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IGNORING THESE INSTRUCTIONS, CAN BE DANGEROUS TO LIFE AND LIMB. IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC SAFETY. Please insert the serial numbers of your motorcycle in the boxes below Chassis number Engine number Key number Stamp of dealer...
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We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed by a KTM workshop. If mainten- ance work should become necessary during a competition, it must be performed by a trained mechanic.
2-STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS KTM EXC and MXC 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.
SERIAL NUMBER LOCATIONS 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.
The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.
The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display. If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped.
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The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.
SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received.
SETUP menu NOTE: If you retrofit this Tripmaster on another motorcycle, the power can also be supplied by the 12 V vehicle electric system. You will need an additional cable harness, spare part no. 583.14.069.210, which you can order from your KTM dealer.
Short circuit button (SX) The short circuit button the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. = Light off (this function is not available in all models) = Low beam on = High beam on You may use button to actuate the horn.
2,3,4,5 (6) Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON.
Push the side stand to the ground with your foot and load it with the motorcycle. Make sure that you put your bike on solid ground and in a secure position. For off-road riding, you can use the rubber band additionally secure the center stand in its folded-up position.
Control). Low and high speed refers to the movement of the shock absorber during compression 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...
Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for your first ride – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Thoroughly read the whole instruction manual before starting for your first tour.
Arrange for the braking system to be checked by an authorized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings.
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH LWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING CAUTION O NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP THE ENGINE WHEN COLD INCE THE PISTON WARMS UP AND EXPANDS FASTER THAN THE WATER...
Mixture ratio 1:40 - 1:60 Fuel and engine oil should only be mixed immediately before E RECOMMEND YOU RUN use. KTM recommends Motorex Cross Power 2T. ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS SHOULD BE USED WHEN HANDLING GASOLINE...
Treat electric contacts and switches with contact grease Change hydraulic clutch fluid Change break fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! ERVICE NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN AINTENANCE WORK DONE BY...
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MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box...
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ECOMMENDED INSPECTION OF THE USED FOR ENDURO COMPETITIONS BY YOUR Check the reed-type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing...
MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF.
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 mainte- nance service.
The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. 4,0 N/mm...
Adjusting the spring preload on the fork (SX) The spring preload on the SX models can be adjusted (changed) by 10 mm by turning adjusting screw Turning in a clockwise direction will increase the prestress, turning in a counterclockwise direction will decrease the prestress. Changing the spring preload will not affect the rebound damping adjustment.
Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer tou- ches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 8 - 10 mm (0.31 - 0.39 in).
O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL HEN MOUNTING THE CHAIN JOINT POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear, and replace if necessary.
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake fluids is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
min. 1 mm Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw . In this way, the position of the point of pressure (i.e. the resis- tance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size.
Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motorcycle on the rear brake cylinder. No air bubble should be visible in inspection glass parked in a vertical position.
PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground.
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer tou- ches the ground. Loosen the collar nut...
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer.
Check/set distance of the magnetic sensor The distance between the magnet and the sensor must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing the sensor in or off. Replacing the headlight lamp/parking light lamp Loosen both rubber bands and tilt the headlight mask to the front.
Remount the radiator protection. NOTE: The radiator shutter can be obtained from your KTM dealer Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see diagram).
The SX models do not have a throttle cap. O NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE . KTM THE FOAM RECOMMENDS THE PRODUCTS MADE BY MAINTENANCE...
SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased at your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with biode-...
(basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the air control screw. and start the motorcycle. GRADE TWO STROKE ENGINE OIL THER TYPES OF 2T).
JET NEEDLE RANGE OF ACTION TYPE RICHER NOZD NOZE NOZF NOZG NOZH 60° Opening up main jet Engine behavior when the throttle opens. The idle jet and the shape of the jet needle throttle valve influences this range. If, despite good idling-speed and part- throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level...
Make sure you do not turn the dolly screw since this will impair the engine characteristic. If you prefer a smoother engine power application, you can mount a diffe- rent ignition rotor and a different exhaust. Ask your KTM dealer for more information.
TOO LITTLE OR LOW GRADE OIL Changing the transmission oil (125/200) * To change the gear oil warm up the engine and park the motorcycle on a horizontal surface. Remove oil drain plugs into an appropriate container. Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets.
– 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.
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TANDARD DJUSTMENT 125/200 SX WP 4860 MXMA 1418Y743 Compression adjuster Rebound adjuster Spring 4,2 N/mm Spring preload 6 mm Air chamber length 90 mm Fork oil SAE 5 TANDARD DJUSTMENT HOCK 125/200 SX WP 5018 PDS-DCC 1218Y767 Compression adjuster 17 LS (low speed) 2 HS (high speed) Rebound adjuster Spring...
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Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and clutch cover bolts Spark plug Swingarm pivot Other screws BASIC CARBURETOR SETTING 125 SX Carburetor Keihin PWK 39 Carburetor setting number 141102 Main jet 188 (185/190) Idling jet...