KTM 125 EXC Owner's Manual
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OWNER'S MANUAL
2015
125 EXC Six Days EU
125 EXC Factory Edition EU
200 XC‑W US
250 EXC Six Days EU
250 EXC Factory Edition EU
250 XC‑W US
300 EXC Six Days EU
300 EXC Factory Edition EU
300 XC‑W Six Days US
300 XC‑W US
Art. no. 3213233en
125 EXC EU
200 EXC EU
200 EXC AU
250 EXC EU
250 EXC AU
300 EXC EU
300 EXC AU
300 EXC BR
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Table of Contents
Related Manuals for KTM 125 EXC
Summary of Contents for KTM 125 EXC
- Page 1 OWNER'S MANUAL 2015 125 EXC EU 125 EXC Six Days EU 125 EXC Factory Edition EU 200 EXC EU 200 EXC AU 200 XC‑W US 250 EXC EU 250 EXC AU 250 EXC Six Days EU 250 EXC Factory Edition EU 250 XC‑W US...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.25 Foot brake lever ..........18 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.26 Side stand............19 Symbols used ........... 5 6.27 Steering lock (All EXC models) ......19 Formats used............ 5 6.28 Locking the steering (All EXC models) ....19 SAFETY ADVICE............ - Page 5 TABLE OF CONTENTS 11.4 Adjusting the high-speed compression 12.38 Adjusting the chain tension......69 damping of the shock absorber......42 12.39 Checking the chain, rear sprocket, engine 11.5 Adjusting the rebound damping of the shock sprocket and chain guide ......... 70 absorber............
- Page 6 22.6 Tires ............122 22.7 Fork............. 122 22.7.1 125 EXC EU, all 200 models, 125 EXC Factory Edition EU ...... 122 22.7.2 250/300 EXC EU/AU, XC-W US, 250/300 EXC Factory Edition, 300 EXC BR ..........122 22.7.3 125 EXC Six Days EU ....... 123 22.7.4...
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (All EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
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) B02140-10 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) B02141-10 Filler cap Throttle grip ( p. 13) Chassis number ( p. 11) Kick starter ( p. 18) Foot brake lever ( p. 18) Level viewer for brake fluid, rear... -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401946-10 Type label The type label is fixed to the front of the steering head. 401946-10 Key number (All EXC models) ... -
Page 14: Shock Absorber 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. 0 0 1 401948-10... -
Page 15: Controls
CONTROLS Clutch lever (All 125/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 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 (Six Days Eu)
CONTROLS Kill switch (Six Days EU) The kill switch is fitted on the left side of the handlebar. Possible states in the basic position – In this position, the ignition circuit is closed • Kill switch and the engine can be started. is pressed –... -
Page 17: Light Switch (Six Days Eu)
CONTROLS 6.10 Light switch (Six Days EU) The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on –... -
Page 18: Electric Starter Button (All 200/250/300 Eu/Us Models, 300 Exc Br)
CONTROLS 6.15 Electric starter button (All 200/250/300 EU/US models, 300 EXC BR) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. •... -
Page 19: Closing The Filler Cap
CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. -
Page 20: Choke
CONTROLS 6.22 Choke The choke lever is fitted on the left side of the carburetor. Activating the choke function frees an opening in the carburetor through which the engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a cold start. -
Page 21: Side Stand
CONTROLS 6.26 Side stand The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber ... -
Page 22: Unlocking The Steering (All Exc Models)
CONTROLS 6.29 Unlocking the steering (All EXC models) – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. -
Page 23: Speedometer
SPEEDOMETER Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. -
Page 24: Setting The Speedometer Functions
SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. -
Page 25: Display Mode Speed (Speed)
SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –... -
Page 26: Setting The Unit Of Measurement
SPEEDOMETER Briefly press the Activates the flashing display and changes to the next display button Press the button No function for 2–3 seconds. Briefly press the Deactivates the flashing display and changes to the next dis- button play Press the button No function for 2–3 seconds. -
Page 27: Setting The Clock
SPEEDOMETER 7.12 Setting the clock Condition • The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. Press the button Increases the value for 2–3 seconds. -
Page 28: Display Mode Speed/Odo (Odometer)
SPEEDOMETER 7.15 Display mode SPEED/ODO (odometer) – Repeatedly press the button briefly until ODO appears at the bottom right of the display. The total traveled distance is shown in display mode ODO. Press the button No function for 2–3 seconds. Briefly press the Next display mode button... -
Page 29: Display Mode Speed/A1 (Average Speed 1)
SPEEDOMETER Info The TR2 value can also be corrected manually during the journey with the but- and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the button Increases value of TR2. for 2–3 seconds. Briefly press the Increases value of TR2. -
Page 30: Display Mode Speed/S1 (Stop Watch 1)
SPEEDOMETER 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the dis- play. S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor. -
Page 31: Table Of Conditions And Menu Activation
SPEEDOMETER 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 stop watch Next display Stops the clock. Starts the stop SPEED/LAP (lap and the lap time... -
Page 32: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 33: Running In The Engine
PREPARING FOR USE – 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 34: 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. 137) – Mount the steel sprocket. -
Page 35: 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. 137) – Mount the steel sprocket. -
Page 36: Preparing For Riding At Low Temperatures Or In Snow
Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 Your authorized KTM workshop can recommend the right carburetor tuning. -
Page 37: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 107) –... -
Page 38: Start Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 39: Stopping, Parking
RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. –... -
Page 40: Refueling
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 41: Service Schedule
● ● Check the idle. ● ● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ● Periodic interval... -
Page 42: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●... -
Page 43: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 44: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 45: Measuring The Sag Of The Unloaded Rear Wheel
TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) B00792-10 Rebound damping Comfort 28 clicks... -
Page 46: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 47: Adjusting The Riding Sag
TUNING THE CHASSIS Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) Finishing work –... -
Page 48: Adjusting The Compression Damping Of The Fork
Make the same adjustment on both fork legs. – Turn counterclockwise by the number of clicks corresponding to the fork type. M00090-10 Guideline (125 EXC EU, all 200 models, 125 EXC Factory Edition EU) Compression damping Comfort 22 clicks Standard... -
Page 49: Adjusting The Rebound Damping Of The Fork
Make the same adjustment on both fork legs. – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline (125 EXC EU, all 200 models, 125 EXC Factory Edition EU) B02145-10 Rebound damping Comfort 20 clicks... -
Page 50: Adjusting The Spring Preload Of The Fork (Exc, Xc-W, Exc Factory Edition)
Make the same adjustment on both fork legs. – Turn clockwise by the number of turns corresponding to the fork type. Guideline (125 EXC EU, all 200 models, 125 EXC Factory Edition EU) Spring preload - Preload Adjuster M00092-01 Comfort... -
Page 51: 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 52: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) Neither wheel is in contact with the ground. -
Page 53: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Loosen the fork protection. ( p. 51) Main work – Push dust boots of both fork legs downwards. -
Page 54: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Remove the front wheel. p. 86) – Remove the headlight mask with the headlight. ( p. 94) Main work –... -
Page 55: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS (EXC Factory Edition) – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp. -
Page 56: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 12.10 Installing the fork protector Main work – 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 fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 57: Installing The Lower Triple Clamp (Exc, Xc-W)
SERVICE WORK ON THE CHASSIS Main work – Remove screw . Remove screw . Pull off the upper triple clamp with the han- dlebar and hang it to one side. Info Protect the components against damage by covering them. Do not bend the cables and lines. - Page 58 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) B02153-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B02153-11 – Tighten screw Guideline Screw, top steering stem 20 Nm...
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Page 59: Installing The Lower Triple Clamp (Six Days, Exc Factory Edition)
SERVICE WORK ON THE CHASSIS 12.14 Installing the lower triple clamp (Six Days, EXC Factory Edition) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 137) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 60: 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 61: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –... -
Page 62: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS (EXC Factory Edition) – Loosen screws . Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –... -
Page 63: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 12.19 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B02156-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B02155-11 Finishing work... -
Page 64: Removing The Seat
SERVICE WORK ON THE CHASSIS Guideline Screw, bottom shock 80 Nm Loctite ® 2701™ absorber (59 lbf ft) Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. -
Page 65: Removing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS – Mount and tighten screw of the seat fixation. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00817-10 12.24 Removing the air filter box lid – Pull off the air filter box lid in area ... -
Page 66: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 12.27 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 137) 301262-10 – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. -
Page 67: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 12.29 Sealing the air filter box Preparatory work – Remove the air filter box lid. ( p. 63) Main work – Seal the air filter box in the marked area 401527-10 Finishing work – Install the air filter box lid. -
Page 68: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove screws – Pull out inner tube – Remove glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –... -
Page 69: 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 70: 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. 68) 400678-01 12.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –... -
Page 71: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain ten- sion Info The bottom chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain ... -
Page 72: 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. 50) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »... -
Page 73: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must be replaced. Repair of the frame is not authorized by KTM. 401347-01... -
Page 74: 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 75: 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 76: 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 77 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Hydraulic fluid (15) ( p. 136) – On the slave cylinder of the clutch, remove bleeder screw and mount bleed- ing syringe B02164-10 –...
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Page 78: Removing The Engine Guard (Six Days, Exc Factory Edition)
SERVICE WORK ON THE CHASSIS 12.48 Removing the engine guard (Six Days, EXC Factory Edition) – Turn quick release counterclockwise until it disengages. Remove the engine guard. B01204-10 12.49 Installing the engine guard (Six Days, EXC Factory Edition) – Attach the engine guard at the back of the frame and swing it up at front. -
Page 79: 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 80: 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 81: 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 82: 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 83: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the full set of brake linings. -
Page 84: 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 85: Adding Brake Fluid For The Rear Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 86: Changing The Brake Linings Of The Rear Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. - Page 87 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.
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Page 88: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 89: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –... -
Page 90: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 91: 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 92 WHEELS, TIRES – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
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Page 93: 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 94: Recharging The Battery (All 200/250/300 Models)
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 95: Changing The Main Fuse (All 200/250/300 Models)
ELECTRICAL SYSTEM 15.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover. -
Page 96: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15.5 Removing the headlight mask with the headlight – Switch off all power consumers and switch off the engine. – Remove screw and take off the clamp. – Release rubber straps . Slide the headlight mask up and swing it forward. 602762-10 (All EXC models) –... -
Page 97: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and fix it with rubber straps The holding lugs engage. – Position the brake line and wiring harness. Put the clamp on and mount and tighten screw 602762-11 Finishing work – Check the headlight setting. -
Page 98: Checking The Headlight Setting
ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze orange cap in the area of the holding lugs and take it off. –... -
Page 99: Changing The Speedometer Battery
ELECTRICAL SYSTEM 15.11 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 94) Main work – Remove screws – Pull the speedometer upward out of the holder. 602746-10 – Using a coin, turn protection cap all the way counterclockwise and remove it. -
Page 100: 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 101: 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 102: Refilling With Coolant
COOLING SYSTEM (All 250/300 models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) B02168-11 16.5... - Page 103 COOLING SYSTEM – Place the vehicle back on a level surface. – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. M00597-10 Finishing work – Check the coolant level. ( p.
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Page 104: 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 105: Carburetor - Adjusting The Idle Speed
TUNING THE ENGINE The idle speed is adjusted with adjusting screw The idle mixture is adjusted with the idle air adjusting screw Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw ... -
Page 106: Emptying The Carburetor Float Chamber
TUNING THE ENGINE – Adjust the idle speed with adjusting screw Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 18) 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 107: 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 108 TUNING THE ENGINE Main work – Remove screws B02129-10 – Take cap , adjusting spring , auxiliary spring , and spring insert out of the clutch cover. – Pull both springs off of the spring insert. B00056-11 –...
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Page 109: 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 110: 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 111: Adding Gear Oil
SERVICE WORK ON THE ENGINE – Mount and tighten the oil filler plug. 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 112 SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight. Finishing work – Check the gear oil level. ( p. 107)
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Page 113: 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 114: 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 115: 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. 50) – Cover the vehicle with a tarp or cover that is permeable to air. -
Page 116: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 35) tric starter) – Battery discharged Recharge the battery. p. 92) (All 200/250/300 models) – Check the charging voltage. –... - Page 117 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Engine takes in bad air Check the intake flange and carburetor for carburetor tightness. – The connector or ignition coil is loose Clean the connector and treat it with contact or oxidized spray.
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Page 118: 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 119: 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 120: 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 half keystone 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 121: 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 122: Capacities
TECHNICAL DATA Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) – 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 ®... -
Page 123: Electrical System
TECHNICAL DATA 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) Secondary ratio (All 125 models) 14:50 (13:50) -
Page 124: Tires
Dunlop GEOMAX AT 81 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 125 EXC EU, all 200 models, 125 EXC Factory Edition EU Fork part number 14.18.7L.61 WP Suspension Up Side Down 4860 MXMA PA Fork Compression damping... -
Page 125: Exc Six Days Eu
−0.79 Fork oil per fork leg 625 ml (21.13 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 135) 22.7.3 125 EXC Six Days EU Fork part number 24.18.7N.61 Fork WP Suspension Up Side Down 4860 4CS Compression damping Comfort... -
Page 126: Shock Absorber
TECHNICAL DATA Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 3.8 N/mm (21.7 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.2 N/mm (24 lb/in) Fork length 932 mm (36.69 in) Air chamber length... -
Page 127: Chassis Tightening Torques
TECHNICAL DATA Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload Comfort 7 mm (0.28 in) Standard 7 mm (0.28 in) Sport 7 mm (0.28 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75…... - Page 128 TECHNICAL DATA – Screw, top steering stem (EXC, XC‑W) 20 Nm (14.8 lbf ft) Screw, top steering stem (Six Days, 17 Nm (12.5 lbf ft) Loctite ® 243™ EXC Factory Edition) – Screw, top triple clamp (EXC, XC‑W) 20 Nm (14.8 lbf ft) –...
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Page 129: Carburetor
TECHNICAL DATA 22.10 Carburetor 22.10.1 All 125 models Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (N1EF / N1EG) Main jet 100 (172/175) Idling jet 38x38 (42/45) Starting jet 50 (85) Idle air adjusting screw Open... - Page 130 TECHNICAL DATA 402138-01 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!
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Page 131: 22.10.3 200 Exc Eu
TECHNICAL DATA 22.10.3 200 EXC EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK027 Needle position 3rd position from top Jet needle NPRH (N1EH / N1EI / N1EJ) Main jet 100 (162/165) Idling jet 35x35 (40) Starting jet 50 (85) Idle air adjusting screw Open... - Page 132 TECHNICAL DATA 402139-01 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!
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Page 133: 22.10.7 250 Exc Eu, 250 Exc Six Days Eu, 250 Exc Factory Edition Eu
TECHNICAL DATA 22.10.7 250 EXC EU, 250 EXC Six Days EU, 250 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N2ZW / N2ZH / N2ZJ) Main jet 110 (172/175) Idling jet... - Page 134 TECHNICAL DATA 402140-01 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!
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Page 135: 22.10.11 300 Exc Eu, 300 Exc Six Days Eu, 300 Exc Factory Edition Eu
TECHNICAL DATA 22.10.11 300 EXC EU, 300 EXC Six Days EU, 300 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N8RG / N8RH) Main jet 115 (170/172/175) Idling jet 38X38 (35) -
Page 136: 22.10.15 General Carburetor Tuning
TECHNICAL DATA 402141-01 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! 22.10.15 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 137: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 138 SUBSTANCES Hydraulic fluid (15) Standard/classification – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...
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Page 139: Auxiliary Substances
Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® –... - Page 140 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 141: 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 142: Index
INDEX Clutch INDEX fluid level, checking/correcting ....74 Accessories ........8 fluid, changing . - Page 143 INDEX Fork Kick starter ........18 basic setting, checking ..... . . 45 Kill switch .
- Page 144 INDEX installing ....... . . 61 removing ....... . . 61 Use definition .
- Page 145 *3213233en* 3213233en 10/2014 KTM Motorrad AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...