KTM 125 EXC 2015 Setup Instructions
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KTM 125 EXC 2015 Setup Instructions

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SETUP INSTRUCTIONS
2015
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AU
200 XC‑W US
250 EXC EU
250 EXC AU
250 EXC SIX DAYS EU
250 XC‑W US
300 EXC EU
300 EXC AU
300 EXC SIX DAYS EU
300 EXC BR
300 XC‑W US
300 XC‑W SIX DAYS US
Art. no. 3213196en

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Summary of Contents for KTM 125 EXC 2015

  • Page 1 SETUP INSTRUCTIONS 2015 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AU 200 XC‑W US 250 EXC EU 250 EXC AU 250 EXC SIX DAYS EU 250 XC‑W US 300 EXC EU 300 EXC AU 300 EXC SIX DAYS EU 300 EXC BR 300 XC‑W US...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 5 SETUP Unpacking and setting up the vehicle Packaging 2 – Remove the box and the plastic packaging. Info An assistant prevents the motorcycle from falling over. To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you have finished. –...
  • Page 6 SETUP – Route the clutch line with the clutch master cylinder toward the front between the upper and lower triple clamps. (EXC, XC‑W) – Position the fork legs and tighten the screws of the triple clamp. Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) Screw, bottom triple clamp...
  • Page 7 SETUP – Position the controls on the right half of the handlebar. Info The routing of the cables can be seen in the figure. B02185-01 – Position the controls on the left half of the handlebar. Info The figure shows how to route the clutch line and wiring harness. B02186-01 (All EXC models) –...
  • Page 8 SETUP (SIX DAYS EU) – Mount the turn signal switch and connect the plug-in connector with the wiring harness. 402148-01 (All XC-W models) – Connect pull switch  with the yellow and white cables. – Install the front fender. ( p.
  • Page 9 Set the clock. ( p. 17) – Position all controls in their exact positions on the handlebar. Tighten all screws. – Refuel. ( p. 15) – Print out the current PDI form found on KTM DEALER.NET and perform the B00909-01 pre-delivery inspection.
  • Page 10 WORK Raising the motorcycle with the lift stand 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. Lift stand (54829055000) The wheels are no longer in contact with the ground.
  • Page 11 WORK –  Mount and tighten screw of the seat fixation. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00817-10 Removing the fuel tank 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.
  • Page 12 WORK Installing the fuel tank 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 13: Tighten Screws

    WORK Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. (All 250/300 models) –...
  • Page 14 – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 15 WORK 3.10 Installing the battery (All 200/250/300 models) Main work – Insert the battery into the battery compartment with the terminals facing to the front. (All 200/250/300 EU/AU/US models) Battery (YTX4L-BS) (300 EXC BR) Battery (YTX5L-BS) – Attach rubber band ...

  • Page 16: Checking The Headlight Setting

    WORK 3.12 Refitting the headlight mask with the headlight Main work –  Connect the electric plug connector 602763-10 –  Position the headlight mask and fix it with the rubber band Info Ensure that the holding lugs engage in the fender. –...

  • Page 17: Tighten Screw

    WORK –  Tighten screw 3.15 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 18 WORK – Switch off the engine. – Open the filler cap. ( p. 15) – Fill the fuel tank with fuel up to measurement  Guideline 35 mm (1.38 in)  Measurement of Total fuel tank 9.5 l Super unleaded (95 octane) mixed capacity, approx.

  • Page 19: Setting The Clock

    WORK Info If no button is pressed for 10–12 seconds, the settings are automatically stored. If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the Setup menu is closed.

  • Page 20: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) – Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) – Remaining nuts, chassis 5 Nm (3.7 lbf ft) – Remaining screws, chassis 5 Nm (3.7 lbf ft) –...
  • Page 21 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 21) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 22: Auxiliary Substances

    AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000...
  • Page 23 STANDARDS JASO FD JASO FD 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.
  • Page 24 *3213196en* 3213196en 06/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

125 exc six days 2015200 exc 2015200 xc-w 2015250 exc 2015250 exc six days 2015250 xc-w 2015 ... Show all

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