Page 2 - ENGLISH; IMPORTANT; WARNING; Chassis number; Tampering with noise control system prohibited; COMSUMER INFORMATION FOR AUSTRALIA ONLY
ENGLISH 1 IMPORTANT PLEASE 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 INTE- REST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOW...
Page 3 - Introduction; At the time this manual was typeset,
ENGLISH 2 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bringyou lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride...
Page 4 - IMPORTANT WARRANTY AND; THE SX/SXS AND MXC MODELS ARE PROHIBITED ON PUBLIC ROADS.; The EXC models are designed for off-road sports endurance; not suitable for predominant motocross
ENGLISH 3 IMPORTANT WARRANTY AND GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usualwear and tear of normal use in competitions.The motorcycles comply with the regulations and categories currently ineffect with the leading international motorcycle associatio...
Page 5 - TABLE OF CONTENTS
ENGLISH 4 Page IMPORTANT WARRANTY AND GUARANTEE INFORMATION .3 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5 OPERATION INSTR...
Page 6 - SERIAL NUMBER LOCATIONS; Clutch lever
ENGLISH 5 Chassis number The chassis number is stamped on the right side of the steering head tube.Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side ofthe engine below the engine sprocket. Enter this number on...
Page 7 - Electronic speedometer; Anzeigemodus SPEED/ODO
ENGLISH 6 Electronic speedometer, indicator lamp (EXC) The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp 2 lights up when the high beam is on. Electronic speedometer The electronic speedometer display is activated as so...
Page 8 - Tripmaster switch; MODE
ENGLISH 7 Tripmaster switch The switch has three buttons: MODE, + (plus) and – (minus). WARNING D O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING . Y OUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO ANACCIDENT . Electronic speedometer functions provided by t...
Page 10 - Setting the clock
ENGLISH 9 SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary toTRP1, the displayed figure can be changed using the + and – buttons. Thisis a very useful function for trips taken according to a roadbook.TRP2 is activated by the first impulse received f...
Page 11 - OVERVIEW OF TRIPMASTER FUNCTIONS; Kilometers or miles
ENGLISH 10 X X X X X X X X X X X X X X X X X X X X X no function no function starts / stops LAP figure LAP remains next figure no function no function no function no function no function increases TRP2 figure no function starts / stops STP2 Press + Display SPEED / ODO SPEED / MAX SPEED / LAP LAP / L...
Page 12 - Flasher switch
ENGLISH 11 Short circuit button (SX) The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. A = Light off (this function is not available in all models) B =...
Page 13 - Filler cap; Fuel tap; OFF; Choke knob; Shift lever; ON; SX
ENGLISH 12 Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation t...
Page 14 - Kickstarter; Steering lock; CAUTION
ENGLISH 13 Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part canbe swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic posi-tion can be adjusted to your seat position (see maintenance work). Side stand Push the s...
Page 15 - Compression damping of fork
ENGLISH 14 Compression damping of fork Hydraulic compression damping determines the reaction when the fork iscompressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap 1 . Turn the knob 2 clockwise to increase damping, turn it...
Page 17 - Instructions for your first ride; GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE
ENGLISH 16 WARNING – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE . SMART KTM DRIVERS ALWAYS WEAR A HELMET , BOOTS , GLOVES , AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A SHORT RIDE . T HE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER USERS OF THE ROADS C...
Page 18 - What you should check before each start; DRIVING INSTRUCTIONS
ENGLISH 17 What you should check before each start When you start off, the motorcycle must be in a perfect technical condition.For safety reasons, you should make it a habit to perform an overall checkof your motorcycle before each start.The following checks should be performed: 1 CHECK TRANSMISSION...
Page 19 - Starting when the engine is cold; Starting when the engine is warm; What to do when the engine is “flooded”
ENGLISH 18 Starting when the engine is cold 1 Open fuel tap2 Turn on ignition or emergency OFF switch3 Put the gear in neutral4 Activate cold-starting aid (choke)5 Leave throttle closed or open it no more than 1 / 3 and kick down kickstar- ter vigorously all the way. WARNING – F OR STARTING ALWAYS P...
Page 20 - Braking; Stopping and parking
ENGLISH 19 Refueling, fuel 125-300: Unleaded premium gasoline RON 95 mixed with high grade two stroke oil. Mixture ratio 1:40 - 1:60 Fuel and engine oil should only be mixed immediately beforeuse. KTM recommends Motorex Cross Power 2T. WARNING G ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS . E XTREME C...
Page 21 - PERIODIC MAINTENANCE SCHEDULE; A clean motorcycle can be checked more quickly which saves money!; MPORTANT; WHEELS
ENGLISH 20 PERIODIC MAINTENANCE SCHEDULE after 20 hours or 2000 kilometers 1st service after 10 hours or 1000 kilometers after 4000 kilometer or once a year IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE I NTERVALS SHOULD NEVER BE EXCEEDED BY MO...
Page 23 - EXC
ENGLISH 22 R ECOMMENDED INSPECTION OF THE 125/200/250/300 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ( ADDITIONAL ORDER FOR THE KTM WORKSHOP ) Check the reed-type intake valve for wear ● ● ● ● ● ● Check the clutch shoes for wear ● ● ● ● ● ● Check the length of the clutch spr...
Page 25 - MAINTENANCE WORK ON CHASSIS AND ENGINE; Checking and adjusting the steering head bearing *
ENGLISH 24 WARNING MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZEDKTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF. ! C...
Page 26 - How to change the handlebar position; Breather plug front fork; Cleaning the dust sleeves of the telescopic fork
ENGLISH 25 How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put thehandlebar in the position that is the most convenient for you. The upper tri-ple clamp 1 includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another. The bores at th...
Page 27 - Basic suspension setup for the weight of the driver; Determining the riding sag of the shock absorber
ENGLISH 26 Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork, shockabsorber, swing arm and frame from being damaged, the basic setup of thesuspension components must be suitable for your weight. At delivery,KTM's offroad motorcycles a...
Page 28 - Checking the basic setup of the telescopic fork
ENGLISH 27 According to our experience, the damping rate of the compression stagecan remain unchanged. The damping rate of the rebound stage can bereduced by a few clicks for a softer spring or increased by a few clicks for aharder spring. Checking the basic setup of the telescopic fork The precise ...
Page 29 - Adjusting the spring preload on the fork (SX)
ENGLISH 28 Adjusting the spring preload on the fork (SX) The spring preload on the SX models can be adjusted (changed) by 10 mmby turning adjusting screw 1 . Turning in a clockwise direction will increase the prestress, turning in acounterclockwise direction will decrease the prestress.Changing the ...
Page 30 - Check chain tension; Correct chain tension
ENGLISH 29 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer tou-ches the ground.Press the chain upward at the end of the chain sliding component. Thedistance between the chain and the swing arm should be approx. 8 - 10 mm(0.31 - 0.39 in). In the course of this...
Page 31 - Chain maintenance; Chain wear
ENGLISH 30 Chain maintenance For long chain life, good maintenance is very important. X-ring chainsrequire only modest maintenance. The best way is to use lots of water, butnever use brushes or solvents. After letting the chain dry, you can use aspecial X-ring chain spray (Motorex Chainlube 622). WA...
Page 32 - General information about KTM disc brakes
ENGLISH 31 General information about KTM disc brakes BRAKE CALIPERS:The brake calipers of this series use a ”floating” mount. This means that thebrake calipers are not solidly attached to the caliper support, which enablesthem to ”float” for maximum braking contact.Secure the screws of the cali-per ...
Page 33 - Adjusting the free travel at the hand brake lever; Checking the brake fluid level - front brake; Refilling the front brake fluid reservoir *; Checking the front brake pads
ENGLISH 32 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustmentscrew 1 . In this way, the position of the point of pressure (i.e. the resis- tance you feel on the hand brake lever when the brake pads are pressedagainst the brake ...
Page 34 - Replacing the front brake pads *; Changing the basic position of the foot brake pedal *; Checking the rear brake fluid level; Refilling the rear brake fluid reservoir *
ENGLISH 33 Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in itsbasic position. Remove clips 1 and pull out bolt 2 . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper supportwith compressed air. Check the ...
Page 35 - Checking the rear brake pads; Replacing the rear brake pads *; Dismounting and mounting the front wheel
ENGLISH 34 Checking the rear brake pads The brake pads can be inspected from the rear. The thickness of the liningsmay not be less than 1 mm (0.04 in). WARNING A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM , OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAF...
Page 36 - Dismounting and mounting the rear wheel
ENGLISH 35 Before remounting the front wheel, clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushings To install the front wheel, lift it into the fork, position and mount the axleshaft. Mount the collar nut 5 , tighten the clamping ...
Page 37 - Checking spoke tension; Replacing the battery of the digital speedometer
ENGLISH 36 Tires, air pressure Tire type, tire condition, and air pressure level affect the way your motorcy-cle rides and must therefore be checked whenever you are getting ready togo anywhere on your motorcycle.– Tire size can be found in the technical specifications and in the homolo- gation cert...
Page 38 - Check/set distance of the magnetic sensor
ENGLISH 37 Check/set distance of the magnetic sensor The distance between the magnet 2 and the sensor 1 must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing the sensor 1 in or off. Replacing the headlight lamp/parking light lamp Loosen bot...
Page 39 - Cooling system; Radiator cover for the cold season; when engine is cold
ENGLISH 38 Cooling system The water pump in the engine circulates the cooling liquid. However, thecooling liquid can only circulate properly if the cooling circuit contains no airbubbles.Bleeding of the cooling system is therefore requireda) after adding more than 0.25 l cooling liquid andb) after r...
Page 40 - Refilling/Bleeding the cooling system
ENGLISH 39 Refilling/Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0.25 l (0.06 US gallons) coolingliquid.Make sure that the drain screw 1 is fastened. Pour approx. 0.5 litres (0.13 US gallons) coolant into ...
Page 41 - Changing the original position of the clutch lever; Checking the oil level of the hydraulic clutch; Bleeding of the hydraulic clutch; bk
ENGLISH 40 Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal positionfor every hand size.Turning the adjusting screw clockwise reduces the distance betwee...
Page 42 - Carburetor adjustment *; Basic information on the original carburetor setting; Definitions
ENGLISH 41 Cleaning the spark arrestor (EXC USA) * With these models, the spark arrestor is part of the exhaust silencer. Clean itevery 4000 km (2500 miles) to guarantee proper functioning. Also clean thespark arrestor when replacing the glassfiber yarn filling.After assembling the silencer, remove ...
Page 43 - Opening up
ENGLISH 42 Opening up B Engine behavior when the throttle opens. The idle jet and the shape of thethrottle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fullyopened and develops its full power not smoothly bu...
Page 46 - USE AFTER A PERIOD OF STORAGE; STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION
ENGLISH 45 Should you wish to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING)– Change engine oil (old engine oil contains aggressive contaminants).– Check antifreeze and amount of cooling liquid.– Let the engi...
Page 47 - TECHNICAL SPECIFICA
ENGLISH 46 125 SX 125 EXC 200 SX 200 EXC Frame Central chrome-moly-steel frame Fork W hite P ower – U pside down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 ( P rogressive D amping S ystem) shock absorber, aluminium swingarm Front brake Disc brake with carbon-...
Page 49 - TECHNICAL DA
ENGLISH 48 Engine 125 SX 125 EXC 200 SX 200 EXC Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm 193 ccm Bore / stroke 54 / 54.5 mm (2.126 / 2.145 in) 64 / 60 mm (2.52 / 2.362 in) Fuel unleaded fuel with at least RON 95 (USA = Pre...
Page 50 - TIGHTENING TORQUES - ENGINE
ENGLISH 49 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head M 7 18 Nm Nuts-cylinder base M 8 30 Nm Flywheel collar nut M 12 x1 60 Nm Nut for primary sprocket (LH thread) M 16x1.5 180 Nm Nut for inner clutch hub M 18 x1.5 120 Nm Crankcase and clutch cover bolts M 6 8 Nm Spark plug M 14x1.25 2...
Page 52 - IGHTENING
ENGLISH 51 Collar screw, front wheel spindle M 24x1,5 40 Nm Brake caliper, front M 8 Loctite 243 + 25 Nm Brake disk, front M 6 10.9 Loctite 243 + 15 Nm Brake disk, rear M 6 Loctite 243 + 15 Nm Clamping screws, upper fork bridge M 8 20 Nm Clamping screws, lower fork bridge M 8 15 Nm Clamping screws, ...
Page 53 - KTM T
ENGLISH 52 Engine 250 SX 250 EXC 300 MXC/EXC Desgin Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 293,15 ccm Bore / stroke 66,4 / 72 mm (2.62 / 2.84 in) 72 / 72 mm (2.84 / 2.84 in) Fuel unleaded fue...
Page 54 - TIGHTENING TORQUES
ENGLISH 53 TIGHTENING TORQUES Flange bolts - cylinder-head M 8 35 Nm Nuts-cylinder base M 10 35 Nm Flywheel collar nut M 12 x1 60 Nm Nut for primary sprocket (LH thread) M 18 x1.5 Loctite 243 + 150 Nm Nut for inner clutch hub M 18 x1.5 Loctite 243 + 100 Nm Crankcase and cover bolts M 6 8 Nm Swingarm...
Page 55 - INDEX
ENGLISH 54 Page Activating/deactivating the display modes . . . . . . . . . . . .9Adjusting the free travel at the hand brake lever . . . . . .32Adjusting the spring preload on the fork (SX) . . . . . . . .28Basic suspension setup for the weight of the driver . . . .26Bleeding of the hydraulic clutc...
Page 57 - wiring diagramm
ANHANG – APPENDICE APPENDIX – APÉNDICE 2 flasher rel ay G st op but to n br wh horn sw itc h high/ low b e a m s w itc h v bu re bl bl bl capacit o r bl hor n front brake sw itc h wiring diagramm EXC 125-300 2004 flasher s w itc h I main harness D C 503.11.075.850 pi ck u p 22.05.2003 igniti on c oi...
Page 62 - VERGASERREGULIERUNG; TEMPERA; NEEDLE; NICHT FÜR STRASSENBETRIEB
ANHANG – APPENDICE APPENDIX – APÉNDICE 7 VERGASERREGULIERUNG KTM 125 SX EUROP A / USA 2004 KEIHIN PWK 39 CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F TEMPERA TUR ME...
Page 63 - CARBURETOR SETTING
ANHANG – APPENDICE APPENDIX – APÉNDICE 8 VERGASERREGULIERUNG KTM 125 EXC EUR 2004 KEIHIN PWK 38 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F TEMPERA TUR MEERESHÖ...
Page 66 - Slide
ANHANG – APPENDICE APPENDIX – APÉNDICE 11 VERGASERREGULIERUNG KTM 250, 300 MXC/EXC EUR/USA 2004 KEIHIN PWK S36 AG CARBURETOR SETTING -20°C bis -7°C -6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C 37°C bis 49°C -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 99°F to 120°F TEMPE...
