KTM 125 EXE 2001 Owner's Handbook Manual
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KTM 125 EXE 2001 Owner's Handbook Manual

KTM 125 EXE 2001 Owner's Handbook Manual

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  • Page 3 PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE. Please insert the series numbers of your motorcycle in the boxes below Chassis number Engine number Stamp of dealer KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATI COLORS MATERIALS...
  • Page 4 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.

  • Page 5: Table Of Contents

    Engine number, engine type ..... .4 General informations about KTM disc brakes ..18 Adjusting of free travel at the hand brake lever .

  • Page 6: Serial Number Locations

    SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.

  • Page 7: Speedometer, Indicator Lamps

    Speedometer, indicator lamps The mileage indicator in the speedometer indicates overall mileage. When the turn indicator is on, the green indicator lamp will be flashing in the same rhythm. The blue indicator lamp will be lit when the high beam is on Ignition lock Switch positions of ignition lock = Ignition off...

  • Page 8: Filler Cap

    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 without kinks. Fuel This motorcycle is equipped with separate lubrication. This means that the two-stroke oil required for engine lubrication is not admixed to the fuel but contained in a separate oil tank (see below).

  • Page 9: Oil Tank

    Engine oil: 2-stroke engine oil suitable for a mixing ratio of 1:50 and for separate lubrication KTM recommends SHELL ADVANCE Ultra 2 To open it: pull vent hose out of the frame and turn closure cap counter- clockwise. To close it: apply closure cap and turn it clockwise. Stick vent hose into frame and install it without kinks.

  • Page 10: Steering Lock

    Steering lock The handlebar can be locked by means of the lock located on the steering head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw. CAUTION EVER LEAVE THE KEY INSERTED IN THE STEERING LOCK F YOU TURN THE HANDLE BAR TO THE LEFT THE KEY COULD GET DAMAGED Center stand...

  • Page 11: Compression Damping Of Shock Absorber

    Compression damping of shock absorber The damping force of the compression damping can be adjusted with knob The higher the number the higher the damping force. STANDARD ADJUSTMENT: WP 1218T715......3 clicks WARNING HE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN EVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN...

  • Page 12: Driving Instructions

    – Motorcycle ready for operation and tank full Arrange for the braking system to be checked by a KTM – Luggage specialist garage, as complete failure of the braking system –...

  • Page 13: Starting Off

    Starting when the engine is cold a) Open the fuel tap b) Turn on the ignition (ignition key position: c) Switch the gear to NEUTRAL d) Operate the choke lever e) Swing up the stand. f) Push the kick starter right the way down without accelerating.
  • Page 14 Shifting/Riding WARNING You are now in first gear, refered to as the drive or uphill gear. F THE RADIATOR CAP IS REMOVED WHEN THE ENGINE IS HOT HOT COO Depending on the conditions (traffic, road gradient, etc.), you LING LIQUID THAT IS UNDER PRESSURE CAN SPRAY OUT AND CAUSE can shift to a higher gear.

  • Page 16: Periodic Maintenance

    125 EXE PERIODIC MAINTENANCE 2001 125 SUPERMOTO every 1. Service after 2. Service after 4000 km A washed motorcycle can be checked more quickly which saves money! 1000 km 4000 km once a year Check oil level in oil tank and verify kink-less arrangement of bleeder hose Change transmission oil Check spark plug, set electrode gap, replace plug if necessary Check carburetor connection boots for cracks and leaks...
  • Page 17 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check oil level in oil tank and bleeder hose for its kink-less arrangement Check transmission oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals...

  • Page 18: Maintenance Work On Chassis And Engine

    MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOW- LEDGE. FOR YOUR OWN SAFETY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER CAUTION – W HEN CLEANING THE MOTORCYCLE...

  • Page 19: Checking And Adjusting The Steering Head Bearing

    Checking and adjusting the steering head bearing * Check steering head bearing for play periodically. For check put motorcycle on stand so that the front wheel is off the ground. Now try to move the fork forward and backward. For readjusting, loosen the five pinch bolts of the top triple clamp and turn steering stem bolt clockwise until there is no more play.

  • Page 20: Breather Plug Front Fork

    Changing the spring preload of the shock absorber * KTM sets the shock absorber for driver only, weighing approximately 75 kg (165 lb). If you want to take a passenger with you, of if you weigh consi- derably more or less than 75 kg (165 lb), you should change the spring pre- load accordingly.

  • Page 21: Pivot Bearing

    Pivot bearing The pivot bearing for PDS suspension struts at the swinging fork is Teflon-coated and must not be lubricated with either grease or other lubri- cants. Grease and other lubricants cause the Teflon coat to dissolve, whereby the bearing’s lifecycle will be reduced dramatically. When cleaning your bike with a high-pressure cleaner, do not aim the high- pressure spray directly at the pivot bearing.

  • Page 22: Chain Maintenance

    In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 23: Adjusting Of Free Travel At The Hand Brake Lever

    Adjusting of 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 min.

  • Page 24: Checking Rear Brake Fluid Level

    Changing the basic position of the foot brake pedal * The basic position of the foot brake pedal can be altered by turning the stop screw . The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20 in) of free play, before the piston rod can move the piston in the...

  • Page 25: Dismounting And Mounting The Front Wheel

    Dismounting and mounting the front wheel * To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws on the left fork leg. Then loosen the collar nuts before loosening the clamp screws on the right fork leg.

  • Page 26: Tires, Air Pressure

    (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING...

  • Page 27: Main Fuse

    Main fuse The main fuse , which is located above the carburetor, protects the follo- wing current consumers: – Brake light – Parking light – Flasher lights – Horn Rated fuse current is 10 amperes CAUTION NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE “...

  • Page 28: Cooling System

    Cooling system Coolant is circulated by a water pump located in the engine. When the engine is cold, the cooling liquid circulates only through the cylinder and cylinder head. As soon as the cooling liquid has reached a tem- perature of approx. 65°C, the thermostat opens and the cooling liquid is pumped through the radiator.

  • Page 29: Checking The Oil Level Of The Hydraulic Durch

    Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws and cover together with the rubber boot . The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge.

  • Page 30: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 31 TROUBLE CAUSE REMEDY Engine will not reach full Fuel supply partically interrupted or Clean and check fuel system as well as carburettor power carburettor dirty float is not tight replace the float Air filter very dirty Clean or replace air filter Exhaust leaking or blocked Check if exhaust is damaged Electronical ignition timing faulty...

  • Page 32: Cleaning

    CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 33: Technical Specifications Chassis

    TECHNICAL SPECIFICATIONS CHASSIS 125 EXE / 125 SUPERMOTO 2000 125 EXE 125 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 40 TA Wheel travel front/rear 220/260 mm (8,7/10,2 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc, brake caliper floated Front brake disc...
  • Page 34 TECHNICAL DATA - ENGINE 125 EXE / 125 Supermoto 2000 Engine 125 EXE Design Liquid-cooled single-cylinder two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm Bore / stroke 54,0 / 54,5 mm (2.125 / 2.145 in) Fuel unleaded fuel with a least RON 91 Lubrication separate lubrication Oil / gasolin ratio...

  • Page 35: Head Word Index

    Breather plug front fork ............16 Fuel ..................6 Center stand .................8 Fuel tap ................6 Chain maintenance .............18 General informations about KTM disc brakes ......18 Chain wear .................18 Hand brake lever ..............4 Changing the basic position of the brake pedal....20 Head word index ..............31 Changing the original position of the clutch lever ....25...

This manual is also suitable for:

125 supermoto 2001

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