KTM 125 EXC, EXC SIX DAYS, 200 XC, XC-W, EXC, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, XC-W, EXC-E, EXC-E SIX DAYS Owner's Manual
Ktm owner's manual motorcycle 125 exc, exc six days 200 xc, xc-w, exc 250 xc, xc-w, exc, exc six days 300 xc, xc-w, exc-e, exc-e six days
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Also See for 125 EXC, EXC SIX DAYS, 200 XC, XC-W, EXC, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, XC-W, EXC-E, EXC-E SIX DAYS:
- Owner's manual (150 pages) ,
- Owner's handbook manual (45 pages) ,
- Manual (12 pages)
Related Manuals for KTM 125 EXC, EXC SIX DAYS, 200 XC, XC-W, EXC, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, XC-W, EXC-E, EXC-E SIX DAYS
Summary of Contents for KTM 125 EXC, EXC SIX DAYS, 200 XC, XC-W, EXC, 250 XC, XC-W, EXC, EXC SIX DAYS, 300 XC, XC-W, EXC-E, EXC-E SIX DAYS
- Page 1 OWNER’S MANUAL 2008 125 EXC, EXC SIX DAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXC SIX DAYS 300 XC, XC-W, EXC-E, EXC-E SIX DAYS 3211226en...
- Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
- Page 3 2-STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS KTM EXC and EXC-E models were designed for offroad use only and are only suitable for longer rides on public roads to a certain extent. The engine is subjected to completely different performance demands on public roads and must be adapted to these operating conditions.
- Page 4 SPARE PARTS, ACCESSORIES For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. TRANSPORT When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position.
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Page 5: Table Of Contents
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......16 Instructions for your first ride ....16 Running in . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. -
Page 7: Electronic Speedometer
H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motor- cycles, making the service hour counter a very practical function. - Page 8 SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press button Changes to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures...
- Page 9 OPERATION INSTRUMENTS » LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds.
- Page 10 OPERATION INSTRUMENTS » SPEED / S1 display mode (stop watch 1) S1 shows the traveling time based on TR1 and continues to run whenever it receives impulses from the wheel sensor. The calculation of this figure is acti- vated by the first impulse received from the wheel sensor and stops 3 sec- onds after the last impulse is received.
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Page 11: Indicator Lamps (Exc)
OPERATION INSTRUMENTS display briefly press + button SPEED / H SPEED / CLK starts/stops LAP without SPEED / LAP clearing LAP figure LAP / LAP SPEED / ODO SPEED / TR1 SPEED / TR2 increases the TR2 figure SPEED / A1 SPEED / A2 SPEED / S1 SPEED / S2... -
Page 12: Combination Switch (Exc)
OPERATION INSTRUMENTS » Combination switch (EXC/EXC Six Days) The light switch has 2, respectively 3 switch positions. [A] = Light off (this function is not available in all models) [B] = Low beam on [C] = High beam on You may use button [2] to actuate the horn. The red short circuit button [3] serves to switch off the engine. -
Page 13: Filler Cap
OPERATION INSTRUMENTS » Emergency OFF switch (EXC-E Australia) The red emergency-OFF switch [1] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. -
Page 14: Shift Lever
» OPERATION INSTRUMENTS Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. 2,3,4,5, (6) Kickstarter The kickstarter is mounted on the left side of the engine. -
Page 15: Compression Damping Of Fork
OPERATION INSTRUMENTS » Compression damping of fork (XC) Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the top of the fork legs. Turn the screw [1] clockwise to increase damping, turn it counterclockwise to reduce damping during compression. -
Page 16: Shock Absorber Compression Damping
(Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.The high-speed setting is effective at fast compression rates. -
Page 17: General Tips And Warnings For Starting The Motorcycle
Do not drive at full load for the first 500 kilometers (300 miles) or 5 hours! – Wear suitable clothing when driving a motorcycle. smart KTM drivers always wear a helmet, boots, gloves, and a jacket, regardless of whether driving all day or just go for a short ride. -
Page 18: Driving Instructions
Arrange for the braking system to be checked by an author- ized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings. -
Page 19: Starting When The Engine Is Cold
Always pro- vide adequate ventilation while the engine is running. Do not ride your motorcycle with full load and do not rev up the engine when cold. Since the piston warms up and expands faster than the water cooled cylinder, this might cause engine damage. -
Page 20: Shifting/Riding
– In the event that, while riding on your motorcycle, you notice any unusual operation-related noise, stop immediately, turn the engine off, and contact an authorized KTM dealer. Braking Close the throttle and apply the hand and foot brake simultane- ously. -
Page 21: Periodic Maintenance Schedule
Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver! »... - Page 22 PERIODIC MAINTENANCE SCHEDULE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle...
- Page 23 Clean and lubricate chain, clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver! »...
- Page 24 PERIODIC MAINTENANCE SCHEDULE 250/300 XC/XC-W/EXC/EXC Six Days/EXC-E/EXC-E Six Days 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle...
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Page 25: Maintenance Work On Chassis And Engine
OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out. -
Page 26: Basic Suspension Setup For The Weight Of The Driver
EXAMPLE: Motorcycle jacked up (dimension A) ..... .600 mm Motorcycle on ground, unloaded (dimension B) ... .– 565 mm Static sag . -
Page 27: Changing The Spring Preload On The Telescopic Fork
[2] a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on the road, it will suffice to have this job performed in the course of the periodical maintenance service. -
Page 28: Cleaning The Dust Sleeves Of The Telescopic Fork
Checking and adjusting the steering head bearing * Check steering head bearing for play periodically. To check, put the motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. -
Page 29: Changing The Fork Offset (Caster) Xc/Exc Six Days
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) XC/EXC Six Days * The fork offset [A] in the XC/EXC Six Days models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the handling to match the race course. -
Page 30: How To Change The Handlebar Position
» MAINTENANCE WORK ON CHASSIS AND ENGINE Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw. Tighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages. -
Page 31: Adapting Chain Guide To The Rear Sprocket
Remount the chain guide and tighten the screws. Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The dis- tance between the chain and the swing arm should be approx. -
Page 32: Check Chain Tension
– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. -
Page 33: General Information About Ktm Disc Brakes
DOT 4 brake fluid. Do not, in any event, use DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTM motor- cycle gaskets and brake hoses are not designed for DOT 5 brake fluid. -
Page 34: Changing Basic Position Of The Hand Brake Lever
If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4]. -
Page 35: Replacing The Front Brake Pads
If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A]. -
Page 36: Changing The Basic Position Of The Foot Brake Pedal
MAINTENANCE WORK ON CHASSIS AND ENGINE 3-5mm min. 1 mm Changing the basic position of the foot brake pedal * To change the basic position of the foot brake lever, loosen the counternut [1] and turn the stop screw [2] as needed. Be sure to adjust the free travel of the foot brake lever. -
Page 37: Dismounting And Mounting The Front Wheel
– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. -
Page 38: Dismounting And Mounting The Rear Wheel
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle behaves. -
Page 39: Checking Spoke Tension
Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. – Spokes can tear if you continue to ride with them loose. This may lead to an unstable handling of your motorcycle. -
Page 40: Battery
Quick charging at a high amperage has an adverse effect on the service life. To charge the battery while mounted, always use the KTM battery charger (Item no. 58429074000) to ensure that the electric system is not damaged by excess voltage. -
Page 41: Fuse
Replace a blown fuse only with an equivalent one. If a new fuse that has just been installed gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere. Under no circumstances is a stronger fuse allowed to be installed or a fuse allowed to be “repaired”. -
Page 42: Checking The Coolant Level
[3] and filter support [4] from the filter box. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter maintenance (Dirt Bio Remover and Liquid Bio Power). -
Page 43: Checking The Oil Level Of The Hydraulic Clutch
Exhaust system * If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to “burn out”. -
Page 44: Bleeding The Hydraulic Clutch
Please note that Motorex 75 clutch fluid must be used for the 125/200 models and Motorex DOT. 5.1 brake fluid for the 250/300 models. Both are available from your KTM dealer. Turn the handlebar until the master cylinder is in a horizontal position, remove the screws [1], the cover [2] and the rubber boot [3]. - Page 45 MAINTENANCE WORK ON CHASSIS AND ENGINE JET NEEDLE RANGE OF ACTION TYPE RICHER N8RG N8RH N8RW N8RJ JET NEEDLE RANGE OF ACTION TYPE RICHER NOZD NOZE NOZF NOZG NOZH NOZI Definitions Mixture too rich: Too much fuel in proportion to air. Mixture too lean: Not enough fuel in proportion to air.
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Page 46: Draining The Float Chamber Of The Carburetor
» MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber leads to engine malfunction. Make sure you do this while the engine is cold. -
Page 47: Adjusting The Engine Characteristic Via The Auxiliary Spring
Auxiliary spring for aggressive engine characteristic (included in scope of sup- ply). Spare part number 548.37.072.000, RED color mark To mount, tilt the motorcycle approx. 45° to the left, remove both screws [2], lift off the closing cover [3] and remove the springs including the spring insert [4] from the clutch cover. -
Page 48: Check Transmission Oil Level
4T 15W50). Changing the transmission oil (125/200) * To change the gear oil warm up the engine and park the motorcycle on a hor- izontal surface. Remove oil drain plugs [3] and [4] and drain the used oil into an appropriate container. Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets. -
Page 49: Cleaning
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes. -
Page 51: Technical Specifications - Chassis 125 / 200
Weight (without fuel) 125/200 EXC/EXC Six Days 200 XC 200 XC-W * further tire releases are available on the Internet at www.ktm.com 125/200 XC/XC-W/EXC/EXC SIX DAYS Central chrome-moly-steel frame WP Suspension – 4860 MXMA PA (Open Cartridge) WP Suspension – 4860 MXMA CC (Closed Cartridge) 300/335 mm (11.8/13.2 in) - Page 52 TECHNICAL SPECIFICATIONS – CHASSIS 125 EXC/SIX DAYS, 200 XC/XC-W/EXC 2008 STANDARD ADJUSTMENT – FORK 125/200 XC-W/EXC WP 4860 MXMA PA 14187D02 Compression adjuster 22 clicks Rebound adjuster 22 clicks Spring 432.505.00.040W Preload Adjuster 2 turns Air chamber length 110 mm (4,3 in) Fork oil SAE 5 STANDARD ADJUSTMENT –...
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Page 53: Technical Specifications - Engine 125 / 200
TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 ENGINE 125 EXC/EXC SIX DAYS Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm Bore / stroke 54 / 54.5 mm (2.126 / 2.145 in) Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil Oil / gasoline ratio... - Page 54 TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 BASIC CARBURETOR SETTING 125 EXC EU 4.4 KW Carburetor Keihin PWK 36S AG Carburetor setting mark FK019 Main jet 140 (168/170/172) Idling jet 38x38 (45/48) Starting jet 50 (85) Jet needle R84I (NOZE/NOZF) Needle position from top 5 (4)
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Page 55: Technical Specifications - Chassis 250 / 300
250 XC-W USA 300 EXC-E/EXC-E Six Days 300 XC 300 XC-W * further tire releases are available on the Internet at www.ktm.com 250 XC/XC-W/EXC/EXC SIX DAYS 300 XC/XC-W/EXC-E/EXC-E SIX DAYS Central chrome-moly-steel frame WP Suspension – 4860 MXMA CC (Closed Cartridge) WP Suspension –... - Page 56 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC-E/EXC-E SIX DAYS 2008 STANDARD ADJUSTMENT – FORK 250/300 XC-W/EXC/EXC-E 250/300 EXC-E EXC-E SIX DAYS 250/300 XC WP 4860 MXMA PA WP 4860 MXMA PA WP 4860 MXMA CC 14.18.7D.04 Compression adjuster 22 clicks Rebound adjuster 20 clicks Spring 432.505.00.042W 432.505.00.044W 432.455.00.044W...
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Page 57: Technical Specifications - Engine 250
250 EXC 250 EXC SIX DAYS Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber 249 ccm 66.4 / 72 mm (2.62 / 2.84 in) unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil (Motorex Cross Power 2T) 1:60 when using high grade, two- stroke oil. - Page 58 TECHNICAL SPECIFICATIONS – ENGINE 250 XC/XC-W/EXC/EXC SIX DAYS 2008 BASIC CARBURETOR SETTING 250 XC Carburetor Keihin PWK 36S AG Carburetor setting mark FK022 Main jet 168 (170) Idling jet Starting jet Jet needle N8RH (N8RG) Needle position from top Throttle valve Air adjustment screw open 1 Performance restrictor TIGHTENING TORQUES - ENGINE...
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Page 59: Technical Specifications - Engine 300
Air-filter 300 XC Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber 293 ccm 72 / 72 mm (2.84 / 2.84 in) unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil (Motorex Cross Power 2T) 1:60 when using high grade, two- stroke oil. - Page 60 TECHNICAL SPECIFICATIONS – ENGINE 300 XC/XC-W/EXC-E/EXC-E SIX DAYS 2008 BASIC CARBURETOR SETTING 300 XC 300 XC-W 300 EXC-E SIX DAYS Carburetor Keihin PWK 36S AG Carburetor setting mark FK024 Main jet 165 (162) Idling jet Starting jet Jet needle N2ZJ (N2ZW) Needle position from top Throttle valve Air adjustment screw open 1...
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Page 61: Wiring Diagram
» SCHALTPLAN WIRING DIAGRAMM... - Page 62 » SCHALTPLAN WIRING DIAGRAMM...
- Page 63 » SCHALTPLAN WIRING DIAGRAMM...
- Page 64 » SCHALTPLAN WIRING DIAGRAMM...
- Page 65 » SCHALTPLAN WIRING DIAGRAMM c t i g i l c t i c t i c t i c t i...
- Page 66 » SCHALTPLAN WIRING DIAGRAMM ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Flasher switch Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Horn button Ignition coil Ignition curve selector Ignition switch Left front flasher Left rear flasher...
- Page 67 » SCHALTPLAN WIRING DIAGRAMM ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Flasher switch Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Horn button Ignition coil Ignition curve selector Ignition switch Left front flasher Left rear flasher...
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Page 68: Carburetor Table
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. - Page 69 EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles.
- Page 70 » VERGASERTABELLE VERGASERREGULIERUNG CARBURETOR SETTING 250 XC 2008 KEIHIN PWK 36S AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C ALTITUDE TEMPERATURE -2°F to 20°F 3000 m 10000 ft NADEL NEEDLE N8RH 2301 m 7501 ft 2300 m 7500 ft NADEL NEEDLE N8RG 1501 m 5001 ft...
- Page 71 Modelos EXC/EXC-E: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.
- Page 72 Modelos EXC/EXC-E: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.
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Page 73: Index
....43 General information about KTM disc brakes ..32 General tips and warnings for starting the motorcycle . .16 Hand brake lever . - Page 74 *3211226en* 3211226en KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com...