Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for KTM 125 EXC EU 2010
Summary of Contents for KTM 125 EXC EU 2010
- Page 1 OWNER'S MANUAL 2010 125 EXC EU 125 EXC SIX DAYS EU 150 XC USA 200 EXC EU 200 EXC AUS 200 XC‑W USA 250 EXC EU 250 EXC SIX DAYS EU 250 EXC AUS 250 XC EU/USA 250 XC‑W USA 300 EXC EU 300 EXC SIX DAYS EU 300 EXC AUS...
- 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
300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC) ... 13 Important maintenance work to be carried out by an Electric starter button (250/300 EXC AUS)...... 13 authorized KTM workshop (as additional order)....36 Light switch (EXC, EXC SIX DAYS) ........14 Important checks and maintenance work to be carried Light switch (XC-W) ............ - Page 5 TABLE OF CONTENTS Removing the headlight mask with the headlight (EXC, Cooling system .............. 76 EXC SIX DAYS) ............. 52 Checking the antifreeze and coolant level ......77 Refitting the headlight mask with the headlight (EXC, Checking the coolant level..........77 EXC SIX DAYS) .............
- Page 6 TABLE OF CONTENTS 300 XC EU/USA, 300 XC‑W USA........103 Carburetor configuration (125 EXC EU, 125 EXC SIX DAYS EU) .......... 104 Carburetor configuration (150 XC USA) ....105 Carburetor configuration (All 200 models) ....106 Carburetor configuration (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC‑W USA) .............
-
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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 8: Important Information
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. - Page 9 IMPORTANT INFORMATION Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. –...
-
Page 10: View Of Vehicle
VIEW OF VEHICLE View of the vehicle from the left front (example) B00077-10 Hand brake lever Short circuit button Clutch lever Air filter box lid Fuel tap Shift lever Chain guide Side stand... -
Page 11: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) B00076-10 Shock absorber rebound adjustment Level viewer for brake fluid, rear Foot brake lever Kickstarter Bleeder screw, fork leg Throttle grip Chassis number Filler cap... -
Page 12: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. B00015-10 Type label The type label is fixed to the front of the steering head. 400284-10 Key number (EXC, EXC SIX DAYS) The key number is stamped on the key strap. -
Page 13: Shock Absorber Part Number
LOCATION OF 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. 500083-10... -
Page 14: Controls
CONTROLS Clutch lever (All 125/150/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B00001-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. ... -
Page 15: Short Circuit Button (Xc-W/Xc)
CONTROLS Short circuit button (XC‑W/XC) Short circuit button is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition circuit is • Short circuit button closed, and the engine can be started. pressed –... -
Page 16: Light Switch (Exc, Exc Six Days)
CONTROLS Light switch (EXC, EXC SIX DAYS) 5.10 The light switch is fitted on the left side of the handlebar. Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on –... -
Page 17: Controls (All Exc/Xc-W Models)
CONTROLS (ALL EXC/XC-W MODELS) Speedometer – Press the key 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 In its condition at delivery, the display mode SPEED/H and SPEED/ODO is acti- vated. -
Page 18: Setting The Clock
CONTROLS (ALL EXC/XC-W MODELS) – Press the button for 3 - 5 seconds. The settings are stored and the setup menu is closed. Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the setup menu closed. -
Page 19: Querying The Lap Time
CONTROLS (ALL EXC/XC-W MODELS) Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the setup menu closed. Querying the lap time Info This function can be called only if lap times are measured. Condition The motorcycle is stationary. -
Page 20: Display Mode Speed/Clk (Clock)
CONTROLS (ALL EXC/XC-W MODELS) Display mode SPEED/CLK (clock) 6.10 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button . -
Page 21: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS (ALL EXC/XC-W MODELS) Press the button Next display mode briefly. Display mode SPEED/TR2 (trip master 2) 6.14 – 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 22: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS (ALL EXC/XC-W MODELS) Display mode SPEED/S1 (stop watch 1) 6.17 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor. - Page 23 CONTROLS (ALL EXC/XC-W MODELS) Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary vated Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...
-
Page 24: Controls
CONTROLS 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 – No fuel can flow from the tank to the carburetor. •... -
Page 25: Choke (Exc Eu, Exc Six Days)
CONTROLS Choke (EXC EU, EXC SIX DAYS) The choke lever is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated. -
Page 26: Foot Brake Lever
CONTROLS 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. B00007-10 Side stand Note Danger of damage The parked vehicle may roll away or fall over. –... -
Page 27: Unlocking The Steering (Exc, Exc Six Days)
CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible. -
Page 28: General Tips And Hints On Putting Into Operation
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 29: Running In The Engine
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – 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. Info Motorcycles react sensitively to any changes of weight distribution. -
Page 30: Preparations For Riding On Wet Sand
Sand cover for air filter (59006022000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600871-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 132) –... -
Page 31: Preparations For Riding On Wet And Muddy Surfaces
Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 132) –... -
Page 32: Preparations For Riding At High Temperatures And Riding Slowly
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 The recommended carburetor tuning is available from your authorized KTM workshop. -
Page 33: Riding Instructions
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the gear oil level. ( p. -
Page 34: Starting Up
Do not change into a low gear at high engine speed. The engine overspeeds and the rear wheel can block. 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 35: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components get very hot when the vehicle is in use. –... - Page 36 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 9.5 l Super unleaded gasoline, mixed with capacity, approx. (2.51 US gal) 2-stroke engine oil (1:60) ( p.
-
Page 37: Service Schedule
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop 10.1 S10N S20A S40A Engine Check the gear oil level. ( p. 88) • • • • Change the gear oil. p. 88) Check spark plug and replace if required. -
Page 38: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)
SERVICE SCHEDULE S20A: every 20 operating hours S40A: every 40 operating hours/after every race Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 10.2 Competition use Hobby use S10A S20N S30A S10A S20A S40A... -
Page 39: Important Checks And Maintenance Work To Be Carried Out By The Rider
SERVICE SCHEDULE Competition use Hobby use S10A S20N S30A S10A S20A S40A S80A S20A S40A S60A S80A Check exhaust con- trol for functioning • • • • • • • • and smooth opera- tion, clean. Change the crankshaft main •... -
Page 40: Maintenance Work On Chassis And Engine
Danger 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 41: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
Danger 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 42: Adjusting The Rebound Damping Of The Shock Absorber
11.7 Danger 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.) – Turn adjusting screw clockwise with a screwdriver to the last click. -
Page 43: Measuring The Sag Of The Unloaded Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE (250/300 XC) Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Measuring the sag of the unloaded rear wheel 11.8 –... -
Page 44: Checking The Riding Sag Of The Shock Absorber
Danger 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 45: Adjusting The Riding Sag
MAINTENANCE WORK ON CHASSIS AND ENGINE 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) –... -
Page 46: Installing The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the shock absorber 11.14 – Push splash protector to the side and position the shock absorber. Mount and tighten screw Guideline Screw, top shock absorber 80 Nm Loctite ® 243™ (59 lbf ft) –... -
Page 47: Adjusting The Rebound Damping Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. – Mount protection covers (XC) – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the top end of the fork legs. ... -
Page 48: Adjusting The Spring Preload Of The Fork (Exc, Exc Six Days, Xc-W)
MAINTENANCE WORK ON CHASSIS AND ENGINE (XC) – Remove protection covers – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. –... -
Page 49: Bleeding The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding the fork legs 11.19 – Jack up the motorcycle. ( p. 38) – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. –... -
Page 50: 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 for a lengthy period with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. -
Page 51: Removing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) (EXC SIX DAYS, XC‑W) – Loosen screws . Remove screw – Loosen and retighten screw ... -
Page 52: Installing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE (XC) – Loosen screws . Remove the fork leg on the left. – Loosen screws . Remove the fork leg on the right. B00021-10 Installing the fork legs 11.26 – Position the fork legs. Info The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp. -
Page 53: Removing The Fork Protector
MAINTENANCE WORK ON CHASSIS AND ENGINE (XC) – Position the brake line. Put on the clamp and mount and tighten screws – Install the front wheel. p. 67) Removing the fork protector 11.27 – Remove the fork legs. p. 49) –... -
Page 54: Removing The Headlight Mask With The Headlight (Exc, Exc Six Days)
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the headlight mask with the headlight (EXC, EXC SIX DAYS) 11.31 – Switch off all power consumers. – Remove screw and take off the clamp. – Release rubber band . Slide the headlight mask up and swing it forward. ... -
Page 55: Installing The Start Number Plate (Xc-W/Xc)
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the start number plate (XC‑W/XC) 11.34 – Position the start number plate. Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Ensure that the holding lugs engage in the fender. –... -
Page 56: Checking The Play In The Throttle Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 11.37 – Move the handlebar to the straight-ahead position. – Push back bellows – Pull back the throttle cable casing until you sense a resistance. – Now check throttle cable play ... -
Page 57: Checking The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 132) Off-road chain spray ( p. 132) 400725-01 Checking the chain tension 11.41 Warning Danger of accidents Danger caused by incorrect chain tension. –... -
Page 58: Adjusting The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE – Shift gear to neutral. – Pull on the upper part of the chain with the specified weight Guideline 0 0 A Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section. -
Page 59: Adjusting The Chain Guide
MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen nut – Loosen nuts – Adjust the chain tension by turning the adjusting screws to the left and right. Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn adjusting screws on the left and right so that the markings on the left ... -
Page 60: Checking The Brake Discs
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ... -
Page 61: Adjusting The Basic Position Of The Hand Brake Lever (Xc-W/Xc)
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes 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 62: Adding Front Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 63: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes 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 64: Checking The Free Travel Of The Foot Brake Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove locking split pins , withdraw bolt , and take out the brake linings. – Clean the brake caliper and brake caliper support. 100396-10 – Check that leaf spring in the brake caliper and sliding plate in the brake ... -
Page 65: Adjusting The Basic Position Of The Foot Brake Lever
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 66: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 67: Removing The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 68: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 69: Installing The Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged. -
Page 70: Removing The Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 11.64 – Jack up the motorcycle. ( p. 38) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. -
Page 71: Checking The Tire Condition
DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires are changed at the latest after 5 years, regardless of the actual state of wear. »... -
Page 72: 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 73: Engine Characteristic - Auxiliary Spring (All 250/300 Models)
MAINTENANCE WORK ON CHASSIS AND ENGINE Engine characteristic - auxiliary spring (All 250/300 models) 11.69 The auxiliary spring is located on the right side of the engine below the water pump cover. Possible states Auxiliary spring with yellow marking – Auxiliary spring mounted at the factory with •... -
Page 74: Removing The Battery
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 75: Removing A Fuse (250 Exc Aus/Xc-W/Xc, All 300 Models)
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. -
Page 76: Checking The Headlight Setting (Exc, Exc Six Days)
MAINTENANCE WORK ON CHASSIS AND ENGINE – Refit the fuse. Fuse (58011109110) Info A reserve fuse is located in the starter relay. Replace a burned-out fuse only by an equivalent fuse. – Replace the protection cover. – Install the air filter box lid. ( p. -
Page 77: Mounting The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 11.79 – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. – Make sure that the seat is correctly locked in. –... -
Page 78: Installing The Fuel Tank
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 11.81 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 79: Checking The Antifreeze And Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE (All 250/300 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 ... -
Page 80: Draining The Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in) » If the level of the coolant does not meet specifications: –... -
Page 81: Refilling With Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE Refilling with coolant 11.86 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. -
Page 82: Removing The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the main silencer 11.87 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 83: Installing The Glass Fiber Yarn Filling Of The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the glass fiber yarn filling of the main silencer 11.91 – Slide the glass fiber yarn filling over the inner tube. 0 0 4 0 0 3 – Slide the outer tube over the glass fiber yarn filling. -
Page 84: Installing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE – Detach air filter holder at the bottom and swing it to one side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. B00039-10 Installing the air filter 11.96... -
Page 85: Adjusting The Basic Position Of The Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the basic position of the clutch lever 11.98 (All 125/150/200 models) – Adjust the basic setting of the clutch lever to your hand size by turning adjust- ing screw Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. -
Page 86: Changing The Hydraulic Clutch Fluid
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the hydraulic clutch fluid 11.100 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (All 125/150/200 models) –... -
Page 87: Checking The Basic Position Of The Shift Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Inject the liquid into the system until it escapes from hole of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –... -
Page 88: Carburetor - Adjusting The Idle Speed
MAINTENANCE WORK ON CHASSIS AND ENGINE Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) ( p. 131) (EXC, EXC SIX DAYS, XC-W, 250/300 XC) Altitude above sea level 500 m (1,640 ft) Ambient temperature 20 °C (68 °F) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. -
Page 89: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous 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 90: Checking The Gear Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a cloth beneath the carburetor to soak up emerging fuel. – Remove plug – Completely drain the fuel. – Mount and tighten the plug. B00047-10 Checking the gear oil level 11.106 Info The gear oil level must be checked when the engine is cold. -
Page 91: Draining The Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the gear oil 11.108 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 92: Adding Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – Start the engine and check that it is oil-tight. – Check the gear oil level. ( p. 88) Adding gear oil 11.110 Info Too little gear oil or poor-quality oil results in premature wear of the transmission. The gear oil must be added when the engine is cold. -
Page 93: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 31) (250 EXC AUS/XC‑W/XC, – Battery discharged Recharge the battery. p. 72) all 300 models) –... - Page 94 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Lack of fuel Turn handle of the fuel tap to the ON posi- carburetor tion. – Refuel. ( p. 33) – Engine takes in bad air Check the intake flange and carburetor for tightness.
-
Page 95: Cleaning
CLEANING Cleaning the motorcycle 13.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 96: Storage
Storage temperature of battery without direct sunlight 0… 35 °C (32… 95 °F) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 38) –... -
Page 97: Technical Data - Engine
TECHNICAL DATA - ENGINE 125 EXC EU, 125 EXC SIX DAYS EU 15.1 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... -
Page 98: All 200 Models
TECHNICAL DATA - ENGINE Ignition Kokusan 2K-3 Ignition point (BTDC) 1.4 mm (0.055 in) Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kickstarter All 200 models 15.3 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 193 cm³... -
Page 99: All 300 Models
TECHNICAL DATA - ENGINE Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydraulically activated Gearbox 5-gear, claw shifted Transmission ratio (250 XC EU/USA) 1st gear 14:30 2nd gear 16:26 3rd gear 18:24 4th gear 21:24 5th gear 22:21 Transmission ratio (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC‑W USA) 1st gear 14:30 2nd gear... -
Page 100: Capacity - Gear Oil
TECHNICAL DATA - ENGINE 4th gear 20:20 5th gear 29:23 Ignition Kokusan E Ignition point (BTDC) 1.9 mm (0.075 in) Spark plug NGK BR 7 ES Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kickstarter and electric starter Capacity - gear oil 15.6 Gear oil... -
Page 101: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES All 125/150/200 models 16.1 – Remaining screws, engine 6 Nm (4.4 lbf ft) – Screw, alternator cover 5 Nm (3.7 lbf ft) – Screw, exhaust control cover 5 Nm (3.7 lbf ft) ® Screw, ignition system/stator 6 Nm (4.4 lbf ft) Loctite ®... - Page 102 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Nuts, cylinder base 35 Nm (25.8 lbf ft) – Remaining screws, engine 45 Nm (33.2 lbf ft) – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.3 lbf ft) –...
-
Page 103: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 125 EXC EU, 125 EXC SIX DAYS EU 17.1 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0191 Needle position 5th position from top Jet needle N84I (NOZE / NOZF) Main jet 140 (168 / 170 / 172) Idling jet 38x38 (45 / 48) Starting jet... -
Page 104: 200 Xc-W Usa
TECHNICAL DATA - CARBURETOR 200 XC‑W USA 17.5 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0200 Needle position 4th position from top Jet needle NOZH (NOZG) Main jet 162 (160 / 165) Idling jet Starting jet Idle air adjusting screw Open 1 turn Throttle slide... -
Page 105: 250 Xc-W Usa
TECHNICAL DATA - CARBURETOR 250 XC‑W USA 17.9 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0230 Needle position 4th position from top Jet needle N8RW (N8RH / N8RJ) Main jet 165 (162) Idling jet Starting jet Idle air adjusting screw Open 1 turn Throttle slide... -
Page 106: Carburetor Configuration (125 Exc Eu, 125 Exc Six Days Eu)
TECHNICAL DATA - CARBURETOR Carburetor configuration (125 EXC EU, 125 EXC SIX DAYS EU) 17.13 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. 400748-01 M/FT ASL Sea level... -
Page 107: Carburetor Configuration (150 Xc Usa)
TECHNICAL DATA - CARBURETOR Carburetor configuration (150 XC USA) 17.14 400710-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! -
Page 108: Carburetor Configuration (All 200 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 200 models) 17.15 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. 400749-01 M/FT ASL Sea level... -
Page 109: Carburetor Configuration (250 Exc Eu, 250 Exc Six Days Eu, 250 Exc Aus, 250 Xc-W Usa)
TECHNICAL DATA - CARBURETOR Carburetor configuration (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC‑W USA) 17.16 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 110: Carburetor Configuration (250 Xc Eu/Usa)
TECHNICAL DATA - CARBURETOR Carburetor configuration (250 XC EU/USA) 17.17 400750-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! -
Page 111: Carburetor Configuration (All 300 Models)
TECHNICAL DATA - CARBURETOR Carburetor configuration (All 300 models) 17.18 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. 400752-01 M/FT ASL Sea level... -
Page 112: General Carburetor Configuration
TECHNICAL DATA - CARBURETOR General carburetor configuration 17.19 1... 5 Needle position from above The five needle positions are shown here. 0 0 1 The carburetor configuration depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4 0 0 5 B00075-10... -
Page 113: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork (EXC, EXC SIX DAYS, XC-W) WP Suspension Up Side Down 4860 MXMA PA Fork (XC) WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 300 mm (11.81 in) Rear... -
Page 114: Lighting Equipment
80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 18.3 Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) approx. -
Page 115: Technical Data - Fork
TECHNICAL DATA - FORK All 125/200 models 19.1 Fork part number 14.18.7J.02 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s) -
Page 116: All 250/300 Exc/Xc-W Models
TECHNICAL DATA - FORK All 250/300 EXC/XC-W models 19.3 Fork part number 14.18.7J.04 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s) -
Page 117: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER All 125/200 models 20.1 Shock absorber part number 12.18.7J.02 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns... -
Page 118: All 250/300 Exc/Xc-W Models
TECHNICAL DATA - SHOCK ABSORBER Shock absorber oil ( p. 131) SAE 2.5 All 250/300 EXC/XC-W models 20.3 Shock absorber part number 12.18.7J.04 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort... - Page 119 TECHNICAL DATA - SHOCK ABSORBER Riding sag 107 mm (4.21 in) Fitted length 411 mm (16.18 in) Shock absorber oil ( p. 131) SAE 2.5...
-
Page 120: Technical Data - Tightening Torques For Chassis
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, spoiler on fuel tank (XC‑W/XC) M5x12 1.5 Nm (1.11 lbf ft) – Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) –... - Page 122 WIRING DIAGRAM...
-
Page 123: Wiring Diagram
WIRING DIAGRAM Wiring diagram (125 EXC EU, 125 EXC SIX DAYS EU, 200 EXC EU, 200 EXC AUS, 250 EXC EU, 22.1 250 EXC SIX DAYS EU) CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 AK1/2 CW3/2 DG/4 CW2/2 AH1/2 CX3/2 CX2/2 BP/4 ye-bl BA/1... - Page 124 WIRING DIAGRAM Components CDI controller Wheel speed sensor Alternator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay Ignition pulse generator...
- Page 125 WIRING DIAGRAM...
-
Page 126: Wiring Diagram (250/300 Exc Aus, 300 Exc Eu, 300 Exc Six Days Eu)
WIRING DIAGRAM Wiring diagram (250/300 EXC AUS, 300 EXC EU, 300 EXC SIX DAYS EU) 22.2 CX/2 CZ/3 D DB/4 CW/2 CY/3 D DA/4 AK1/2 D DG/4 CW2/2 CW3/2 AH1/2 CX2/2 CX3/2 BP/4 ye-bl bu bu-wh ye-r -re ye-r -re ye-r -re or or or or... - Page 127 WIRING DIAGRAM Components CDI controller Wheel speed sensor Battery Alternator Right rear turn signal Left front turn signal Left rear turn signal Right front turn signal Brake/tail light Parking light License plate lamp Low/high beam Horn Turn signal indicator light High beam indicator light Starter relay with main fuse Turn signal relay...
-
Page 128: Wiring Diagram (150 Xc Usa, 200 Xc-W Usa)
WIRING DIAGRAM Wiring diagram (150 XC USA, 200 XC‑W USA) 22.3 bu-wh bu-wh ye-bl ye-bl re-wh re-bl re-bl re-wh B00086-10... - Page 129 WIRING DIAGRAM Components CDI controller Wheel speed sensor (XC-W) Alternator Ignition pulse generator Ignition coil Voltage regulator/rectifier Speedometer (XC-W) Tripmaster switch (optional) Light switch (XC-W) Short circuit button Ignition curve plug connection Cable colors Black bl-wh Black-white Brown Blue bu-wh Blue-white Green Gray...
-
Page 130: Wiring Diagram (250/300 Xc-W, 250/300 Xc)
WIRING DIAGRAM Wiring diagram (250/300 XC‑W, 250/300 XC) 22.4 bu-wh ye-bl bu-wh ye-bl re-wh re-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re B00087-10... - Page 131 WIRING DIAGRAM Components CDI controller Wheel speed sensor Battery Alternator Starter relay with main fuse Ignition pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer (XC-W) Tripmaster switch (optional) Light switch (XC-W) Short circuit button Electric starter button Ignition curve plug connection Cable colors Black bl-wh...
-
Page 132: Substances
– Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®... - Page 133 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 134) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) According to –...
-
Page 134: 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 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –... - Page 135 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
-
Page 136: 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 137: Index
INDEX Compression damping INDEX fork, adjusting ......44 Accessories ........6 Compression damping, high-speed Air filter shock absorber, adjusting... - Page 138 INDEX Front wheel installing ....... . . 67 Putting into operation removing .
- Page 139 INDEX Technical data carburetor ......101-110 chassis ......111-112 chassis tightening torques .
- Page 140 *3211466en* 3211466en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...