KTM 200 MXC, 380 SX, 250 MXC, 125 MXC, 300 MXC User Manual

OWNERS HANDBOOK

MANUALE D’USO

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

Art.Nr. 320571 7/99

2000

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

BEDIENUNGSANLEITUNG

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

Frame 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

Attachments:

1 spare parts manual chassis
1 spare parts manual engine

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 . . . . .13

Changing the original position of the clutch lever

. . . . . . .13

Checking and adjusting the steering head bearing . . . . .13

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .14

Cleaning the dust sleeves of the telescopic fork . . . . . . .14

How to change the handlebar position . . . . . . . . . . . . .14

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .16

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

General informations about KTM disc brakes . . . . . . . .17

Adjusting of free travel at the hand brake lever . . . . . . .17

Checking of brake fluid level - front brake . . . . . . . . . . .18

Refilling the front brake fluid reservoir . . . . . . . . . . . . . .16

Page

Checking the front brake pads . . . . . . . . . . . . . . . . . . .18

Replacing the front brake pads . . . . . . . . . . . . . . . . . . .18

Changing the basic position of the brake pedal . . . . . .19

Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .19

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .19

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .20

Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .20

Dismounting and mounting the front wheel . . . . . . . . .20

Dismounting and mounting the rear wheel . . . . . . . . .21

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .22

Replacing the battery of the digital speedometer . . . . .22

Check/set distance of magnetic sensor . . . . . . . . . . . . .24

Replacing head light lamp (H4) . . . . . . . . . . . . . . . . . .25

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Radiator cover for the cold season . . . . . . . . . . . . . . . .26

Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .26

Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . .26

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .27

Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Cleaning the spark arrestor (EXC USA) . . . . . . . . . . . . .27

Draining of float chamber of the carburetor . . . . . . . . .27

Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . .28

Checking the float level . . . . . . . . . . . . . . . . . . . . . . . .29

Checking the oil level of the hydraulic clutch . . . . . . . .29

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .29

Check transmission oil level (125/200) . . . . . . . . . . . . .30

Changing the transmission oil (125/200) . . . . . . . . . . .30

Check transmission oil level (250/300/380) . . . . . . . . .30

Changing the transmission oil (250/300/380) . . . . . . .30

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

CONSERVATION FOR WINTER OPERATION . . . . . . . . .31

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Use after period of storage . . . . . . . . . . . . . . . . . . . . . .31

TECHNICAL SPECIFICATIONS - CHASSIS (125/200) . . . .32

TECHNICAL SPECIFICATIONS - ENGINE (125/200)

. . . . . . . . .33

TECHNICAL SPECIFICATIONS - CHASSIS (250/300/380) . .35

TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)

Only USA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)

All models out of USA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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



I

F 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

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 = Reloj

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.

1

2

6

8

TRP

STP

DST

CLK

3

A

5

7

4

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



G

ASOLINE 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.

–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

.

–O

NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL.

–N

EVER 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

.

–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 9,5 l tank: 1.3 l (0,35 US gallons)
Reserve of the 12 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



–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

.

–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



I

F 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 0518U783..............16 clicks

Type White Power 0518U784..............14 clicks

Type White Power 0518U785..............14 clicks

Type White Power 0518U787..............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 0518U783..............12 clicks

Type White Power 0518U783..............12 clicks

Type White Power 0518U783..............12 clicks

Type White Power 0518U783..............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 1218U717................4 clicks

Type White Power 1218U718................4 clicks

Type White Power 1218U719................5 clicks

Type White Power 1218U720................5 clicks



WARNING



T

HE 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

. S

EVERE 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 1218U717..............20 clicks

Type White Power 1218U718..............18 clicks

Type White Power 1218U719..............20 clicks

Type White Power 1218U720..............20 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

!

–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

.

–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 A

BOVE 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 UND FLING YOUR FOOT UPWARDS

.

–F

ORCEFULLY 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.

–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

!

–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

. THE ENGINE WILL OVERREV, DAMAGING THE VALVES.

I

N 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

.

–I

N 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

.

–R

IDES 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

.

–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



–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING

.

–M

OTORCYCLE 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

.

–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

.

–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

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



–B

EFORE 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

.

–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 LUBRICATION AND MAINTENANCE SCHEDULE

Check transmission oil level ●

Change transmission oil ●●●

Check spark plug and electrode gap ●●●

Change spark plug ●

Functional testing of the exhaust control system ●

Check intake manifold for leaks and cracks ●●

Drain and clean carburetor float chamber ●●

Adjust idling ●●

Check breather hoses of engine case and gas tank for correct position without buckles

●

Clean and check airfilter element, box and carburetor connection boot ●●●

Check chain, sprockets, guides and chain wear ●●●

Clean and oil chain ●●

Check chain tension ●●●

Check coolant level ●●●

Check quality of antifreeze ●

Check cooling system for leaks - visual inspection ●●●

Check exhaust system for cracks and leaks ●

Replace glass fiber yarn of silencer ●●

Check of the exhaust suspension system ●●

Check brake fluid level front and rear ●●●

Change brake fluid ●

Check thickness of disc brake pads ●●

Check brake disks for wear and wobbling ●

Inspect condition and installation of front and rear brake hoses ●●●

Check free travel and free movability of hand brake lever and foot brake lever ●●●

Check the oil level in the master cylinder of the hydraulic clutch ●●

Change the oil of the hydraulic clutch ●

Check telescopic fork action ●●

Check telescopic fork for leaks ●

Clean the dust scrabbers of the telescopic force ●●●

Undo the bleeder screws at the fork legs ●

Change oil of telescopic fork ●

Service telescopic fork completely ●

Check steering head bearing free play ●●

Clean and regrease steering head bearing ●●

Check setting and damping of shock absorber ●●

Service shock absorber completely ●

Grease swingarm needle bearings (dont grease the pivot bearing for the shock absorber) ●

Check for even spoke tension and rim alignment ●●●

Check wheel bearings ●●

Check tires for cuts and air pressure ●●

Check cables for damage and free movement ●●

Adjust and oil control cables ●● ●

Check electrical system ●●●

Check adjustment of headlight ●

Apply contact spray to light switches, flasher switches and emergency off switch ●●

Check all bolts, nuts, screws and clamps for proper tightness ●●●

Clean and lubricate control lever pivot points ●●●●

AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES)

SERVICE IS TO BE DONE AFTER EVERY RACE

KTM
rider

KTM

dealer

before each start

after washing

after 2000 km

(1250 miles) or 20 hours

after 4000 km

(2500 miles) or once a year

at least

once a year

1st service after 1000 km

(600 miles) or 10 hours

125-380 6.99

ENGLISH

13



WARNING



MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND
TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED
KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED
SKILLED STAFF.

!

CAUTION

!

–W

HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE

, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-

BURETOR, ELECTRIC CONNECTORS ETC.

–W

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

THE FUEL TAP IS IN THE

OFF POSITION

- IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK

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

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

.

–D

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

LOOSE

. INSTEAD, USE SELF-LOCKING NUTS.

–L

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

–R

EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.

–U

NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL CONTAMINATES

1.000.000

LITERS WATER.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Changing the original position of the clutch lever

The adjusting screw 1 can be used for individual adjustment of the original
position of the clutch lever, thus allowing adjustment to an optimal position
for every hand size.
Turning the adjusting screw clockwise reduces the distance between the
clutch lever and the handlebar. Turning the adjusting screw counterclock­wise increases the distance between the clutch lever and the handlebar.

!

CAUTION

!

A

DJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS

.

O

NLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE.

Checking and adjusting the steering head bearing *

Check steering head bearing for play periodically. For check put motorcycle
on stand so that the front wheel is off the ground. Now try to move the fork
forward and backward. For readjusting, loosen the five pinch bolts

2 of the

top triple clamp and turn steering stem bolt clockwise

3 until there is no

more play. Don’t tighten the steering stem bolt all the way, otherwise the
bearings will be damaged. With a plastic hammer, lightly rap on the triple
clamp to release tension. Retighten the five pinch bolts to 20 Nm (15 ft.lb).



WARNING



I

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

WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL

.

!

CAUTION

!

I

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

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

.

The steering head bearings should be regreased at least once a year
(i.e. Shell Advance Grease).

1

2

3

ENGLISH

Breather plug front fork

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

1 a few turns in order to relieve excess pressure from the inside of

the fork. To do this, place the motorcycle on a stand with the front wheel
lifted off the ground. When riding the motorcycle mainly on street, it will be
enough to have this job performed in the course of the periodical mainten­ance service.

!

CAUTION

!

E

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

YOUR FORK IS LEAKING

, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE

HAVING THE SEALS REPLACED

.

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows 2 are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind
the dust-protection bellows. If this dirt is not removed, the oil sealing rings
located behind it may start to leak.
Use a screwdriver to lever the dust-protection bellows out of the outer
tubes and slide them downward.

Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with silicone spray or engine oil. Then, push dust-pro­tection bellows into the outer tubes by hand.

How to change the handlebar position

The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar to the position that is the most convenient for you. The upper tri­ple clamp

3 includes 2 bores arranged at a distance of 15 mm (0,6 in) from

one another. The bores at the handlebar support

4 are offset from the cen-

ter by 3.5 mm (0,13 in). Accordingly, you can mount the handlebar in
4 different positions.

For this purpose, remove screws

5 of the handlebar clamps and screws 6

of the handlebar support. Position handlebar support, and tighten screws 6
to 40 Nm (30 ft.lbs). Mount handlebar and handlebar clamps, and tighten
screws 5 to 20 Nm (15 ft.lbs). The gap between handlebar support and
handlebar clamps is to be of equal size in the front and in the rear.

14

3

4

5

6

15 mm

3,5 mm

1

2

ENGLISH

15

Pivot bearing

The pivot bearing 1 for PDS suspension struts at the swinging fork is
Teflon-coated and must not be lubricated with either grease or other lubri­cants. Grease and other lubricants cause the Teflon coat to dissolve, whe­reby the bearing’s lifecycle will be reduced dramatically.

When cleaning your bike with a high-pressure cleaner, do not aim the high­pressure spray directly at the pivot bearing.

Check chain tension

– To check the chain tension, park the motorcycle.
– Press chain upward at the end of the chain sliding component. The

distance between chain and swing arm should be approx. 15 mm (0.6 in).
In the course of this procedure, the upper chain portion A must be taut
(see drawing).

– If necessary, correct chain tension.



WARNING



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

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

CESSARY STRESS

, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE

.

–T

OO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS

. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE

.

–I

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

15 mm

B

1

ENGLISH

16

15 KG
33 lbs

max. 272 mm

1 2 3

16 17 18

✓

2

3

4

5

3

4

Correct chain tension

– Loosen collar nut 2, loosen lock nuts 3, and turn right and left adju-

sting screws

4 equally far. Tighten lock nuts.

– Before tightening the collar nut, verify that the chain adjusters

5 are sit-

ting close to the adjusting screws and that the rear wheel has been aligned
with the front wheel.

– Tighten collar nut

2 to 80 Nm (60 ft.lb).



WARNING



–I

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

HAVE THE TIGHTENING TORQUE CORRECTED BY A

KTM DEALER AS SOON AS

POSSIBLE

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

YOUR MOTORCYCLE

.

–T

IGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE

.

Chain maintenance

For long chain life, good maintenance is very important. Chains with­out O-rings should be cleaned in fireproof solvent regularly and after­wards treated with hot grease or chain spray (i.e. Shell Advance Bio
Chain).
O-ring chains on the other hand are very simple to clean. The best
way is to use lots of water, but never use brushes or cleaning liquids.
After letting the chain dry, you can use a special O-ring chain spray
(i.e. Shell Advance Bio Chain).



WARNING



NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS

, EITHER-

WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRON-
GLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL.

!

CAUTION

!

W

HEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK

CLIP MUST POINT IN RUNNING DIRECTION

.

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

Chain wear

In order to check the chain wear, regard the following indications:
Shift the gear into idling and pull the upper chain strand with approx. 10-15
Kilogramm (33 lb) upwards (see figure). Now one can measure a space of
18 chain reels at the lower chain strand. The chain should be replaced at the
latest when a space of 272 mm (10.70 in) is measured. Chains do not
always wear off evenly, therefore repeat the measurement at different pla­ces on the chain.

NOTE:
If you mount a new chain, the sprockets should also be replaced. New
chains wear faster if used on old used sprockets.

!

CAUTION

!

W

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

ENGLISH

17

General information about KTM disc brakes

BRAKE CALIPERS:
The brake calipers of this series use a „floating” mount. This means that the
brake calipers are not solidly attached to the caliper support, which enables
them to „float” for maximum braking contact.

BRAKE PADS:
Since KTM motorcycles are mainly designed for races under extremely dirty
conditions (e.g. water in connection with sand and mud), the front wheel is
equipped with brake pads with sintered lining. These linings cover almost
the entire operative range of the motorcycle.

BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face

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

discs must not be more than 0.40 mm (0,016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location

B outside

the contact face. Check wear in several locations.



WARNING



–B

RAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,4 MM (0,016 IN) CONSTI-

TUTE A SAFETY RISK

. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS

THEY REACH THE WEAR LIMIT

.

–H

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

BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been desi­gned in such a way that even if the brake pads are worn it is not necessary
to top up the brake fluid. If the brake fluid level drops below the minimum
level either the brake system has a leak or the brake pads are completely
worn.
In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:
KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake
fluid, one of the best brake fluids that is currently available. We recommend
that you continue to use it. DOT 5.1 brake fluid is based on glycol ether
and of an amber color. If you do not have any DOT 5.1 for refilling, you
may use DOT 4 brake fluid. However, you should replace it as soon as
possible by DOT 5.1.
Never use brake fluid DOT 5. The color of this silicon oil-based product is
purple red. The gaskets and brake hoses of KTM motorcycles are not desi­gned for DOT 5 brake fluid!

Adjusting of free travel at the hand brake lever

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

2. In this way, the position of the point of pressure (i.e., the resi-

stance you feel on the hand brake lever when the brake pads are pressed
against the brake disc) can be adjusted for any hand size.

!

CAUTION

!

A

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

THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED

(TO BE RECOGNIZED BY

THE GREATER RESISTANCE OF THE HAND BRAKE LEVER

). IF THIS FREE TRAVEL IS NOT PRO-

VIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE
MAY FAIL DUE TO OVERHEATING

.

DOT

5.1

DOT

5

✓

✕

min. 3 mm

2

A
B

1

ENGLISH

18

Checking of brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the hand­lebar and the reservoir is provided with an inspection glass. With the reservoir
in a horizontal position, the brake fluid level should not drop below the
middle of the glass.



WARNING



I

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

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN

. IN THIS CASE, CONSULT AN AUTHO-

RIZED KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws 1 and remove lid 2 and membrane 3.
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (i.e.
Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws.
Rinse off spilled or overflowing brake fluid with water.



WARNING



–N

EVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR

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

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–B

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

YOU GET BRAKE FLUID IN YOUR EYES

, RINSE WITH PLENTY OF WATER AND CONSULT A

DOCTOR

!

CAUTION

!

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

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the front brake pads

The brake pads can be inspected from below. The linings nust be at least
1 mm (0.04 in) thick.



WARNING



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

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

.

!

CAUTION

!

I

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

WORN

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

THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing front brake pads *

Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips

4 and pull out bolt 5. Remove brake pads

from the brake caliper. Clean the brake caliper and the brake caliper support
with compressed air. Check the sleeves of the guide bolts for damage, and
grease guide bolts if necessary.

min.

1 mm

5 mm

1

2

3

4

4

5

Mount the right brake pad and fix it with the bolt. Mount the left brake pad
and insert the bolt until it stops. Mount the clips.
When mounting the brake pads, be sure to check for correct fit of the sli­ding metal-sheet

6 in the caliper support and of the leaf spring 7.



WARNING



–I

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

O

THERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

–A

FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

–

H

AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALWAYS

ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER

,

RESPECTIVELY SO AS TO
ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE
POINT IS ESTABLISHED

.

Changing the basic position of the foot brake pedal *

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

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

means of the piston rod

2.

Measured on the outside, the foot brake pedal must have 3-5 mm
(0.12–0.20 in) of free play, before the piston rod can move the piston in the
brake cylinder (to be recognised from the resistance on the foot brake
pedal).

!

CAUTION

!

I

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

WHEN DRIVING

, CAUSING THE REAR WHEEL TO BRAKE

.THE BRAKING SYSTEM OVERHEATS

AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES

.

Checking rear brake fluid level

The brake fluid reservoir of the rear disc brake is located on the right side of
the motorcycle next to the kickstarter. The brake fluid level must not drop
below the „MlN” marking when the vehicle is in an upright position.



WARNING



I

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

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN

. IN THIS CASE, CONSULT AN AUTHO-

RIZED KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

For this purpose, it is recommended to remove screw 3 and to pull the
brake fluid reservoir outwards. Now the screw cap

8 and the rubber boot

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

5.1) until the brake fluid level reaches the ”MAX” mark, then mount the
screw cap together with the rubber boot. Restore the brake fluid reservoir
to its original position and fix it with the screw. The connecting hose bet­ween the reservoir and the foot brake cylinder must be carefully positioned,
preventing kinks and keeping a safe distance between the hose and the
exhaust pipe. Spilled brake fluid must be rinsed off with water.



WARNING



–N

EVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR

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

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–B

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

YOU GET BRAKE FLUID IN YOUR EYES

, RINSE WITH PLENTY OF WATER AND CONSULT A

DOCTOR

.

!

CAUTION

!

–D

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

REMOVER

.

–U

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

ENGLISH

19

6

7

4

5

3-5mm

8

9

5

1

2

3

ENGLISH

20

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).



WARNING



A

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

OTHERWISE THEY COULD LEAD TO BRAKE FAILURE

. FOR YOUR OWN SAFETY DON’T PUT

OFF HAVING YOUR BRAKE PADS CHANGED

.

!

CAUTION

!

I

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

WORN

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

THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing the rear brake pads *

Press brake caliper 1 in direction of chain wheel for the brake piston to
reach its basic position. Remove safety device 2, knock out the guide pin 3
from the brake caliper with a drift towards the chain wheel and remove
brake pads. Carefully clean the brake caliper with compressed air and check
sleeves of the guide pins for damage.

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

3 in as far as it will go. Mount safety

device

2.



WARNING



–I

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

O

THERWISE

, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

–A

FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

–H

AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALWAYS

ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER

,

RESPECTIVELY SO AS TO
ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE
POINT IS ESTABLISHED

.

Dismounting and mounting the front wheel

–

To remove the front wheel, jack the motorcycle up on its frame so that
the front wheel no longer touches the ground.

– Loosen the collar nut 4.
–

Loosen the 4 clamping screws

5 on the fork fists.

– Hold the front wheel, pull out the wheel spindle

6

NOTE: The wheel spindle can be easily removed if you slightly revolve it
with a ring span-ner (SW 21 mm) or a hexagon socket screw key (6 mm).

–

Remove front wheel carefully from the fork and take the speedometer
drive

7 off the hub.

NOTE: Models with a digital speedometer have a distance bushing
instead of the speed-ometer drive.

!

CAUTION

!

–D

O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED

.

–M

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

OTHERWISE THE BRAKE DISC CAN BE DAMAGED.

– Prior to mounting the front wheel, clean and grease sealing ring 8 and

running surface

9 at the speedometer drive.

– Zum Einbauen des Vorderrades dieses in die Gabel heben und Tachoan-

trieb bzw. Distanzbüchse in die Nabe stecken. Dabei müssen die Mitneh­mernasen

bk in die Schlitze des Tachoantriebs eingreifen.

– Vorderrad samt Tachoantrieb bzw. Distanzbüchse positionieren und

Steckachse montieren

min.

1 mm

2

7

5

6

4

5

7

8

9

10

1

3

ENGLISH

21

– Mount collar nut 4, turn speedometer drive in a way that the flexible

speedometer shaft will curve upwards in a slight bow (see pict.) and
tighten collar nut to 40 Nm (30 ft.lb).

– Take the motorcycle off the stand and bounce the fork hard a few times

to align the fork legs

– Then tighten clamping screws

5 to a max. torque of 10 Nm (7 ft.lbs)



WARNING



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

HAVE THE TIGHTENING TORQUE CORRECTED BY A

KTM DEALER AS SOON AS POSSI-

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

.

–A

FTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS

.

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

,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED

.

Dismounting and mounting the rear wheel

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

ches the ground.

– Loosen the collar nut

1, remove chain tensioner 2, hold the rear wheel

and pull out the wheel spindle

3 until the rear wheel is free but the

brake caliper support is still held.

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

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

!

CAUTION

!

–

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

–M

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

OTHERWISE THE BRAKE DISC CAN BE DAMAGED

.

–I

F THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND

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

.

The rear wheel is remounted in reverse order. Before tightening the collar
nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain ten­sioners lie on the tension screws.



WARNING



–I

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

HAVE THE TIGHTENING TORQUE CORRECTED BY A

KTM DEALER AS SOON AS POSSI-

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

.

–A

FTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL THE

PRESSURE POINT RETURNS

.

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

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

–T

IGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE

.

1

2

3

ENGLISH

22

Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motorcy­cle rides, and they must therefore be checked whenever you are getting
ready to go anywhere on your motorcycle.
– Tire size can be found in the technical specifications and in their homolo-

gation certificate

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

motorcycle. Before leaving, check tires for punctures and nails or other
sharp objects that might have become embedded in them.
Refer to the specific regulations in your country for minimum tire tread
requirements. We recommend you replace the tires at the latest when
the tread is down to 2 mm (0.08 in).

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

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



WARNING



–D

O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY

KTM. OTHER TIRES

COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES

.

–

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

. USE HOMOLOGATED TIRES
–FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.
–W

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

FORMS

, ESPECIALLY ON WET SURFACES

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

RESULT

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels
and thus for riding safety. A loose spoke causes the wheel to become unba­lanced and before long other spokes will have come loose. Check spoke
tension, especially on a new motorcycle, in regular intervals. For checking,
tap on each spoke with the blade of a screwdriver (see photo). A clear tone
must be the result. Dull tones are indicators of loose spokes. If necessary,
have the spokes retightened and the wheel centered by a KTM dealer.



WARNING



S

POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE

. T

HIS MAY LEAD TO AN

UNSTABLE HANDLING OF YOUR MOTORCYCLE

.

Replacing the battery of the digital speedometer

After approx. 2 years, the battery of the digital speedometer will be empty
and must be replaced. For this purpose, the speedometer must be
dismounted.
Remove headlight mask, and pull speedometer illumination system

1 out

of the speedometer housing.

Use a screwdriver to lever the blue speedometer glass 2 downward and
out of the speedometer housing 3. The two noses A must be disengaged
from the speedometer housing. Remove screws

4, and take speedometer

out of housing.
Before you remove the battery, do not forget to write down the following
data:
– total kilometer reading (DST)
– wheel circumference (WS) (KTM standard tires = 2205 mm)

– Remove the battery cover on the back of the speedometer and detach the

batteries. The new batteries must be inserted with the plus pole on top.

– Make sure that the seal ring has the right position on the cover when

mounting the battery cover.

– Now total mileage, wheel circumference and time have to be entered.

To mount the speedometer, proceed by following the reverse order of the
above procedure.

1

3

2

4

A

A

front rear

Off road 1,0 bar 1,0 bar

Road driver only 1,5 bar 2,0 bar

TIRES-AIR PRESSURE

ENGLISH

23

TOTAL MILEAGE „DST“

TIME „CLK“

after changing battery

1 sec

5 sec

1 sec

1. use the right button to select

the position to be changed

1. make sure the time is indicated
and push the button on the
back approx. 5 seconds (time
starts blinking)

2. push the left button until the right
figure is showed in the display

3. by pushing the right button you
jump to the next figure

4. repeat nos. 2 + 3 until correct time is indicated

5. push the button on

the back approx. 1
second to terminate
the setting procedure

2. push the left button until the right
figure is showed in the display

3. by pushing the right button
you jump to the next figure

4. repeat nos. 2 + 3 until the previously
noted total mileage is indicated

5. push the button on the back
with a sharp object approx. 1
second to terminate the set­ting procedure (the value is
thus stored)

ENGLISH

Check/set distance of the magnetic sensor

The distance between magnet 2 and sensor 1 must be 2-4 mm, otherwise
malfunctions on the speedometer might occur.

This distance can be corrected by screwing in or off the sensor

1.

24

WHEEL CIRCUMFERENCE „WS“

1. make sure that the indication "TRP" is

active and push the button on the
back approx. 5 seconds ("WS"
appears)

2. use the right button to select the
position to be changed

3. push the left button until the right
figure is showed in the display

4. repeat nos. 2 + 3 until correct
wheel circumference is indicated

5. push the button on the back
for approx. 1 second to termi­nate the setting procedure

5 sec

1 sec

mm x 3,14

km/h:

WS = mm x 3,14

mp/h:

WS = (mm x 3,14) : 1,61

1

1

2

Wheel circumference with standard tires = 2205 mm

ENGLISH

25

Replacing headlight lamp (H4)

Loosen both rubber bands 3 and tilt headlight mask to the front. Remove
bulb plug

4 and remove rubber cap 5. Turn the supporting ring counter-

clockwise and remove it from the reflector together with the bulb.

Insert a new bulb such that the noses

6 fit into the recess 7. Do not touch

the glass body of the bulb, to keep if free from grease. Mount supporting
ring, rubber cap and plug. Position headlight mask with the bottom holders,
and fasten it with the rubber bands.

Cooling system

The water pump in the engine circulates the cooling liquid. However, the
cooling liquid can only circulate properly if the cooling circuit contains no air
bubbles.
Bleeding of the cooling system is therefore required
a) after adding more than 0.25 l cooling liquid and
b) after refilling the entire cooling system.
(see Bleeding the cooling system).

Some models are equipped with a thermostat

8 so that the engine reaches

its operating temperature more quickly. When the engine is cold, the liquid
coolant circulates in the cylinder and the cylinder head. As soon as the coo­ling liquid has reached a temperature of approximately 55°C, the ther­mostat opens and the cooling liquid is also pumped through the two alumi­num radiators.

The cooling liquid is cooled by the air stream. This means that the cooling
effect decreases with the travelling speed. Dirty radiators additionally
reduce the cooling effect.



WARNING



–

I

F POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD

. I

F YOU

HAVE TO OPEN THE RADIATOR CAP

1

WHEN THE ENGINE IS HOT, USE A RAG TO COVER

THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE

. C

AUTION- SCALDING HAZARD

!

–DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE ESCAPING

HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS

.

–IN CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING

COLD WATER RIGHT AWAY

!

–C

OOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN!

–IN CASE COOLANT IS INGESTED, GO SEE A DOCTOR IMMEDIATELY!
–I

F COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDIATELY

AND GO SEE A DOCTOR

!

A mixture of 40% anti freeze liquid and 60% water is used as coolant.
However, the anti-freeze protection must be at least -25° C (-13° F). This
mixture offers anti-freeze protection but also good corrosion protection and
should therefore not be replaced by pure water.

!

CAUTION

!

F

OR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (I.E. SHELL

ADVANCE COOLANT). USING LOWER-GRADE ANTIFREEZE AGENTS, CAN CAUSE CORRO-

SION AND COOLANT FOAMING.

Pressure induced by heating of the coolant in the system is controlled by a
valve in the radiator cap

1; a water temperature of up to 120° C (248° F) is

admissible therefore, having to expect any trouble.

3

4

5

6

7

1

8

ENGLISH

26

Radiator cover for the cold season

To ensure that the engine reaches its operative temperature also at low
temperatures, the radiator cover

5 must be mounted.

For this purpose, detach the left radiator protection

6 and mount the cover

in front of the left radiator as illustrated.
Remount the radiator protection.

Note: Not all models are equipped with the cover.

Checking the coolant level

The coolant should be 10 mm (0.4 in) above the radiator fins when the
engine is cold (cf. diagram). In the event of the coolant being drained,
always fill and bleed the system.



WARNING



I

F POSSIBLE

, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU

HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT

, USE A RAG TO COVER THE

CAP AND OPEN SLOWLY TO RELEASE PRESSURE

.

!

CAUTION

!

T

HE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQUID OR AFTER

ADDING MORE THAN

0.25 L (0.06 US GALLONS) COOLING LIQUID.

Refilling/Bleeding the cooling system

The cooling system must be bled as described below after draining of the
cooling liquid or after adding more than 0.25 l (0.06 US gallons) cooling
liquid.

– Make sure that the drain screw

2 is fastened.

– Pour approx. 0.5 litres (0.13 US gallons) coolant into the system.

– Remove screw

3 at the cylinder head. Reinstall it as soon as the cooling

liquid emerges free of air bubbles (only for 125/200 engines).

– Remove the screw

4 on the right radiator.

– Now add cooling liquid until it emerges free of bubbles at the right

radiator. Then immediately mount the screw so that no more air can
enter the right radiator.

– Top up the left radiator until the coolant can be seen approx. 10 mm

(0.4 in) above the radiator fins.

– Check the coolant level again after a short ride.

when engine is cold

10 mm

2

2

3

4

5

6

6

5

ENGLISH

27

Cleaning the air filter *

The air filter must be cleaned prior to every race or whenever the motorcycle
has been exposed to great quantities of dust.
For this purpose, rotate the two quick-release fasteners

1 counter-clockwise

and pull them outward up to the stop, pull the filter box cover forward and
remove it. Unhook the filter holding brackets

2 at the bottom, swing them

sideways and take the air filter

3 together with the filter support 4 out of

the filter box.

!

CAUTION

!

D

O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE

FOAM

. KTM RECOMMENDS THE PRODUCTS MADE BY PUTOLINE FOR AIR FILTER

MAINTENANCE

.„ACTION CLEANER” FOR CLEANING PURPOSES AND „ACTION FLUID” TO

OIL THE AIR FILTER

.

Thoroughly wash the air filter in special cleaning fluid and allow it to dry
well. Only press out the filter, do not wring it out under any circumstances.
Oil the dry air filter with a high-grade filter oil. Also clean the air filter box.
Check carburetor collar for damage and that it is filled correctly.
Mount the air filter on the filter support. Apply grease to the face

A of the

filter to improve its sealing properties. Mount the filter together with the fil­ter support in the filter box, making sure to properly center them, and fix
them with the filter holding bracket.

Exhaust system *

Silencers whose caps 5 is detachable are filled with glass-fiber yarn. Let this
package be ckecked at least after 4000 km or at once a year. Glass-fiber
yarn that is too loose may cause a drop in performance and curtail the silen­cer’s silencing effect.
To replace the glass-fiber yarn packing

6, remove the silencer cap and pull

off the outer tube

7. Use adhesive tape to attach the new glass-fiber yarn

packing to the inner tube, and slide on outer tube. Mount silencer cap.
Glass-fiber yarn packings are available at your authorized KTM dealer.



WARNING



T

HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING

. DO

NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN

, TO

AVOID BURNS

.

Cleaning the spark arrestor (EXC USA) *

With these models, the spark arrestor is part of the exhaust silencer. Clean it
every 4000 km (2500 miles) to guarantee proper functioning. Also clean the
spark arrestor when replacing the glass fiber yarn filling.
After assembling the silencer, remove the plug

8 and start the motorcycle.

Close the opening of the muffler with a rag and press the accelerator
approximately 20 times. The carbon deposits will be blown out through the
opening. Then turn off the engine and let the exhaust system cool down.
Grease the plug with molycote grease and mount the plug.

Draining of float chamber of the carburetor

Following every wet-cleaning procedure, the float chamber of the carbure­tor should be drained in order to remove any water that may have penetra­ted into it. Water in the float chamber leads to engine malfunction.
Make sure you do this while the engine is cold. Close the fuel tap, and place
a cloth under the carburetor, which is capable of absorbing the leaking fuel.
Unscrew the plug

9, and clean it with compressed air. Then, mount plug

together with gasket, open fuel tap, and check float chamber for leaks.



WARNING



F

UEL IS EASILY FLAMMABLE AND TOXIC. WHEN HANDLING FUEL, BE SURE TO EXERCISE

THE UTMOST CAUTION

. NEVER PERFORM ANY WORK ON THE FUEL SYSTEM IN THE PRO-

XIMITY OF OPEN FLAMES OR BURNING CIGARETTES. ALWAYS ALLOW THE ENGINE TO
COOL OFF FIRST

. IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED.

M

ATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE. IN CASE YOU INGESTED

FUEL OR FUEL SPLASHED INTO YOUR EYES

, CONSULT A DOCTOR IMMEDIATELY.

D

ISPOSE THE FUEL PROPERLY!

5

5

7

7

SX

EXC

6

6

6

1

3

2

4

A

8

9

ENGLISH

28

Carburetor adjustment *

Basic information on the original carburetor setting

The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient tempe­rature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ).
Mixing ratio (2-stroke motor oil : super fuel)

1:40 – 1:60 (depands on oil quality)

Basic information on a change of the carburetor setting

Always start with the original carburetor setting (the provided factory setting is meant for break-in operation; after the break-in
period, the carburetor needs to be adjusted according to the carburetor datasheet - see appendix). Essential requirements are a clean
air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and
the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance.

RULE OF THUMB: high altitude or high temperatures

➞ choose leaner carburetor adjustment

low altitude or low temperatures

➞ choose richer carburetor adjustment



WARNING



–ONLY USE PREMIUM-GRADE GASOLINE ROZ 95

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

FAILURE

, AND USE OF SAME WILL VOID YOUR WARRANTY.

–O

NLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS

(i. e. Shell Advance Racing X).

–N

OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON

. USING TOO MUCH OIL, THE ENGINE CAN START SMOKING AND FOUL THE

SPARK PLUG AND THE EXHAUST CONTROL SYSTEM

.

–IN THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY. ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID

OVERHEATING AND PISTON SEIZURE

.

NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system.

Basic information on carburetor wear

As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carbu­retor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles).

Definitions

Mixture too rich:

Too much fuel in proportion to air.

Mixture too lean:

Not enough fuel in proportion to air.

Idling range A

Operation with closed throttle valve. This range is influenced by the posi­tion of the air control screw

1 and the air control screw 2. Only make

adjustments when the engine is hot.
To this end, slightly increase the idling speed of the engine by means of the
air control screw. Turning it clockwise produces a higher idling speed and
turning the screw counterclockwise produces a lower idling speed. Create a
round and stable engine speed using the air control screw (basic position of
the air control screw = open by 1.5 turns). Then adjust to the normal idling
speed by means of the air control screw.

Opening up B

Engine behavior when the throttle opens. The idle jet and the shape of the
throttle valve influences this range. If, despite good idling-speed and part­throttle setting, the engine sputters and smokes when the throttle is fully
opened and develops its full power not smoothly but suddenly at high
engine speeds, the mixture to the carburetor will be too rich, the fuel level
too high or the float needle is leaking.

main jet
jet needle

jet needle

air control screw
idle adjusting screw

idle jet
throttle valve

1

2

D

C

B

A

ENGLISH

29

Part-throttle range C

Operation with partly open throttle valve. This range is only influenced by
the jet needle (shape and position). The optimum part-throttle setting is
controlled by the idling setting in the lower range and by the main jet in the
upper range. If the engine runs on a four-stroke cycle or with reduced
power when it is accelerated with the throttle partly open, the jet needle
must be lowered by one notch. If then the engine pings, especially when
accelerating under full power at maximum engine revs, the jet needle
should be raised.
If these faults should occur at the lower end of the part throttle range at a
four-stroke running, make the idling range leaner; if the engine pings,
adjust the idling range richer.

Full throttle range D

Operation with the throttle fully open (flat out). This range is influenced by
the main jet and the jet needle. If the porcelain of the new spark plug is
found to have a very bright or white coating or if the engine rings, after a
short distance of riding flat out, a larger main jet is required. If the porce­lain is dark brown or black with soot the main jet must be replaced by a
smaller one.

Checking the float level *

Arrange the carburetor diagonally at about 60° so that the spring in the
float needle valve is not pressed together. In this position, the edge of
the

float should be parallel with the float chamber sealing surface (see

illustration).

Checking the oil level of the hydraulic clutch

To check the oil level in the master cylinder of the clutch remove the
cover. For this purpose, remove screws

1 and cover 2 together with

the rubber boot

3. The oil level in the horizontal-standing master cylin-

der should be 4 mm below the upper edge. If necessary add SAE 10
hydraulic oil

!

CAUTION

!

O

NLY USE SAE 10 MINERAL HYDRAULIC OIL

(i.e. Shell Naturelle HF-E15) TO REFILL

THE MASTER CYLINDER

. NEVER USE BRAKE FLUID!

Bleeding of the hydraulic clutch

For bleeding, the cover of the master cylinder of the clutch needs to be
removed. For this purpose, remove screws

1 and take off cover 2 together

with rubber bellows

3. At the slave cylinder of the clutch, remove the blee-

der nipple

4. It its place, mount the bleeder syringe 5 which is filled with

SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore

6 of the

master cylinder in a bubble-free state. Make sure that the oil does not over­flow. The bleeder syringe can be purchased at your KTM dealer.

!

CAUTION

!

H

AVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL

LEVEL IN THE MASTER CYLINDER IS CORRECT

. FOR FILLING OF THE MASTER CYLINDER, USE

SAE 10 MINERAL HYDRAULIC OIL (e.g. Shell Naturelle HF-E15) ONLY; NEVER USE

BRACKE FLUID

!

NOZD

NOZE

NOZF

NOZG

NOZH

JET NEEDLE

RANGE OF ACTION

TYPE RICHER LEANER

60°

1

2

3

4

5

6

5

2

Check transmission oil level (125/200)

In order to check the transmission oil level the control screw 1 on the clutch
cover is to be removed. Oil should just barely escape from the inspection
opening when the motorcycle is in an upright position. If necessary, remove
the plug

2 and top up with engine oil 20W-40 (i. e. Shell Advance VSX 4).

!

CAUTION

!

T

RANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR

, IF YOU USE

TOO LITTLE OR LOW GRADE OIL

. USE ONLY HIGH-GRADE OIL (i. e. Shell Advance VSX 4).

Changing the transmission oil (125/200) *

To change the gear oil warm up the engine and park the motorcycle on a
horizontal surface. Remove oil drain plugs

3 and 4 and drain the used oil

into an appropriate container. Clean the magnets of the oil drain plugs and
mount them together with the appropriate gaskets. Fill in 0.7 l engine oil
20W-40 (i. e. Shell Advance VSX 4), mount the plug

2 and check the

engine for leaks.

!

CAUTION

!

T

RANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR, IF YOU USE

TOO LITTLE OR LOW GRADE OIL

. USE ONLY HIGH-GRADE OIL (i. e. Shell Advance VSX 4).

Check transmission oil level (250/300/380)

In order to check the transmission oil level the control screw 5 on the clutch
cover is to be removed. Oil should just barely escape from the inspection
opening when the motorcycle is in an upright position. If necessary, remove
the plug

6 and top up with engine oil 20W-40 (i. e. Shell Advance VSX 4).

!

CAUTION

!

T

RANSMISSION AND CLUTCH WILL BE SUBJECT TO EXCESSIVE WEAR AND TEAR, IF YOU USE

TOO LITTLE OR LOW GRADE OIL

. USE ONLY HIGH-GRADE OIL (i. e. Shell Advance VSX 4).

Changing the transmission oil (250/300/380) *

To change the transmission oil run the engine warm and set up the motorcy­cle on a horizontal surface. Remove the oil drain screw

7 and drain used oil

into a container. Clean the magnet of the oil drain screw and reinstall oil
drain screw with seal. Pour in 0.8 litres (0.21 US gallons) engine oil 20W-40
(i. e. Shell Advance VSX 4), replace plug

6 and check engine for leaks.

!

CAUTION

!

T

RANSMISSION AND CLUTCH WILL BE SUBJECT TO EXCESSIVE WEAR AND TEAR, IF YOU USE

TOO LITTLE OR LOW GRADE OIL

. USE ONLY HIGH-GRADE OIL (i. e. Shell Advance VSX 4).

1

3

4

6

7

ENGLISH

30

ENGLISH

31

Should you desire to make a pause over a longer space of time, please observe the following instructions:

– Clean motorcycle thoroughly (see chapter: CLEANING)
– Change engine oil, oil filter and micro filter (old engine oil contains aggresive contaminants).
– Check antifreezer and amount of cooling liquid.
– Let the engine warm up again, close fuel cock and wait until the engine dies off by itself. By this means, carburetor jets are preven-

ted from becoming resinous by the old fuel.

– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in

order to distribute the oil onto the cylinder walls and mount the spark plug.
– Let fuel flow out of tank into an appropriate container.
– Correct tire pressure.
– Lubricate bearing points of the control levers, foot rests, etc. as well as the chain.
– Service the rear suspension linkage
– The storage place should be dry and not be subject to too big temperature fluctuations.
– Cover the motorcycle with an air permeated tarp or blanket. Do not use non air permeable materials as a possible humidity might

not be able to escape and thereby cause corrosion.

!

CAUTION

!

I

T WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH

AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST

.

RE-INITIATION AFTER TIME OF STORAGE

– Fill up tank with fresh fuel.
– Check motorcycle as before each start (see driving instructions)
– Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any ser­vice jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics'
shops). This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.

STORAGE

Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.
The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.

The hard dirt can be removed before washing with the help of a soft water jet.

!

CAUTION

!

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE

ELECTRICAL COMPONENTS

, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE

DESTRUCTION OF THESE PARTS

.

– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should be cleaned additionally with

the help of a paint brush.

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive

until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water
can evaporate from inaccessable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of

the motorcycle is allowed to evaporate.
– After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Treat the chain with a chain spray too.
– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, the short circuit button, the

light switch and the socket connectors with contact spray.

CLEANING

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre­cautions against the aggressive road salt.
– clean motorcycle thoroughly and let it dry after each riding
– treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion

agent.



WARNING



K

EEP ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER

.

!

CAUTION

!

A

FTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL!

CONSERVATION FOR WINTER OPERATION

ENGLISH

32

Collar nut front wheel spindle M 16x1,5 40 Nm (30 ft.lb)

Brake caliper front M 8 25 Nm (19 ft.lb)

+ Loctite 242

Clamping screws upper fork bridge

M 8 20 Nm (15 ft.lb)

Clamping screws lower fork bridge

M 8 15 Nm (11 ft.lb)

Clamping screws fork stubs M8 10 Nm (7 ft.lb)

Collar nut rear wheel spindle M 20x1.5 80 Nm (59 ft.lb)

Hexagon nut swing arm bolt M 14x1.5 100 Nm (74 ft.lb)

Collar screw handlebar clamp M 8 20 Nm (15 ft.lb)

Allen head screw handlebar support

M 10 40 Nm (30 ft.lb)

Shock absorber top M 12 60 Nm (44 ft.lb)

Shock absorber bottom M 12 60 Nm (44 ft.lb)

Screw adjusting ring spring preload

M 6 8 Nm (6 ft.lb)

Other screws on chassis M 6 10 Nm (7 ft.lb)

M 8 25 Nm (19 ft.lb)

M 10 45 Nm (33 ft.lb)

TIGHTENING TORQUES - CHASSIS

* Dead-weight without fuel

WP 1218U717 WP 1218U719

Compression adjuster 4 5

Rebound adjuster 20 20

Spring PDS2–250 PDS1-250

Spring preload 5 mm (0.2 in) 5 mm (0.2 in)

STANDARD ADJUSTMENT - SHOCK ABSORBER

WP 0518U783 WP 0518U784

Compression adjuster 16 14

Rebound adjuster 12 12

Spring 3,8 N/mm 3,8 N/mm

Spring preload 6 mm (0.24in) 6,5 mm (0.26in)

Air chamber length 140 mm (5.5in) 150 mm (5.9in)

Capacity per fork leg approx. 840 ccm approx. 830 ccm

Fork oil SAE 5 SAE 5

STANDARD ADJUSTMENT - FORK

125 SX 125 EXC 200 MXC 200 EXC

Frame Central chrome-moly-steel frame

Fork White Power – Up Side Down 43 MA

Wheel travel front/rear 295/320 mm (11,3/12,6 in)

Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm

Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake discs Wear limit max. 0,4 mm (0,016 in)
Front tires 80/100 - 21“51M 90/90 - 21“ 54R – 90/90 - 21“ 54R

Front tires USA 80/100 - 21“51M 80/100 - 21“51M 80/100 - 21“51M 80/100 - 21“51M
Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi)
Air pressure road driver only

– 1,5 bar (21psi) – 1,5 bar (21psi)

Rear tires 100/90 - 19“ 57M 120/90 - 18“ 65R – 120/90 - 18“ 65R
Rear tires USA 100/90 - 19“ 57M 100/100 - 18“ 59M 100/100 - 18“ 59M 100/100 - 18“ 59M

Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi)
Air pressure road driver only

– 2,0 bar

(28psi)

– 2,0 bar

(28psi)

Fuel tank capacity

7,5 liter (2 US Gallons) 9,5 liter (2,5 US Gallons) 12 liter (3,2 US Gallons)

9,5/12 liter (2,5/3,2 US Gallons)

Final drive ratio 13:50t 14:38t – 14:45t / 14:48t
Final drive ratio USA 13:50t 13:50t 14:48t 14:48t

Chain

5/8 x 1/4 "

Available final sprockets

38t, 40t, 42t, 45t, 48t, 50t, 52t

Steering head angle 63°

Wheel base 1461 ± 10 mm (57,3 ± 0,4 in)

S

eat height, unloaded

925 mm (36,5 in)

Ground clearance, unloaded

385 mm (15,2 in)

Dead-weight

* 92 kg (203 lbs) 100 kg (221 lbs) – 101 kg (223 lbs)

Dead-weight USA * 92 kg (203 lbs) 96 kg (212 lbs) 96 kg (212 lbs) 97 kg (214 lbs)

TECHNICAL SPECIFICATIONS CHASSIS 125 SX / EXC, 200 MXC / EXC 2000

ENGLISH

33

Engine 125 SX 125 EXC 200 MXC 200 EXC

Design Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control

Piston displacement 124.8 ccm 193 ccm

Bore / stroke 54.25 / 54 mm (2.136 / 2.126 in) 64 / 60 mm (2.52 / 2.362 in)

Fuel unleaded SUPER fuel, research octane no 95, mixed with high grade two stroke oil

Oil / gasolin ratio 1:40-1:60 when using high grade two stroke oil (Shell Advance Racing X). When in doupt, please contact your importer

Crankshaft bearing 1 deep-groove ball bearing / 1 cylinder roller bearing

Connecting rod bearing needle bearing

Piston pin bearing needle bearing

Piston forged piston cast piston

Piston ring one plain compression ring two plain compression rings

Dimension "X"

0.60 mm (0.024 in) 0.55 mm (0.22 in)

Ignition timing 1.4 mm (0.055 in) (16.5°) BTDC 1.6 mm (0.063 in) (17°) BTDC

Spark plug NGK BR9 EVX NGK BR 8 EG

Electrode gap 0.60 mm (0,024 in)

Dimension "Z"

42 mm (1.65 in) 46 mm (1.81 in)

Primary drive straight cut spur gears, primary ratio 23:73

Clutch multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)

Transmission 6 speed, claw actuated

Gear ratio

1st gear 13 : 32 12 : 33 13 : 32 12 : 33

2nd gear 15 : 30 15 : 31 15 : 30 15 : 31

3rd gear 17 : 28 17 : 28 17 : 28 17 : 28

4th gear 19 : 26 19 : 26 19 : 26 19 : 26

5th gear 21 : 25 21 : 25 21 : 25 17 : 19

6th gear 22 : 24 20 : 20 22 : 23 22 : 20

Gear lubrication 0.7 l engine oil 20W-40 (Shell Advance VSX4)

Available chain sprockets

13t / 14t / 15t for chain

5

/8 x

1

/4"

Coolant 1.2 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)

Ignition system KOKUSAN 2K-1 KOKUSAN 2K-3 – KOKUSAN 2K-3

Gener

ator output no generator 12V / 110 W – 12V 110 W

Ignition system USA KOKUSAN 2K-1 KOKUSAN 2K-2

Gener

ator output no generator 12V 40 W

Carburetor flat-slide carburetor, carburetor setting see table

Air-filter wet foam type air filter insert

(upper edge piston-

upper edge cylinder

height of the

control flap

TECHNICAL DATA - ENGINE 125 / 200 2000

ENGLISH

34

TIGHTENING TORQUES - ENGINE

Flange bolts - cylinder-head M 7 18 Nm (13 ft.lb)

Nuts-cylinder base M 8 30 Nm (22 ft.lb)

Flywheel collar nut M 12 x1 60 Nm (44 ft.lb)

Nut for primary sprocket (LH thread) M 16x1.5 180 Nm (133 ft.lb)

Nut for inner clutch hub M 18x1.5 120 Nm (88 ft.lb)

Crankcase and clutch cover bolts M 6 8 Nm (6 ft.lb)

Spark plug M 14x1.25 20 Nm (14 ft.lb)

Other screws M 6 10 Nm (7 ft.lb)

M 8 25 Nm (19 ft.lb)

M 10 45 Nm (33 ft.lb)

Piston fitting clearance 125 = 0.06 mm 200 = 0.085 mm

Piston ring end cap max. 0.40 mm

Connecting rod bearing - radial clearance

0.025–0.035 mm

Transmission shafts end float 0.20– 0.40 mm

Clutch springs - length new = 39 mm, minimum length = 38 mm

TOLERANCES AND FITTING CLEARANCES

GASKET THICKNESSES

Crankcase 0,5 mm

Clutch cover 0,5 mm

Clutch driving cylinder 0.30 / 0.50 / 0.75 mm

Cylinder bottom gasket as required

Available bottom gasket

0.07 / 0.15 / 0.20 / 0.25 / 0.40 / 0.5 0 / 0.75 mm

Cylinder-head gasket 1.10 mm + O-ring

125 SX

125/200

MXC, EXC

Carburetor

Carburetor setting number

Main jet

Idling jet

Starting jet

Jetneedle

Needle position from top

Throttle valve

Air adjustment screw top

Performance restrictor

Keihin PWK 39

100499

190 (188/192)

48 (45/50)

85

R 1467 D (R 1468 D)

III

55

1,5

–

Keihin PWK 38 AG

120499

180 (185)

45 (48)

85

NOZ H (NOZ I)

III

6

1,5

–

200 EXC

throttled

125 EXC

throttled

Keihin PWK 39

030799

142

35

85

R 1472 N

V

6

1,5

–

Keihin PWK 38 AG

040799

180

35

85

R 1475 J

IV

6

1,5

slide stop 36mm

BASIC CARBURETOR SETTING

ENGLISH

35

* Dead-weight without fuel

WP 1218U718 WP 1218U720

Compression adjuster 4 5

Rebound adjuster 18 20

Spring PDS3–250 PDS2-250

Spring preload 5 mm (0.2 in) 5 mm (0.2 in)

STANDARD ADJUSTMENT - SHOCK ABSORBER

WP 0518U785 WP 0518U787

Compression adjuster 14 14

Rebound adjuster 12 12

Spring 4,0 N/mm 4,0 N/mm

Spring preload 6 mm (0.24in) 6,5 mm (0.26in)

Air chamber length 140 mm (5.5in) 150 mm (5.9in)

Capacity per fork leg approx. 840 ccm approx. 830 ccm

Fork oil SAE 5 SAE 5

STANDARD ADJUSTMENT-FORK

250/380 SX 250/300/380 MXC 250/300/380 EXC

Frame Central chrome-moly-steel frame

Fork White Power – Up Side Down 43 MA

Wheel travel front/rear 295/320 mm (11,3/12,6 in)

Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm

Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake discs Wear limit max. 0,4 mm (0,016 in)
Front tires 80/100 - 21“51M – 90/90 - 21“ 54R

Front tires USA 80/100 - 21“51M 80/100 - 21“51M 80/100 - 21“51M
Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi)
Air pressure road driver only

– 1,5 bar (21psi) 1,5 bar (21psi)

Rear tires 100/90 - 19“ 62M – 140/80 - 18“ 70R
Rear tires USA 100/90 - 19“ 62M 100/100 - 18“ 64M 100/100 - 18“ 64M

Air pressure offroad 1,0 bar (14psi) 1,0 bar (14psi) 1,0 bar (14psi)
Air pressure road driver only

– 2,0 bar

(28psi)

2,0 bar

(28psi)

Fuel tank capacity

7,5 liter (2 US Gallons) 12 liter (3,2 US Gallons) 9,5/12 liter (2,5/3,2 US Gallons)

Final drive ratio 14:50t – 15:48t / 14:50t
Final drive ratio USA 14:50t 14:52t 14:52t

Chain

5/8 x 1/4 "

Available final sprockets

38t, 40t, 42t, 45t, 48t, 50t, 52t

Steering head angle 63,5°

Wheel base 1481 ± 10 mm (58,3 ± 0,4 in)

S

eat height, unloaded

925 mm (36,5 in)

Ground clearance, unloaded

385 mm (15,2 in)

Dead-weight

* 101 kg (223 lbs) – 109 kg (240,6 lbs)

Dead-weight USA * 101 kg (223 lbs) 102,5 kg (226,3 lbs) 103,7 kg (229 lbs)

TECHNICAL SPECIFICATIONS CHASSIS 250/300/380 SX, MXC, EXC 2000

Collar nut front wheel spindle M 16x1,5 40 Nm (30 ft.lb)

Brake caliper front M 8 25 Nm (19 ft.lb)

+ Loctite 242

Clamping screws upper fork bridge

M 8 20 Nm (15 ft.lb)

Clamping screws lower fork bridge

M 8 15 Nm (11 ft.lb)

Clamping screws fork stubs M8 10 Nm (7 ft.lb)

Collar nut rear wheel spindle M 20x1.5 80 Nm (59 ft.lb)

Hexagon nut swing arm bolt M 14x1.5 100 Nm (74 ft.lb)

Collar screw handlebar clamp M 8 20 Nm (15 ft.lb)

Allen head screw handlebar support

M 10 40 Nm (30 ft.lb)

Shock absorber top M 12 60 Nm (44 ft.lb)

Shock absorber bottom M 12 60 Nm (44 ft.lb)

Screw adjusting ring spring preload

M 6 8 Nm (6 ft.lb)

Other screws on chassis M 6 10 Nm (7 ft.lb)

M 8 25 Nm (19 ft.lb)

M 10 45 Nm (33 ft.lb)

TIGHENING TORQUES - CHASSIS

ENGLISH

36

Engine 250 SX 250 EXC, MXC 300 EXC, MXC 380 SX 380 EXC, MXC

Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber

Piston displacement 249 ccm 297 ccm 368 ccm

Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in) 72 / 73 mm (2.84 / 2.88 in) 78 / 77 mm (3 / 2.98 in)

Fuel unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)

Oil / gasolin ratio 1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side

Crankshaft bearing 1 deep-groove ball bearing / 1 cylinder roller bearing

Connecting rod bearing

needle bearing

Piston pin bearing needle bearing

Piston cast piston forged piston cast piston

Piston ring one plain compression rings two plain compression rings

Dimension "X"

0 +0.1 mm (0 + 0.004 in)

Ignition timing 2.0 mm (0.07 in) (17 °) BTDC 2.2 mm (0.09 in) (17 °) BTDC

Spark plug NGK BR 8 ECM

Electrode gap 0.6 mm (0.024 in)

Dimension "Z"

50,5 mm (1.99 in) 46 mm (1.7 in) 50.5 mm (1.99 in)

TVC start open 5400/min 5300/min 5200/min

TVC fully open 7550/min 7750/min 7200/min

Primary drive straight cut spur gears, primary ratio 25:72 straight cut spur gears, primary ratio 26:72

Clutch multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)

Transmission 5 speed, claw actuated

Gear ratio EXC MXC EXC MXC EXC MXC

1

st

Gear 15:29 15:29 15:29 15:29 15:29 15:29 15:29 15:29

2

nd

Gear 17:27 18:26 17:27 18:26 18:26 18:26 18:26 18:26

3

rd

Gear 19:25 19:22 19:25 19:22 19:24 19:24 19:22 19:24

4

th

Gear 21:23 21:20 21:23 21:20 21:23 21:23 21:20 21:23

5

th

Gear 23:21 23:18 23:21 23:18 23:21 23:21 23:18 23:21

Gear lubrication 0.8 l engine oil 20W-40 (Shell Advance VSX4)

Available chain sprockets

13t / 14t / 15t for chain

5

/8 x

1

/4"

Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)

Ignition system KOKUSAN 2K-4 KOKUSAN 2K-2 KOKUSAN 2K-1 KOKUSAN 2K-3

Generator output no generator 12V 40W no generator 12V 110W

Carburetor flat-slide carburetor, carburetor setting see table 3

Air-filter wet foam type air filter insert

(upper edge piston -

upper edge cylinder)

(height of the

control flap)

TECHNICAL DATA - ENGINE 250/300/380 SX / MXC / EXC 2000 (only USA)

ENGLISH

37

TIGHTENING TORQUES - ENGINE

Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb)

Nuts-cylinder base M 10 35 Nm (25 ft.lb)

Flywheel collar nut M 12x1 60 Nm (44 ft.lb)

Nut for primary sprocket (LH thread) M 18x1.5 Loctite 242 150 Nm (110 ft.lb)

Nut for inner clutch hub M 18x1.5 Loctite 242 100 Nm (74 ft.lb)

Crankcase and cover bolts M 6 8 Nm (6 ft.lb)

Swingarm pivot M 14 100 Nm (74 ft.lb)

Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb)

Other screws M 6 10 Nm (7 ft.lb)

M 8 25 Nm (19 ft.lb)

M 10 45 Nm (33 ft.lb)

Piston fitting clearance 0.05 mm (250) 0.06 mm (300) 0.08 mm (380)

Piston ring end gap 0.3 –0.4 mm

Connecting rod bearing - radial clearance 0.021–0.032 mm

Transmission shafts end float 0.1 –0.2 mm

Clutch springs - length Ø 2.5 new = 43 mm, minimum length = 42 mm

TOLERANCES AND FITTING CLEARANCES

GASKET THICKNESSES

Crankcase 0.5 mm

Clutch cover 0.5 mm

Cylinder bottom gasket as required

Available cylinder bottom gaskets 0.2/0.4/ 0.5/0.75 mm

Cylinder-head gasket O-rings

250 SX 250 MXC, EXC

TABLE 3

BASIC CARBURETOR SETTING

Keihin PWK 38 AG PJ

110499

172 (170,175)

48 (45,50)

85

NOZ E (NOZ F)

III

7

1,5

–

55

Keihin PWK 38 AG

130499

180 (178,182)

45 (48)

85

NOZ G (NOZ H)

III

6

1,5

–

–

300 MXC, EXC

Keihin PWK 38 AG

140499

175 (172,178)

45 (48)

85

NOZ H (NOZ I)

III

6

1,5

–

–

380 SX, MXC, EXC

Keihin PWK 38 AG

150499

170 (168,172)

45 (48)

85

NOZ H (NOZ I)

III

6

1,5

–

–

Carburetor

Carburetor setting number

Main jet

Idling jet

Starting jet

Jet needle

Needle position from top

Throttle valve

Air adjustment screw open

Performance restrictor

Power jet jet

ENGLISH

38

Engine 250 SX 250 EXC 300 EXC 380 SX 380 EXC

Design Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber

Piston displacement 249 ccm 297 ccm 368 ccm

Bore / stroke 66.4 / 72 mm (2.62 / 2.84 in) 72 / 73 mm (2.84 / 2.88 in) 78 / 77 mm (3 / 2.98 in)

Fuel unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)

Oil / gasoline ratio 1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side

Crankshaft bearing 1 deep-groove ball bearing / 1 cylinder roller bearing

Connecting rod bearing needle bearing

Piston pin bearing needle bearing

Piston cast piston forged piston cast piston

Piston ring one plain compression ring two plain compression rings

Dimension "X"

0 + 0.1 mm (0 + 0.004 in)

Ignition timing 2.0 mm (0.07 in) (17 °) BTDC 2.2 mm (0.08 in) (17 °) BTDC

Spark plug NGK BR 8 ECM

Electrode gap 0.6 mm (0.024 in)

Dimension "Z"

50,5 mm (1.99 in) 46 mm (1.7 in) 50.5 mm (1.99 in)

TVC start open 5400/min 5300/min 5200/min

TVC fully open 7550/min 7750/min 7200/min

Primary drive straight cut spur gears, primary ratio 25:72 straight cut spur gears, primary ratio 26:72

Clutch multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)

Transmission 5 speed, claw actuated

Gear ratio

1

st

Gear 15:29 15:29 15:29 15:29

2

nd

Gear 17:27 18:26 18:26 18:26

3

rd

Gear 19.25 19:22 19:24 19:22

4

th

Gear 21:23 21:20 21:23 21:20

5

th

Gear 23:21 23:18 23:21 23:18

Gear lubrication 0,8 l engine oil 20W-40 (Shell Advance VSX4)

ailable chain sprockets 13t / 14t / 15t for chain

5

/8 x

1

/4"

Coolant 1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)

Ignition system KOKUSAN 2K-4 KOKUSAN 2K-3 KOKUSAN 2K-1 KOKUSAN 2K-3

Generator output no generator 12V 110W no generator 12V 110W

Carburetor flat-slide carburetor, carburetor setting see table 3

Air-filter wet foam type air filter insert

(upper edge piston -

upper edge cylinder)

(height of the

control flap)

TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2000 (all models out of USA)

ENGLISH

39

TIGHTENING TORQUES

Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb)

Nuts-cylinder base M 10 35 Nm (25 ft.lb)

Flywheel collar nut M 12x1 60 Nm (44 ft.lb)

Nut for primary sprocket (LH thread) M 18x1.5 Loctite 242 150 Nm (110 ft.lb)

Nut for inner clutch hub M 18x1.5 Loctite 242 100 Nm (74 ft.lb)

Crankcase and cover bolts M 6 8 Nm (6 ft.lb)

Swingarm pivot M 14 100 Nm (74 ft.lb)

Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb)

Other screws M 6 10 Nm (7 ft.lb)

M 8 25 Nm (19 ft.lb)

M 10 45 Nm (33 ft.lb)

Piston fitting clearance 0.05 mm (250) 0.06 mm (300) 0.08 mm (380)

Piston ring end gap 0.3 –0.4 mm

Connecting rod bearing - radial clearance 0.021–0.032 mm

Transmission shafts end float 0.1 –0.2 mm

Clutch springs - length Ø 2.5 new = 43 mm, minimum length = 42 mm

TOLERANCES AND FITTING CLEARANCES

GASKET THICKNESSES

Crankcase 0.5 mm

Clutch cover 0.5 mm

Cylinder bottom gasket as required

Available cylinder bottom gaskets 0.2/0.4/ 0.5/0.75 mm

Cylinder-head gasket O-rings

250 SX

250 MXC, EXC

TABLE 3

BASIC CARBURETOR SETTING

Keihin PWK 38 AG PJ

110499

172 (170,175)

48 (45,50)

85

NOZ E (NOZ F)

III

7

1,5

–

55

Keihin PWK 38 AG

130499

180 (178,182)

45 (48)

85

NOZ G (NOZ H)

III

6

1,5

–

–

300 MXC, EXC

Keihin PWK 38 AG

140499

175 (172,178)

45 (48)

85

NOZ H (NOZ I)

III

6

1,5

–

–

250/300 EXC

throttled

Keihin PWK 38 AG

050799

175

35

85

R 1475 J

III

6

1,5

slide stop 34mm

–

380 SX, MXC, EXC

Keihin PWK 38 AG

150499

170 (168,172)

45 (48)

85

NOZ H (NOZ I)

III

6

1,5

–

–

Carburetor

Carburetor setting number

Main jet

Idling jet

Starting jet

Jet needle

Needle position from top

Throttle valve

Air adjustment screw open

Performance restrictor

Power jet jet

NOTES

ANHANG – APPENDICE

APPENDIX – APÉNDICE

1

SPORTMOTORCYCLES

ANHANG – APPENDICE

APPENDIX – APÉNDICE

2

SPORTMOTORCYCLES

ANHANG – APPENDICE

APPENDIX – APÉNDICE

3

ANHANG – APPENDICE

APPENDIX – APÉNDICE

4

SPORTMOTORCYCLES

ANHANG – APPENDICE

APPENDIX – APÉNDICE

5

VERGASERREGULIERUNG

KTM 125 SX EUROPA / USA 2000 KEIHIN PWK 39

CARBURETOR SETTING

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4

LD IJ 45 42 40 38 38 38

NADEL

NEEDLE

R1468D R1469D R1469D R1469D R1469D R1469D

POS POS 232311

HD MJ 185 182 180 178 175 175

LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2

LD IJ 48 45 42 40 38 38

NADEL

NEEDLE

R1468D R1468D R1469D R1469D R1469D R1469D

POS POS 323221

HD MJ 188 185 182 180 178 175

LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4

LD IJ 50 48 45 42 40 38

NADEL

NEEDLE

R1467D R1468D R1468D R1469D R1469D R1469D

POS POS 332322

HD MJ 190 188 185 182 180 178

LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2

LD IJ 52 50 48 45 42 40

NADEL

NEEDLE

R1467D R1467D R1468 R1468D R1469D R1469D

POS POS 433232

HD MJ 192 190 188 185 182 180

LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4

LD IJ 55 52 50 48 45 42

NADEL

NEEDLE

R1467D R1467D R1467D R1468D R1468D R1469D

POS POS 543323

HD MJ 195 192 190 188 185 182

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

ANHANG – APPENDICE

APPENDIX – APÉNDICE

6

VERGASERREGULIERUNG

KTM 125 MXC/EXC EUR/USA 2000 KEIHIN PWK 38

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4

LD IJ 48 45 42 40 38 38

NADEL

NEEDLE

NOZH NOZH NOZH NOZI NOZI NOZI

POS POS 332111

HD MJ 175 172 170 168 165 165

LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2

LD IJ 50 48 45 42 40 38

NADEL

NEEDLE

NOZG NOZH NOZH NOZI NOZI NOZI

POS POS 433211

HD MJ 178 175 172 170 168 165

LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4

LD IJ 52 50 48 45 42 40

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZH NOZI

POS POS 443321

HD MJ 180 178 175 172 170 168

LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2

LD IJ 55 52 50 48 45 42

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZI NOZI

POS POS 443332

HD MJ 182 180 178 175 172 170

LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4

LD IJ 55 52 50 50 48 45

NADEL

NEEDLE

NOZF NOZG NOZG NOZH NOZH NOZI

POS POS 544332

HD MJ 185 182 180 178 175 172

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

ANHANG – APPENDICE

APPENDIX – APÉNDICE

7

VERGASERREGULIERUNG

KTM 200 MXC/EXC EUR/USA 2000 KEIHIN PWK 38

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 3/4 1 3/4 1 3/4 2 2 1 3/4

LD IJ 45 45 42 42 42 40

NADEL

NEEDLE

NOZH NOZH N0ZI NOZI NOZI NOZI

POS POS 222111

HD MJ 180 178 175 172 170 170

LSCHR AS 1 1/4 1 3/4 1 3/4 1 3/4 2 2

LD IJ 45 45 45 42 42 42

NADEL

NEEDLE

NOZG NOZH NOZH NOZI NOZI NOZI

POS POS 322211

HD MJ 182 180 178 175 172 170

LSCHR AS 1 1/2 1 1/4 1 1/2 1 3/4 1 3/4 2

LD IJ 48 45 45 45 42 42

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZI NOZI

POS POS 332221

HD MJ 182 182 180 178 175 172

LSCHR AS 1 1/4 1 1 1/4 1 1/2 1 3/4 1 3/4

LD IJ 48 48 45 45 45 42

NADEL

NEEDLE

NOZG NOZG NOZG NOZH NOZH NOZI

POS POS 433222

HD MJ 185 182 182 180 178 175

LSCHR AS 1 1 1/4 1 1/2 1 1/4 1 1/2 1 3/4

LD IJ 48 48 48 45 45 45

NADEL

NEEDLE

NOZF NOZG NOZG NOZG NOZH NOZH

POS POS 443322

HD MJ 188 185 182 182 180 178

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

ANHANG – APPENDICE

APPENDIX – APÉNDICE

8

VERGASERREGULIERUNG

KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ

CARBURETOR SETTING

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4

LD IJ 48 45 45 42 42 40

NADEL

NEEDLE

NOZD NOZE NOZE NOZF NOZG NOZH

POS POS 332211

HD MJ 170 168 165 161628 160 160

LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2

LD IJ 50 48 45 45 45 42

NADEL

NEEDLE

NOZD NOZD NOZE NOZE NOZF NOZG

POS POS 332222

HD MJ 172 170 168 165 162 160

LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4

LD IJ 50 48 48 48 48 45

NADEL

NEEDLE

NOZD NOZD NOZE NOZE NOZF NOZF

POS POS 433222

HD MJ 175 172 170 168 165 162

LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2

LD IJ 52 50 48 48 48 45

NADEL

NEEDLE

NOZC NOZD NOZE NOZE NOZE NOZF

POS POS 443332

HD MJ 178 175 172 170 168 165

LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4

LD IJ 52 50 48 48 48 45

NADEL

NEEDLE

NOZC NOZC NOZD NOZD NOZE NOZE

POS POS 443332

HD MJ 180 178 180 172 170 168

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

ANHANG – APPENDICE

APPENDIX – APÉNDICE

9

VERGASERREGULIERUNG

KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 3/4 1 3/4 1 3/4 2 2 1/2 1 3/4

LD IJ 40 40 40 38 38 38

NADEL

NEEDLE

NOZH NOZH NOZH NOZI NOZI NOZI

POS POS 332222

HD MJ 178 175 172 170 170 168

LSCHR AS 1 1/4 1 1/2 1 3/4 1 3/4 2 2

LD IJ 42 42 40 40 40 40

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZI NOZI

POS POS 332222

HD MJ 180 178 175 172 170 168

LSCHR AS 1 1/4 1 1/2 1 1/2 1 3/4 1 3/4 2

LD IJ 45 45 42 42 42 40

NADEL

NEEDLE

NOZG NOZG NOZG NOZH NOZI NOZI

POS POS 433222

HD MJ 182 180 178 175 172 170

LSCHR AS 1 1/4 1 1/4 1 1/4 1 1/2 1 3/4 1 3/4

LD IJ 45 45 45 42 42 42

NADEL

NEEDLE

NOZF NOZG NOZG NOZG NOZH NOZH

POS POS 443332

HD MJ 185 182 180 178 175 172

LSCHR AS 1 1 1/4 1 1/2 1 1/4 1 1/2 1 3/4

LD IJ 50 48 45 45 42 42

NADEL

NEEDLE

NOZE NOZF NOZG NOZG NOZH NOZH

POS POS 543332

HD MJ 188 185 182 180 178 175

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

ANHANG – APPENDICE

APPENDIX – APÉNDICE

10

VERGASERREGULIERUNG

KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4

LD IJ 45 42 40 40 40 38

NADEL

NEEDLE

NOZH NOZH NOZH NOZI NOZI NOZI

POS POS 321111

HD MJ 172 170 168 165 162 162

LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2

LD IJ 48 45 42 42 42 40

NADEL

NEEDLE

NOZG NOZH NOZH NOZI NOZI NOZI

POS POS 321111

HD MJ 175 172 170 168 165 162

LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4

LD IJ 48 45 45 45 45 42

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZH NOZI

POS POS 3322222

HD MJ 178 175 172 170 168 165

LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2

LD IJ 50 48 45 45 45 42

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZI NOZI

POS POS 322222

HD MJ 180 178 175 172 170 168

LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4

LD IJ 50 48 45 45 42 42

NADEL

NEEDLE

NOZF NOZG NOZG NOZH NOZH NOZI

POS POS 433211

HD MJ 182 180 178 175 172 170

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

ANHANG – APPENDICE

APPENDIX – APÉNDICE

11

VERGASERREGULIERUNG

KTM 380 SX / MXC / EXC EUR / USA 2000

KEIHIN

PWK 38

-20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C

-2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F

TEMPERATURMEERESHÖHE

ALTIDUDE

LSCHR AS 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4

LD IJ 45 45 40 40 40 38

NADEL

NEEDLE

NOZH NOZH NOZH NOZI NOZI NOZI

POS POS 321111

HD MJ 172 170 168 165 162 162

LSCHR AS 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2

LD IJ 48 45 42 42 42 40

NADEL

NEEDLE

NOZG NOZH NOZH NOZI NOZI NOZI

POS POS 321111

HD MJ 175 172 170 168 165 162

LSCHR AS 1 1 1/4 1 1/2 1 3/4 2 2 1/4

LD IJ 48 45 45 45 45 42

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZH NOZI

POS POS 3322222

HD MJ 178 175 172 170 168 165

LSCHR AS 3/4 1 1 1/4 1 1/2 1 3/4 2

LD IJ 50 48 45 45 45 42

NADEL

NEEDLE

NOZG NOZG NOZH NOZH NOZI NOZI

POS POS 322222

HD MJ 180 178 175 172 170 168

LSCHR AS 1/2 3/4 1 1 1/4 1 1/2 1 3/4

LD IJ 50 48 45 45 42 42

NADEL

NEEDLE

NOZF NOZG NOZG NOZH NOZH NOZI

POS POS 433211

HD MJ 182 180 178 175 172 170

3000 m

10000 ft

2301 m

7501 ft

2300 m

7500 ft

1501 m

5001 ft

1500 m

5000 ft

751 m

2501 ft

750 m

2500 ft

301 m

1001 ft

300 m

1000 ft

Meeresniveau

Sea level

LSCHR = Luftregulierschraube offen

LD = Leerlaufdüse

POS = Clip Position von oben

HD = Hauptdüse

AS = Air screw open from fully-seated

IJ = Idling jet

POS = Clip position from top

MJ = Main jet

NICHT FÜR STRASSENBETRIEB

Kraftstoff: Euro-Super bleifrei ROZ 95

NOT FOR HIGHWAY USE

Fuel: Euro-Super unleaded ROZ 95

21.06.99

1.

3.

5.

2.

4.

KTM SPORTMOTORCYCLE AG

Harlochnerstr. 13 · A - 5230 Mattighofen

Tel. [phone] · Fax [phone]

Internet: http://www.ktm.at