KTM 125 2007, 200 2007, 250 2007, 300 2007 Owner's manual

125 EXC SIX DAYS, EXC

200 XC, XC-W, EXC 250 XC, XC-W, EXC SIX DAYS, EXC 300 XC, XC-W, EXC SIX DAYS, EXC

OWNER’S MANUAL 2007

ART. NR. 3.211.144EN

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IMPORTANT

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

Frame number

Engine number

Key number

Stamp of dealer

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

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.

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

COMSUMER INFORMATION FOR AUSTRALIA ONLY

Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or

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

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

tive by any person.

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INTRODUCTION

INTENDED PURPOSE

KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.

THE XC/XC-W MODELS ARE PROHIBITED ON PUBLIC ROADS.

The EXC models are only allowed on public roads in the original homologated (throttled) version. Without this performance restriction (i.e. dethrottled), these models are only allowed to be driven off-road but not on public roads. The EXC models are designed for off-road sports endurance competitions(enduro) and not

suitable for predominant motocross use.

2-STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS

KTM EXC models were designed for offroad use only and are only suitable for longer rides on public roads to a certain extent. The engine is subjected to completely different performance demands on public roads and must be adapted to these operating conditions. Ask your KTM dealer for more information.

OWNER’S MANUAL

Please read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly. Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance.

In your own interest, please pay particular attention to notices that are marked as follows:

At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it.

SERVICE

Observance of the service, maintenance and tuning instructions for the engine and chassis specified in the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on checking the basic chassis setting). The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached.

– Ignoring these instructions can be dangerous to life and limb!

– ignoring these instructions may damage parts of the motorcycle or impair the motorcycle’s traffic safety!

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INTRODUCTION

The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle.

WARRANTY The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle.

AUTOMOTIVE FLUIDS

The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule.

SPARE PARTS, ACCESSORIES

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

TRANSPORT

When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position. Be sure that the fuel tap is closed. If the motorcycle topples over, fuel can flow out of the carburetor or fuel tank

ENVIRONMENT

Offroad-Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others.

Enjoy driving your motorcycle !

KTM-SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

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TABLE OF CONTENTS

Page

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

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

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

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

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

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

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

Indicator lamps (EXC) . . . . . . . . . . . . . . . . . . . . . . .10

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

Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . .11

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

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

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

Filler cap (XC, XC-W) . . . . . . . . . . . . . . . . . . . . . . . .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

Spring preload of the fork(XC/EXC Six Days) . . . . . . . .14

Compression damping of shock absorber (XC-W, EXC) .15 Shock absorber compression damping (XC-W/EXC) . . .15

Shock absorber rebound damping XC-W, 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 and parking . . . . . . . . . . . . . . . . . . . . . . . .19

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

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .20

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .24

Changing the spring preloading of the shock absorber

. .24

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Basic suspension setup for the weight of the driver . . .25

Checking the shock absorber and spring . . . . . . . . . .25

Determining the static sag of the shock absorber . . . .25

Determining the riding sag of the shock absorber . . . .25

Changing the spring preload on the telescopic fork . . .26

Checking the basic setup of the telescopic fork . . . . .26

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

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .27

Cleaning the dust sleeves of the telescopic fork . . . . .27

Changing the fork offset (caster) (XC) . . . . . . . . . . . .28

Checking and adjusting the steering head bearing . . .29

Page

How to change the handlebar position . . . . . . . . . . . .30

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .30

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .31

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

General information about KTM disc brakes . . . . . . . .32

Adjusting the free travel at the hand brake lever . . . . .33

Checking the brake fluid level - front brake . . . . . . . .33

Refilling the front brake fluid reservoir . . . . . . . . . . .33

Checking the front brake pads . . . . . . . . . . . . . . . . .33

Replacing the front brake pads . . . . . . . . . . . . . . . . .34

Changing the basic position of the foot brake pedal . .34

Checking the rear brake fluid level . . . . . . . . . . . . . .34

Refilling the rear brake fluid reservoir . . . . . . . . . . . .34

Checking the rear brake pads . . . . . . . . . . . . . . . . . .35

Replacing the rear brake pads . . . . . . . . . . . . . . . . .35

Dismounting and mounting the front wheel . . . . . . . .35

Dismounting and mounting the rear wheel . . . . . . . . .36

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .37

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37

Replacing the battery of the digital speedometer . . . .37

Check/set distance of the magnetic sensor . . . . . . . . .38

Replacing the headlight lamp/parking light lamp . . . .38

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

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

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

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

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

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

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

Bleeding the hydraulic clutch . . . . . . . . . . . . . . . . .42

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

Draining the float chamber of the carburetor . . . . . . .44

Checking the float level . . . . . . . . . . . . . . . . . . . . . .44

Adjusting the engine characteristic via the ignition curve

. .44

Adjusting the engine characteristic via the auxiliary spring

.45

Check transmission oil level (125/200) . . . . . . . . . . .46

Changing the transmission oil (125/200) . . . . . . . . . .46

Check transmission oil level (250/300) . . . . . . . . . . .46

Changing the transmission oil (250/300) . . . . . . . . . .46

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .47

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

TECHNICAL SPECIFICATIONS – CHASSIS 125 / 200 . . .48

TECHNICAL SPECIFICATIONS – ENGINE 125 / 200 . . .50

TECHNICAL SPECIFICATIONS – CHASSIS 250 / 300 . . .52

TECHNICAL SPECIFICATIONS – ENGINE 250 / 300 . . .54

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

WIRING DIAGRAM, CARBURETOR TABLE . . . . .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

The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1.

Clutch lever

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

Hand brake lever

The hand brake lever [2] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see maintenance work on chassis and engine).

OPERATION INSTRUMENTS »

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OPERATION INSTRUMENTS

TEST

All of the display segments briefly light up for the display function test.

WS (wheel size)

The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires). Afterwards the display will return to the previous display mode.

Electronic speedometer

The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The | button is used to change between display modes. The + and – buttons are used to control various functions.

SPEED display mode / H (service hours)

Only the SPEED / H and SPEED / ODO display modes are activated in the condition at delivery. SPEED/H is displayed whenever the display is activated and the front wheel is not turning. It automatically changes to the SPEED/ODO display mode as soon as the front wheel starts turning.

SPEED displays the speed.

H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motorcycles, making the service hour counter a very practical function.

SPEED / ODO display mode (odometer)

The SPEED/ODO mode displays the speed and the total distance traveled. The display automatically changes to the SPEED/H display mode when the front wheel stops turning.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. changes to the next display mode

The electronic speedometer has a number of display modes (functions) that you can also activate (reveal) (see: Activating and deactivating display modes).

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OPERATION INSTRUMENTS

SPEED / LAP (lap time) display mode

You can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds.

+ button Starts and stops the stop watch, lap time is not

reset to 0

– button Stops the stop watch, stores the lap time and restarts

the stop watch again. The time is reset to 0. A total of 10 lap times can be stored. If the lap time continues to run after you press the - button, all 10 memory locations are occupied.To clear all of the stored lap times, hold the | button for 3 seconds in the SPEED/LAP mode.Up to 10 lap times can be stored in this way.

briefly press | button Changes to the next display mode.If no lap time is

stored or the motorcycle is driving, the LAP/LAP mode will be skipped.

hold | button 3 secs. Clears all LAP figures

SPEED / CLK (time) display mode

CLK displays the time in hours, minutes and seconds.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. set the clock menu

To set the clock, see „Setting the clock“.

Activating and deactivating display modes

In the display mode SPEED/H, press and hold the | button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blinking function can be activated by pressing the + button and deactivated by pressing the – button. Press and hold the | button 3 seconds to store the settings. If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode.

+ button activates the blinking display – button deactivates the blinking display

briefly press | button changes to the next display without changing any

settings

hold | button 3 secs. starts the SETUP

stores the settings and changes to the SPEED/H mode

The following display modes can be activated: TR1 tripmaster 1 TR2 tripmaster 2 A1 average speed 1 A2 average speed 2 S1 stop watch 1 S2 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH/MPH display in kilometers or miles (see: Kilometers or miles)

If you have activated all of the display modes, they will be displayed in the following order: SPEED/H, SPEED/CLK, SPEED/LAP, LAP/LAP, SPEED/MAX, SPEED/ODO, SPEED/TR1, SPEED/TR2, SPEED/A1, SPEED/A2, SPEED/S1, SPEED/S2

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LAP / LAP display mode (to view lap times)

The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds. Press the + button to access the next lap time. To clear all of the stored lap times, hold the | button for 3 seconds in the SPEED/LAP mode.

+ button changes to the next lap time – button no function

briefly press | button changes to the next display mode hold | button 3 secs. changes to the next display mode

SPEED / MAX display mode (maximum speed)

MAX displays the maximum speed traveled and is always active.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. clears the MAX figure

SPEED / TR1 display mode (tripmaster 1)

The TR1 tripmaster is always active and counts to 999.9. It is used to measure the length of a trip or the distance between 2 refueling stops. TR1 is linked to A1 (average speed 1). 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 TR1, A1 and S1 figures are automatically cleared after passing 999.9.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. clears the TR1, S1, A1 figures

SPEED / TR2 display mode (tripmaster 2)

The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the displayed figure can be changed using the + and – buttons. This is a very use- ful function for trips taken according to a roadbook.

+ button increases the TR2 figure – button decreases the TR2 figure

briefly press | button changes to the next display mode hold | button 3 secs. clears the TR2 figure

SPEED / A1 display mode (average speed 1)

A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (stop watch 1) figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. clears the TR1, S1, A1 figures

OPERATION INSTRUMENTS

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Kilometers or miles

The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly. The TR1, A1, S1, TR2 and A2 figures will be cleared. To select the unit, select the SPEED/H mode and hold the | button for 3 seconds to access the SETUP menu. Press the | button until the KMH/MPH function blinks. Press the + button briefly to move to the options. Press the + button for KMH or the – button for MPH. To set, briefly press the | button 1 x and hold for 3 seconds until the display returns to the SPEED/H mode. If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode.

+ button to access the menu

to activate the KMH display

– button to activate the MPH display briefly press | button changes to the next mode

changes from the menu to the SETUP menu

hold | button 3 secs. stores and closes the SETUP menu

SPEED / A2 display mode (average speed 2)

A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. changes to the next display mode

SPEED / S1 display mode (stop watch 1)

S1 shows the traveling time based on TR1 and continues to run whenever it receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

+ button no function – button no function

briefly press | button changes to the next display mode hold | button 3 secs. clears the TR1, S1, A1 figures

SPEED / S2 display mode (stop watch 2)

S2 is a manual stop watch. Start the stop watch by pressing the + button, press again to hold. Press again to continue timing. Press the | button to change to the next mode. The S2 display will blink in the other modes if S2 continues to run in the background. To stop S2, return to the SPEED/S2 mode and press the + button.

+ button starts and stops the stop watch – button no function

briefly press | button changes to the next display mode hold | button 3 secs. clears the S2 figure

OPERATION INSTRUMENTS

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OPERATION INSTRUMENTS

Setting the clock

To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the | button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the | button to move to the next digit. 012 will show the time in the 12-hour mode, 0-24 in the 24-hour mode. Press and hold the | button for 3 seconds to store the settings. If no button is pressed for 20 seconds, the settings will be stored automatically and the display will return to the SPEED/CLK mode.

+ button time + – button time –

briefly press | button changes to the next digit hold | button 3 secs. starts the SETUP menu

stores the time and changes to the SPEED/CLK display mode

If the CLK, LAP, MAX, TR1, TR2 A1, A2, S1 and S2 figures are suddenly cleared, the battery in the electronic speedometer is empty and must be replaced (see: Replacing the battery in the electronic speedometer).

A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar.

Motorcycle is standing

Motorcycle is driving

OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS

display

briefly press + button

briefly press – button

briefly press | button hold | button 3 secs.

SPEED / H

no function no function next display mode

displays the SETUP menu

X X

SPEED / CLK

no function no function next display mode setting the clock menu

X X

SPEED / LAP

starts/stops LAP without

clearing LAP figure

stops LAP, stores LAP

figure, resets LAP to 0

next display mode clears all LAP figures

LAP / LAP

next figure no function next display mode next display mode

X X

SPEED / MAX

no function no function next display mode clears MAX

SPEED / ODO

no function no function next display mode next display mode

X X

SPEED / TR1

no function no function next display mode clears TR1, S1, A1

X X

SPEED / TR2

increases the TR2 figure reduces the TR2 figure next display mode clears TR2

X X

SPEED / A1

no function no function next display mode clears TR1, S1, A1

X X

SPEED / A2

no function no function next display mode next display mode

X X

SPEED / S1

no function no function next display mode clears TR1, S1, A1

X X

SPEED / S2

starts - stops S2 no function next display mode clears S2

Indicator lamps (EXC)

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.

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OPERATION INSTRUMENTS

Combination switch (EXC/EXC Six Days)

The light switch has 2, respectively 3 switch positions.

[A] = Light off (this function is not available in all models) [B] = Low beam on [C] = High beam on

You may use button [2] to actuate the horn. The red short circuit button [3] serves to switch off the engine. Leave the switch pressed until the engine stops.

Headlamp switch (XC-W)

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

Flasher switch

The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system.

Flasher left

Flasher right

Emergency OFF switch (Australia)

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

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

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

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Filler cap (EXC/EXC Six Days)

To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise.

Filler cap (XC, XC-W)

To open the filler cap: Turn the filler cap 45° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° 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 carbure-

tor.

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

the fuel can flow to the carburetor. With the twist grip in this position the tank will be emptied until only the reserve is left.

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

to the RES position. Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time, too.

Reserve of the 8.5/10 l tank . . . . .1.3 l (0.34 US gallons)

Reserve of the 11.2 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.

OPERATION INSTRUMENTS

EXC

2,3,4,5, (6)

ENGLISH

OPERATION INSTRUMENTS

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.

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.

Never leave the key inserted in the steering lock. If you turn the handlebar to the left the key could get damaged.

ENGLISH

OPERATION INSTRUMENTS

3 3

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 screw [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

Typ WP Suspension 14187C02 . . . . .20 clicks

Typ WP Suspension 14187C04 . . . . .20 clicks

Typ WP Suspension 14187C27 . . . . .18 clicks

Typ WP Suspension 14187C28 . . . . .18 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw [3], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it 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

Typ WP Suspension 14187C02 . . . . .20 clicks

Typ WP Suspension 14187C04 . . . . .20 clicks

Typ WP Suspension 14187C27 . . . . .20 clicks

Typ WP Suspension 14187C28 . . . . .20 clicks

Spring preload of the fork (XC, EXC Six Days)

The fork's preload can be adjusted by means of the adjusting screws [4]. Use a 24 mm fork wrench. More information is provided in the chapter "Adjusting the fork and shock absorber.“

Damping action during compression of shock absorber (XC. EXC Six Days)

The shock absorber on the XC/EXC Six Days models can synchronize the 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 [5] to the limit in a clockwise direction using a

screwdriver .

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

absorber in a counterclockwise direction.

Typ WP Suspension 14187C27 . . . . .15 clicks

Typ WP Suspension 14187C28 . . . . .15 clicks

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).

ENGLISH

OPERATION INSTRUMENTS

Compression damping of shock absorber (XC-W, EXC)

The compression damping (during compression) can be adjusted for the XC-W and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [2] with a screwdriver. Turning in a clockwise direction will increase the damping, 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.

Typ WP Suspension 14187C02 . . . . .17 clicks

Typ WP Suspension 14187C04 . . . . .15 clicks

Typ WP Suspension 14187C27 . . . . .15 clicks

Typ WP Suspension 14187C28 . . . . .15 clicks

Rebound damping of shock absorber

By using the adjusting screw [4], the degree of damping of the rebound can be adjusted. Turn the knob to the right side to increase damping, turn it to the left side to reduce damping during rebounding.

STANDARD ADJUSTMENT:

– Turn the adjusting screw clockwise to the stop. – Then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

Typ WP Suspension 14187C02 . . . . .26 clicks

Typ WP Suspension 14187C04 . . . . .25 clicks

Typ WP Suspension 14187C27 . . . . .24 clicks

Typ WP Suspension 14187C28 . . . . .24 clicks

STANDARD HIGH-SPEED SETTING:

– Turn the adjusting screw [1] to the limit in a counterclockwise direction

using a box wrench.

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

in a clockwise direction.

Typ WP Suspension 14187C27 . . . . .1 turns

Typ WP Suspension 14187C28 . . . . .1,25 turns

ENGLISH

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for your first ride

– Make sure the work for the "pre-delivery inspection" was per-

formed by your authorized KTM workshop. The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.

– Thoroughly read the whole instruction manual before starting

for your first tour. – Familiarize yourself with the controls. – Adjust the clutch lever, the hand brake lever and the foot brake

pedal to the most comfortable position. – Get used to handling the motorcycle on an empty parking lot

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

as slowly as possible while standing upright, to improve your

feeling for the vehicle. – Do not drive along off-road trails which go beyond your ability

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

foot rests while driving. – Remove your foot from the foot brake lever when you are not

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

rub continuously and the braking system is overheated. – Do not make any alterations to the motorcycle and always use

ORIGINAL KTM SPARE PARTS. Spare parts from other man-

ufacturers can impair the safety of the motorcycle. – Motorcycles are sensitive to alterations in the distribution of

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

as close as possible to the middle of the vehicle; distribute the

weight evenly between 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.

Do not drive at full load for the first 500 kilometers (300 miles) or 5 hours!

– Wear suitable clothing when driving a motorcycle. smart KTM

drivers always wear a helmet, boots, gloves, and a jacket, regardless of whether driving all day or just go for a short ride. The protective clothing should be brightly colored so that other users of the roads can see you as early as possible. Of course your passenger will also need suitable protective clothing.

– Always turn on the light to make sure that other drivers become

aware of you as early as possible. – Do not drive after having consumed alcohol. – Only use accessory parts recommended by KTM. For example,

front panelling can impair the driving characteristics of the motor-

cycle. Cases, extra tanks etc. can alter the weight distribution

and thus also impair the vehicle’s driving characteristics. – The front and rear wheel are allowed to be fitted only with tires

that have the same profile type. – Be sure to check the spoke tension after 30 minutes' running time.

The spoke tension will decrease quickly on new wheels. If you con-

tinue to drive with loose spokes, the spokes may crack and lead

to unstable handling (see "Checking the spoke tension")

– Observe the traffic regulations, drive defensively and try to look

ahead as far as possible so that you recognize any hazards as

early as possible. – Adjust your driving speed to the conditions and your driving skills. – Drive carefully on unknown roads or in unknown territory. – When driving off-road, always have a friend on a second motor-

cycle to keep you company, so that you can help each other

should difficulties arise. – Replace the helmet visor or goggle glasses early enough. When

light shines directly on a scratched visor or goggles, you will

be practically blind. – Never leave your motorcycle without supervision as long as the

engine is running. – The Above Models were designed and built for one person only

- no additional passenger allowed!

– Neither do these models meet the applicable statutory regula-

tions and safety standards. Using them on public roads, high-

ways, freeways, etc. is against the law. – When riding your motorcycle, please bear in mind that other

people may feel molested by excessive noise.

ENGLISH

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.

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.

ENGLISH

DRIVING INSTRUCTIONS

Starting when the engine is cold

1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Swing up the side stand 4 Put the gear in neutral 5 Activate cold-starting aid (choke) 6 Leave throttle closed or open it no more than 1/3 and kick down kick-

starter vigorously all the way.

– 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.

– Check for power transmission at temperatures below 0°C (32°F) before

you actuate the kickstarter. If you depress the kickstarter without feeling any resistance, power is not being transmitted. This could cause injuries.

– 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.

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.

NOTE: The highly inflammable components in modern fuels volatilize if left standing for longer periods of time. If the motorcycle has not been used for over 1 week, the fuel should be drained from the float chamber. The engine will start up immediately if the float chamber is filled with fresh, ignitable fuel

Starting when the engine is warm

1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Swing up the side stand 4 Put the gear in neutral 5 Open throttle to 1/2 and kick down kickstarter vigorously

What to do when the engine is „flooded“

1 Close fuel tap 2

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

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

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and accelerate at the same time.

– Before you start off, check that the main or side stand has been swung

right up to the top. If the stand drags on the floor, you may lose control of your motorcycle.

– Before starting for an off-road tour, it is recommended to additionally secure

the side stand with the rubber band on the air filter box.

ENGLISH

DRIVING INSTRUCTIONS

Shifting/Riding

You are now in first gear, referred to as the drive or uphill gear. Depending on the conditions (hill size, etc.), you can shift to a higher gear. Turn down the throttle, at the same time pull the clutch lever in and shift to the next higher gear. Let the clutch lever go again and open the throttle. If you turned on the choke, make sure you turn it off again as soon as engine is warm. When you reach full speed through opening the throttle all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Only give as much gas as the engine can handle. Through quick and high revving of throttle, the gas 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.

– After falling with the motorcycle, check all its functions thor-

oughly before using it again.

– A twisted handlebar must always be replaced. Do not adjust

the handlebar, it will lose stability.

– 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 motorcycle 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 immediately, turn the engine off, and contact an authorized KTM dealer.

Braking

Turn off the gas and apply the hand and foot brakes at the same time. When driving on sandy, wet or slippery ground, use mainly the rear wheel brake. Always brake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed.

– 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 weaker the breaking effect. In extreme cases, the entire braking system can fail.

– If the resistance in the hand brake lever or foot brake pedal

feels “spongy” (too much give), this is an indication that 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.

Stopping and parking

Close the throttle and apply the hand and foot brake simultaneously. Be especially careful when you apply the brakes on sandy, wet or slick surfaces. Always apply the brakes intuitively, locked wheels can cause the bike to skid or crash. Shift down to a lower gear to match your speed. Always apply the brakes before you enter a curve.

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.

– Close the fuel tap when leaving your vehicle. Otherwise the car-

buretor may get flooded and fuel will enter the engine. – Never park your motorcycle in places where there exist fire haz-

ards due to dry grass or other easily flammable materials. – The side stand is only designed for the weight of the motorcy-

cle. If you get on your motorcycle and thus put additional

weight on the motorcycle, the side stand or the frame can be

damaged or the motorcycle may fall on the side.

Refueling, fuel

125-300: Unleaded premium gasoline RON 95 mixed with high grade two stroke oil. Mixture ratio 1:40 - 1:60 Fuel and engine oil should only be mixed immediately before use. KTM recommends Motorex Cross Power 2T.

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.

– Only use premium-grade gasoline ROZ 98 respectively 95

mixed with high-grade two-stroke engine oil. Other types of gaso-

line can cause engine failure. – Do not use premixed two-stroke oils, oils for outboard engines

or normal engine oil to prepare the mixture. – Do not use gasoline and oil mixtures that are older than one

week. The lubrication properties of some two-stroke oils can

deteriorate very rapidly. – Only use known brands of high-grade 2-stroke engine oil (i.e.

Motorex Cross Power 2T). – Never mix synthetic oils and mineral oils. – Not enough oil or low-grade oil can cause erosion of the pis-

ton. when Using too much oil, the engine may start smoking

and foul the spark plug. – If your motorcycle is equipped with a catalytic converter, always

keep in mind that leaded fuel will destroy the catalytic converter. – Fuel expands when its temperature rises. Therefore do not fill

the tank to the top. (see fig.)

35 mm

ENGLISH

PERIODIC MAINTENANCE SCHEDULE

125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007

A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY

Before each

race

1st service after

10 hours

every 20 hours

every 40 hours

at least once

a year

ENGINE

Check gear box oil level

Change gear box oil

z z z z

Check spark plugs, adjust distance between electrodes

z z

Renew spark plugs

z z

Clean the spark-plug connector and check for a tight fit

z z z

Check the screws on the kick starter and shift lever for a tight fit

z z z

CARBURETOR

Check the carburetor connection boot and intake flange for cracks or leaks

z z z

Check idle speed setting

z z z z

Check that vent hoses are not damaged or bent

z z z z

ADD-ON-PARTS

Check cooling system for leaks, check quantity of antifreeze

z z z z

Check exhaust system for leaks and fitment

z z z

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

z z z

Check the fluid level in the master cylinder of the hydraulic clutch

z z z z

Clean air filter and filter box

z z z z z

Check electric wires for damage and bends

z z

Check headlamp setting

z z

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

z z z

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

BRAKES

Check brake fluid level, lining thickness, brake lining

z z z

Check brake lines for damage and leaks

z z z

Check/adjust the function, smooth operation and free travel of the hand/foot brake lever

z z z

Check the screws and guide bolts on the brake system for a tight fit

z z z

CHASSIS

Check shock absorber and fork for leaks and function

z z z z

Clean dust bellows

z z z

Bleed fork legs

z z z

Check swing arm bearings

z z

Check/adjust steering head bearings

z z z

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

z z z

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

WHEELS

Check spoke tension and rim joint

z z z z

Check tires and air pressure

z z z z

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

z z z z

Lubricate chain, Clean and grease the adjusting screws on the chain tensioner

z z z z

Check clearance of wheel bearings

z z z

The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!

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