KTM 125 EXC EU Owner's Manual
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KTM 125 EXC EU Owner's Manual

2014
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OWNER'S MANUAL
2014
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
250 EXC EU
250 EXC AUS
250 EXC SIX DAYS EU
250 XC‑W USA
300 EXC EU
300 EXC AUS
300 EXC SIX DAYS EU
300 XC‑W USA
300 XC‑W SIX DAYS USA
Art. no. 3213034en

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Summary of Contents for KTM 125 EXC EU

  • Page 1 OWNER'S MANUAL 2014 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AUS 200 XC‑W USA 250 EXC EU 250 EXC AUS 250 EXC SIX DAYS EU 250 XC‑W USA 300 EXC EU 300 EXC AUS 300 EXC SIX DAYS EU 300 XC‑W USA...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 7.1.2 Activation and test ........20 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 7.1.3 Setting kilometers or miles ......20 Symbols used ........... 5 7.1.4 Adjusting the speedometer functions .... 21 Formats used............ 5 7.1.5 Setting the clock ........21 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS RIDING INSTRUCTIONS..........42 12.20 Removing the shock absorber ...... 68 Checks and maintenance work when preparing 12.21 Installing the shock absorber ....... 68 for use ............42 12.22 Removing the seat .......... 69 Starting............42 12.23 Mounting the seat ........... 69 Start off ............
  • Page 6 Tires ............129 15.4 Changing the main fuse 22.7 Fork............. 129 (All 200/250/300 models)......100 22.7.1 125 EXC EU, all 200 models..... 129 15.5 Removing the headlight mask with the 22.7.2 250/300 EXC EU/AUS, XC-W USA ..... 129 headlight............101 22.7.3 125 EXC SIX DAYS EU......

  • 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

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply 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

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 11: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 602694-10 Hand brake lever ( p. 13) Kill switch ( p. 13) Kill switch ( p. 14) Clutch lever ( p. 13) Chain guide Air filter box lid Side stand ( p.

  • Page 12: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) 602695-10 Filler cap Bleeder screw, fork leg 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. 602696-10 Type label The type label is fixed to the front of the steering head. 602696-11 Key number (All EXC models) The key number for the steering lock is stamped onto the key connector.

  • Page 14: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. B00786-10...

  • 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. 602726-10 (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 Aus)

    CONTROLS 6.10 Emergency OFF switch (EXC AUS) 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: Overview Of Indicator Lamps (300 Xc-W Six Days Usa)

    CONTROLS 6.15 Overview of indicator lamps (300 XC‑W SIX DAYS USA) Possible states The high beam indicator lamp lights up blue – inoperative EFI warning lamp (MIL) – inoperative Low fuel warning lamp – inoperative 602770-01 6.16 Opening the filler cap Danger Fire hazard Fuel is highly flammable.

  • Page 19: Fuel Tap

    CONTROLS 6.18 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 carbure- tor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. •...

  • Page 20: Kick Starter

    CONTROLS 6.21 Kick starter The kick starter is fitted on the right side of the engine. The top part can be swiveled. B00787-10 6.22 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. B00788-10 6.23 Side stand...

  • Page 21: Locking The Steering (All Exc Models)

    CONTROLS 6.25 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 EXC, XC‑W 7.1.1 Speedometer overview – Press the button to change the display mode or change to one of the Setup menus. – 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.

  • Page 23: Adjusting The Speedometer Functions

    SPEEDOMETER 7.1.4 Adjusting 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. – briefly and repeatedly until H appears at the bottom right of the Press the button display.

  • Page 24: Display Mode Speed (Speed)

    SPEEDOMETER Condition The motorcycle is stationary. – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. – Press the button briefly. LAP 1 appears on the left side of the display. – Laps 1-10 can be displayed by pressing the button –...

  • Page 25: Unit Of Measurement Menu

    SPEEDOMETER Press the button . Activates the flashing display Press the button . Deactivates the flashing display Press the button Changes to the next display without changes briefly. Press the button Setup menu starts, stores the settings, and changes to H or for 3 - 5 seconds.

  • Page 26: Display Mode Speed/Lap (Lap Time)

    SPEEDOMETER 7.1.13 Display mode SPEED/LAP (lap time) – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. In the LAP display mode, up to 10 lap times can be timed with the stop watch. Info If the lap time continues running after the button is pressed, 9 memory loca-...

  • Page 27: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER Press the button Next display mode briefly. 7.1.17 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

  • Page 28: Display Mode Speed/A2 (Average Speed 2)

    SPEEDOMETER 7.1.20 Display mode SPEED/A2 (average speed 2) – Press the button briefly and repeatedly until A2 appears at the top right of the display. 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 29: Table Of Conditions And Menu Activation

    SPEEDOMETER Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. Setting the clock Increases the value Reduces the value Starts and exits the Changes to the next SETUP menu value Display mode SPEED/LAP Starts or stops the Times the current lap...

  • Page 30: Activation And Test

    SPEEDOMETER 7.2.2 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. Display test To enable you to check that the display is functioning properly, all display segments light up briefly.

  • Page 31: Setting The Clock

    SPEEDOMETER – 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 is displayed and the active functions are shown. Info If no button is pressed for 10–12 seconds, the settings are automatically stored.

  • Page 32: Display Mode Speed (Speed)

    SPEEDOMETER 7.2.7 Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Making the setting according to the country.

  • Page 33: Setting The Unit Of Measurement

    SPEEDOMETER 7.2.10 Setting the unit of measurement Condition • The motorcycle is stationary. – briefly until H appears at the bottom right of the Repeatedly press the button display. – Press the button for 2–3 seconds. – Repeatedly press the button briefly until Km/h/Mph flashes.

  • Page 34: Display Mode Speed/Lap (Lap Time)

    SPEEDOMETER 7.2.13 Display mode SPEED/LAP (lap time) – Repeatedly press the button briefly until LAP appears at the bottom right of the display. In the LAP display mode, up to 10 lap times can be timed with the stop watch. Info If the lap time continues running after the button is pressed, 9 memory loca-...

  • Page 35: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER Displays of TR1, A1 and S1 are reset to 0,0. Press the button for 2–3 seconds. Briefly press the Next display mode button Press the button No function for 2–3 seconds. Briefly press the No function button 7.2.17 Display mode SPEED/TR2 (trip master 2) –...

  • Page 36: Display Mode Speed/A2 (Average Speed 2)

    SPEEDOMETER Press the button No function for 2–3 seconds. Briefly press the No function button 7.2.20 Display mode SPEED/A2 (average speed 2) – briefly until A2 appears at the top right of the dis- Repeatedly press the button 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 37: Table Of Functions

    SPEEDOMETER 7.2.23 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 38: Table Of Conditions And Menu Activation

    SPEEDOMETER 7.2.24 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 39: 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 record at vehicle handover.

  • Page 40: Running In The Engine

    PREPARING FOR USE – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels.

  • Page 41: Preparations For Riding On Dry Sand

    Info Read the KTM PowerParts installation 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. 142) – Mount the steel sprocket.

  • Page 42: Preparations For Riding On Wet And Muddy Surfaces

    Info Read the KTM PowerParts installation 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. 142) – Mount the steel sprocket.

  • Page 43: 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 44: 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. 114) –...

  • Page 45: 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 46: 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 47: 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 48: Service Schedule

    Check the headlight setting. ( p. 103) ● ● Check the idle. ● ● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in KTM DEALER.NET and in the service record. ● Periodic interval...

  • Page 49: 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 50: 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 51: 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 52: Measuring The Sag Of The Unloaded Rear Wheel

    TUNING THE CHASSIS – Turn adjusting screw clockwise with a screwdriver to the last click. Info Do not loosen nut – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) Rebound damping B00792-10 Comfort 28 clicks...

  • Page 53: 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 54: 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 55: Adjusting The Compression Damping Of The Fork

    Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. B01510-10 Guideline (125 EXC EU, all 200 models) Compression damping Comfort 22 clicks Standard 20 clicks Sport...

  • Page 56: Adjusting The Rebound Damping Of The Fork

    Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline 602708-10 (125 EXC EU, all 200 models) Rebound damping Comfort 20 clicks Standard 18 clicks Sport...

  • Page 57: Adjusting The Spring Preload Of The Fork (Exc, Xc-W)

    Info Make the same adjustment on both fork legs. – Turn back clockwise by the number of turns corresponding to the fork type. Guideline (125 EXC EU, all 200 models) Spring preload - Preload Adjuster 602708-11 Comfort 1 turn Standard...

  • Page 58: Adjusting The Handlebar Position

    TUNING THE CHASSIS 11.16 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side.

  • Page 59: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand (All 125/200 models) 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.

  • Page 60: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. 602710-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 61: Positioning The Fork Protection

    SERVICE WORK ON THE CHASSIS 12.6 Positioning the fork protection – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Position the clamp and mount and tighten screws –...

  • Page 62: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS (SIX DAYS) – Position the fork legs. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw). 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 63: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS Main work – Remove screws on the left fork leg. Lift off the fork protector. – Remove the screws on the right fork leg. Lift off the fork protector. 101327-10 12.10 Installing the fork protector Main work –...

  • Page 64: Removing The Lower Triple Clamp (Six Days)

    SERVICE WORK ON THE CHASSIS 12.12 Removing the lower triple clamp (SIX DAYS) Preparatory work – Raise the motorcycle with the lift stand. ( p. 57) – Remove the front wheel. p. 93) – Remove the headlight mask with the headlight. ( p.
  • Page 65 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.

  • Page 66: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Finishing work – Mount the handlebar cushion. – Install the front fender. ( p. 67) – Install the front wheel. p. 93) – Refit the headlight mask with the headlight. ( p. 101) – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly.
  • Page 67 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 602738-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 602739-10 – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite...

  • Page 68: 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 69: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) Finishing work – Check the play of the steering head bearing. ( p.

  • Page 70: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 602712-11 Finishing work – Refit the headlight mask with the headlight. ( p. 101) – Check the headlight setting. ( p. 103) 12.20 Removing the shock absorber Preparatory work...

  • Page 71: Removing The Seat

    SERVICE WORK ON THE CHASSIS (All 250/300 models) – Push splash protector to the side and position the shock absorber. Mount and tighten screw Guideline Screw, top shock 80 Nm Loctite ® 2701™ absorber (59 lbf ft) – Mount and tighten screw Guideline 602714-11 Screw, bottom shock...

  • Page 72: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 12.24 Removing the air filter box lid – Pull off the air filter box lid in area sideways and remove it toward the front. 602716-10 12.25 Installing the air filter box lid – Insert the air filter box lid into the rear area and clip it into the front area 602716-11 12.26...

  • Page 73: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 74: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12.30 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws –...

  • Page 75: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Remove screws . Pull out inner tube – Pull the glass fiber yarn filling from the inner tube. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling on the inner tube.

  • Page 76: 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 12.34 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 77: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 12.35 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 75) 400678-01 12.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 78: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Push the chain at the end of the chain sliding component upwards to measure chain tension Info The bottom chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 79: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS 12.39 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 57) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...

  • Page 80: 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 always be changed. Repair of the frame is not authorized by KTM. 401347-01...

  • Page 81: 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 12.42 Checking the routing of the throttle cable Preparatory work –...

  • Page 82: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12.43 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 83: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12.46 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 84: Removing The Engine Guard (Six Days)

    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 B01224-10 –...

  • Page 85: Installing The Engine Guard (Six Days)

    SERVICE WORK ON THE CHASSIS 12.49 Installing the engine guard (SIX DAYS) – Attach the engine guard at the back of the frame and swing it up at front. – Turn quick release all the way clockwise. B01205-10...

  • Page 86: 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 87: 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 88: 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 89: 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 90: 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 brake linings, insert the pin, and mount the cotter pins. – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point.

  • Page 91: 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 92: Checking The Rear 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 93 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 94 BRAKE SYSTEM – Correct the brake fluid level to marking Brake fluid DOT 4 / DOT 5.1 ( p. 140) – Mount screw cap with membrane and the O-ring. Info Wash off overflowed or spilled brake fluid immediately with water. 400233-10...

  • Page 95: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 57) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 96: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc.

  • Page 97: Checking The Tire Condition

    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 98: 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 99 WHEELS, TIRES Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)

  • Page 100: 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 101: Recharging The Battery (All 200/250/300 Models)

    – 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 102: 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 by-pass 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 103: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15.5 Removing the headlight mask with the headlight – Switch off all power consumers. – Remove screw and take off the clamp. – Release rubber band . Slide the headlight mask up and swing it forward. 602762-10 – Disconnect the electrical plug-in connection and take off the headlight mask with the headlight.

  • Page 104: Changing The Turn Signal Bulb (All Exc Models)

    ELECTRICAL SYSTEM Main work – Turn protection cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull lamp socket of the parking light out of the reflector. B01562-10 – Pull out headlight bulb – Insert the new headlight bulb.

  • Page 105: Checking The Headlight Setting

    ELECTRICAL SYSTEM 15.9 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark a distance under the first mark.
  • Page 106 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with washers. 101407-10 (SIX DAYS) –...

  • Page 107: 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 108: 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 109: 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) B00835-11 16.5 Refilling with coolant...
  • Page 110 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. 602751-10 Finishing work – Check the coolant level. ( p. 106)

  • Page 111: 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 112: 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 and the idle air adjusting screw Transition range B Behavior of the engine when the throttle slide is being opened.

  • Page 113: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE 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 114: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17.6 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
  • Page 115 TUNING THE ENGINE Main work – Remove screws B00057-10 – Take cap , adjusting spring , auxiliary spring , and spring insert out of the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring and adjusting spring and slide them into the clutch cover together.

  • Page 116: 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 117: 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 118: Adding Gear Oil

    SERVICE WORK ON THE ENGINE – Mount and tighten the screw cap. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 119 SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight.

  • Page 120: 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 121: 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 122: 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 the lift stand. ( p. 57) – Cover the vehicle with a tarp or cover that is permeable to air.

  • Page 123: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 42) tric starter) – Battery discharged Recharge the battery. p. 99) (All 200/250/300 models) – Check the charging voltage. –...
  • Page 124 TROUBLESHOOTING Faults Possible cause Action – of the fuel tap to the ON posi- Engine stalls or is popping into the Lack of fuel Turn handle carburetor tion. – Refuel. ( p. 45) – Engine takes in bad air Check the intake flange and carburetor for tightness.

  • Page 125: 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 126: All 250 Models

    TECHNICAL DATA 5th gear 17:19 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) 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...

  • Page 127: Engine Tightening Torques

    TECHNICAL DATA Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48.5 mm (1.909 in) Primary transmission...

  • Page 128: All 250/300 Models

    TECHNICAL DATA – Screw, gear oil level check 10 Nm (7.4 lbf ft) ® Screw, ignition system/stator 8 Nm (5.9 lbf ft) Loctite 243™ (All 200 models) – Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) ® Screw, kick starter stop plate 10 Nm (7.4 lbf ft) Loctite...

  • Page 129: Capacities

    TECHNICAL DATA ® Screw, shift lever 14 Nm (10.3 lbf ft) Loctite 243™ – Screw, slave cylinder of the clutch 10 Nm (7.4 lbf ft) – Screw, starter motor 8 Nm (5.9 lbf ft) ® Screw, stator 8 Nm (5.9 lbf ft) Loctite 243™...

  • Page 130: Electrical System

    TECHNICAL DATA Brake discs - wear limit Front 2.5 mm (0.098 in) Rear 3.5 mm (0.138 in) Tire air pressure, road (All EXC models) Front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi)

  • Page 131: Tires

    Dunlop GEOMAX MX 51 Dunlop GEOMAX MX 51 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 14.18.7L.61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort...

  • Page 132: Exc Six Days Eu

    TECHNICAL DATA Comfort 1 turn Standard 2 turns Sport 2 turns Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 513 mm (20.2 in) Weight of rider: 75… 85 kg (165… 187 lb.) 513 mm (20.2 in) Weight of rider: 85…...

  • Page 133: Shock Absorber

    TECHNICAL DATA Fork length 932 mm (36.69 in) Air chamber length 100 mm (3.94 in) Fork oil per fork leg 635 ml (21.47 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 140) 22.8 Shock absorber 22.8.1 All 125/200 models Shock absorber part number 12.18.7L.61 Shock absorber...

  • Page 134: Chassis Tightening Torques

    TECHNICAL DATA 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… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85…...

  • Page 135: Carburetor

    TECHNICAL DATA Loctite ® 2701™ Screw, bottom shock absorber 80 Nm (59 lbf ft) Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ – Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –...

  • Page 136: 22.10.5 250 Exc Eu, 250 Exc Six Days Eu

    TECHNICAL DATA Carburetor identification number Needle position 3rd position from top Jet needle N1EI (N1EH / N1EJ) Main jet 158 (160) Idling jet Starting jet Idle air adjusting screw Open 2.0 turns 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...

  • Page 137: 22.10.8 300 Exc Eu, 300 Exc Six Days Eu

    TECHNICAL DATA 22.10.8 300 EXC EU, 300 EXC SIX DAYS EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N4DW / N4DJ / N4DK) Main jet 115 (165 / 168) Idling jet 38X38 (35) Starting jet...

  • Page 138: Carburetor Tuning (All 200 Models)

    TECHNICAL DATA 401769-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 22.10.11 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.

  • Page 139: Carburetor Tuning (All 250 Models)

    TECHNICAL DATA 401526-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 22.10.12 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.

  • Page 140: Carburetor Tuning (All 300 Models)

    TECHNICAL DATA 401770-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 22.10.13 Carburetor tuning (All 300 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.

  • Page 141: General Carburetor Tuning

    TECHNICAL DATA 401767-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 22.10.14 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.

  • Page 142: Substances

    SUBSTANCES 2-stroke engine oil According to – JASO FC ( p. 144) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to –...
  • Page 143 Hydraulic fluid (15) According to – 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. KTM recommends Motorex ® products. Supplier Motorex ® –...

  • Page 144: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 145 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motorex ®...

  • Page 146: Standards

    STANDARDS JASO FC JASO FC 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. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –...

  • Page 147: Index

    INDEX Clutch INDEX fluid level, checking/correcting ....81 Accessories ........8 fluid, changing .
  • Page 148 INDEX Fork Kick starter ........18 basic setting, checking ..... . . 52 Kill switch .
  • Page 149 INDEX installing ....... . . 68 Type label ........11 removing .
  • Page 150 *3213034en* 3213034en 04/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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