KTM 125 EXC EU Owner's Manual
201 year
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Also See for 125 EXC EU:
- Owner's manual (150 pages) ,
- Owner's handbook manual (45 pages) ,
- Manual (12 pages)
Related Manuals for KTM 125 EXC EU
Summary of Contents for KTM 125 EXC EU
- Page 1 OWNER'S MANUAL 2013 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AUS 200 XC‑W USA 250 EXC EU 250 EXC AUS 250 EXC SIX DAYS EU 250 XC‑W USA 300 EXC EU 300 EXC AUS 300 EXC SIX DAYS EU 300 XC‑W USA...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.14.16 Display mode SPEED/A2 (average speed 2) ... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.14.17 Display mode SPEED/S1 (stop watch 1)..20 Symbols used ........... 5 6.14.18 Display mode SPEED/S2 (stop watch 2)..21 Formats used............ - Page 5 TABLE OF CONTENTS 10.14 Adjusting the spring preload of the fork 11.48 Changing the hydraulic clutch fluid ....71 (EXC EU/AUS, XC‑W)........44 11.49 Removing the engine guard (EXC SIX DAYS)..72 10.15 Handlebar position.......... 44 11.50 Installing the engine guard (EXC SIX DAYS)..72 10.16 Adjusting the handlebar position ....
- Page 6 Preparing for use after storage......109 20 TROUBLESHOOTING ..........110 21 TECHNICAL DATA............ 112 21.1 Engine ............112 21.1.1 125 EXC EU, 125 EXC SIX DAYS EU ..112 21.1.2 All 200 models......... 112 21.1.3 All 250 models......... 113 21.1.4 All 300 models.........
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) B01138-10 Hand brake lever ( p. 13) Kill switch ( p. 13) Clutch lever ( p. 13) Air filter box lid Fuel tap ( p. 23) Chain guide Side stand ( p. -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) B01137-10 Filler cap Bleeder screw, fork leg Throttle grip ( p. 13) Chassis number ( p. 11) Kick starter ( p. 24) Foot brake lever ( p. 24) Level viewer for brake fluid, rear... -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 303438-10 Type label The type label is fixed to the front of the steering head. 303439-10 Key number (All EXC models) The key number for the steering lock is stamped onto the key connector. -
Page 14: Shock Absorber Part Number
SERIAL NUMBERS Shock 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. B00786-10... -
Page 15: Controls
CONTROLS Clutch lever (All 125/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01140-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. -
Page 16: Kill Switch (Xc-W)
CONTROLS Kill switch (XC-W) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition circuit is closed and • Kill switch the engine can be started. pressed – In this position, the ignition circuit is interrupted, a run- •... -
Page 17: Emergency Off Switch (Exc Aus)
CONTROLS 6.10 Emergency OFF switch (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 run- ning engine stops, and a non-running engine will not start. Ignition on –... -
Page 18: Activation And Test
CONTROLS 6.14.2 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. Display test To enable you to check that the display is functioning properly, all display segments light up briefly. -
Page 19: Setting The Clock
CONTROLS 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 activated functions are shown. –... -
Page 20: Display Mode Speed (Speed)
CONTROLS – 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 –... -
Page 21: Display Mode Speed/Lap (Lap Time)
CONTROLS 6.14.11 Display mode SPEED/LAP (lap time) – 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... -
Page 22: Display Mode Speed/A1 (Average Speed 1)
CONTROLS . Reduces value of TR2. Press the button Press the button Deletes value of TR2. for 3 - 5 seconds. Press the button Next display mode briefly. 6.14.15 Display mode SPEED/A1 (average speed 1) – Press the button briefly and repeatedly until A1 appears at the top right of the display. -
Page 23: Display Mode Speed/S2 (Stop Watch 2)
CONTROLS 6.14.18 Display mode SPEED/S2 (stop watch 2) – 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 . -
Page 24: Opening The Filler Cap
CONTROLS 6.15 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 25: Fuel Tap
CONTROLS 6.17 Fuel 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 carbure- tor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. •... -
Page 26: Kick Starter
CONTROLS 6.20 Kick starter The kick starter is fitted on the right side of the engine. The top part can be swiveled. B00787-10 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. B00788-10 6.22 Side stand... -
Page 27: Locking The Steering (All Exc Models)
CONTROLS 6.24 Locking the steering (All EXC models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –... -
Page 28: Preparing For Use
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. -
Page 29: Running In The Engine
PREPARING FOR USE – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – 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. -
Page 30: Preparations For Riding On Dry Sand
Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info 600871-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 131) – Mount the steel sprocket. -
Page 31: Preparations For Riding On Wet And Muddy Surfaces
Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info 600870-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 131) – Mount the steel sprocket. -
Page 32: Preparing For Riding At Low Temperatures Or In Snow
Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 Your authorized KTM workshop can recommend the right carburetor tuning. -
Page 33: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 103) –... -
Page 34: Start Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 35: Stopping, Parking
RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. –... -
Page 36: Refueling
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 37: Service Schedule
• Final check: Check the vehicle for safe operation and take a test ride. • • Make the service entry in KTM DEALER.NET and in the service record. • • S20A: Every 20 operating hours S40A: Every 40 operating hours/after every race... -
Page 38: Service Work (As Additional Order)
Check the starter drive. (All 200/250/300 models) • • Change the piston and check the cylinder. (125 EXC EU, 125 EXC SIX DAYS EU) • Change the piston and check the cylinder. (All 200/250/300 models) • Change the connecting rod, conrod bearing and crank pin. -
Page 39: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 41: Measuring The Sag Of The Unloaded Rear Wheel
TUNING THE CHASSIS – Turn adjusting screw clockwise with a screwdriver to the last click. Info Do not loosen nut – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) Rebound damping B00792-10 Comfort 28 clicks... -
Page 42: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 43: Adjusting The Riding Sag
TUNING THE CHASSIS Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) Finishing work –... -
Page 44: Adjusting The Compression Damping Of The Fork
Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. B00295-10 Guideline (125 EXC EU, all 200 models) Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks (250/300 EXC EU, 250/300 EXC AUS, 250/300 XC‑W) -
Page 45: Adjusting The Rebound Damping Of The Fork
Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline 800017-10 (125 EXC EU, all 200 models) Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks (250/300 EXC EU, 250/300 EXC AUS, 250/300 XC‑W) -
Page 46: Adjusting The Spring Preload Of The Fork (Exc Eu/Aus, Xc-W)
Info Make the same adjustment on both fork legs. – Turn back clockwise by the number of turns corresponding to the fork type. Guideline (125 EXC EU, all 200 models) Spring preload - Preload Adjuster B00795-01 Comfort 1 turn Standard... -
Page 47: Adjusting The Handlebar Position
TUNING THE CHASSIS 10.16 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. -
Page 48: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand (All 125/200 models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. -
Page 49: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. 303391-10 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 50: Positioning The Fork Protection
SERVICE WORK ON THE CHASSIS 11.6 Positioning the fork protection – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Position the clamp and mount and tighten screws –... -
Page 51: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS (EXC SIX DAYS) – Position the fork legs. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs. -
Page 52: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS Main work – Remove screws on the left fork leg. Lift off the fork protector. – Remove the screws on the right fork leg. Lift off the fork protector. B00801-10 11.10 Installing the fork protector Main work –... -
Page 53: Removing The Lower Triple Clamp (Exc Six Days)
SERVICE WORK ON THE CHASSIS 11.12 Removing the lower triple clamp (EXC SIX DAYS) Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) – Remove the front wheel. p. 82) – Remove the headlight mask with the headlight. ( p. - Page 54 SERVICE WORK ON THE CHASSIS – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.
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Page 55: Installing The Lower Triple Clamp (Exc Six Days)
SERVICE WORK ON THE CHASSIS Finishing work – Mount the handlebar cushion. – Install the front fender. ( p. 56) – Install the front wheel. p. 82) – Refit the headlight mask with the headlight. ( p. 90) – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly. - Page 56 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) B01214-12 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B01215-12 – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite...
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Page 57: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 58: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) Finishing work – Check the play of the steering head bearing. ( p. -
Page 59: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS Main work (All 125/200 models) – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. – Remove screw , push splash protector to the side, and remove the shock absorber. -
Page 60: Removing The Seat
SERVICE WORK ON THE CHASSIS 11.22 Removing the seat – Remove screw . Lift up the seat at the rear, pull it back and then remove from above. B00817-10 11.23 Mounting the seat – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. -
Page 61: Removing The Air Filter
SERVICE WORK ON THE CHASSIS 11.26 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 62: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 131) Info Only squeeze the air filter to dry it; never wring it out. –... -
Page 63: Changing The Glass Fiber Yarn Filling Of The Main Silencer
SERVICE WORK ON THE CHASSIS 11.32 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"... -
Page 64: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Turn handle of the fuel tap to the OFF position. (Figure 601157-10 p. 23) – Pull off the fuel hose. Info Remaining fuel may run out of the fuel hose. – Remove screws with the collar sleeve. -
Page 65: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS – Mount the fuel tank vent hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) (All EXC models) – Position the horn with the horn bracket. B00822-11 –... -
Page 66: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 131) Off-road chain spray ( p. 131) 400725-01 11.37 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –... -
Page 67: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Push the chain at the end of the chain sliding component upwards to measure chain tension Info The bottom chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat this measurement at different chain positions. - Page 68 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even;...
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Page 69: Adjusting The Chain Guide
SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –... -
Page 70: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401347-01 11.42 Checking the swingarm –... -
Page 71: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS (All 250/300 models) – Check the routing of the throttle cable. The throttle cable must be routed behind the handlebar, on the right of the upper frame tube, and to the carburetor. » If the throttle cable is not routed as specified: –... -
Page 72: Checking/Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. -
Page 73: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11.48 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (All 125/200 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. -
Page 74: Removing The Engine Guard (Exc Six Days)
SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from hole of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –... -
Page 75: Brake System
BRAKE SYSTEM 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 76: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 77: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 78: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 79: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the brake linings, insert the pin, and mount the cotter pins. – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point. -
Page 80: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 81: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 82 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
- Page 83 BRAKE SYSTEM – Correct the brake fluid level to marking Brake fluid DOT 4 / DOT 5.1 ( p. 129) – Mount screw cap with membrane and the O-ring. Info Wash off overflowed or spilled brake fluid immediately with water. 400233-10...
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Page 84: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 85: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. -
Page 86: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 87: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 88 WHEELS, TIRES Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 89: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery (All 200/250/300 models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 90: Recharging The Battery (All 200/250/300 Models)
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 91: Changing The Main Fuse (All 200/250/300 Models)
ELECTRICAL SYSTEM 14.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover. -
Page 92: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 14.5 Removing the headlight mask with the headlight – Switch off all power consumers. – Remove screw and take off the clamp. – Release rubber band . Slide the headlight mask up and swing it forward. B00833-10 – Disconnect the electrical plug-in connection and take off the headlight mask with the headlight. -
Page 93: Changing The Turn Signal Bulb (All Exc Models)
ELECTRICAL SYSTEM Main work – Turn rubber cap together with the underlying lamp socket counterclockwise all the way and remove it. – Pull lamp socket of the parking light out of the reflector. 100861-10 – Press headlight bulb lightly into the lamp socket, turn it counterclockwise and pull it out. -
Page 94: Checking The Headlight Setting
ELECTRICAL SYSTEM 14.9 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark a distance under the first mark. - Page 95 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with the washers. 100864-10 Finishing work –...
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Page 96: Cooling System
COOLING SYSTEM 15.1 Cooling system (All 125/200 models) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 97: Checking The Coolant Level
COOLING SYSTEM 15.3 Checking the coolant level 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. -
Page 98: Refilling With Coolant
COOLING SYSTEM (All 250/300 models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) B00835-11 15.5 Refilling with coolant... - Page 99 COOLING SYSTEM – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. B00836-10 Finishing work – Check the coolant level. ( p. 95)
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Page 100: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 101: Carburetor - Adjusting The Idle Speed
– Screw in idle air adjusting screw all the way and turn it to the specified basic position. Guideline Idle air adjusting screw (125 EXC EU, 125 EXC SIX DAYS EU) Open 2.75 turns Idle air adjusting screw (XC-W) Open 2.0 turns... -
Page 102: Emptying The Carburetor Float Chamber
TUNING THE ENGINE Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 23) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall. -
Page 103: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE 16.6 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…... - Page 104 TUNING THE ENGINE Main work – Remove screws B00057-10 – Take cap , adjusting spring , auxiliary spring , and spring insert out of the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring and adjusting spring and slide them into the clutch cover together.
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Page 105: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (All 125/200 models) –... -
Page 106: Draining The Gear Oil
SERVICE WORK ON THE ENGINE 17.3 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 107: Adding Gear Oil
SERVICE WORK ON THE ENGINE – Mount and tighten the screw cap. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. - Page 108 SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight.
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Page 109: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 110: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 111: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 46) – Cover the vehicle with a tarp or cover that is permeable to air. -
Page 112: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 31) tric starter) – Battery discharged Recharge the battery. p. 88) (All 200/250/300 models) – Check the charging voltage. –... - Page 113 TROUBLESHOOTING Faults Possible cause Action – of the fuel tap to the ON posi- Engine stalls or is popping into the Lack of fuel Turn handle carburetor tion. – Refuel. ( p. 34) – Engine takes in bad air Check the intake flange and carburetor for tightness.
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Page 114: Technical Data
TECHNICAL DATA 21.1 Engine 21.1.1 125 EXC EU, 125 EXC SIX DAYS EU Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) -
Page 115: All 250 Models
TECHNICAL DATA 5th gear 17:19 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 21.1.3... -
Page 116: Engine Tightening Torques
TECHNICAL DATA Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48.5 mm (1.909 in) Primary transmission... -
Page 117: All 250/300 Models
TECHNICAL DATA – Axle for control flap, exhaust control Step 1 3 Nm (2.2 lbf ft) Step 2 (loosen, counter- clockwise) 1/4 turn – Nut, cylinder base 30 Nm (22.1 lbf ft) ® Screw, kick starter 25 Nm (18.4 lbf ft) Loctite 243™... -
Page 118: Capacities
Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Secondary ratio (125 EXC EU, 125 EXC SIX DAYS EU) 14:50 (13:50) Secondary ratio (200 EXC EU, 200 EXC AUS) 14:45 Secondary ratio (All 250/300 EXC models) 14:50 (13:50) Secondary ratio (250/300 XC‑W) -
Page 119: Electrical System
Ground clearance unloaded 355 mm (13.98 in) Weight without fuel, approx. (All 200 models) 100.2 kg (220.9 lb.) Weight without fuel, approx. (125 EXC EU, 95 kg (209 lb.) 125 EXC SIX DAYS EU) Weight without fuel, approx. (All 250/300 models) 102.4 kg (225.8 lb.) -
Page 120: Fork
TECHNICAL DATA 21.7 Fork 21.7.1 125 EXC EU, all 200 models Fork part number 14.18.7L.61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping Comfort 20 clicks... -
Page 121: Exc Six Days Eu
TECHNICAL DATA Weight of rider: 85… 95 kg (187… 209 lb.) 4.4 N/mm (25.1 lb/in) Fork length 940 mm (37.01 in) Air chamber length mm (4.33 +0.39 −20 −0.79 Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. -
Page 122: Shock Absorber
TECHNICAL DATA 21.8 Shock absorber 21.8.1 All 125/200 models Shock absorber part number 12.18.7L.61 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns... -
Page 123: Chassis Tightening Torques
TECHNICAL DATA Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (411 lb/in) Spring length 250 mm (9.84 in) Gas pressure... -
Page 124: Carburetor
243™ – Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) 21.10 Carburetor 21.10.1 125 EXC EU, 125 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle... -
Page 125: 21.10.5 250 Exc Eu, 250 Exc Six Days Eu
TECHNICAL DATA Carburetor identification number BM9 0 Needle position 3rd position from top Jet needle N1EI (N1EH / N1EJ) Main jet 158 (160) Idling jet Starting jet Idle air adjusting screw Open 2.0 turns Throttle slide 7 with cut-out Slide stop 21.10.5 250 EXC EU, 250 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG... -
Page 126: 21.10.8 300 Exc Eu, 300 Exc Six Days Eu
Throttle slide 7 with cut-out Slide stop 21.10.10 Carburetor tuning (125 EXC EU, 125 EXC SIX DAYS EU) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. -
Page 127: Carburetor Tuning (All 200 Models)
TECHNICAL DATA 401348-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.11 Carburetor tuning (All 200 models) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. -
Page 128: Carburetor Tuning (All 250 Models)
TECHNICAL DATA 401526-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.12 Carburetor tuning (All 250 models) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. -
Page 129: Carburetor Tuning (All 300 Models)
TECHNICAL DATA 401043-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.13 Carburetor tuning (All 300 models) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. - Page 130 TECHNICAL DATA 401044-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.14 General carburetor tuning 1... 5 Needle position from above The five needle positions are shown here. 0 0 1 The carburetor tuning depends on the defined ambient and operating conditions.
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Page 131: General Carburetor Tuning 16.7 Adjusting The Basic Position Of The Shift 22
SUBSTANCES 2-stroke engine oil According to – JASO FC ( p. 133) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to –... - Page 132 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® –...
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Page 133: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –... - Page 134 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motorex ®...
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Page 135: Engine Characteristic - Auxiliary Spring 24 Standards
STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –... -
Page 136: Index
INDEX Cleaning, care ......107-108 INDEX Clutch Accessories ........8 fluid level, checking/correcting . - Page 137 INDEX Fork Kick starter ........24 basic setting, checking ..... . . 41 Kill switch .
- Page 138 INDEX installing ....... . . 57 removing ....... . . 56 Use definition .
- Page 139 *3211861en* 3211861en 06/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...