KTM 125 MXC, 380 MXC, 380 EXC, 380 SX, 300 MXC Manual

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KTM 125 MXC, 380 MXC, 380 EXC, 380 SX, 300 MXC Manual

125/200/250/300/380 SX, MXC, EXC

BEDIENUNGSANLEITUNG

OWNERS HANDBOOK MANUALE D’USO MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

2001

Art.Nr. 3.205.90 06/2000

IMPORTANT

WE STRONGLY SUGGEST THAT YOU 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 ENDANGER YOUR BODY AND YOUR LIFE.

CAUTION

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

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

Chassis number

Engine 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 SUBSTI-

TUTING THEM WITH OTHERS. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT. IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION. WE SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS.

ENGLISH 1

	Introduction
	We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this
	opportunity to thank you for putting your trust in us; we will not let you down.
	You are now owner of a sporty and modern motorcycle which you are bound to have a great time
	with provided you care for it properly. Before going for a first ride on your motorbike, you should
	read this Owner’s Handbook carefully, even if this takes some of your precious time, so as to
	familiarize yourself with how your motorbike is to be operated and which features it offers you.
	Only by doing so will you learn how you can best tune your motorcycle to your needs and how
ENGLISH	you can avoid bodily injuries. In addition, this Owner’s Handbook contains invaluable informa-
ENGLISH	your case, you will be able to use this Owner’s Handbook to carry out most of the maintenance
	tion about motorcycle maintenance. At the time of printing, this User's Guide corresponded to the
	latest state of this model family. It is, however, possible that we may have made slight modificati-
	ons in the meantime due to development in our motorcycle design.
	The Owner’s Handbook is an essential part of the motorbike and should - when the bike is sold -
	be handed over to the new owner.
	Many motorcyclists have a good working knowledge of motorcycle mechanics; if this is true in
	steps yourself. If, on the other hand, you are not very familiar with motorcycles, it might be better

2to have a professional KTM dealer perform those steps marked by * found in the chapter entitled “Maintenance Work on Chassis and Engine” of this manual.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Be sure to have any maintenance jobs performed by an authorized KTM dealer.

Address your special requests to an authorized KTM dealer who, should the need arise, will be supported by the KTM importer.

Please do not forget to don your helmet, eye protection, and protective clothing when going for a ride. KTM riders are responsible riders! We wish you a lot of fun when driving !

KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the beginning of an on-going total re-engineering quality plan for a brighter tomorrow.

KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

INDEX

Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine number, engine type (125/200) . . . . . . . . . . . . . .4 Engine number, engine type (250/300/380) . . . . . . . . . .4

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Digital speedometer, indicator lamp (EXC) . . . . . . . . . . .5 Digital speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Odometer (EXC USA) . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Speedometer, indicator lamps (EXC - Australia) . . . . . . . .5 Short circuit button (SX) . . . . . . . . . . . . . . . . . . . . . . . . .5 Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6 Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . . . . . .6 Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Emergency OFF switch (Australia) . . . . . . . . . . . . . . . . . .6 Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Choke knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Compression damping of fork . . . . . . . . . . . . . . . . . . . . .8 Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .8 Compression damping of shock absorber . . . . . . . . . . . .9 Rebound damping of shock absorber . . . . . . . . . . . . . . .9 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .10

PERIODIC LUBRICATIONAND MAINTENANCE-SCHEDULE . .12

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .14 Changing the original position of the clutch lever . . . . . . .14 Checking and adjusting the steering head bearing . . . . .14 Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .15 Cleaning the dust sleeves of the telescopic fork . . . . . . .15 How to change the handlebar position . . . . . . . . . . . . .15 Changing the spring preloading of the shock absorber .16 Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .17 Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 General informations about KTM disc brakes . . . . . . . .18 Adjusting of free travel at the hand brake lever . . . . . . .18 Checking of brake fluid level - front brake . . . . . . . . . . .19

Page Refilling the front brake fluid reservoir . . . . . . . . . . . . .19 Checking the front brake pads . . . . . . . . . . . . . . . . . . .19 Replacing the front brake pads . . . . . . . . . . . . . . . . . . .19 Changing the basic position of the foot brake pedal . . .20 Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .20 Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .20 Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .21 Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .21 Dismounting and mounting the front wheel . . . . . . . . .21 Dismounting and mounting the rear wheel . . . . . . . . .22 Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .23 Replacing the battery of the digital speedometer . . . . .23 Adjustin digital speedometer . . . . . . . . . . . . . . . . . . . .25 Check/set distance of magnetic sensor . . . . . . . . . . . . .25 Replacing head light lamp (H4) . . . . . . . . . . . . . . . . . .26 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Radiator cover for the cold season . . . . . . . . . . . . . . . .27 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .27 Refilling / Bleeding the cooling system . . . . . . . . . . . . .27 Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .28 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Cleaning the spark arrestor (EXC USA) . . . . . . . . . . . . .28 Draining of float chamber of the carburetor . . . . . . . . .28 Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . .29 Checking the float level . . . . . . . . . . . . . . . . . . . . . . . .30 Checking the oil level of the hydraulic clutch . . . . . . . .30 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .30 Check transmission oil level (125/200) . . . . . . . . . . . . .31 Changing the transmission oil (125/200) . . . . . . . . . . .31 Check transmission oil level (250/300/380) . . . . . . . . .31 Changing the transmission oil (250/300/380) . . . . . . .31

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

CONSERVATION FOR WINTER OPERATION . . . . . . . . .32

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 RE Iniation After Time of storage . . . . . . . . . . . . . . . . .32

TECHNICAL SPECIFICATIONS - CHASSIS (125/200) . . . .33

TECHNICAL SPECIFICATIONS - ENGINE (125/200) . . . . . . . . .34

TECHNICAL SPECIFICATIONS - CHASSIS (250/300/380) . .36

TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)

Only USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)

All models out of USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Head Word Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

WIRING DIAGRAMME, CARBURETOR SETTING . . .Appendix

ENGLISH 3

ENGLISH 4

SERIAL NUMBER LOCATIONS

Chassis number

The chassis number is stamped on the right side of the steering head tube. Write this number into 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. Please note this number down on page 1.

Engine number, engine type (250/300/380)

Engine number and engine type are stamped on the right hand side of the engine in front of the kickstarter. Write this number into the relevant area on page 1.

OPERATION INSTRUMENTS

Clutch lever

The clutch lever 1 is located on the left side of the handlebar. 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

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

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY” (TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

Digital speedometer, indicator lamp (EXC)

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

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

TRP

STP

DST

CLK

Speedometer – digital

Some models are equipped with a digital speedometer 3.

KMH = Speed, max. 200 km/h (is always indicated)

Aside from speed indication the following indications can be selected:

TRP	= Trip distance
STP	= Stopwatch max. 10 h, automatic start/stop function
DST	= Total distance up to 99.999 km
CLK	= clock

See maintenance work for change of battery and basic setting.

Odometer (EXC USA)

The odometer is a mileage indicator and can be set to 0 by means of the adjustment wheel 4.

Speedometer, indicator lamps (EXC AUS)

The mileage indicator A in the speedometer 5 indicates overall mileage. When the turn indicator is on, the green indicator lamp 6 will be flashing in the same rhythm.

The blue indicator lamp 7 will be lit when the high beam is on

Short circuit button (SX)

The short circuit button 8 turns off the engine. When pressing this button,

the ignition circuit is short-cicuited.

ENGLISH 5

ENGLISH 6

		Combination switch (EXC)
2	1	The light switch has 2, respetively 3 switch positions.
2	1	A = Light off (this function is not available in all models)
		B = Low beam on
		C = High beam on
		You may use button 1 to actuate the horn.
		The red short circuit button 2 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 3.

Flasher switch

Flasher left

Flasher right

Emergency OFF switch (Australia)

The emergency OFF switch 4 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.

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

Filler cap

To open it: turn filler cap counter-clockwise.

5 To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose 5 without kinks.

35 mm

OFF

RES

MXC

EXC

Refueling, fuel

125-380: 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 DOCTOR’S 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 NOR- MAL 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.

–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 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.)

Fuel tap

OFF In this position the fuel tap is closed. No fuel may 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 8,5 l tank: 1.2 l (0,32 US gallons) Reserve of the 11 l tank: 1.7 l (0,45 US gallons)

CAUTION

THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.

Choke knob

When pulling the choke knob 1 fully towards the top, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This encoure the 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.

ENGLISH 7

2,3,4,5 (6)

ENGLISH 8

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.

WARNING

– IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICK- STARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE.

–ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED

THROTTLE GRIP INCREASE THE KICK-BACK HAZARD.

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).

WARNING

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.

Turn the knob 1 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

1	1	Type White Power 0518V701	..............16 clicks
1	1	Type White Power 0518V702 ..............	16 clicks
		Type White Power 0518V703 ..............	14 clicks
		Type White Power 0518V704 ..............	14 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is rebo- 2 und. By turning the adjusting screw 2 (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 0518V701 ..............	16 clicks
Type White Power 0518V702 ..............	12 clicks
Type White Power 0518V703 ..............	12 clicks
Type White Power 0518V704 ..............	12 clicks

Compression damping of shock absorber

The damping force of the compression damping can be adjusted with knob 1

The higher the number the higher the damping force.
STANDARD ADJUSTMENT:
Type White Power 1218V728 ................		5 clicks
Type White Power 1218V729 ................		5 clicks
Type White Power 1218V730 ................		5 clicks
Type White Power 1218V731 ................		5 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.

Rebound damping of shock absorber
		ENGLISH
By using the adjusting screw 2, 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 1218V728	..............25 clicks
Type White Power 1218V729 ..............	23 clicks
Type White Power 1218V730 ..............	25 clicks
Type White Power 1218V731 ..............	25 clicks
		9

Steering lock

The handlebar can be locked by means of the lock located on the steering head. To lock it, turn handlebar all the way to the right, insert key, turn it to left, press it in, turn it to 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.

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

CAUTION

– THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE. IF YOU GET ON THE MOTORCYCLE AND THUS PUT ADDITIONAL WEIGHT ON THE SIDE STAND, THE SIDE STAND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE MAY FALL ON THE SIDE.

– ALWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE SIDE STAND AS FAR AS POSSIBLE. IF THE STAND TOUCHES THE GROUND WHILE YOU ARE DRIVING, YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE.

DRIVING INSTRUCTIONS

ENGLISH

What you should check before each start

When you start off, the motorcycle must be in a perfect technbical 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 chain and chain wheels.

4TIRES

Check for damaged tyres. 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 at hand brake lever and foot brake lever.

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.

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 COLO- RED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE. OF COURSE YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING.

–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 MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’S DRIVING CHA- RACTERISTICS.

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 in 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 the straps or to the driver, with his feet on the passenger foot rests.

–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.

WARNING

IMPORTANT INSTRUCTIONS FOR MODELS SX, MXC, AND EXC:

–THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON

ONLY - NO ADDITIONAL PASSENGER ALLOWED!

– NEITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY REGU- LATIONS AND SAFETY STANDARDS. USING THEM ON PUBLIC ROADS, HIGHWAYS, FREEWAYS ETC. IS AGAINST THE LAW.

– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.

Running in

– EVEN VERY PRECISELY MACHINED SECTIONS OF ENGINE COMPONENTS HAVE ROUGHER SURFACES THAN COMPONENTS WHICH HAVE BEEN SLI- DING 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!

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 MOMEN- TUM 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 VENTILA- TION 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 IS 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 CONTROL OF YOUR MOTORCYCLE.

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

– 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 clutch lever in and shift to the next higher gear. Let 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 increase. When shifting down, use the brakes if necessary and turn down at the same time. Pull clutch lever and shift down to the next lower gear. Let clutch lever go slowly and open throttle or shift down again.

WARNING

– 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.

– 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 HANDLEBAR, IT WILL LOSE STA-BILITY.

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 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 BLOCKS 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 IMMEDIA- TELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER.

Braking

Turn off 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 BRA- KING 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.

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

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING.

– 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.

– THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE. IF YOU GET ON YOUR MOTOR-CYCLE 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.

ENGLISH

			PERIODIC MAINTENANCE SCHEDULE			125/200 SX/MXC/EXC
			PERIODIC MAINTENANCE SCHEDULE			250/300/380 SX/MXC/EXC
				1. service after		after	after
					10 hours	20 hours	4000 kilometer
	A washed motorcycle can be checked more quickly which saves money!				10 hours	20 hours	4000 kilometer
					or	or	or
					or	or	or
				1000 kilometer		2000 kilometer	once a year

ENGINE		Check gear box oil level				●

		Change gear box oil			●		●
		Change gear box oil			●		●

		Check spark plugs, adjust distance between electrodes			●	●

		Renew spark plugs					●

CARBURETOR		Check the carburettor 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 anti freeze			●		●

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-, high beam, break light, indicator,			●		●
		indicator lamps, speedometer illumination, horn, emergency OFF switch or button
BRAKES		Check break fluid level, lining thickness, break lining			●		●

		Check break lines for damage and leaks			●		●
		Check break lines for damage and leaks			●		●

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

		Check tightness of break system screws			●		●

		Check shock absorber and fork for leaks and function			●		●

CHASSIS		Clean dust bellows					●

		Bleed fork legs					●
		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 join					●
WHEELS
WHEELS		Check tyres and air pressure			●		●
		Check tyres 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 fibre yarn filling of the exhaust main silencer						●

Treat electric contacts and switches with contact grease						●

Change hydraulic clutch fluid						●

Change break fluid						●

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

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

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