oil level the control screw 5on the clutch

cover is to be removed. Oil should just barely escape from the inspection

opening when the motorcycle is in an upright position. If necessary, remove

the plug 6and top up with oil (see technical data- engine).

CAUTION

TRANSMISSION AND CLUTCH WILL BE SUBJECTED TO EXCESSIVE WEAR AND TEAR IF YOU USE

TOO LITTLE OR LOW GRADE OIL. USE ONLY HIGH-GRADE OIL.

Changing the transmission oil (250/300) *

To change the transmission oil run the engine warm and set up the motorcy-

cle on a horizontal surface. Remove the oil drain screw 7and drain used oil

into a container. Clean the magnet of the oil drain screw and reinstall oil

drain screw with seal. Pour in 0.8 litres engine oil (see technical data engine),

replace plug 6and check engine for leaks.

CAUTION

TRANSMISSION AND CLUTCH WILL BE SUBJECT TO EXCESSIVE WEAR AND TEAR, IF YOU USE

TOO LITTLE OR LOW GRADE OIL. USE ONLY HIGH-GRADE OIL.

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CLEANING

Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.

The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.

The hard dirt can be removed before washing with the help of a soft water jet.

CAUTION

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE

ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR, ETC. AND CAUSE DISTURBANCES OR LEAD TO

DESTRUCTION OF THESE PARTS.

PREMATURE

– 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.

CONSERVATION FOR WINTER OPERATION

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre-

cautions against the aggressive road salt.

– clean the motorcycle thoroughly and let it dry after each ride

– treat the engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corro-

sion agent.

WARNING

KEEP THE ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER.

CAUTION

AFTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL.

STORAGE

Should you wish to make a pause over a longer space of time, please observe the following instructions:

– Clean motorcycle thoroughly (see chapter: CLEANING)

– Change engine oil (old engine oil contains aggressive contaminants).

– Check antifreeze and amount of cooling liquid.

– Let the engine warm up again, close fuel cock and wait until the engine dies off by itself. In this way the carburetor jets are preven-

ted from becoming resin- clogged by the old fuel.

– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in

order to distribute the oil onto the cylinder walls and mount the spark plug.

– Let fuel flow out of tank into an appropriate container.

– Correct tire pressure.

– Lubricate bearing points of the control levers, footrests, etc. as well as the chain.

– The storage place should be dry and not be subjected to too big temperature fluctuations.

– Cover the motorcycle with an air permeated tarp or blanket. Do not use non airtight materials as a possible humidity might not be

able to escape and thereby cause corrosion.

CAUTION

IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH

AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST.

USE AFTER A PERIOD OF STORAGE

– Fill up the tank with fresh fuel.

– Check the motorcycle as before each start (see driving instructions)

– Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any service

jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics'

shops). This way, you can avoid the long waiting times at your shop at the beginning of the next biking season.

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STANDARD ADJUSTMENT - FORK

STANDARD ADJUSTMENT - SHOCK ABSORBER

WP 4860 MXMA

1418X725

WP 4860 MXMA

WP 5018 PDS-DCC

1218X756

WP 5018 PDS-MCC

1418X735

1218X757

Compression adjuster

Rebound adjuster

Spring

Compression adjuster

17 LS (low speed)

2 HS (high speed)

4.0 N/mm

5 mm (0.2in)

100 mm (5.1in)

SAE 5

3.8 N/mm

5 mm (0.2in)

110 mm (4,3in)

SAE 5

Rebound adjuster

Spring

Spring preload

Air chamber length

Fork oil

71-90/260

66-86/260

7 mm (0.2 in)

Spring preload

6 mm (0.2 in)

TIGHTENING TORQUES - CHASSIS

Collar screw, front wheel spindle

M 24x1,5

40 Nm

Brake caliper, front

M 8

Loctite 243 + 25 Nm

Loctite 243 + 15 Nm

20 Nm

Brake disk, front

M 6 10.9

M 6

Brake disk, rear

Clamping screws, upper fork bridge

Clamping screws, lower fork bridge

Clamping screws, fork stubs

Collar nut, rear wheel spindle

Hexagon nut, swing arm bolt

Hexagon collar screw, handlebar clamp

Allan head screw, handlebar support

Shock absorber, top

M 8

15 Nm

M 8

10 Nm

M 20x1,5

M 14x1,5

M 8

80 Nm

100 Nm

20 Nm

M 10

M 12

M 8

Loctite 243 + 40 Nm

60 Nm

Shock absorber, bottom

Sprocket screws

60 Nm

Loctite 243 + 35 Nm

Loctite 243 + 10 Nm

45 Nm

Ball joint for push rod

M 6

Engine mounting bolt

M 10

M 8

Engine brace

33 Nm

Screw adjusting ring spring preload shock abs.

Spoke nipple

8 Nm

M4,5 /M5

5 Nm

Other screws on chassis

M 6

M 8

M 10

10 Nm

25 Nm

45 Nm

Other collar nuts on chassis

M 6

M 8

M 10

15 Nm

30 Nm

50 Nm

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TIGHTENING TORQUES - ENGINE

Flange bolts - cylinder-head

Nuts-cylinder base

M 7

18 Nm

30 Nm

60 Nm

180 Nm

120 Nm

8 Nm

M 8

Flywheel collar nut

M 12x1

M 16x1.5

M 18x1.5

M 6

Nut for primary sprocket (LH thread)

Nut for inner clutch hub

Crankcase and clutch cover bolts

Spark plug

M 14x1.25

20 Nm

Swingarm pivot

Other screws

M 14x1.5

M 6

100 Nm

10 Nm

25 Nm

45 Nm

M 8

M 10

BASIC CARBURETOR SETTING

200 EXC AUS

200 EXC EU

125 EXC EU

125 EXC AUS

125 SX

200 MXC/EXC USA

200 SX

Carburetor

Keihin PWK 39

Keihin PWK 38 AG

Keihin PWK 39

Keihin PWK 38 AG

100202

Keihin PWK 38 AG

070202

Carburetor setting number

Main jet

060202

080202

090202

185 (188/190)

178(180/185)

190 (188,192)

180 (178)

35 (45/48)

148 (180/185)

35 (45/48)

Idling jet

48 (45)

45 (48)

48 (45)

Starting jet

Jet needle

R 1469 D (R 1470 D)

NOZ E (NOZ F)

R 1468G (R1469G)

R 1475J (NOZ E/NOZ F) R 1472 N (NOZ E/NOZ F)

Needle position from top

Throttle valve

III

5.5 (6)

1.5

III

6.5

1.5

–

III

5.5

1.5

–

III

6.5

1.5

–

6.5

1.5

Air adjustment screw open

Performance restrictor

–

slide stop 36mm

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TECHNICAL SPECIFICATIONS CHASSIS 250/300 MXC, EXC 2003

250/300 MXC

250/300 EXC

Frame

Central chrome-moly-steel frame

White Power – Up Side Down 48 MA

300/335 mm (11.8/13.2 in)

Fork

Wheel travel front/rear

Rear suspension

Front brake

Rear brake

WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm

Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Wear limit max. 0,4 mm (0,016 in)

Brake discs

Front tires

–

90/90 - 21“ 54R

80/100 - 21“51M

1,0 bar (14psi)

Front tires USA

Air pressure offroad

Air pressure road driver only

80/100 - 21“51M

1,0 bar (14psi)

1,5 bar (21psi)

Rear tires

Rear tires USA

Air pressure offroad

Air pressure road driver only

–

140/80 - 18“ 70R

100/100 - 18“ 64M

1,0 bar (14psi)

100/100 - 18“ 64M

1,0 bar (14psi)

2,0 bar

(28psi)

Fuel tank capacity

11 liter (2,9 US Gallons)

9/11 liter (2,3/2,9 US Gallons)

Final drive ratio

Final drive ratio USA

Chain

–

15:48t / 14:50t

14:52t

5/8 x 1/4 "

Available final sprockets

Bulbs

38t, 40t, 42t, 45t, 48t, 50t, 52t

headlight

HS1 12V 35/35W

parking light

12V 5W (base W2, 1x9,5d)

12V 1,2W (base W2, 1x4,6d)

12V 21/5W (base BaY15d)

12V 10W (basel Ba15s)

12V 1,2W (base 1x4,6d)

instrument light

brake- rear light

flasher light

license plate illumination

Steering head angle

Wheel base

63,5°

1481 10 mm (58,3 0,4 in)

925 mm (36,5 in)

eat height, unloaded

Ground clearance, unloaded

385 mm (15,2 in)

STANDARD ADJUSTMENT - SHOCK ABSORBER

STANDARD ADJUSTMENT-FORK

WP 5018-MCC

1218X759

WP 4860 MXMA

1418X736

Compression adjuster

Rebound adjuster

Spring

Compression adjuster

Rebound adjuster

Spring

71-90/260

7 mm (0.27 in)

4,0 N/mm

5 mm (0.20in)

110 mm (4,3 in)

SAE 5

Spring preload

Air chamber length

Fork oil

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TIGHTENING TORQUES - CHASSIS

Collar screw, front wheel spindle

M 24x1,5

40 Nm

Loctite 243 + 25 Nm

Loctite 243 + 15 Nm

20 Nm

Brake caliper, front

M 8

Brake disk, front

M 6 10.9

M 6

Brake disk, rear

Clamping screws, upper fork bridge

Clamping screws, lower fork bridge

Clamping screws, fork stubs

Collar nut, rear wheel spindle

Hexagon nut, swing arm bolt

Hexagon collar screw, handlebar clamp

Allan head screw, handlebar support

Shock absorber, top

M 8

15 Nm

M 8

10 Nm

M 20x1,5

M 14x1,5

M 8

80 Nm

100 Nm

20 Nm

M 10

M 12

M 8

Loctite 243 + 40 Nm

60 Nm

Shock absorber, bottom

Sprocket screws

60 Nm

Loctite 243 + 35 Nm

Loctite 243 + 10 Nm

45 Nm

Ball joint for push rod

M 6

Engine mounting bolt

M 10

M 8

Engine brace

33 Nm

Screw adjusting ring spring preload shock abs.

Spoke nipple

8 Nm

M4,5 /M5

5 Nm

Other screws on chassis

M 6

M 8

M 10

10 Nm

25 Nm

45 Nm

Other collar nuts on chassis

M 6

M 8

M 10

15 Nm

30 Nm

50 Nm

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TIGHTENING TORQUES

Flange bolts - cylinder-head

M 8

35 Nm (25 ft.lb)

Nuts-cylinder base

M 10

Flywheel collar nut

M 12x1

M 18x1.5

M 6

60 Nm (44 ft.lb)

Nut for primary sprocket (LH thread)

Nut for inner clutch hub

Crankcase and cover bolts

Swingarm pivot

Loctite 243 150 Nm (110 ft.lb)

Loctite 243 100 Nm (74 ft.lb)

8 Nm (6 ft.lb)

M 14

100 Nm (74 ft.lb)

Flat head screw release plate kickstarter

Other screws

M 6x16

Loctite 648 19 Nm (14 ft.lb)

M 6

M 8

M 10

10 Nm (7 ft.lb)

25 Nm (19 ft.lb)

45 Nm (33 ft.lb)

BASIC CARBURETOR SETTING

250 EXC USA

300 MXC / EXC

250/300 EXC

throttled

300 EXC AUS

throttled

USA

Keihin PWK 38 AG

Carburetor

Keihin PWK 38 AG

140202

130202

150202

Carburetor setting number

Main jet

120202

182 (185)

175 (172,178)

175 (182,185)

35 (45,48)

45 (48)

Idling jet

35 (48)

Starting jet

N3CH (N3CW)

R1475J (NOZ H/NOZ I)

NOZ H (NOZ I)

Jet needle

R 1475 J (N3CH/N3CW)

6.5

1.5

–

III

6.5

1.5

–

Needle position from top

Slide

III

6.5

1.5

Air adjustment screw open

Performance restrictor

Power jet nozzle

1.5

slide stop 34mm

–

slide stop 34mm

–

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INDEX

Page

Adjusting the free travel at the hand brake lever.................32

Adjusting the spring preload on the fork (SX)......................28

Basic suspension setup for the weight of the driver.............26

Bleeding of the hydraulic clutch ..........................................41

Braking ...............................................................................19

Breather plug front fork ......................................................25

Carburetor adjustment........................................................42

Chain maintenance.............................................................30

Chain wear .........................................................................30

Changing the basic position of the foot brake pedal ...........33

Changing the original position of the clutch lever ..............41

Changing the spring preload on the telescopic fork (MXC/EXC models) ...27

Changing the spring preload on the telescopic fork (SX models)27

Changing the spring preloading of the shock absorber........28

Changing the transmission oil (125/200) ............................44

Changing the transmission oil (250/300) ............................44

Chassis number.....................................................................5

Checking and adjusting the steering head bearing ..............24

Checking the basic setup of the telescopic fork...................27

Checking the brake fluid level - front brake ........................32

Checking the chain tension.................................................29

Checking the coolant level..................................................39

Checking the float level ......................................................43

Checking the front brake pads............................................32

Checking the oil level of the hydraulic clutch ......................41

Checking the rear brake fluid level......................................33

Checking the rear brake pads..............................................34

Checking the shock absorber and spring.............................26

Checking the spoke tension ................................................36

Checking the transmission oil level (125/200).....................44

Checking the transmission oil level (250/300).....................44

Checking/setting the distance of the magnetic sensor.........38

Choke knob........................................................................12

Cleaning .............................................................................45

Cleaning the air filter ..........................................................40

Cleaning the dust sleeves of the telescopic fork ..................25

Cleaning the spark arrestor (EXC USA)................................42

Clutch lever .........................................................................5

Combination switch (EXC) ..................................................11

Compression damping of fork.............................................14

Compression damping of shock absorber (MXC, EXC)........15

Compression damping of shock absorber (SX) ....................14

Conservation for winter operation ......................................45

Cooling system ...................................................................39

Correct the chain tension....................................................29

Determining the riding sag of the shock absorber ...............26

Determining the static sag of the shock absorber................26

Dismounting and mounting the front wheel .......................34

Dismounting and mounting the rear wheel.........................35

Draining the float chamber of the carburetor......................43

Driving instructions.............................................................17

Electronic speedometer.........................................................6

Electronic speedometer, indicator lamp (EXC) .......................6

Emergency OFF switch (Australia).......................................11

Page

Engine number, engine type (125/200) ................................5

Engine number, engine type (250/300) ................................5

Exhaust system ...................................................................41

Filler cap .............................................................................12

Flasher switch .....................................................................11

Foot brake pedal.................................................................13

Fuel tap ..............................................................................12

General information about KTM disc brakes .......................31

General tips and warnings for starting the motorcYcle ........16

Hand brake lever ..................................................................5

Headlamp switch (EXC USA)...............................................11

How to change the handlebar position ...............................25

Index ..................................................................................54

Instructions for your first ride..............................................16

Kickstarter...........................................................................13

Maintenance work on chassis and engine ...........................24

Operation instruments .........................................................5

Periodic lubrication - and maintenance-schedule.................20

Pivot bearing ......................................................................28

Radiator cover for the cold season ......................................39

Rebound damping of fork...................................................14

Rebound damping of shock absorber (SX, MXC, EXC)........15

Refilling / Bleeding the cooling system................................40

Refilling the front brake fluid reservoir ................................32

Refilling the rear brake fluid reservoir..................................33

Refueling, fuel ....................................................................19

Replacing fork springs.........................................................27

Replacing the battery of the electronic speedometer...........36

Replacing the front brake pads ...........................................33

Replacing the headlight lamp..............................................38

Replacing the rear brake pads.............................................34

Running in..........................................................................16

Serial number locations.........................................................5

Setting the clock of the electronic speedometer ..................37

Shift lever ...........................................................................12

Shifting, Riding ...................................................................18

Short circuit button (SX)......................................................11

Side stand...........................................................................13

Starting off .........................................................................18

Starting when the engine is cold .........................................18

Starting when the engine is warm.......................................18

Steering lock.......................................................................13

Stopping, Parking ...............................................................19

Storage...............................................................................45

Technical specifications - chassis (125/200) ........................46

Technical specifications - chassis (250/300) ........................50

Technical specifications - engine (125/200) ........................48

Technical specifications - engine (250/300) ........................52

Tires, air pressure................................................................36

Tripmaster switch..................................................................7

Using re iniation..................................................................45

What to do when the engine is “flooded“..........................18

What you should check before each start ...........................17

Wiring diagram, carburetor setting...........................Appendix

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