Related Manuals for KTM 125 EXC 2016
Summary of Contents for KTM 125 EXC 2016
- Page 1 OWNER'S MANUAL 2016 125 EXC 200 EXC 200 XC‑W 250 EXC 250 XC‑W 300 EXC 300 XC‑W Art. no. 3213334en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Setting kilometers or miles....... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Setting the speedometer functions....21 Symbols used ........... 5 Setting the clock..........21 Formats used............ 5 Viewing the lap time........21 SAFETY ADVICE............6 Display mode SPEED (speed) ...... - Page 5 TABLE OF CONTENTS 11.10 Adjusting the riding sag ....... 45 12.43 Adjusting the basic position of the clutch lever .............. 77 11.11 Checking the basic setting of the fork ....45 12.44 Checking/correcting the fluid level of the 11.12 Adjusting the compression damping of the hydraulic clutch..........
- Page 6 TABLE OF CONTENTS 17.3 Carburetor - idle..........106 23 CARBURETOR TUNING ..........134 17.4 Carburetor - adjusting the idle speed ... 107 23.1 Carburetor tuning (All 125 models) ..... 134 17.5 Emptying the carburetor float chamber ..108 23.2 Carburetor tuning (All 200 models) .....
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (All EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) 102249-10 Hand brake lever ( p. 13) Light switch ( p. 14) Kill switch ( p. 13) Turn signal switch ( p. 14) Horn button ( p. 14) Kill switch ( p. -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) 102250-10 Filler cap Throttle grip ( p. 13) Chassis number ( p. 11) Kick starter ( p. 18) Foot brake lever ( p. 18) Level viewer for brake fluid, rear... -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401946-10 Type label The type label is fixed to the front of the steering head. 401946-10 Key number (All EXC models) ... -
Page 14: Shock Absorber Article Number
SERIAL NUMBERS Shock absorber article number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10... -
Page 15: Controls
CONTROLS Clutch lever (All 125/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 102251-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. -
Page 16: Kill Switch (All Xc-W Models)
CONTROLS Kill switch (All XC-W models) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition circuit is closed and • Kill switch the engine can be started. pressed –... -
Page 17: Emergency Off Switch (Exc Au)
CONTROLS 6.10 Emergency OFF switch (EXC AU) The emergency OFF switch is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a run- ning engine stops, and a non-running engine will not start. Ignition on –... -
Page 18: Opening The Filler Cap
CONTROLS 6.15 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 19: Fuel Tap
CONTROLS 6.17 Fuel tap The fuel tap is on the left side of the fuel tank. Tap handle on the fuel tap is used to open or close the supply of fuel to the carbu- retor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. •... -
Page 20: Kick Starter
CONTROLS 6.20 Kick starter Kick starter is fitted on the right side of the engine. The top part of the kick starter pivots. Info 0 0 1 Before riding, swing the top part of the kick starter inward toward the engine. 401954-10 6.21 Foot brake lever... -
Page 21: Locking The Steering (All Exc Models)
CONTROLS 6.24 Locking the steering (All EXC models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –... -
Page 22: Speedometer
SPEEDOMETER Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. -
Page 23: Setting The Speedometer Functions
SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. -
Page 24: Display Mode Speed (Speed)
SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –... -
Page 25: Setup Menu
SPEEDOMETER Setup menu Condition • The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached. -
Page 26: Display Mode Speed/Clk (Time)
SPEEDOMETER 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button The display changes to the Setup menu of the clock. for 2–3 seconds. -
Page 27: Viewing The Lap Time
SPEEDOMETER 7.14 Viewing the lap time Condition • The motorcycle is stationary. – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button Press the button The stop watch and the lap time are reset. for 2–3 seconds. -
Page 28: Display Mode Speed/Tr2 (Trip Master 2)
SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) – Repeatedly press the button briefly until TR2 appears at the top right of the dis- play. TR2 (trip master 2) runs constantly and counts up to 999.9. Press the button Clears the values TR2 and A2. for 2–3 seconds. -
Page 29: Display Mode Speed/A2 (Average Speed 2)
SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) – Repeatedly press the button briefly until A2 appears at the top right of the dis- play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running. -
Page 30: Table Of Functions
SPEEDOMETER 7.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service... -
Page 31: Table Of Conditions And Menu Activation
SPEEDOMETER 7.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •... -
Page 32: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 33: Running In The Engine
PREPARING FOR USE – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any luggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri- bution between the front and rear wheels. -
Page 34: Preparing For Rides On Dry Sand
Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info 600871-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 143) – Fit the steel sprocket. -
Page 35: Preparations For Riding On Wet And Muddy Surfaces
Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 143) – Fit the steel sprocket. -
Page 36: Preparing For Riding At Low Temperatures Or In Snow
Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 Your authorized KTM workshop can recommend the right carburetor tuning. -
Page 37: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 111) –... -
Page 38: Start Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 39: Stopping, Parking
RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. –... -
Page 40: Refueling
RIDING INSTRUCTIONS Refueling 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 41: Service Schedule
● ● Check the idle. ● ● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ● Periodic interval... -
Page 42: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●... -
Page 43: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 44: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 45: Measuring The Sag Of The Unloaded Rear Wheel
TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) B00792-10 Rebound damping Comfort 28 clicks... -
Page 46: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 47: Adjusting The Riding Sag
TUNING THE CHASSIS Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) Finishing work –... -
Page 48: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression), harder springs must be fit to avoid damage to the fork and frame. 401000-01 11.12 Adjusting the compression damping of the fork... -
Page 49: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS (250/300 Six Days) Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC EU/AU) –... -
Page 50: Adjusting The Spring Preload Of The Fork (Exc, Xc-W)
TUNING THE CHASSIS (250/300 Six Days) Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) –... -
Page 51: Handlebar Position
TUNING THE CHASSIS Info Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload. -
Page 52: Adjusting The Handlebar Position
TUNING THE CHASSIS (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) On the upper triple clamp, there are two holes at a distance of to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. - Page 53 TUNING THE CHASSIS (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines.
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Page 54: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a 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 (78129955100) Neither wheel is in contact with the ground. -
Page 55: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS (Six Days) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. 602754-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 52) 12.4 Cleaning the dust boots of the fork legs Preparatory work... -
Page 56: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and wiring harness. Put on the clamp and mount and ... -
Page 57: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work (EXC EU/AU) – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp. -
Page 58: Removing The Lower Triple Clamp (200 Xc-W Us, 250 Xc-W Us, 300 Exc Br, 300 Xc-W Us)
SERVICE WORK ON THE CHASSIS (Six Days) – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws Guideline Screw, bottom triple clamp 15 Nm V00039-11 (11.1 lbf ft) – Position the brake caliper, and mount and tighten screws with the washers. -
Page 59: Removing The Lower Triple Clamp (Exc Eu, Exc Six Days, Exc Eu/Au, Six Days)
SERVICE WORK ON THE CHASSIS 12.10 Removing the lower triple clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days) Preparatory work – Raise the motorcycle with a lift stand. ( p. 52) – Remove the front wheel. p. 90) –... - Page 60 SERVICE WORK ON THE CHASSIS – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.
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Page 61: Installing The Lower Triple Clamp (Exc Eu, Exc Six Days, Exc Eu/Au, Six Days)
SERVICE WORK ON THE CHASSIS Finishing work – Mount the handlebar cushion. – Install the front fender. ( p. 65) – Install the front wheel. p. 90) – Refit the headlight mask with the headlight. ( p. 98) – Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. - Page 62 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) 102275-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 102276-10 – Mount and tighten screw Guideline Screw, top steering stem 17 Nm...
- Page 63 SERVICE WORK ON THE CHASSIS (Six Days) – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 143) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. –...
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Page 64: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 65: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –... -
Page 66: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) – Loosen screws – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. -
Page 67: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 12.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B02156-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B02155-11 Finishing work... -
Page 68: Removing The Seat
SERVICE WORK ON THE CHASSIS Guideline Screw, bottom shock 80 Nm Loctite ® 2701™ absorber (59 lbf ft) 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. -
Page 69: Removing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS – Mount and tighten screw of the seat fixation. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00817-10 12.22 Removing the air filter box lid – Pull off the air filter box lid in area ... -
Page 70: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 12.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 143) 301262-10 – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. -
Page 71: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 12.27 Sealing the air filter box Preparatory work – Remove the air filter box lid. ( p. 67) Main work – Seal the air filter box in the marked area 401527-10 Finishing work – Install the air filter box lid. -
Page 72: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove screws – Pull out inner tube – Remove glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –... -
Page 73: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 602721-10 12.32 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. -
Page 74: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS 12.33 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 72) 400678-01 12.34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –... -
Page 75: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain ten- sion Info The bottom chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain ... -
Page 76: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS 12.37 Checking the chain, rear sprocket, motor sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 52) Main work – Shift the transmission to idle. – Check the rear sprocket and motor sprocket for wear. »... -
Page 77: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must be replaced. Repair of the frame is not authorized by KTM. 401347-01... -
Page 78: Checking The Swingarm
If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 401341-01 12.40 Checking the routing of the throttle cable Preparatory work –... -
Page 79: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.41 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. -
Page 80: Checking/Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 12.44 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining discs. (All 125/200 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. - Page 81 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Hydraulic fluid (15) ( p. 141) – On the slave cylinder of the clutch, remove bleeder screw and mount bleed- ing syringe B02164-10 –...
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Page 82: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS 12.46 Removing the engine guard – Turn quick release counterclockwise until it disengages. Remove the engine guard. B01204-10 12.47 Installing the engine guard – Attach the engine guard at the back of the frame and swing it up at front. –... -
Page 83: Brake System
BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 84: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 85: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 86: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 87: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the full set of brake linings. -
Page 88: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 89: Adding Brake Fluid For The Rear Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 90: Changing The Brake Linings Of The Rear Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. - Page 91 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.
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Page 92: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 52) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 93: Removing The Rear Wheel
WHEELS, TIRES (Six Days) – Align the brake disc guard so that gaps are the same size. M01022-10 – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. -
Page 94: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 95: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 96 WHEELS, TIRES – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
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Page 97: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery (All 200/250/300 models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 98: Recharging The Battery (All 200/250/300 Models)
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 99: Changing The Main Fuse (All 200/250/300 Models)
ELECTRICAL SYSTEM 15.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover. -
Page 100: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15.5 Removing the headlight mask with the headlight – Switch off all power consumers and switch off the engine. – Remove screw and take off the clamp. – Release rubber straps . Slide the headlight mask up and swing it forward. 602762-10 (All EXC models) –... -
Page 101: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and fix it with rubber straps The holding lugs engage. – Position the brake line and wiring harness. Put the clamp on and mount and tighten screw 602762-11 Finishing work – Check the headlight setting. -
Page 102: Checking The Headlight Setting
ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze orange cap in the area of the holding lugs and take it off. –... -
Page 103: Changing The Speedometer Battery
ELECTRICAL SYSTEM 15.11 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 98) Main work – Remove screws – Pull the speedometer upward out of the holder. 602746-10 – Using a coin, turn protection cap all the way counterclockwise and remove it. -
Page 104: Cooling System
COOLING SYSTEM 16.1 Cooling system (All 125/200 models) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 105: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 106: Refilling With Coolant
COOLING SYSTEM (All 250/300 models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) B02168-11 16.5... - Page 107 COOLING SYSTEM – Place the vehicle back on a level surface. – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. M00597-10 Finishing work – Check the coolant level. ( p.
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Page 108: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 109: Carburetor - Adjusting The Idle Speed
TUNING THE ENGINE The idle speed is adjusted with adjusting screw The idle mixture is adjusted with the idle air adjusting screw Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw ... -
Page 110: Emptying The Carburetor Float Chamber
TUNING THE ENGINE – Adjust the idle speed with adjusting screw Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 17) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall. -
Page 111: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE 17.6 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –... -
Page 112: Engine Characteristic - Setting The Auxiliary Spring (All 250/300 Models)
TUNING THE ENGINE 17.9 Engine characteristic - setting the auxiliary spring (All 250/300 models) Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. -
Page 113: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (All 125/200 models) –... -
Page 114: Draining The Gear Oil
SERVICE WORK ON THE ENGINE 18.3 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 115: Adding Gear Oil
SERVICE WORK ON THE ENGINE Main work – Remove filler plug and fill up with gear oil. 0 0 1 Gear oil 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 140) (All 125/200 models) Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. - Page 116 SERVICE WORK ON THE ENGINE (All 250/300 models) Screw, gear oil level check 10 Nm (7.4 lbf ft) – Mount and tighten filler plug Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. –...
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Page 117: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 118: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 119: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 52) – Cover the vehicle with a tarp or cover that is permeable to air. -
Page 120: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 35) tric starter) – Battery discharged Recharge the battery. p. 96) (All 200/250/300 models) – Check the charging voltage. –... - Page 121 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Engine takes in bad air Check the intake flange and carburetor for carburetor tightness. – The connector or ignition coil is loose Clean the connector and treat it with contact or oxidized spray.
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Page 122: Technical Data
TECHNICAL DATA 22.1 Engine 22.1.1 All 125 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing... -
Page 123: All 250 Models
TECHNICAL DATA 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 22.1.3 All 250 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and... -
Page 124: Engine Tightening Torques
TECHNICAL DATA Gearbox 6-gear, claw shifted Transmission ratio 1. gear 14:32 2. gear 16:26 3. gear 20:25 4. gear 22:23 5. gear 25:22 6. gear 26:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK BR 7 ES Spark plug electrode gap 0.60 mm (0.0236 in) -
Page 125: All 250/300 Models
TECHNICAL DATA – Axle for control flap, exhaust control Step 1 3 Nm (2.2 lbf ft) Step 2 (loosen, counter- clockwise) 1/4 turn – Nut, cylinder base 30 Nm (22.1 lbf ft) Screw, kick starter 25 Nm (18.4 lbf ft) Loctite ®... -
Page 126: Capacities
TECHNICAL DATA – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 120 Nm (88.5 lbf ft) Loctite ®... -
Page 127: Electrical System
TECHNICAL DATA Secondary ratio (200 EXC EU, 200 EXC AU) 14:45 Secondary ratio (200 XC‑W US) 14:48 Secondary ratio (All 250/300 EXC EU/AU models) 14:50 (13:50) Secondary ratio (All 250/300 XC-W models) 13:50 Secondary ratio (300 EXC BR) 13:52 Chain 5/8 x 1/4"... -
Page 128: Tires
90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 125 EXC EU, all 200 models Fork part number 14.18.7P.61... -
Page 129: Exc Six Days Eu
TECHNICAL DATA Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload - Preload Adjuster Comfort 0 turns Standard 0 turns Sport 1 turn Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 510 mm (20.08 in) Weight of rider: 75…... -
Page 130: Shock Absorber
TECHNICAL DATA Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.4 N/mm (25.1 lb/in) Fork length 932 mm (36.69 in) Air chamber length... -
Page 131: Chassis Tightening Torques
TECHNICAL DATA Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload Comfort 7 mm (0.28 in) Standard 7 mm (0.28 in) Sport 7 mm (0.28 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75…... - Page 132 TECHNICAL DATA – Screw, top steering stem 20 Nm (14.8 lbf ft) (200 XC‑W US, 250 XC‑W US, 300 EXC BR, 300 XC‑W US) Loctite ® 243™ Screw, top steering stem (EXC EU, 17 Nm (12.5 lbf ft) EXC Six Days, EXC EU/AU, Six Days) –...
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Page 133: Carburetor
TECHNICAL DATA 22.10 Carburetor 22.10.1 All 125 models Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (N1EF / N1EG) Main jet 100 (172/175) Idling jet 38x38 (42/45) Starting jet 50 (85) Idle air adjusting screw Open... -
Page 134: 22.10.5 250 Exc Eu, 250 Exc Six Days Eu
TECHNICAL DATA Throttle slide 7 with cut-out Slide stop 22.10.5 250 EXC EU, 250 EXC Six Days EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N2ZW / N2ZH / N2ZJ) Main jet 110 (172/175) Idling jet... -
Page 135: 22.10.9 300 Exc Au
TECHNICAL DATA Open 1.75 turns Throttle slide 7 with cut-out Slide stop Present 22.10.9 300 EXC AU Carburetor type KEIHIN PWK 36S AG Carburetor identification number 3600 Needle position 1. Position from top Jet needle N3CJ (N8RG / N8RH / N2ZH / N2ZJ / N2ZW) Main jet 160 (170/172/175) Idling jet... -
Page 136: Carburetor Tuning
CARBURETOR TUNING 23.1 Carburetor tuning (All 125 models) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402138-01 M/FT ASL Sea level... -
Page 137: Carburetor Tuning (All 200 Models)
CARBURETOR TUNING 23.2 Carburetor tuning (All 200 models) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402139-01 M/FT ASL Sea level... -
Page 138: Carburetor Tuning (All 250 Models)
CARBURETOR TUNING 23.3 Carburetor tuning (All 250 models) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402140-01 M/FT ASL Sea level... -
Page 139: Carburetor Tuning (All 300 Exc Eu/Au/Six Days, 300 Xc-W Us/Six Days)
CARBURETOR TUNING 23.4 Carburetor tuning (All 300 EXC EU/AU/Six Days, 300 XC-W US/Six Days) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402141-01 M/FT ASL Sea level... -
Page 140: Carburetor Tuning (300 Exc Br)
CARBURETOR TUNING 23.5 Carburetor tuning (300 EXC BR) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. KEIHIN PWK 36S AG ... -
Page 141: General Carburetor Tuning
CARBURETOR TUNING 23.6 General carburetor tuning 1... 5 Needle position from above The five needle positions are shown here. 0 0 1 The carburetor tuning depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4 0 0 5 B00075-10... -
Page 142: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 143 SUBSTANCES Hydraulic fluid (15) Standard/classification – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...
- Page 144 SUBSTANCES Info Do not use fuel made of methanol (e. g. M15, M85, M100). Do not use fuel with less than 20 % ethanol (e. g. E10). Do not use fuel with more than 25 % ethanol (e. g. E30, E85, E100).
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Page 145: Auxiliary Substances
Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ® –... - Page 146 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 147: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 148: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 149: List Of Symbols
LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. EFI warning lamp (MIL) – inoperative Low fuel warning lamp – inoperative 28.2 Green and blue symbols Green and blue symbols reflect information. -
Page 150: Index
INDEX Cleaning, care ......115-116 INDEX Clutch Accessories ........8 fluid level, checking/correcting . - Page 151 INDEX Fork legs Kill switch ....... . . 13-14 bleeding ....... . . 52 dust boots, cleaning .
- Page 152 INDEX Shock absorber Turn signal switch ......14 compression damping, general ....41 Type label .
- Page 153 *3213334en* 3213334en 02/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...