Мануал ктм ехс 200

OWNER’S MANUAL 2012

125 EXC EU

125 EXC SIX DAYS EU

200 EXC EU

200 EXC AUS

200 XC W USA

250 EXC EU

250 EXC AUS

250 EXC SIX DAYS EU

250 XC W USA

300 EXC EU

300 EXC AUS

300 EXC SIX DAYS EU

300 XC W USA

Art. no. 3211718en

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

Chassis number ( p. 10)

Dealer’s stamp

Engine number ( p. 11)

Key number (All EXC models) ( p. 10)

The owner’s manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

TABLE OF CONTENTS	4
Carburetor configuration (All 200 models) x……………..	115
Carburetor configuration (All 250 models) x……………..	116
Carburetor configuration (All 300 models) x……………..	117
General carburetor configuration x…………………………	118
TECHNICAL DATA — CHASSIS ……………………………………	119
Lighting equipment ……………………………………………..	120
Tires ………………………………………………………………..	120
Capacity — fuel…………………………………………………….	120
TECHNICAL DATA — FORK…………………………………………	121
All 125/200 models …………………………………………….	121
All 250/300 models …………………………………………….	121
TECHNICAL DATA — SHOCK ABSORBER ………………………	123
All 125/200 models …………………………………………….	123
All 250/300 models …………………………………………….	123
TECHNICAL DATA — TIGHTENING TORQUES FOR
CHASSIS ………………………………………………………………	125
SUBSTANCES………………………………………………………..	126
AUXILIARY SUBSTANCES…………………………………………	128
STANDARDS………………………………………………………….	130
INDEX ………………………………………………………………….	131

MEANS OF REPRESENTATION

5

Symbols used

The symbols used are explained below.

Indicates an expected reaction (e.g., to a work step or a function).

Indicates an unexpected reaction (e.g., to a work step or a function).

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.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained below.

Specific name	Identifies a specific name.
Name®	Identifies a protected name.
Brand™	Identifies a brand available on the open market.

IMPORTANT INFORMATION

6

Use definition (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.

Info

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. The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.

Use definition (XC-W)

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.

Info

The motorcycle must be used only on closed off property remote from public road traffic.

The motorcycle is designed for offroad sport endurance competition (Enduro) and not for predominant motocross use.

Service

A prerequisite for perfect operation and prevention of wear is that the engine and chassis service, care and adjustment work described in the owner’s manual is properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner’s manual.

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)

When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts.

Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

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.

–Switch off the engine.

–Turn handle of the fuel tap to the OFF position.

–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner’s manual

–It is important that you read this owner’s manual carefully and completely before making your first trip. It contains information and tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle to your own requirements and how to protect yourself from injury. The owner’s manual also contains important information on servicing the motorcycle.

–The owner’s manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

View3.1 of vehicle, front left (example)

B00784-10

1Hand brake lever ( p. 12)

2Kill switch ( p. 12)

3Clutch lever ( p. 12)

4Air filter box lid

5Fuel tap ( p. 21)

6Chain guide

7Side stand ( p. 23)

8Shift lever ( p. 22)

9Fork rebound adjustment

10Fork compression adjustment

View3.2 of vehicle, rear right (example)

B00783-10

1Filler cap

2Bleeder screw, fork leg

3Throttle grip ( p. 12)

4Chassis number ( p. 10)

5Kickstarter ( p. 22)

6Foot brake lever ( p. 23)

7Shock absorber, compression adjustment

8Level viewer, rear brake fluid

9Shock absorber, rebound adjustment

Chassis4.1 number

(XC-W)

The chassis number is stamped on the right side of the steering head.

B00015-10

(All EXC models)

The chassis number is stamped on the right side of the steering head.

303438-10

Type4.2 label

(XC-W)

The type label is fixed to the front of the steering head.

400284-10

(All EXC models)

The type label is fixed to the front of the steering head.

303439-10

Key4.3 number (All EXC models)

The key number for the steering lock is stamped onto the key connector.

500125-10

Engine4.4 number

The engine number is stamped on the left side of the engine under the engine sprocket.

B00016-10

Fork4.5 part number

The fork part number is stamped on the inner side of the fork stub.

B00265-01

Shock4.6 absorber part number

The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

B00786-10

Clutch5.1 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.

B00001-10

(All 250/300 models)

The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

B00009-10

Hand5.2 brake lever

Hand brake lever is located on the right side of the handlebar.

The hand brake lever is used to activate the front brake.

400196-10

Throttle5.3 grip

Throttle grip is fitted on the right side of the handlebar.

B00060-10

Kill5.4 switch (All EXC models)

The kill switch is fitted on the left side of the handlebar.

Possible states

•Kill switch in basic position – In this position, the ignition circuit is closed and the engine can be started.

•Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

B00078-10

Emergency5.10 OFF switch (250/300 EXC AUS)

The emergency OFF switch is fitted on the right side of the handlebar.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed, and the engine can be started.

B00079-10

Electric5.11 starter button (250/300 EXC EU, EXC SIX DAYS, 250/300 XC W)

The electric starter button is fitted on the right side of the handlebar.

Possible states

•Electric starter button in basic position

•Electric starter button pressed – In this position, the electric starter is actuated.

B00080-10

Electric5.12 starter button (250/300 EXC AUS)

The electric starter button is fitted on the right side of the handlebar.

Possible states

•Electric starter button in basic position

•Electric starter button pressed – In this position, the electric starter is actuated.

B00081-10

Light5.13 switch (XC-W)

Light switch is located to the right of the speedometer.

Possible states

•The light switch has no function when the vehicle is delivered – It can be used to retrofit the vehicle with a lighting system.

500146-10

Overview5.14 of indicator lamps (All EXC models)

Possible states

High beam indicator lamp lights up blue – High beam is switched on.

Turn signal indicator lamp flashes green – Turn signal light is switched on.

500147-01

–Press the button for 3 — 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

Setting5.19 the clock

Condition

The motorcycle is stationary.

–Press the button briefly and repeatedly until CLK appears at the bottom right of the display.

–Press the button for 3 — 5 seconds.

The hour display flashes.

– Set the hour display with the button and/or button .

– Press the button briefly.

The next segment of the display flashes and can be set.

–You can set the following segments in the same way as the hours by pressing the

400330-01 button and the button .

Info

The seconds can only be set to zero.

–Press the button for 3 — 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed.

Adjusting5.20 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.

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

–Press the button for 3 — 5 seconds.

The Setup menu is displayed and the activated functions are shown.

– Change to the desired function by pressing the button briefly.

The selected function flashes.

Activating a function

–Press the button .

400318-01	The symbol remains on the screen and the display changes to the next
	function.

Deactivating the function

–Press the button .

The symbol on the screen goes out and the display changes to the next function.

–All desired functions are activated or deactivated accordingly.

–Press the button for 3 — 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed.

Querying5.21 lap time

Info

This function can be called up only if lap times are measured.

Condition

The motorcycle is stationary.

–Press the button briefly and repeatedly until LAP appears at the bottom right of the display.

–Press the button briefly.

LAP 1 appears on the left side of the display.

– Laps 1-10 can be displayed by pressing the button .

– The button has no function.

–Press the button briefly. Next display mode

400321-01

Info

If an impulse is received from the wheel speed sensor, the left side of the display changes back to the SPEED mode.

Display5.22 mode SPEED (speed)

–Press the button briefly and repeatedly until SPEED appears on the left side of the display.

The current speed is displayed in the SPEED display mode.

The current speed can be displayed in Km/h or Mph.

Info

Making the setting according to the country.

When an impulse comes from the front wheel, the left side of the speedometer display changes to the SPEED mode and the current speed is shown.

400317-02

Display5.23 mode SPEED/H (operating hours)

Condition

•The motorcycle is stationary.

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

In display mode H, the operating hours of the engine are displayed.

The operating hours counter stores the total traveling time.

Info

The operating hours counter is necessary for ensuring that maintenance work is 400316-01 carried out at the right intervals.

If the speedometer is in H display mode at the start of the journey, it automatically changes to the ODO display mode.

The H display mode is suppressed during the journey.

Press the button .	No function
Press the button .	No function
Press the button	The display changes to the Setup menu of the speedometer
for 3 — 5 seconds.	functions.
Press the button	Next display mode
briefly.

Display5.28 mode SPEED/TR2 (trip master 2)

–Press the button briefly and repeatedly until TR2 appears at the top right of the display.

TR2 (trip master 2) runs constantly and counts up to 999.9.

The displayed value can be set manually with the button and the button . This is a very practical function when riding using the road book.

							Info
							The TR2 value can also be corrected manually during the journey with the but-
							ton and the button .
						If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
400324-01

Press the button .	Increases value of TR2.
Press the button .	Reduces value of TR2.
Press the button	Deletes value of TR2.
for 3 — 5 seconds.
Press the button	Next display mode
briefly.

Display5.29 mode SPEED/A1 (average speed 1)

–Press the button briefly and repeatedly until A1 appears at the top right of the display.

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip master 1) and S1 (stop watch 1).

The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

				Press the button .	No function
				Press the button .	No function
	400325-01		Press the button	The TR1, A1 and S1 displays are reset to 0.0.
				for 3 — 5 seconds.
				Press the button	Next display mode
				briefly.

Display5.30 mode SPEED/A2 (average speed 2)

–Press the button briefly and repeatedly until A2 appears at the top right of the display.

A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

Info

The displayed value can differ from the actual average speed if S2 was not timed after the ride.

400326-01		Press the button .	No function
		Press the button .	No function
		Press the button	–
		for 3 — 5 seconds.
		Press the button	Next display mode
		briefly.

	CONTROLS		21
	Table of conditions and menu activation
	Display	The motorcycle is	Menu can be acti-
		stationary.	vated
	Display mode SPEED/LAP (lap time)		•
	Display mode SPEED/TR1 (trip master 1)		•
	Display mode SPEED/TR2 (trip master 2)		•
	Display mode SPEED/A1 (average speed 1)		•
	Display mode SPEED/A2 (average speed 2)		•
	Display mode SPEED/S1 (stop watch 1)		•
	Display mode SPEED/S2 (stop watch 2)		•

Fuel5.33 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 carburetor.

Possible states

•Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

•Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve.

•Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.

601157-10

Opening5.34 the filler cap

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.

–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

–Press release button , turn the filler cap counterclockwise and lift it free.

303520-10

Closing5.35 the filler cap

–Replace the filler cap and turn clockwise until the release button locks in place.

Info

Run the fuel tank breather hose without kinks.

303521-10

Shift5.36 lever

Shift lever is mounted on the left side of the engine.

B00005-10

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

B00005-12

Kickstarter5.37

The kickstarter is fitted on the right side of the engine. The top part can be swiveled.

B00787-10

Unlocking5.42 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.

400731-01

Advice6.1 on first use

Danger

Danger of accidents Danger arising from the rider’s judgement being impaired.

–Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be undamaged and meet legal requirements.

Warning

Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

–The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

–Adapt your riding speed to the road conditions and your riding ability.

Warning

Danger of accidents Accident risk caused by presence of a passenger.

–Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidents Failure of brake system.

–If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Unstable riding behavior.

–Do not exceed the maximum permissible weight and axle loads.

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.

Info

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.

–Before your first trip, read the entire operating instructions carefully.

–Get to know the controls.

–Adjust the basic position of the clutch lever. ( p. 66)

(XC-W)

–Adjust the basic position of the hand brake lever. ( p. 69)

(All EXC models)

– Adjust the free travel of the hand brake lever. ( p. 69)

–Adjust the basic position of the foot brake lever. x( p. 73)

–Adjust the basic position of the shift lever. x( p. 96)

–Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info

Offroad, you should be accompanied by another person on another machine so that you can help each other.

–Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

–Do not make any offroad trips that over-stress your ability and experience.

–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 distribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

–Do not exceed the overall maximum permitted weight and the axle loads. Guideline

	Maximum permissible overall weight	335 kg (739 lb.)
	Maximum permissible front axle load	145 kg (320 lb.)
	Maximum permissible rear axle load	190 kg (419 lb.)
– Check the spoke tension. ( p. 81)

Info

The spoke tension must be checked after half an hour of operation.

–Run the engine in.

Running6.2 in the engine

–During the running-in phase, do not exceed the specified engine performance. Guideline

Maximum engine performance
During the first 3 operating hours	< 70 %
During the first 5 operating hours	< 100 %

– Avoid fully opening the throttle!

Preparing6.3 the vehicle for difficult operating conditions

Info

Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

–Seal the air filter box. x

Tip

Seal the air filter box at the edges against dirt.

–Clean the air filter and air filter box. x( p. 57)

Info

Check the air filter approx. every 30 minutes.

–Additionally secure the rubber grip. ( p. 66)

–Check the electrical connector for humidity and corrosion and to ensure it is firmly seated. » If humidity, corrosion, or damage is found:

–Clean and dry the connector, or change it if necessary.

Difficult operating conditions are:

–Riding on dry sand. ( p. 27)

–Riding on wet sand. ( p. 27)

–Riding on wet and muddy surfaces. ( p. 28)

–Riding at high temperatures and low speeds. ( p. 28)

–Rides at low temperatures or in snow. ( p. 29)

–Change the radiator cap.

–Mount the rain cover for the air filter.

Rain cover for air filter (59006021000)

		Info
		Read the KTM PowerParts installation instructions.
		– Adjust the carburetor jetting and setting.
	600870-01	Info
	Recommendations on the carburetor setting are available from your autho-
		rized KTM workshop.

			–	Clean the chain.
				Chain cleaner ( p. 128)
			– Mount the steel sprocket.
							Tip
							Do not grease the chain.
			– Clean the radiator fins.
			–	Carefully align bent radiator fins.
	600868-01

– If used in sand regularly, replace the piston every 10 operating hours.

Preparations6.6 for riding on wet and muddy surfaces

–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.

–Mount the steel sprocket.

–Clean the motorcycle. ( p. 101)

–Carefully align bent radiator fins.

600868-01

Preparations6.7	for riding at high temperatures and low speeds
		– Check the radiator cap.
			Value on the radiator cap	1.8 bar (26 psi)

			» If the displayed value does not equal the setpoint value:
					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
	600872-10
					and cooling system to cool down. In case of scalding, rinse
					immediately with lukewarm water.

–Change the radiator cap.

–Adjust the secondary ratio to the terrain.

Info

The engine oil heats up rapidly if the clutch needs to be operated too frequently because the secondary ratio is too long.

–Clean the chain.

				Chain cleaner ( p. 128)
			– Clean the radiator fins.
	600868-01
		– Carefully align bent radiator fins.
			– Check the coolant level. ( p. 90)

Preparing6.8 for rides 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					The recommended carburetor tuning is available from your authorized KTM
						workshop.

Checks7.1 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. 98)

–Check the electrical system.

–Check the front brake fluid level. ( p. 70)

–Check the rear brake fluid level. ( p. 74)

–Check the front brake linings. ( p. 71)

–Check the rear brake linings. ( p. 75)

–Check that the brake system is functioning properly.

–Check the coolant level. ( p. 90)

–Check the chain for dirt. ( p. 60)

–Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 61)

–Check the chain tension. ( p. 61)

–Check the tire condition. ( p. 80)

–Check the tire air pressure. ( p. 81)

–Check the spoke tension. ( p. 81)

–Clean the dust boots of the fork legs. ( p. 45)

–Bleed the fork legs. ( p. 44)

–Check the air filter.

–Check the settings of all controls and ensure that they can be operated smoothly.

–Check all screws, nuts and hose clamps regularly for tightness.

–Check the fuel supply.

Starting7.2

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 ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Note

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

–Always warm up the engine at low engine speeds.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.

If the float chamber is filled with fresh fuel, the engine starts immediately.

Engine has been out of use for more than 1 week

– Empty the carburetor float chamber. x( p. 95)

–Turn handle of the fuel tap to the ON position. (Figure 601157-10 p. 21) Fuel can flow from the fuel tank to the carburetor.

–Remove the motorcycle from the stand.

–Shift gear to neutral.

(200 EXC AUS)

–Turn the emergency OFF switch to the position .

(250/300 EXC AUS)

–Turn the emergency OFF switch to the position .

(All 250/300 models)

–Press the electric starter button or press the kick starter robustly through its full range.

Info

Do not open the throttle.

(All 125/200 models)

–Press the kick starter forcefully through its full range.

Info

Do not open the throttle.

Start7.3 off

Info

Before riding, switch on the lights if your vehicle is equipped with a lighting system. This will make it easier for other road users to see you.

When you are riding, the side stand must be folded up and secured with the rubber band.

–Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting,7.4 riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

–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.

–When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

–If the choke function was activated, deactivate it after the engine has warmed up.

–When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces vehicle speed but lowers fuel consumption considerably.

–Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

–To shift down, brake and close the throttle at the same time.

–Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

–Switch off the engine if you expect to be standing for a long time. Guideline

≥2 min

–Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.

–Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

Braking7.5

Warning

Danger of accidents If you brake too hard, the wheels can lock.

–Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.

–Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking efficiency due to wet or dirty brakes.

–Clean or dry dirty or wet brakes by riding and braking gently.

–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,7.6 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 become very hot when the vehicle is operated.

–Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

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.

Note

Material damage Damage and destruction of components by excessive load.

–The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

–Brake the motorcycle.

–Shift gear to neutral.

(All EXC models)

–Press and hold the kill switch while the engine is idling until the engine stops.

(XC-W)

– Press and hold the short circuit button while the engine is idling until the engine stops.

–Turn handle of the fuel tap to the OFF position.

–Park the motorcycle on firm ground.

Refueling7.7

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.

–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

–Switch off the engine.

–Open the filler cap. ( p. 21)

	– Fill the fuel tank with fuel up to measurement .
	Guideline
	Measurement of		35 mm (1.38 in)
A	Total fuel tank	9.5 l	Super unleaded gasoline, mixed with
	capacity, approx.	(2.51 US gal)	2-stroke engine oil (1:60) (	p. 127)
	(EXC EU,
	EXC SIX DAYS)
	Total fuel tank	10 l (2.6 US gal)	Super unleaded gasoline, mixed with
400382-10	capacity, approx.		2-stroke engine oil (1:60) (	p. 127)
	(EXC AUS, XC W)

2-stroke engine oil ( p. 126)

–Close the filler cap. ( p. 22)

	SERVICE SCHEDULE				34
	Service8.1	schedule
								S20A	S40A
	Check that the electrical equipment is functioning properly.	•	•
	Check and charge the battery. x	(All 250/300 models)	•	•
	Change the gear oil. x(	p. 98)			•	•
	Check the front brake linings. (		p. 71)			•	•
	Check the rear brake linings. (	p. 75)			•	•
	Check the brake discs. (	p. 70)				•	•
	Check the brake lines for damage and leakage.		•	•
	Check the rear brake fluid level. (	p. 74)			•	•
	Check the free travel of the foot brake lever. (	p. 73)	•	•
	Check the frame and swingarm. x			•	•
	Check the swingarm bearing. x					•
	Check the heim joints at the top and bottom of the shock absorber. x	•	•
	Check the tire condition. (	p. 80)			•	•
	Check the tire air pressure. (	p. 81)			•	•
	Check the wheel bearing for play. x			•	•
	Check the wheel hubs. x						•	•
	Check the rim run-out. x						•	•
	Check the spoke tension. (	p. 81)			•	•
	Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 61)	•	•
	Check the chain tension. (	p. 61)			•	•
	Grease all moving parts (e.g. side stand, hand lever, chain, …) and check for smooth operation. x	•	•
	Check the fluid level of the hydraulic clutch. (	p. 67)	•	•
	Check the front brake fluid level. ( p. 70)		•	•
	Check the free travel of the hand brake lever. (	p. 69)	•	•
	Check the play of the steering head bearing. (	p. 52)	•	•
	Change the spark plug and spark plug connector. x	•	•
	Check the intake diaphragm. x				•	•
	Check the exhaust control for functioning and smooth operation. x		•
	Check the clutch. x							•
	Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing. x	•	•
	Check the antifreeze and coolant level. (	p. 89)	•	•
	Check the cables for damage and routing without sharp bends. x	•	•
	Check that the throttle cables are undamaged, routed without sharp bends and set correctly.	•	•
	Clean the air filter and air filter box. x(	p. 57)	•	•
	Change the glass fiber yarn filling of the main silencer. x( p. 58)	•	•
	Check the screws and nuts for tightness. x		•	•
	Check the headlight setting. (All EXC models) (	p. 87)	•	•
	Check the idle.						•	•
	Final check: Check the vehicle for safe operation and take a test ride.	•	•
	Make the service entry in KTM DEALER.NET and in the service record. x	•	•

S20A: Every 20 operating hours

S40A: Every 40 operating hours/after every race

	SERVICE SCHEDULE					35
	Maintenance8.2	work (as an additional order)
				S10N	S40A	S80A	J1A
	Change the front brake fluid. x					•
	Change the rear brake fluid. x					•
	Change the foot brake cylinder seals. x					•
	Change the hydraulic clutch fluid. x(	p. 67)				•
	Grease the steering head bearing. x(	p. 53)				•
	Check/set the carburetor components. x				•	•
	Perform a fork service. x		•	•	•
	Service the shock absorber. x			•	•
	Check the starter drive. x(All 250/300 models)		•	•
	Change the piston and check the cylinder. x(125 EXC EU, 125 EXC SIX DAYS EU)		•	•
	Change the piston and check the cylinder. x(All 200/250/300 models)			•
	Change the connecting rod, conrod bearing and crank pin. x			•
	Check the transmission and shift mechanism. x			•
	Change all engine bearings. x				•

S10N: Once after 10 operating hours

S40A: Every 40 operating hours

S80A: Every 80 operating hours/every 40 operating hours when used for motorsports

J1A: Annually

TUNING THE CHASSIS	37
	(All 250/300 models)
		Compression damping, high-speed
		Comfort	2 turns
		Standard	1.5 turns
		Sport	1.25 turns
		Full payload	1.25 turns

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting9.4 the low-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 low-speed setting can be seen during the slow to normal compression of the shock absorber.

		– Turn adjusting screw clockwise with a screwdriver to the last click.
						Info
						Do not loosen nut !
		– Turn back counterclockwise by the number of clicks corresponding to the shock
			absorber type.
			Guideline
			(All 125/200 models)
	B00794-10				Compression damping, low-speed
						Comfort	25 clicks
						Standard	20 clicks
						Sport	15 clicks
						Full payload	15 clicks
			(All 250/300 models)
					Compression damping, low-speed
						Comfort	25 clicks
						Standard	20 clicks
						Sport	15 clicks
						Full payload	15 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting9.5 the rebound 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.)

Checking9.7 the static sag of the shock absorber

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

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• This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold.This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.No part of this publication may be reproduced without written pe …

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• This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold.This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.No part of this publication may be …

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The Austrian company KTM is one of the largest and most famous manufacturers of sports motorcycles in Europe. The official date of foundation of the enterprise is 1934. It was
then that a young but very ambitious engineer named Hans Trunkenpolz, who lived in the city of Mattinghofen, opened a metal processing workshop, which received the name Kraftfahrzeuge Trunkenpolz
Mattighofen (KTM).

This series consists of two machines: the dual-use 125EXE and the urban enduro 125 Supermoto. They differ from each other mainly in wheels, dressed in universal
tires (125ЕХЕ) and highway «rubber» (125 Supermoto). Both motorcycles are equipped with a new two-stroke engine, unified in design with sports power units. The frame is tubular, welded, made of
chrome-molybdenum steel. Telescopic front fork — inverted type. The rear suspension of the PDS (Progressive Damping System) system, as on all “adult” KTMs, provides a progressive characteristic
without an intermediate linkage only due to the design of the shock absorber itself.