KTM 200, 125, 250 User Manual

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KTM 200, 125, 250 User Manual

125/200/250/300 SX, MXC, EXC

BEDIENUNGSANLEITUNG

OWNERS HANDBOOK MANUALE D’USO MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

2003

Art.Nr. 3.210.49 04/2002

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 INTEREST, 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 maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

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

ENGLISH 1

ENGLISH 2

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 characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury. 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 upgrades of these motorcycles.This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it.

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 maintenance work should become necessary during a competition, it must be performed by a trained mechanic.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Have services carried out by a KTM dealer so that your warranty claim remains intact.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure 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

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

© by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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.

ENGLISH 3

In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

ENGLISH 4

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

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

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

 

 

Page

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

CLEANING..........................................................................

 

45

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

 

45

STORAGE ...........................................................................

 

45

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

 

45

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

1

A

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 1 is located on the left side of the handlebars. The adjusting screw A is used to change the original position of the clutch lever (see maintenance work on chassis and engine).

Hand brake lever

ENGLISH 5

The hand brake lever is mounted on the handlebars on the right and actuates the front wheel brake.

Electronic speedometer, indicator lamp (EXC)

1

The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working.

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

2

ENGLISH

6

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

+ BUTTON
BUTTON

+

 

Tripmaster switch

 

 

MODE

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

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

 

 

 

 

WARNING

 

 

 

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.

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

ENGLISH 7

ENGLISH 8

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 measure 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 activated 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 whenever 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.

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 + button, 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

ENGLISH 9

ENGLISH

10

Standing motorcycle

Driving motorcycle

 

OVERVIEW OF TRIPMASTER FUNCTIONS

 

 

 

 

 

Display

Press +

Press

Press MODE

Hold MODE for 3 sec

 

X

SPEED / ODO

no function

no function

next display mode

no function

 

 

 

 

 

 

 

X

X

SPEED / MAX

no function

no function

next display mode

resets MAX to 0

 

 

 

 

 

 

 

X

X

SPEED / LAP

starts / stops LAP

stops LAP, stores LAP

next display mode

clears all LAP figures

 

 

 

figure LAP remains

figure, resets LAP to 0

 

 

 

 

 

 

 

 

 

X

 

LAP / LAP

next figure

no function

next display mode

next display mode

 

 

 

 

 

 

 

X

X

SPEED / CLK

no function

no function

next display mode

set clock menu

 

 

 

 

 

 

 

X

 

SPEED / H

no function

no function

next display mode

display setup menu

 

 

 

 

 

 

 

X

X

SPEED / TRP1

no function

no function

next display mode

resets TRP1, STP1 and

 

 

 

 

 

 

AVS1 to 0

 

 

 

 

 

 

 

X

X

SPEED / AVS1

no function

no function

next display mode

resets TRP1, STP1 and

 

 

 

 

 

 

AVS1 to 0

 

 

 

 

 

 

 

X

X

SPEED / STP1

no function

no function

next display mode

resets TRP1, STP1 and

 

 

 

 

 

 

AVS1 to 0

 

 

 

 

 

 

 

X

X

SPEED / TRP2

increases TRP2 figure

decreases TRP2 figure

next display mode

resets TRP2 to 0

 

 

 

 

 

 

 

X

X

SPEED / AVS2

no function

no function

next display mode

next display mode

 

 

 

 

 

 

 

X

X

SPEED / STP2

starts / stops STP2

no function

next display mode

sets STP2 to 0

 

 

 

 

 

 

 

1

3

2

B

C

4

Short circuit button (SX)

The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-circuited.

Combination switch (EXC)

The light switch has 2, respectively 3 switch positions. A = Light off (this function is not available in all models) B = Low beam on

C = High beam on

You may use button 2 to actuate the horn.

The red short circuit button 3 serves to switch off 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

ENGLISH

11

Emergency OFF switch (Australia)

The emergency OFF switch 5 is located next to the throttle grip. Primarily designed as safety or emergency OFF switch, it should normally not be in its activated state.

In this position, the ignition circuit is shorted; if the engine is running, it will stall immediately, if it is at standstill, it will not start.

5

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

 

ENGLISH

12

1

OFF ON RES

SX

MXC

EXC

2,3,4,5 (6)

N

1

Filler cap

To open it: turn filler cap counter-clockwise.

To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks.

Fuel tap

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

Choke knob

When pulling the choke knob 2 fully towards the top, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This results in a rich fuel-air mixture, that is needed for a cold start.

When pressing the choke knob downward in the carburetor, the bore is closed again.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

Kickstarter

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

Foot brake pedal

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

1

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.

ENGLISH

13

ENGLISH

14

1

2

3 3

6

4

5

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 2 clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

STANDARD ADJUSTMENT

turn adjusting screw clockwise as far as it will go

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

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 6 CONNECTION (24MM).

2

3

4

Compression damping of shock absorber (MXC, EXC)

The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control).

The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, 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 2 CONNECTION (24MM).

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

By using the adjusting screw 3, the degree of damping of the rebound can be adjusted. Turn the knob to the right side to increase damping, turn it to the 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 4 CONNECTION (15MM).

ENGLISH

15

ENGLISH

16

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for your first ride

Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual).

Thoroughly read the whole instruction manual before starting for your first tour.

Familiarize yourself with the controls.

Adjust the clutch lever, the hand brake lever and the foot brake pedal to the most comfortable position.

Get used to handling the motorcycle on an empty parking lot or open space, before going for a longer ride. Also try to ride as slowly as possible while standing upright, to improve your feeling for the vehicle.

Do not drive along off-road trails which go beyond your ability and experience.

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

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; distribute the weight evenly between the front and the rear wheel. Never exceed the maximum permissible laden weight and the axle weights. The maximum permissible laden weight is made up of the following components:

Motorcycle ready for operation and tank full

Luggage

Driver and passenger with protective clothing and helmet.

Pay attention to running-in procedure.

Running in

Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time. Therefore, every engine needs to be broken in. For this reason, during its first 500 kilometers (300 miles) or 5 hours the engine must not be 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!

 

 

 

WARNING

 

WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. SMART KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES, AND A

JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A SHORT RIDE. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE. OF COURSE YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING.

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM. FOR 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 VEHICLES DRIVING CHARACTERISTICS.

– THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE.

– BE SURE TO CHECK THE SPOKE TENSION AFTER 30 MINUTES' RUNNING TIME. THE SPOKE TENSION WILL DECREASE QUICKLY ON NEW WHEELS. IF YOU 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.

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.

 

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.

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:

1CHECK TRANSMISSION OIL LEVEL

Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism.

2FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.

3CHAIN

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.

4TIRES

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.

5BRAKES

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. DONT RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

6CABLES

Check correct adjustment and easy running of all control cables.

7COOLING FLUID

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

8ELECTRICAL SYSTEM

Check correct functioning of headlamps, tail-lights, brake lights, turn indicators, indicator lamps and horn while the engine is running.

9LUGGAGE

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

ENGLISH

17

ENGLISH

18

Starting when the engine is cold

1Open fuel tap

2Turn on ignition or emergency OFF switch

3Put the gear in neutral

4Activate cold-starting aid (choke)

5Leave throttle closed or open it no more than 1/3 and kick down kickstarter 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

1Open fuel tap

2Turn on ignition or emergency OFF switch

3Put the gear in neutral

4Open throttle to 1/2 and kick down kickstarter vigorously

What to do when the engine is “flooded”

1Close fuel tap

2Start engine with full throttle. If necessary, unscrew spark plug and dry it.

3Once 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 3/4; the speed hardly decreases although the engine will use less gas. Only give as much gas as the engine can handle. Through quick and high revving of throttle, the gas consumption will increase. When shifting down, use the brakes if necessary and turn down at the same time. Pull the clutch lever and shift down to the next lower gear. Let the clutch lever go slowly and open the throttle or shift down again.

 

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.

!

CAUTION

!

– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED TO BE TAKEN.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE VALVES. IN 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.

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.

– 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. DONT RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

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 A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER STARTING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED.

!

CAUTION

!

– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY 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.

Refueling, fuel

125-300: Unleaded premium gasoline RON 95 mixed with high grade two stroke oil. Mixture ratio 1:40 - 1:60

Fuel and engine oil should only be mixed immediately before use. KTM recommends SHELL ADVANCE RACING X.

 

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 DOCTORS ADVICE IMMEDIATELY.

!

CAUTION

!

– ONLY USE PREMIUM-GRADE GASOLINE ROZ 98 RESPECTIVELY 95 MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE.

– DO NOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD ENGINES OR NORMAL ENGINE OIL TO PREPARE THE MIXTURE.

– DO NOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN ONE WEEK. THE LUBRICATION PROPERTIES OF SOME TWO-STROKE OILS CAN DETERIORATE VERY RAPIDLY.

ONLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL (i.e. 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.

– FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL THE TANK TO THE TOP. (SEE FIG.)

35 mm

ENGLISH

19

ENGLISH

20

 

 

 

PERIODIC MAINTENANCE SCHEDULE

125/200 SX/MXC/EXC

 

 

 

250/300 SX/MXC/EXC

 

 

 

 

 

1st service

after

after

 

 

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

after 10 hours

20 hours

4000 kilometer

 

 

 

or

or

or

 

 

 

 

 

 

 

 

 

1000 kilometers

2000 kilometers

once a year

 

 

 

 

 

 

 

ENGINE

 

Check gear box oil level

 

 

 

 

 

 

 

 

 

 

Change gear box oil

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check spark plugs, adjust distance between electrodes

 

 

 

 

 

 

 

 

 

 

 

Renew spark plugs

 

 

 

 

 

 

 

 

 

 

CARBURETOR

 

Check the carburetor connection boot for cracks and leaks

 

 

 

 

 

 

 

 

 

Check that vent hoses are not damaged or bent

 

 

 

 

Check idle speed setting

 

 

 

 

 

 

 

 

 

 

 

Check cooling system for leaks, check quantity of antifreeze

 

 

 

 

 

 

 

 

 

PARTS-ON-ADD

 

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

 

 

 

 

 

 

 

 

 

 

 

BRAKES

 

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

 

 

 

 

 

 

 

 

 

CHASSIS

 

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

 

 

 

WHEELS

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

at least

every 2 years

 

 

 

 

 

 

once a year

or 20000 km

Check function of exhaust control

 

 

 

 

 

 

 

 

 

Complete maintenance of shock absorber

 

 

 

 

 

 

 

 

 

Complete maintenance of fork

 

 

 

 

 

 

 

 

 

Clean and grease steering head bearings and gasket elements

 

 

 

 

 

 

 

 

 

Clean and adjust carburetor

 

 

 

 

 

 

 

 

 

Replace glass fibreyarn filling of the exhaust main silencer

 

 

 

 

 

 

 

 

 

Treat electric contacts and switches with contact grease

 

 

 

 

 

 

 

 

 

Change hydraulic clutch fluid

 

 

 

 

 

 

 

 

 

Change break fluid

 

 

 

 

 

 

 

 

 

 

 

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

SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!

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