KTM 125 MXC, 380 MXC, 380 EXC, 380 SX, 300 MXC User Manual
...
OWNERS HANDBOOK
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2001
125/200/250/300/380 SX, MXC, EXC
BEDIENUNGSANLEITUNG
Art.Nr. 3.205.90 06/2000
ENGLISH
1
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
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 mainten-
ance, 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.
COMSUMER INFORMATION FOR AUSTRALIA ONLY
KTM S
PORTMOTORCYCLE
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
. I
T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS
ANNOUNCEMENT
. I
N THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL
KTM
DEALER FOR INFORMATION
.
W
E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS
.
ENGLISH
2
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
you can avoid bodily injuries. In addition, this Owner’s Handbook contains invaluable information 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 modifications 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
your case, you will be able to use this Owner’s Handbook to carry out most of the maintenance
steps yourself. If, on the other hand, you are not very familiar with motorcycles, it might be better
to 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 SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERNATIONS TO DESIGN AND MODEL.
© by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved
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.
ENGLISH
3
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 LUBRICATION- AND 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
INDEX
ENGLISH
4
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.
SERIAL NUMBER LOCATIONS
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.
1
A
ENGLISH
5
1
2
6
8
TRP
STP
DST
CLK
3
A
5
7
4
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.
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
6
Combination switch (EXC)
The light switch has 2, respetively 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
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.
In this position, the ignition circuit is enabled; the engine should start.
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
5 without kinks.
2
A
B
C
5
1
3
4
ENGLISH
7
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
.
W
IPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK
A DOCTOR
’S ADVICE IMMEDIATELY.
!
CAUTION
!
–O
NLY USE PREMIUM-GRADE GASOLINE ROZ 98 RESPECTIVELY 95 MIXED WITH
HIGH
-GRADE TWO
-STROKE ENGINE OIL
. OTHER TYPES OF GASOLINE CAN CAUSE
ENGINE FAILURE
.
–D
O NOT USE PREMIXED TWO
-STROKE OILS, OILS FOR OUTBOARD ENGINES OR NOR
-
MAL ENGINE OIL TO PREPARE THE MIXTURE
.
–D
O 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.
–N
EVER MIX SYNTHETIC OILS AND MINERAL OILS.
–N
OT 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
.
–I
F YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER, ALWAYS KEEP IN
MIND THAT LEADED FUEL WILL DESTROY THE CATALYTIC CONVERTER
.
–F
UEL 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
!
T
HE 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.
35 mm
ON RESOFF
SX
MXC
EXC
1
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
–I
F 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
.
–A
LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.
K
ICKING 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
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.
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
Type White Power 0518V701 ..............16 clicks
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 rebound. 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
2,3,4,5 (6)
1
N
1
2
2
1
ENGLISH
9
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
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
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
!
N
EVER 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
!
–T
HE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE. IFYOU
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
.
–A
LWAYS 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.
1
2
3
ENGLISH
10
DRIVING INSTRUCTIONS
– 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:
–T
HE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON
ONLY
- NO ADDITIONAL PASSENGER ALLOWED
!
–N
EITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY REGU-
LATIONS AND SAFETY STANDARDS. USING THEM ON PUBLIC ROADS,
HIGHWAYS
, FREEWAYS ETC
. IS AGAINST THE LAW
.
–W
HEN 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
.
–A
PPLY 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
1 Open fuel tap
2 Turn on ignition or emergency OFF switch
3 Put the gear in neutral
4 Activate cold-starting aid (choke)
5 Leave throttle closed or open it no more than
1
/3and kick
down kickstarter vigorously all the way.
WARNING
–F
OR 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.
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:
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 chain and chain wheels.
4 TIRES
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.
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 at hand brake lever and foot brake lever.
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.
WARNING
–
W
EAR 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
. T
HE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLO
-
RED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS
POSSIBLE
. O
F COURSE YOUR PASSENGER WILL ALSO NEED SUITABLE
PROTECTIVE CLOTHING
.
–DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–
O
NLY USE ACCESSORY PARTS RECOMMENDED BY
KTM. F
OR EXAMPLE
,
FRONT PANELLING CAN IMPAIR THE DRIVING CHARACTERISTICS OF THE
MOTORCYCLE
.C
ASES, 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 star-
ting for your first tour.
ENGLISH
11
–REPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.
W
HEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES
,
YOU WILL BE PRACTICALLY BLIND
.
–A
FTER 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
!
–H
IGH 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
.
–N
EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
A LOWER GEAR
. T
HE ENGINE WILL OVERREV, DAMAGING THE VALVES.
I
N ADDITION,
THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE
CAN EASILY GET OUT OF CONTROL
.
–I
F 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
–I
N 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.
–D
IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND
BRAKE DISCS
.
–W
HEN 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
–N
EVER 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
!
–C
LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE
CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE
.
–T
HE 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
.
–D
O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED
AREA
. E
XHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF
CONSCIOUSNESS AND DEATH
. ALWAYS PROVIDE ADEQUATE VENTILA
-
TION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
D
O 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
. A
LWAYS LET ENGINE IDLE UNTIL WARM OR DRIVE IT
WARM AT LOW R
.P.M. SPEEDS.
Starting when the engine is warm
1 Open fuel tap
2 Turn on ignition or emergency OFF switch
3 Put the gear in neutral
4 Open throttle to
1
/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.
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.
–A
LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS
BECOME AWARE OF YOU AS EARLY AS POSSIBLE
.
–B
EFORE 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
–O
BSERVE 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
.
–D
RIVE 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
.
ENGLISH
12
PERIODIC MAINTENANCE SCHEDULE
after
20 hours
or
2000 kilometer
1. service after
10 hours
or
1000 kilometer
after
4000 kilometer
or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
S
ERVICE
I
NTERVALLS 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!
A washed motorcycle can be checked more quickly which saves money!
Check gear box oil level ●
Change gear box oil ●●
Check spark plugs, adjust distance between electrodes ●●
Renew spark plugs ●
Check the carburettor connection boot for cracks and leaks ●
Check idle speed setting ●●
Check that vent hoses are not damaged or bent ●●
Check cooling system for leaks, check quantity of anti freeze ●●
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
Check break fluid level, lining thickness, break lining ●●
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 ●●
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 join ●
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
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 ●
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
125/200 SX/MXC/EXC
250/300/380 SX/MXC/EXC
at least
once a year
every 2 years
or 20000 km
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