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IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: WARNING IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR...
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Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this opportunity to thank you for putting your trust in us; we will not let you down. You are now owner of a sporty and modern motorcycle which you are bound to have a great time with provided you care for it properly.
Chain maintenance ............14 All models out of USA ............32 Chain wear ..............15 General informations about KTM disc brakes ....15 TECHNICAL SPECIFICATIONS - CHASSIS (250/300/380)..34 Adjusting of free travel at the hand brake lever ....15 Checking of brake fluid level - front brake......16 WIRING DIAGRAMME, CARBURETOR SETTING..Appendix...
SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1. Engine number, engine type (125/200) The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.
Speedometer, indicator lamp (EXC) The mileage indicator in the speedometer indicates overall mileage. For further adjustment options and handling, see the appended user’s guide of the SIGMA SPORT BASELINE 500 speedometer. On default factory models, a wheel circumference of 2150 mm (standard tires) is adjusted on the speedometer.
Short circuit button (SX) The short circuit button turns off the engine. When pressing this button, the ignition circuit is short-cicuited. Combination switch (EXC) The light switch has 2, respetively 3 switch positions. = Light off (this function is not available in all models) = Low beam on = High beam on You may use button...
200-380: Unleaded premium gasoline RON 95 mixed with high grade two 35 mm stroke oil. Mixture ratio 1:40 – 1:60 Fuel and engine oil should only be mixed immediately before use. KTM recommends SHELL ADVANCE RACING X. WARNING ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS XTREME CAUTION SHOULD BE USED...
Choke knob When pulling the choke knob fully towards the top, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This encoure the rich fuel-air mixture, that is needed for a cold start. When pressing the choke knob downward in the carburetor, the bore is closed again.
Rebound damping of fork The rebound damping mechanism is built into the right fork tube. It only regulates the degree of damping during rebounding. By turning the adjusting screw (R, REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.
Instructions for your first ride When you start off, the motorcycle must be in a perfect – Verify that your KTM dealer performed the PREPARATION technbical condition. For safety reasons, you should make it a OF VEHICLE jobs (see Customer Service Manual).
Starting when the engine is cold – D RIVE CAREFULLY ON UNKNOWN ROADS OR IN UNKNOWN TERRITORY – W HEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SECOND 1 Open fuel tap MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH 2 Turn on ignition or emergency OFF switch OTHER SHOULD DIFFICULTIES ARISE 3 Put the gear in neutral...
PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE rider dealer 125-380 6.98 AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES) SERVICE IS TO BE DONE AFTER EVERY RACE ● Check transmission oil level ● ● ● Change transmission oil ●...
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOW- LEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER CAUTION – W HEN CLEANING THE MOTORCYCLE...
Pivot bearing The pivot bearing for PDS suspension struts at the swinging fork is Teflon-coated and must not be lubricated with either grease or other lubri- cants. Grease and other lubricants cause the Teflon coat to dissolve, whe- reby the bearing’s lifecycle will be reduced dramatically. When cleaning your bike with a high-pressure cleaner, do not aim the high- pressure spray directly at the pivot bearing.
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake system with ”Shell Advance Brake DOT 5.1”, one of the best brake fluids currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the hand- lebar and the reservoir is provided with an inspection glass. With the reservoir in a horizontal position, the brake fluid level should not drop below the middle of the glass.
Mount the right brake pad and fix it with the bolt. Mount the left brake pad and insert the bolt until it stops. Mount the clips. When mounting the brake pads, be sure to check for correct fit of the sli- ding metal-sheet in the caliper support and of the leaf spring WARNING...
Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings 1 mm may not be less than 1 mm (0.04 in). WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN ’...
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING...
Fuse (CH, Singapore) The fuse located below the seat protects the flasher system and the battery charge. Nominal current: 10 A. CAUTION EVER USE A STRONGER FUSE EVER REPAIR A FUSE MPROPER TREATMENT CAN DEST ROY THE ENTIRE ELECTRICAL SYSTEM Battery (CH, Singapore) The battery is mounted in the air filter box.
A mixture of 40 % antifreeze liquid and 60 % water is used as coolant. However, the anti-freeze protection must be at least for –25° C (–13° F). This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water. CAUTION (Shell Advance Coo- OR THE COOLING SYSTEM...
. Use adhesive tape to attach the new glass-fiber yarn packing to the inner tube, and slide on outer tube. Mount silencer cap. Glass-fiber yarn packings are available at your authorized KTM dealer. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING...
Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient tempe- rature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 98 respectively 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 (125), 1:40 –...
SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore of the master cylinder in a bubble-free state. Make sure that the oil does not over- flow. The bleeder syringe can be purchased at your KTM dealer. CAUTION AVING COMPLETED THE BLEEDING PROCEDURE...
Check transmission oil level (125/200) In order to check the transmission oil level the control screw on the clutch cover is to be removed. Oil should just barely escape from the inspection opening when the motorcycle is in an upright position. If necessary, remove the plug and top up with engine oil 20W-40 (i.
CLEANING Clean your motorcycle regularly in order to keep its painted finish looking shiny and new. – The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet. CAUTION –...
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K T M - S P O R T M O T O R C Y C L E A-5230 Mattighofen • Postfach 91 • Austria I n t e r n e t : h t t p : / / w w w . k t m . c o . a t FN 102019 d - Landesgericht Ried im Innkreis 3.205.51...