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BEDIENUNGSANLEITUNG2005 125 SX, EXC 200 EXC 250 SX, EXC 300 MXC, EXC OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.38...
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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.
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KTM workshop. If maintenance work should become necessary during a competition, it must be performed by a trained mechanic. 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.
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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.
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.
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» OPERATION INSTRUMENTS Activating and deactivating display modes In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blink- ing function can be activated by pressing the + button and deactivated by pressing the –...
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» 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.
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» OPERATION INSTRUMENTS SPEED / A2 display mode (average speed 2) A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.
» OPERATION INSTRUMENTS Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the button to move to the next digit.
» OPERATION INSTRUMENTS Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) 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.
» OPERATION INSTRUMENTS 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 [1] without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carbure- tor.
» OPERATION INSTRUMENTS Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work).
» OPERATION INSTRUMENTS Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap [1]. Turn the screw [2] clockwise to increase damping, turn it counterclockwise to reduce damping during compression.
» OPERATION INSTRUMENTS 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 [1] with a screwdriver.
» GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for your first ride – Verify that your KTM dealer performed the PREPARATION OF – WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. SMART VEHICLE jobs (see Customer Service Manual). KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES, AND A –...
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.
» DRIVING INSTRUCTIONS Starting when the engine is cold 1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Swing up the side stand 4 Put the gear in neutral 5 Activate cold-starting aid (choke) 6 Leave throttle closed or open it no more than 1/3 and kick down kick- starter vigorously all the way.
TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. Stopping and parking Brake motorcycle and shift gears to idling. To switch off the engine, depress short circuit switch until the engine stops or switch off ignition.
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!
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» PERIODIC MAINTENANCE SCHEDULE IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER before after for cross once each every country start cleaning year 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...
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» PERIODIC MAINTENANCE SCHEDULE RECOMMENDED INSPECTION OF THE 125/200/250/300 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) hours hours hours hours hours hours Check the reed-type intake valve for wear...
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.
To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 60 - 70 kg (wear- ing full protective clothing).
The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder 12187A01 69-250 72-250 76-250 spring. 125 SX 12187A02 69-250 72-250 76-250 125/200 EXC 12187A03...
The type number of the telescopic fork is embossed on the inside of the fork leg axle passage. If you are uncertain which spring to use, contact your KTM workshop. 4,4 N/mm 4,2 N/mm According to our experience, the damping rate of the compression stage can remain unchanged.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) (SX) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course.
» 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 80 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 stages.
» MAINTENANCE WORK ON CHASSIS AND ENGINE How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp [1] includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another.
Tighten collar nut [1] to 80 Nm (60 ft.lb). – 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 BEHAV- IOR OF YOUR MOTORCYCLE.
– A BRAKE DISK WORN DOWN TO LESS THAN 2.50 MM (FRONT) / 3.50 MM (REAR) IS A SAFETY RISK. HAVE THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT. – HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER. BRAKE FLUID RESERVOIRS:...
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 AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4].
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 AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].
» MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in). 1 mm AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE.
10 Nm(7 ft. lbs). – 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 BEHAV- IOR OF YOUR MOTORCYCLE.
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. TIRES – AIR PRESSURE – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER front rear TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Check/set distance of the magnetic sensor The distance between the magnet [2] and the sensor [1] must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing the sensor [1] 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). In the event of the coolant being drained, always fill and bleed the system.
The SX models do not have a throttle cap. – DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID BIO POWER).
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex Kupplungs- fluid 75), available from your authorized KTM workshop. KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON- TROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the spark arrestor (EXC USA) * With these models, the spark arrestor is part of the exhaust silencer. Clean it every 4000 km (2500 miles) to guarantee proper functioning. Also clean the spark arrestor when replacing the glassfiber yarn filling.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Part-throttle range C main jet Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled jet needle by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by jet needle...
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 different ignition rotor and a different exhaust. Ask your KTM dealer for more information.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Check transmission oil level (125/200) In order to check the transmission oil level the control screw [1] on the clutch cover is to be removed. Oil should just barely escape from the inspection open- ing when the motorcycle is in an upright position.
» 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. NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET.
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» SCHALTPLAN WIRING DIAGRAMM ENGLISH DEUTSCH ITALIANO Capacitor Kondensator Condensatore Driving light lamp Fernlichtkontrolle Spia abbagliante Flasher relay Blinkerrelais Relè indicatori Flasher switch Blinkerschalter Deviatore indicatori di direzione Front brake switch vorderer Bremslichtschalter Interruttore luce ant. di stop Flasher control lamp Blinkerkontrolle spia lampeggiatori Generator...
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» SCHALTPLAN WIRING DIAGRAMM ENGLISH FRANCAIS ESPANOL Capacitor Condensateur Condensador Driving light lamp Temion feu route Lampara aviso luces largas Flasher relay Relais de clignotants Relé de la luz intermitente Flasher switch Bouton de clignotants Interruptor de la luz intermitente Front brake switch Contacteur de frein avant Interruptor de luz del freno delantero...
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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.
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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.
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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.
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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.
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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.
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