KTM 250 EXC, 125 EXC, 250 XC-W, 300 XC, 200 EXC User Manual
...
OWNER'S MANUAL 2010
125 EXC EU
125 EXC SIX DAYS EU
150 XC USA
200 EXC EU
200 EXC AUS
200 XC
250 EXC EU
250 EXC SIX DAYS EU
250 EXC AUS
250 XC EU/USA
250 XC
300 EXC EU
300 EXC SIX DAYS EU
300 EXC AUS
300 XC EU/USA
300 XC
‑W USA
‑W USA
‑W USA
Art. no. 3211466en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 10) Dealer's stamp
Engine number ( p. 10)
Key number (EXC, EXC SIX DAYS) ( p. 10)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can, however, not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT INFORMATION ................................................ 6
VIEW OF VEHICLE............................................................... 8
View of the vehicle from the left front (example) ................. 8
View of the vehicle from the right rear (example) ................ 9
LOCATION OF SERIAL NUMBERS ...................................... 10
Chassis number............................................................. 10
Type label..................................................................... 10
Key number (EXC, EXC SIX DAYS) .................................. 10
Engine number.............................................................. 10
Fork part number........................................................... 10
Shock absorber part number ........................................... 11
CONTROLS....................................................................... 12
Clutch lever .................................................................. 12
Hand brake lever ........................................................... 12
Throttle grip.................................................................. 12
Short circuit button (EXC, EXC SIX DAYS)........................ 12
Short circuit button (XC‑W/XC)........................................ 13
Emergency OFF switch (200 EXC AUS) ........................... 13
Emergency OFF switch (250/300 EXC AUS) .................... 13
Electric starter button (300 EXC EU,
300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC) ........... 13
Electric starter button (250/300 EXC AUS)...................... 13
Light switch (EXC, EXC SIX DAYS) .................................. 14
Light switch (XC-W) ....................................................... 14
Horn button (EXC, EXC SIX DAYS) .................................. 14
Turn signal switch (EXC, EXC SIX DAYS).......................... 14
Overview of indicator lamps (EXC, EXC SIX DAYS) ............ 14
CONTROLS (ALL EXC/XC-W MODELS)................................. 15
Speedometer................................................................. 15
Speedometer activation and test ..................................... 15
Tripmaster switch .......................................................... 15
Setting kilometers or miles ............................................. 15
Setting the clock ........................................................... 16
Adjusting speedometer functions .................................... 16
Querying the lap time .................................................... 17
Display mode SPEED (speed) ......................................... 17
Display mode SPEED/H (service hours) ............................ 17
Display mode SPEED/CLK (clock) ................................... 18
Display mode SPEED/LAP (lap time) ............................... 18
Display mode SPEED/ODO (odometer) ............................. 18
Display mode SPEED/TR1 (trip master 1) ........................ 18
Display mode SPEED/TR2 (trip master 2) ........................ 19
Display mode SPEED/A1 (average speed 1)...................... 19
Display mode SPEED/A2 (average speed 2)...................... 19
Display mode SPEED/S1 (stop watch 1) .......................... 20
Display mode SPEED/S2 (stop watch 2) .......................... 20
CONTROLS....................................................................... 22
Fuel tap........................................................................ 22
Opening the filler cap .................................................... 22
Closing the filler cap...................................................... 22
Choke (EXC AUS, XC‑W/XC) ............................................ 22
Choke (EXC EU, EXC SIX DAYS) ..................................... 23
Shift lever..................................................................... 23
Kickstarter.................................................................... 23
Foot brake lever............................................................. 24
Side stand .................................................................... 24
Steering lock (EXC, EXC SIX DAYS)................................. 24
Locking the steering (EXC, EXC SIX DAYS)....................... 24
Unlocking the steering (EXC, EXC SIX DAYS) ................... 25
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION...................................................................... 26
Advice on first use ......................................................... 26
Running in the engine.................................................... 27
Preparing the vehicle for difficult operating conditions...... 27
Preparations for riding on dry sand.................................. 27
Preparations for riding on wet sand ................................. 28
Preparations for riding on wet and muddy surfaces ........... 29
Preparations for riding at high temperatures and riding
slowly........................................................................... 30
Preparations for riding at low temperatures and in snow .... 30
RIDING INSTRUCTIONS .................................................... 31
Checks before putting into operation ............................... 31
Starting ........................................................................ 31
Starting up ................................................................... 32
Shifting, riding.............................................................. 32
Braking ........................................................................ 32
Stopping, parking .......................................................... 33
Refueling...................................................................... 33
SERVICE SCHEDULE......................................................... 35
Important maintenance work to be carried out by an
authorized KTM workshop .............................................. 35
Important maintenance work to be carried out by an
authorized KTM workshop (as additional order)................. 36
Important checks and maintenance work to be carried
out by the rider ............................................................. 37
MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 38
Jacking up the motorcycle .............................................. 38
Removing the motorcycle from the work stand.................. 38
Checking the basic chassis setting with the rider's
weight .......................................................................... 38
Compression damping of shock absorber.......................... 38
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 38
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 39
Adjusting the rebound damping of the shock absorber....... 40
Measuring the sag of the unloaded rear wheel .................. 41
Checking the static sag of the shock absorber .................. 41
Checking the riding sag of the shock absorber .................. 42
Adjusting the spring preload of the shock absorber x ...... 42
Adjusting the riding sag x............................................. 43
Removing the shock absorber x..................................... 43
Installing the shock absorber x ..................................... 44
Checking the basic setting of the fork.............................. 44
Adjusting the compression damping of the fork ................ 44
Adjusting the rebound damping of the fork....................... 45
Adjusting the spring preload of the fork (EXC,
EXC SIX DAYS, XC-W) .................................................... 46
Bleeding the fork legs .................................................... 47
Cleaning the dust boots of the fork legs ........................... 47
Loosening the fork protection.......................................... 47
Positioning the fork protection ........................................ 47
Checking the play of the steering head bearing................. 48
Adjusting the play of the steering head bearing x............ 48
Removing the fork legs x.............................................. 49
Installing the fork legs x............................................... 50
Removing the fork protector x....................................... 51
Installing the fork protector x ....................................... 51
Removing the front fender .............................................. 51
Installing the front fender............................................... 51
TABLE OF CONTENTS 3
Removing the headlight mask with the headlight (EXC,
EXC SIX DAYS) ............................................................. 52
Refitting the headlight mask with the headlight (EXC,
EXC SIX DAYS) ............................................................. 52
Removing the start number plate (XC‑W/XC)..................... 52
Installing the start number plate (XC‑W/XC)...................... 53
Handlebar position ........................................................ 53
Adjusting the handlebar position x................................ 53
Checking the play in the throttle cable............................. 54
Adjusting the play in the throttle cable x ....................... 54
Checking the chain for dirt ............................................. 54
Cleaning the chain......................................................... 54
Checking the chain tension ............................................ 55
Checking the rear sprocket/engine sprocket for wear ......... 55
Checking chain wear...................................................... 55
Adjusting the chain tension ............................................ 56
Adjusting the chain guide x.......................................... 57
Checking the brake discs................................................ 58
Checking the free travel of the hand brake lever ............... 58
Adjusting the basic position of the hand brake lever
(XC‑W/XC)..................................................................... 59
Adjusting free travel of hand brake lever (EXC,
EXC SIX DAYS) ............................................................. 59
Checking the front brake fluid level ................................. 59
Adding front brake fluid x ............................................ 60
Checking the front brake linings...................................... 60
Changing the front brake linings x................................. 61
Checking the free travel of the foot brake lever ................. 62
Adjusting the basic position of the foot brake lever x ...... 63
Checking the rear brake fluid level .................................. 63
Adding rear brake fluid x.............................................. 64
Checking the rear brake linings ....................................... 64
Removing the rear brake linings x ................................. 65
Installing the rear brake linings x.................................. 65
Changing the rear brake linings x.................................. 66
Removing the front wheel x .......................................... 66
Installing the front wheel x........................................... 67
Removing the rear wheel x ........................................... 68
Installing the rear wheel x ............................................ 68
Checking the tire condition............................................. 69
Checking the tire air pressure ......................................... 70
Checking the spoke tension ............................................ 70
Engine characteristic - auxiliary spring
(All 250/300 models) .................................................... 71
Engine characteristic - adjusting the auxiliary spring x
(All 250/300 models) .................................................... 71
Removing the battery x (250 EXC AUS/XC‑W/XC,
all 300 models)............................................................. 72
Installing the battery x (250 EXC AUS/XC‑W/XC,
all 300 models)............................................................. 72
Recharging the battery x (250 EXC AUS/XC‑W/XC,
all 300 models)............................................................. 72
Removing a fuse (250 EXC AUS/XC‑W/XC,
all 300 models)............................................................. 73
Replacing the fuse (250 EXC AUS/XC‑W/XC,
all 300 models)............................................................. 73
Checking the headlight setting (EXC, EXC SIX DAYS) ........ 74
Adjusting the headlight range (EXC, EXC SIX DAYS) ......... 74
Removing the seat ......................................................... 74
Mounting the seat ......................................................... 75
Removing the fuel tank x ............................................. 75
Installing the fuel tank x .............................................. 76
Cooling system .............................................................. 76
Checking the antifreeze and coolant level ........................ 77
Checking the coolant level.............................................. 77
Draining the coolant x.................................................. 78
Refilling with coolant x ................................................ 79
Removing the main silencer............................................ 80
Installing the main silencer ............................................ 80
Glass fiber yarn filling of main silencer ............................ 80
Removing the glass fiber yarn filling of the main
silencer x ................................................................... 80
Installing the glass fiber yarn filling of the main
silencer x ................................................................... 81
Changing the glass fiber yarn filling of the main
silencer x ................................................................... 81
Removing the air filter box lid......................................... 81
Installing the air filter box lid.......................................... 81
Removing the air filter x............................................... 81
Installing the air filter x ............................................... 82
Cleaning the air filter x ................................................ 82
Adjusting the basic position of the clutch lever................. 83
Checking the fluid level of the hydraulic clutch ................ 83
Changing the hydraulic clutch fluid x ............................ 84
Checking the basic position of the shift lever.................... 85
Adjusting the basic position of the shift lever x .............. 85
Carburetor .................................................................... 85
Carburetor - adjusting the idle speed x .......................... 86
Emptying the carburetor float chamber x ....................... 87
Checking the gear oil level.............................................. 88
Changing the gear oil x ................................................ 88
Draining the gear oil x ................................................. 89
Refilling with gear oil x ................................................ 89
Adding gear oil x ......................................................... 90
TROUBLESHOOTING......................................................... 91
CLEANING........................................................................ 93
Cleaning the motorcycle ................................................. 93
STORAGE ......................................................................... 94
Storage......................................................................... 94
Putting into operation after storage ................................. 94
TECHNICAL DATA - ENGINE .............................................. 95
125 EXC EU, 125 EXC SIX DAYS EU .............................. 95
150 XC USA ................................................................. 95
All 200 models ............................................................. 96
All 250 models ............................................................. 96
All 300 models ............................................................. 97
Capacity - gear oil.......................................................... 98
Capacity - coolant.......................................................... 98
TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 99
All 125/150/200 models ............................................... 99
All 250/300 models ...................................................... 99
TECHNICAL DATA - CARBURETOR................................... 101
125 EXC EU, 125 EXC SIX DAYS EU ............................ 101
150 XC USA ............................................................... 101
200 EXC EU ............................................................... 101
200 EXC AUS ............................................................. 101
200 XC‑W USA ........................................................... 102
250 EXC EU, 250 EXC SIX DAYS EU ............................ 102
250 EXC AUS ............................................................. 102
250 XC EU/USA .......................................................... 102
250 XC‑W USA ........................................................... 103
300 EXC EU, 300 EXC SIX DAYS EU ............................ 103
300 EXC AUS ............................................................. 103
TABLE OF CONTENTS 4
300 XC EU/USA, 300 XC‑W USA.................................. 103
Carburetor configuration (125 EXC EU,
125 EXC SIX DAYS EU) x .......................................... 104
Carburetor configuration (150 XC USA) x .................... 105
Carburetor configuration (All 200 models) x................. 106
Carburetor configuration (250 EXC EU,
250 EXC SIX DAYS EU, 250 EXC AUS,
250 XC‑W USA) x ..................................................... 107
Carburetor configuration (250 XC EU/USA) x ............... 108
Carburetor configuration (All 300 models) x................. 109
General carburetor configuration x .............................. 110
TECHNICAL DATA - CHASSIS .......................................... 111
Lighting equipment ..................................................... 112
Tires .......................................................................... 112
Capacity - fuel............................................................. 112
TECHNICAL DATA - FORK................................................ 113
All 125/200 models .................................................... 113
150 XC USA ............................................................... 113
All 250/300 EXC/XC-W models ..................................... 114
250/300 XC................................................................ 114
TECHNICAL DATA - SHOCK ABSORBER ........................... 115
All 125/200 models .................................................... 115
150 XC USA ............................................................... 115
All 250/300 EXC/XC-W models ..................................... 116
250/300 XC................................................................ 116
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................ 118
WIRING DIAGRAM .......................................................... 121
Wiring diagram (125 EXC EU, 125 EXC SIX DAYS EU,
200 EXC EU, 200 EXC AUS, 250 EXC EU,
250 EXC SIX DAYS EU) ............................................... 121
Wiring diagram (250/300 EXC AUS, 300 EXC EU,
300 EXC SIX DAYS EU) ............................................... 124
Wiring diagram (150 XC USA, 200 XC‑W USA) .............. 126
Wiring diagram (250/300 XC‑W, 250/300 XC) ............... 128
SUBSTANCES................................................................. 130
AUXILIARY SUBSTANCES................................................ 132
STANDARDS................................................................... 134
INDEX ............................................................................ 135
MEANS OF REPRESENTATION 5
Symbols used
The symbols used are explained below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a specific name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
IMPORTANT INFORMATION 6
Use definition (EXC, EXC SIX DAYS)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for public road traffic in the homologous (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic.
The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.
Use definition (XC‑W/XC)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only on closed off property remote from public road traffic.
The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.
Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the
limit specified in the service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's
service record, since otherwise no warranty claims will be honored. No warranty claims can be considered for damage resulting from
manipulations and/or alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
IMPORTANT INFORMATION 7
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Switch off the engine.
– Turn handle of the fuel tap to the OFF position.
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
– It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and
tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle
to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
VIEW OF VEHICLE 8
3.1View of the vehicle from the left front (example)
1 Hand brake lever
2 Short circuit button
3 Clutch lever
4 Air filter box lid
5 Fuel tap
6 Shift lever
7 Chain guide
8 Side stand
B00077-10
VIEW OF VEHICLE 9
3.2View of the vehicle from the right rear (example)
1 Shock absorber rebound adjustment
2 Level viewer for brake fluid, rear
3 Foot brake lever
4 Kickstarter
5 Bleeder screw, fork leg
6 Throttle grip
7 Chassis number
8 Filler cap
B00076-10
LOCATION OF SERIAL NUMBERS 10
4.1Chassis number
The chassis number is stamped on the right side of the steering head.
B00015-10
4.2Type label
The type label is fixed to the front of the steering head.
400284-10
4.3Key number (EXC, EXC SIX DAYS)
500125-10
4.4Engine number
The key number is stamped on the key strap.
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.5Fork part number
B00016-10
The fork part number is stamped on the inner side of the fork stub.
500082-10
LOCATION OF SERIAL NUMBERS 11
4.6Shock absorber part number
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
500083-10
CONTROLS 12
5.1Clutch lever
(All 125/150/200 models)
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00001-10
(All 250/300 models)
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00009-10
5.2Hand brake lever
5.3Throttle grip
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
400196-10
Throttle grip is fitted on the right side of the handlebar.
B00060-10
5.4Short circuit button (EXC, EXC SIX DAYS)
B00078-10
Short circuit button is fitted on the left side of the handlebar.
Possible states
• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
CONTROLS 13
5.5Short circuit button (XC‑W/XC)
Short circuit button is fitted on the left side of the handlebar.
Possible states
• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
B00002-10
5.6Emergency OFF switch (200 EXC AUS)
The emergency OFF switch is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.
B00087-10
5.7Emergency OFF switch (250/300 EXC AUS)
The emergency OFF switch is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.
B00079-10
5.8Electric starter button (300 EXC EU, 300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC)
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
B00080-10
5.9Electric starter button (250/300 EXC AUS)
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
B00081-10
CONTROLS 14
5.10Light switch (EXC, EXC SIX DAYS)
The light switch is fitted on the left side of the handlebar.
Possible states
Light off – Light switch is turned to the right. In this position, the light
is switched off.
Low beam on – Light switch is in the central position. In this position,
the low beam and tail light are switched on.
High beam on – Light switch is turned to the left. In this position, the
B00082-10
5.11Light switch (XC-W)
Light switch is located to the right of the speedometer.
Possible states
• The light switch has no function when the vehicle is delivered – It can be used to
retrofit the vehicle with a lighting system.
high beam and the tail light are switched on.
500146-10
5.12Horn button (EXC, EXC SIX DAYS)
B00083-10
5.13Turn signal switch (EXC, EXC SIX DAYS)
The horn button is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
Turn signal switch is fitted on the left side of the handlebar.
Possible states
Turn signal off – The turn signal switch is in the central position.
Left turn signal, on – The turn signal switch is turned to the left.
Right turn signal, on – The turn signal switch is turned to the right.
B00088-10
5.14Overview of indicator lamps (EXC, EXC SIX DAYS)
Possible states
500147-01
High beam indicator lamp lights up blue – High beam is switched on.
Turn signal indicator lamp flashes green – Turn signal light is switched
on.
CONTROLS (ALL EXC/XC-W MODELS) 15
6.1Speedometer
– Press the key to change the display mode or change to one of the setup menus.
– Press the button to control different functions.
– Press the button to control different functions.
Info
In its condition at delivery, the display mode SPEED/H and SPEED/ODO is activated.
400312-01
6.2Speedometer activation and test
Activating the speedometer:
The speedometer is activated when one of the keys is pressed or a signal is received
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.
400313-01
WS (wheel size)
After the display function test, the wheel size WS is displayed briefly.
Info
2205 mm corresponds to the size of the 21" front wheel with a series production tire.
The display then changes to the last selected mode.
400314-01
6.3Tripmaster switch
(Option: Tripmaster switch)
You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info
The trip master is an optional accessory.
6.4Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
400329-01
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The setup menu is displayed and the active functions shown.
– Press the button repeatedly until the Km/h/Mph display flashes.
Km/h adjusting
– Press the button .
Mph adjusting
– Press the button .
CONTROLS (ALL EXC/XC-W MODELS) 16
– Press the button for 3 - 5 seconds.
The settings are stored and the setup menu is closed.
Info
If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.
6.5Setting the clock
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
– Press the button for 3 - 5 seconds.
The hour display flashes.
– Set the hour display with the button and/or button .
– Press the button briefly.
The next segment of the display flashes and can be set.
400330-01
– You can set the following segments in the same way as the hours by pressing
the button and the button .
Info
The seconds can only be set to zero.
– Press the button for 3 - 5 seconds.
The settings are stored and the setup menu is closed.
Info
If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.
6.6Adjusting speedometer functions
Info
In its condition at delivery, the display mode SPEED/H and SPEED/ODO is activated.
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The setup menu is displayed and the active functions shown.
– Switch to the function you require by briefly pressing the button .
The selected function flashes.
Activating a function
– Press the button .
400318-01
Deactivating a function
– Press the button .
– Activate or deactivate all functions accordingly
– Press the button for 3 - 5 seconds.
The icon remains in the display and the display changes to the next function.
The icon disappears from the display and the display changes to the next
function.
The settings are stored and the setup menu is closed.
CONTROLS (ALL EXC/XC-W MODELS) 17
Info
If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.
6.7Querying the lap time
Info
This function can be called only if lap times are measured.
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
– Press the button briefly.
LAP 1 appears on the left side of the display.
– Laps 1-10 can be displayed by pressing the button .
– The button has no function
– Press the button briefly.
400321-01
Next display mode
Info
If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.
6.8Display mode SPEED (speed)
400317-02
6.9Display mode SPEED/H (service hours)
400316-01
– Press the button briefly and repeatedly until SPEED appears on the left side of
the display.
The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.
Info
Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.
Condition
• The motorcycle is stationary
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.
Info
The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automatically changes to the ODO display mode.
The H display mode is suppressed during the journey.
Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
The display changes to the Setup menu of the speedometer
functions.
Next display mode
briefly.
CONTROLS (ALL EXC/XC-W MODELS) 18
6.10Display mode SPEED/CLK (clock)
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
The time is displayed in CLK display mode.
Press the button . No function
Press the button . No function
400319-01
6.11Display mode SPEED/LAP (lap time)
Press the button
for 3 - 5 seconds.
Press the button
briefly.
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
Info
If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .
The display changes to the Setup menu of the clock.
Next display mode
400320-01
6.12Display mode SPEED/ODO (odometer)
400317-01
6.13Display mode SPEED/TR1 (trip master 1)
Press the button . Starts or stops the clock.
Press the button . Stops the current lap time and saves it, and the stop watch
starts the next lap.
Press the button
The stop watch and the lap time are reset.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until ODO appears at the bottom right of
the display.
In ODO display mode, the total number of kilometers ridden is displayed.
Press the button . No function
Press the button . No function
Press the button
–
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until TR1 appears at the top right of the
display.
TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
400323-01
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to
0.0.
Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
The TR1, A1 and S1 displays are reset to 0.0.
CONTROLS (ALL EXC/XC-W MODELS) 19
6.14Display mode SPEED/TR2 (trip master 2)
– Press the button briefly and repeatedly until TR2 appears at the top right of the
TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . A very
practical function when riding using the road book.
400324-01
6.15Display mode SPEED/A1 (average speed 1)
– Press the button briefly and repeatedly until A1 appears at the top right of the
A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip master 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.
Press the button
Next display mode
briefly.
display.
Info
The TR2 value can also be corrected manually during the journey with the button and the button .
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
Press the button . Increases value of TR2.
Press the button . Reduces value of TR2.
Press the button
for 3 - 5 seconds.
Press the button
briefly.
display.
Deletes value of TR2.
Next display mode
400325-01
6.16Display mode SPEED/A2 (average speed 2)
– Press the button briefly and repeatedly until A2 appears at the top right of the
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.
400326-01
Press the button . No function
Press the button . No function
Press the button
The TR1, A1 and S1 displays are reset to 0.0.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
display.
Info
The displayed value can differ from the actual average speed if S2 was not
timed after the ride.
Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
briefly.
–
Next display mode
CONTROLS (ALL EXC/XC-W MODELS) 20
6.17Display mode SPEED/S1 (stop watch 1)
– Press the button briefly and repeatedly until S1 appears at the top right of the
display.
S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.
Press the button . No function
400327-01
6.18Display mode SPEED/S2 (stop watch 2)
Press the button . No function
Press the button
Displays of TR1, A1 and S1 are reset to 0,0.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until S2 appears at the top right of the
display.
S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.
Press the button . Starts or stops S2.
Press the button . No function
400328-01
Press the button
for 3 - 5 seconds.
Press the button
Displays of S2 and A2 are reset to 0.0.
Next display mode
briefly.
Table of functions
Display Press the button . Press the button . Press the button for 3 -
5 seconds.
Display mode SPEED/H
(service hours)
No function No function The display changes to
the Setup menu of the
speedometer functions.
Display mode SPEED/CLK
(clock)
No function No function The display changes to
the Setup menu of the
clock.
Display mode SPEED/LAP
(lap time)
Starts or stops the
clock.
Stops the current lap
time and saves it, and
The stop watch and the
lap time are reset.
the stop watch starts
the next lap.
Display mode
No function No function – Next display mode
SPEED/ODO (odometer)
Display mode SPEED/TR1
(trip master 1)
Display mode SPEED/TR2
No function No function The TR1, A1 and S1 dis-
plays are reset to 0.0.
Increases value of TR2. Reduces value of TR2. Deletes value of TR2. Next display mode
(trip master 2)
Display mode SPEED/A1
(average speed 1)
Display mode SPEED/A2
No function No function The TR1, A1 and S1 dis-
plays are reset to 0.0.
No function No function – Next display mode
(average speed 2)
Display mode SPEED/S1
(stop watch 1)
Display mode SPEED/S2
(stop watch 2)
No function No function Displays of TR1, A1 and
S1 are reset to 0,0.
Starts or stops S2. No function Displays of S2 and A2
are reset to 0.0.
Press the button
briefly.
Next display mode
Next display mode
Next display mode
Next display mode
Next display mode
Next display mode
Next display mode
Table of conditions and menu activation
Display The motorcycle is
stationary
Display mode SPEED/H (service hours) •
Menu can be activated
CONTROLS (ALL EXC/XC-W MODELS) 21
Table of conditions and menu activation
Display The motorcycle is
stationary
Display mode SPEED/CLK (clock) •
Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •
Menu can be activated
CONTROLS 22
7.1Fuel tap
The fuel tap is on the left side of the fuel tank.
Tap handle on the fuel tap is used to open or close the supply of fuel to the carburetor.
Possible states
• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.
• Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The
fuel tank empties completely.
B00089-10
7.2Opening the filler cap
7.3Closing the filler cap
– Press release button , turn the filler cap counterclockwise and lift it free.
400199-10
– Replace the filler cap and turn clockwise until the release button locks in place.
Info
Run the fuel tank breather hose without kinks.
400199-11
7.4Choke (EXC AUS, XC‑W/XC)
B00004-10
The choke lever is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated – The choke lever is pulled out all the way.
• Choke function deactivated – The choke lever is pushed in all the way.
CONTROLS 23
7.5Choke (EXC EU, EXC SIX DAYS)
The choke lever is fitted on the left side of the handlebar.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
500136-10
7.6Shift lever
• Choke function activated – The choke lever is pulled to the stop.
• Choke function deactivated – The choke lever is pushed back to the stop.
Shift lever is mounted on the left side of the engine.
7.7Kickstarter
B00005-10
(All 125/150/200 models)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
B00005-12
(All 250/300 models)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
B00005-11
The kickstarter is fitted on the right side of the engine. The top part can be
swiveled.
B00006-10
CONTROLS 24
7.8Foot brake lever
Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
B00007-10
7.9Side stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the
B00085-10
motorcycle when it is supported by the side stand only. The side stand and/or the
frame could be damaged and the motorcycle could fall over.
B00086-10
7.10Steering lock (EXC, EXC SIX DAYS)
B00084-10
To park the motorcycle, press side stand to the ground with your foot and lean the
motorcycle on it.
When you are riding, side stand must be folded up and secured with rubber
band .
Steering lock is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.
7.11Locking the steering (EXC, EXC SIX DAYS)
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
CONTROLS 25
– Park the vehicle.
– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in and turn it to the
right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
400732-01
7.12Unlocking the steering (EXC, EXC SIX DAYS)
– Insert the key in the steering lock, turn it to the left, pull it out and turn it to the
right. Remove the key.
You can now steer the bike again.
Info
Never leave the key in the steering lock.
400731-01
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 26
8.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 83)
(XC‑W/XC)
– Adjust the basic position of the hand brake lever. ( p. 59)
(EXC, EXC SIX DAYS)
– Adjust the free travel of the hand brake lever. ( p. 59)
–
Adjust the basic position of the foot brake lever. x ( p. 63)
–
Adjust the basic position of the shift lever. x ( p. 85)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Offroad, you should be accompanied by another person on another machine so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 27
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-
tribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Check the spoke tension. ( p. 70)
Info
The spoke tension must be checked after riding the motorcycle for one half hour.
– Run the engine in.
8.2Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 service hours < 70 %
During the first 5 service hours < 100 %
– Avoid fully opening the throttle!
8.3Preparing the vehicle for difficult operating conditions
– The use of motorcycles under difficult operating conditions can lead to above-average wear of components such as the drive train
or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is
reached.
Difficult operating conditions are:
– Riding on dry sand. ( p. 27)
– Riding on wet sand. ( p. 28)
– Riding on wet and muddy surfaces. ( p. 29)
– Riding at high temperatures and riding slowly. ( p. 30)
– Riding at low temperatures and in snow. ( p. 30)
8.4Preparations for riding on dry sand
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the value displayed does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
600872-10
– Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
– Change the radiator cap.
–
Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–
Clean the air filter. x ( p. 82)
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 28
Info
Check the air filter approx. every 30 minutes.
– Mount the dust cover for the air filter.
Dust cover for air filter (59006019000)
Info
Follow the KTM PowerParts mounting instructions.
600869-01
– Mount the sand cover for the air filter.
Sand cover for air filter (59006022000)
Info
Follow the KTM PowerParts mounting instructions.
– Adjust the carburetor jetting and setting.
600871-01
600868-01
8.5Preparations for riding on wet sand
600872-10
Info
The recommended carburetor tuning is available from your authorized KTM
workshop.
– Clean the chain.
Chain cleaner ( p. 132)
– Mount the steel sprocket.
Tip
Do not lubricate the chain.
– Clean the radiator fins.
– Carefully align bent radiator fins.
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the value displayed does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
– Change the radiator cap.
–
Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–
Clean the air filter. x ( p. 82)
Info
Check the air filter approx. every 30 minutes.
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