KTM Motorcycle 125 EXC User Manual
OWNER’S MANUAL 2007  
125 EXC SIX DAYS, EXC  
200 XC, XC-W, EXC  
250 XC, XC-W, EXC SIX DAYS, EXC  
300 XC, XC-W, EXC SIX DAYS, EXC  
ART. NR. 3.211.144EN  
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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 bring you lots of fun and  
enjoyment, provided that you clean and maintain it appropriately.  
Please insert the serial numbers of your motorcycle in the boxes below  
Frame number  
Engine number  
Key number  
1
Stamp of dealer  
COMSUMER INFORMATION FOR AUSTRALIA ONLY  
Tampering with noise control system prohibited  
Owners are warned that the law may prohibit:  
(a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or  
replacement, of any device or element of design incorporated into any new vehicle for the purpose of  
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and  
(b) the use of the vehicle after such device or element of design has been removed or rendered inopera-  
tive by any person.  
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right  
to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,  
constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the  
above items, all without previous announcement and without giving reasons. KTM may stop manufactur-  
ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil-  
ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models  
partly contain extra equipment, which is not applied to standard models.  
© 2006 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in  
extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.  
In accordance with the international quality management ISO 9001 standard, KTM uses  
quality assurance processes that lead to the highest possible product quality.  
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IMPORTANT »  
INTENDED PURPOSE  
KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in  
competitions.  
The motorcycles comply with the regulations and categories currently in effect with the leading interna-  
tional motorcycle associations.  
THE XC/XC-W MODELS ARE PROHIBITED ON PUBLIC ROADS.  
The EXC models are only allowed on public roads in the original homologated (throttled) version. Without  
this performance restriction (i.e. dethrottled), these models are only allowed to be driven off-road but not  
on public roads. The EXC models are designed for off-road sports endurance competitions(enduro) and  
not suitable for predominant motocross use.  
2-STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS  
KTM EXC models were designed for offroad use only and are only suitable for longer rides on public roads  
to a certain extent. The engine is subjected to completely different performance demands on public roads  
and must be adapted to these operating conditions.  
Ask your KTM dealer for more information.  
2
OWNER’S MANUAL  
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. Only by doing so will  
you learn how to tune your motorbike to your specific needs and how to protect yourself against injury.  
Besides, this manual contains important information on motorcycle maintenance.  
– Ignoring these instructions can be dangerous to life and limb!  
– ignoring these instructions may damage parts of the motorcycle or impair the motorcycle’s traffic safety!  
At the time this manual was typeset, it was up-to-date with the latest state of this production series. It  
cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design  
upgrades of these motorcycles.This manual is an important part of your motorbike and should be passed  
on to any subsequent owner in case you decide to sell it.  
SERVICE  
Observance of the service, maintenance and tuning instructions for the engine and chassis specified in  
the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An  
improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on  
checking the basic chassis setting).  
The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead  
to higher than average wear on components such as the drive train or the brakes. In this case it may  
become necessary to service or replace wear parts before the service limit specified in the maintenance  
schedule has been reached.  
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IMPORTANT »  
The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM  
workshop and recorded in the service manual otherwise claims under the warranty shall become void. The  
fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications  
must be used in accordance with the maintenance schedule.  
Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding  
these guidelines will significantly increase the life of your motorcycle.  
WARRANTY  
The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM  
workshop and recorded in the service manual otherwise claims under the warranty shall become void.  
No claims can be filed under the warranty for damage or consequential damage caused by manipulations  
or conversions to the motorcycle.  
AUTOMOTIVE FLUIDS  
The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifica-  
tions must be used in accordance with the maintenance schedule.  
SPARE PARTS, ACCESSORIES  
For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that  
arises in connection with the use of other products.  
3
TRANSPORT  
When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright  
position. Be sure that the fuel tap is closed. If the motorcycle topples over, fuel can flow out of the car-  
buretor or fuel tank  
ENVIRONMENT  
Offroad-Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full.  
It may, however, involve potential problems for the environment or lead to conflicts with others. These  
problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of  
motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are  
environmentally conscious and respect the rights of others.  
Enjoy driving your motorcycle !  
KTM-SPORTMOTORCYCLE AG  
5230 MATTIGHOFEN, AUSTRIA  
Attachments: Spare parts manual chassis & engine  
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TABLE OF CONTENTS »  
Page  
Page  
How to change the handlebar position . . . . . . . . . . . .30  
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .30  
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31  
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .31  
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31  
General information about KTM disc brakes . . . . . . . .32  
Adjusting the free travel at the hand brake lever . . . . .33  
Checking the brake fluid level - front brake . . . . . . . .33  
Refilling the front brake fluid reservoir . . . . . . . . . . .33  
Checking the front brake pads . . . . . . . . . . . . . . . . .33  
Replacing the front brake pads . . . . . . . . . . . . . . . . .34  
Changing the basic position of the foot brake pedal . .34  
Checking the rear brake fluid level . . . . . . . . . . . . . .34  
Refilling the rear brake fluid reservoir . . . . . . . . . . . .34  
Checking the rear brake pads . . . . . . . . . . . . . . . . . .35  
Replacing the rear brake pads . . . . . . . . . . . . . . . . .35  
Dismounting and mounting the front wheel . . . . . . . .35  
Dismounting and mounting the rear wheel . . . . . . . . .36  
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .37  
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37  
Replacing the battery of the digital speedometer . . . .37  
Check/set distance of the magnetic sensor . . . . . . . . .38  
Replacing the headlight lamp/parking light lamp . . . .38  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .39  
Checking the coolant level . . . . . . . . . . . . . . . . . . . .39  
Refilling/Bleeding the cooling system . . . . . . . . . . . .40  
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .40  
Checking the oil level of the hydraulic clutch . . . . . . .41  
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . .41  
Changing the original position of the clutch lever . . . .41  
Bleeding the hydraulic clutch . . . . . . . . . . . . . . . . .42  
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .42  
Draining the float chamber of the carburetor . . . . . . .44  
Checking the float level . . . . . . . . . . . . . . . . . . . . . .44  
Adjusting the engine characteristic via the ignition curve . .44  
Adjusting the engine characteristic via the auxiliary spring .45  
Check transmission oil level (125/200) . . . . . . . . . . .46  
Changing the transmission oil (125/200) . . . . . . . . . .46  
Check transmission oil level (250/300) . . . . . . . . . . .46  
Changing the transmission oil (250/300) . . . . . . . . . .46  
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5  
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5  
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .6  
Indicator lamps (EXC) . . . . . . . . . . . . . . . . . . . . . . .10  
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . .11  
Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . .11  
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
Emergency OFF switch (Australia) . . . . . . . . . . . . . . .11  
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Filler cap (XC, XC-W) . . . . . . . . . . . . . . . . . . . . . . . .12  
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Choke knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Compression damping of fork . . . . . . . . . . . . . . . . . .14  
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .14  
Spring preload of the fork(XC/EXC Six Days) . . . . . . . .14  
Compression damping of shock absorber (XC-W, EXC) .15  
Shock absorber compression damping (XC-W/EXC) . . .15  
Shock absorber rebound damping XC-W, EXC) . . . . . .15  
4
GENERAL TIPS AND WARNINGS FOR STARTING THE  
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16  
Instructions for your first ride . . . . . . . . . . . . . . . . . .16  
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16  
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .17  
What you should check before each start . . . . . . . . . .17  
Starting when the engine is cold . . . . . . . . . . . . . . . .18  
Starting when the engine is warm . . . . . . . . . . . . . . .18  
What to do when the engine is „flooded“ . . . . . . . . . .18  
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .19  
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47  
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .47  
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47  
TECHNICAL SPECIFICATIONS – CHASSIS 125 / 200 . . .48  
TECHNICAL SPECIFICATIONS – ENGINE 125 / 200 . . .50  
TECHNICAL SPECIFICATIONS – CHASSIS 250 / 300 . . .52  
TECHNICAL SPECIFICATIONS – ENGINE 250 / 300 . . .54  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56  
WIRING DIAGRAM, CARBURETOR TABLE . . . . .APPENDIX  
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .20  
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .24  
Changing the spring preloading of the shock absorber . .24  
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24  
Basic suspension setup for the weight of the driver . . .25  
Checking the shock absorber and spring . . . . . . . . . .25  
Determining the static sag of the shock absorber . . . .25  
Determining the riding sag of the shock absorber . . . .25  
Changing the spring preload on the telescopic fork . . .26  
Checking the basic setup of the telescopic fork . . . . .26  
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .27  
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .27  
Cleaning the dust sleeves of the telescopic fork . . . . .27  
Changing the fork offset (caster) (XC) . . . . . . . . . . . .28  
Checking and adjusting the steering head bearing . . .29  
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SERIAL NUMBER LOCATIONS »  
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 of the  
engine below the engine sprocket. Enter this number on page 1.  
5
OPERATION INSTRUMENTS »  
Clutch lever  
The clutch lever [1] is located on the left side of the handlebars. The adjust-  
ing screw [A] is used to change the original position of the clutch lever (see  
maintenance work on chassis and engine).  
The clutch is hydraulically actuated and adjusts itself automatically.  
1
A
Hand brake lever  
The hand brake lever [2] is mounted on the handlebars on the right and actu-  
ates the front wheel brake. The adjusting screw [B] can be used to change  
the basic position of the hand brake lever (see maintenance work on chassis  
and engine).  
2
B
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OPERATION INSTRUMENTS »  
Electronic speedometer  
The display in the electronic speedometer is activated as soon as you press  
a button on the speedometer or an impulse is received from the wheel sen-  
sor. The display lights up when the engine is running.  
The display is cleared if no button is pressed for 1 minute or no impulse is  
received from the wheel sensor.  
The | button is used to change between display modes.  
The + and – buttons are used to control various functions.  
TEST  
All of the display segments briefly light up for the display function test.  
6
WS (wheel size)  
The display changes and the circumference of the front wheel is briefly dis-  
played in millimeters (2205 mm corresponds to a front wheel circumference  
of 21" with production tires).  
Afterwards the display will return to the previous display mode.  
SPEED display mode / H (service hours)  
Only the SPEED / H and SPEED / ODO display modes are activated in the  
condition at delivery. SPEED/H is displayed whenever the display is activated  
and the front wheel is not turning. It automatically changes to the SPEED/ODO  
display mode as soon as the front wheel starts turning.  
SPEED displays the speed.  
H displays the engine's service hours. The service hour counter starts to count  
as soon as you start the engine. The displayed figure cannot be changed.  
Service intervals are indicated in service hours for some KTM offroad motor-  
cycles, making the service hour counter a very practical function.  
SPEED / ODO display mode (odometer)  
The SPEED/ODO mode displays the speed and the total distance traveled.  
The display automatically changes to the SPEED/H display mode when the  
front wheel stops turning.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. changes to the next display mode  
The electronic speedometer has a number of display modes (functions) that  
you can also activate (reveal) (see: Activating and deactivating display modes).  
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OPERATION INSTRUMENTS »  
Activating and deactivating display modes  
In the display mode SPEED/H, press and hold the | button for 3 seconds to  
access the SETUP menu. The active functions will be displayed. The blink-  
ing function can be activated by pressing the + button and deactivated by  
pressing the – button.  
Press and hold the | button 3 seconds to store the settings.  
If no button is pressed for 20 seconds, the setting will be stored automati-  
cally and the display will return to the SPEED/H mode.  
+ button  
activates the blinking display  
deactivates the blinking display  
– button  
briefly press | button changes to the next display without changing any  
settings  
hold | button 3 secs. starts the SETUP  
stores the settings and changes to the SPEED/H  
mode  
The following display modes can be activated:  
TR1  
TR2  
A1  
tripmaster 1  
tripmaster 2  
average speed 1  
average speed 2  
stop watch 1  
stop watch 2  
clock  
lap time  
A2  
S1  
S2  
CLK  
LAP  
MAX  
KMH/MPH  
maximum speed  
display in kilometers or miles (see: Kilometers or miles)  
7
If you have activated all of the display modes, they will be displayed in the  
following order:  
SPEED/H, SPEED/CLK, SPEED/LAP, LAP/LAP, SPEED/MAX, SPEED/ODO,  
SPEED/TR1, SPEED/TR2, SPEED/A1, SPEED/A2, SPEED/S1, SPEED/S2  
SPEED / CLK (time) display mode  
CLK displays the time in hours, minutes and seconds.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. set the clock menu  
To set the clock, see „Setting the clock“.  
SPEED / LAP (lap time) display mode  
You can use the manual stop watch to stop and store up to 10 lap times,  
which you can view in the LAP/LAP display mode (see below).  
LAP displays the lap times in hours, minutes and seconds.  
+ button  
Starts and stops the stop watch, lap time is not  
reset to 0  
– button  
Stops the stop watch, stores the lap time and restarts  
the stop watch again. The time is reset to 0. A total  
of 10 lap times can be stored. If the lap time con-  
tinues to run after you press the - button, all 10 mem-  
ory locations are occupied.To clear all of the stored  
lap times, hold the | button for 3 seconds in the  
SPEED/LAP mode.Up to 10 lap times can be stored  
in this way.  
briefly press | button Changes to the next display mode.If no lap time is  
stored or the motorcycle is driving, the LAP/LAP  
mode will be skipped.  
hold | button 3 secs. Clears all LAP figures  
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OPERATION INSTRUMENTS »  
LAP / LAP display mode (to view lap times)  
The LAP/LAP display mode will only be shown if lap times have been stored  
and the front wheel has stopped. It will display the lap number and the  
stopped lap time in hours, minutes and seconds. Press the + button to access  
the next lap time.  
To clear all of the stored lap times, hold the | button for 3 seconds in the  
SPEED/LAP mode.  
+ button  
changes to the next lap time  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. changes to the next display mode  
SPEED / MAX display mode (maximum speed)  
MAX displays the maximum speed traveled and is always active.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. clears the MAX figure  
8
SPEED / TR1 display mode (tripmaster 1)  
The TR1 tripmaster is always active and counts to 999.9. It is used to meas-  
ure the length of a trip or the distance between 2 refueling stops.  
TR1 is linked to A1 (average speed 1). The calculation of these figures is acti-  
vated by the first impulse received from the wheel sensor (when the front wheel  
starts to turn) and stops 3 seconds after the last impulse is received (when  
the front wheel has stopped).  
The TR1, A1 and S1 figures are automatically cleared after passing 999.9.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. clears the TR1, S1, A1 figures  
SPEED / TR2 display mode (tripmaster 2)  
The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the  
displayed figure can be changed using the + and – buttons. This is a very use-  
ful function for trips taken according to a roadbook.  
+ button  
increases the TR2 figure  
decreases the TR2 figure  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. clears the TR2 figure  
SPEED / A1 display mode (average speed 1)  
A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (stop  
watch 1) figures. The calculation of this figure is activated by the first impulse  
received from the wheel sensor and stops 3 seconds after the last impulse is  
received.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. clears the TR1, S1, A1 figures  
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OPERATION INSTRUMENTS »  
SPEED / A2 display mode (average speed 2)  
A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop  
watch 2) figures.  
The displayed figure can deviate from the actual average speed if the TR2  
figure was changed manually or if S2 was not stopped after the trip.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. changes to the next display mode  
SPEED / S1 display mode (stop watch 1)  
S1 shows the traveling time based on TR1 and continues to run whenever it  
receives impulses from the wheel sensor. The calculation of this figure is acti-  
vated by the first impulse received from the wheel sensor and stops 3 sec-  
onds after the last impulse is received.  
+ button  
no function  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. clears the TR1, S1, A1 figures  
9
SPEED / S2 display mode (stop watch 2)  
S2 is a manual stop watch. Start the stop watch by pressing the + button,  
press again to hold. Press again to continue timing.  
Press the | button to change to the next mode. The S2 display will blink in  
the other modes if S2 continues to run in the background. To stop S2, return  
to the SPEED/S2 mode and press the + button.  
+ button  
starts and stops the stop watch  
no function  
– button  
briefly press | button changes to the next display mode  
hold | button 3 secs. clears the S2 figure  
Kilometers or miles  
The unit (kilometers or miles) can also be changed. The ODO figure will be  
retained and converted accordingly. The TR1, A1, S1, TR2 and A2 figures  
will be cleared.  
To select the unit, select the SPEED/H mode and hold the | button for 3 sec-  
onds to access the SETUP menu. Press the | button until the KMH/MPH  
function blinks. Press the + button briefly to move to the options. Press the  
+ button for KMH or the – button for MPH.  
To set, briefly press the | button 1 x and hold for 3 seconds until the dis-  
play returns to the SPEED/H mode.  
If no button is pressed for 20 seconds, the setting will be stored automati-  
cally and the display will return to the SPEED/H mode.  
+ button  
to access the menu  
to activate the KMH display  
to activate the MPH display  
– button  
briefly press | button changes to the next mode  
changes from the menu to the SETUP menu  
hold | button 3 secs. stores and closes the SETUP menu  
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OPERATION INSTRUMENTS »  
Setting the clock  
To set the clock, switch the ignition off and select the SPEED/CLK mode. Press  
and hold the | button for 3 seconds. The blinking digits can be changed  
using the + and – buttons. Press the | button to move to the next digit. 0-  
12 will show the time in the 12-hour mode, 0-24 in the 24-hour mode.  
Press and hold the | button for 3 seconds to store the settings.  
If no button is pressed for 20 seconds, the settings will be stored automati-  
cally and the display will return to the SPEED/CLK mode.  
+ button  
time +  
time –  
– button  
briefly press | button changes to the next digit  
hold | button 3 secs. starts the SETUP menu  
stores the time and changes to the SPEED/CLK dis-  
play mode  
OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS  
display  
SPEED / H  
SPEED / CLK  
briefly press + button  
no function  
briefly press – button  
no function  
briefly press | button  
next display mode  
next display mode  
hold | button 3 secs.  
displays the SETUP menu  
setting the clock menu  
X
X
10  
X
X
no function  
no function  
starts/stops LAP without  
clearing LAP figure  
stops LAP, stores LAP  
figure, resets LAP to 0  
X
SPEED / LAP  
next display mode  
clears all LAP figures  
X
X
LAP / LAP  
SPEED / MAX  
SPEED / ODO  
SPEED / TR1  
SPEED / TR2  
SPEED / A1  
SPEED / A2  
SPEED / S1  
SPEED / S2  
next figure  
no function  
no function  
no function  
no function  
no function  
no function  
no function  
next display mode  
next display mode  
next display mode  
next display mode  
next display mode  
next display mode  
next display mode  
next display mode  
next display mode  
next display mode  
clears MAX  
X
X
X
X
X
X
X
X
next display mode  
clears TR1, S1, A1  
clears TR2  
X
X
X
X
X
X
increases the TR2 figure reduces the TR2 figure  
no function  
no function  
no function  
no function  
no function  
no function  
clears TR1, S1, A1  
next display mode  
clears TR1, S1, A1  
clears S2  
no function  
starts - stops S2  
If the CLK, LAP, MAX, TR1, TR2 A1, A2, S1 and S2 figures are suddenly cleared, the battery in the electronic speedometer is empty  
and must be replaced (see: Replacing the battery in the electronic speedometer).  
A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar.  
Indicator lamps (EXC)  
The green control lamp [1] flashes in the same rhythm as the  
flashing indicator when the indicator is working.  
1
2
The blue control lamp [2] lights up when the high beam is on.  
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OPERATION INSTRUMENTS »  
Combination switch (EXC/EXC Six Days)  
3
2
The light switch has 2, respectively 3 switch positions.  
[A] = Light off (this function is not available in all models)  
[B] = Low beam on  
[C] = High beam on  
You may use button [2] to actuate the horn.  
The red short circuit button [3] serves to switch off the engine. Leave the  
switch pressed until the engine stops.  
A
B
C
Headlamp switch (XC-W)  
In this model the headlamp is switched on with the pull switch [4].  
4
11  
Flasher switch  
The flasher switch is a separate unit and is mounted on the left portion of the  
handlebar.  
The wire harness is designed in a way that whenever you want to use your  
bike off-road, you can dismount the entire turn indicator system without  
affecting the function of the remaining electrical system.  
Flasher left  
Flasher right  
Emergency OFF switch (Australia)  
The emergency OFF switch [5] is located next to the throttle grip. Primarily  
designed as safety or emergency OFF switch, it should normally not be in its  
activated state.  
In this position, the ignition circuit is shorted; if the engine is running,  
it will stall immediately, if it is at standstill, it will not start.  
5
In this position, the ignition circuit is enabled; the engine should start.  
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OPERATION INSTRUMENTS »  
Filler cap (EXC/EXC Six Days)  
To open it: turn filler cap counter-clockwise.  
To close it: put filler cap back on and tighten it by turning it clockwise.  
Filler cap (XC, XC-W)  
1
To open the filler cap: Turn the filler cap 45° counter-clockwise.  
To close the filler cap: Put the filler cap on and turn it 45 ° 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 carbure-  
tor.  
ON During operation the twist grip must be turned to ON. This means that  
the fuel can flow to the carburetor. With the twist grip in this position  
the tank will be emptied until only the reserve is left.  
RES The reserve tank cannot be tapped until the rotating handle is turned  
to the RES position. Fill the tank as soon as possible and remember to  
turn the rotating handle back to the ON position so that you will have  
backup fuel next time, too.  
Reserve of the 8.5/10 l tank . . . . .1.3 l (0.34 US gallons)  
Reserve of the 11.2 l tank . . . . . .1.7 l (0.45 US gallons)  
12  
XC  
EXC  
Choke knob  
When pulling the choke knob [2] fully towards the top, a bore is opened in  
the carburetor. Through this bore the engine can take in additional fuel. This  
results in a rich fuel-air mixture, that is needed for a cold start.  
When pressing the choke knob downward in the carburetor, the bore is closed  
again.  
2
Shift lever  
The shift lever is mounted on the left side of the engine. The position of the  
gears is shown in the illustration. Neutral, or the idle speed, is located between  
first and second gear.  
2,3,4,5, (6)  
N
1
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OPERATION INSTRUMENTS »  
Kickstarter  
The kickstarter is mounted on the left side of the engine. Its upper part can  
be 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).  
13  
Side stand  
Push the side stand to the ground with your foot and load it with the motor-  
cycle. Make sure that you put your bike on solid ground and in a secure posi-  
tion. For off-road riding, you can use the rubber band [1] to additionally secure  
the center stand in its folded-up position.  
1
Steering lock  
The handlebar can be locked by means of the lock located on the steering  
head. To lock it, turn the handlebar all the way to the right, insert the key,  
turn it to the left, press it in, turn it to teh right, and remove it.  
Never leave the key inserted in the steering lock. If you turn the handlebar to  
the left the key could get damaged.  
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OPERATION INSTRUMENTS »  
Compression damping of fork  
Hydraulic compression damping determines the reaction when the fork is com-  
pressed. The degree of compression can be adjusted with adjusting  
screws at the bottom of the fork legs.Remove the protecting cap [1].  
Turn the screw [2] clockwise to increase damping, turn it counterclockwise  
to reduce damping during compression.  
1
STANDARD ADJUSTMENT:  
– turn adjusting screw clockwise as far as it will go  
– turn it back by as many clicks as are specified for the relevant type of fork  
Typ WP Suspension 14187C02 . . . . .20 clicks  
Typ WP Suspension 14187C04 . . . . .20 clicks  
Typ WP Suspension 14187C27 . . . . .18 clicks  
Typ WP Suspension 14187C28 . . . . .18 clicks  
2
2
Rebound damping of fork  
Hydraulic rebound damping determines the reaction when the fork is  
rebound.  
3
3
By turning the adjusting screw [3], the degree of damping of the rebound can  
be adjusted. Turn the knob clockwise to increase damping, turn it counter-  
clockwise to reduce damping during rebounding.  
STANDARD ADJUSTMENT:  
– turn adjusting screw clockwise as far as it will go  
– turn it back by as many clicks as are specified for the relevant type of fork  
Typ WP Suspension 14187C02 . . . . .20 clicks  
Typ WP Suspension 14187C04 . . . . .20 clicks  
Typ WP Suspension 14187C27 . . . . .20 clicks  
Typ WP Suspension 14187C28 . . . . .20 clicks  
14  
Spring preload of the fork (XC, EXC Six Days)  
The fork's preload can be adjusted by means of the adjusting screws [4]. Use  
a 24 mm fork wrench. More information is provided in the chapter "Adjusting  
the fork and shock absorber.“  
4
Damping action during compression of shock absorber (XC. EXC Six Days)  
The shock absorber on the XC/EXC Six Days models can synchronize the com-  
pression damping in the low and high-speed range separately (Dual Compression  
Control).  
Low and high speed refers to the movement of the shock absorber during com-  
pression and not to the speed of the motorcycle.  
The low and high-speed technology overlaps.  
The low-speed setting is primarily for slow to normal shock absorber  
compression rates.The high-speed setting is effective at fast compression  
rates.Turning in a clockwise direction will increase the damping, turning coun-  
terclockwise will decrease the damping.  
STANDARD LOW-SPEED SETTING:  
– Turn the adjusting screw [5] to the limit in a clockwise direction using a  
screwdriver .  
6
– Unscrew the respective number of clicks for the specific type of shock  
absorber in a counterclockwise direction.  
Typ WP Suspension 14187C27 . . . . .15 clicks  
Typ WP Suspension 14187C28 . . . . .15 clicks  
The damping unit of the shock absorber is filled with high-compression nitro-  
gen. Never try to take the shock absorber apart or to do any maintenance work  
yourself. Severe injuries could be the result.  
5
Never unscrew the black screw [6] connection (24mm).  
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OPERATION INSTRUMENTS »  
STANDARD HIGH-SPEED SETTING:  
– Turn the adjusting screw [1] to the limit in a counterclockwise direction  
using a box wrench.  
– Unscrew the respective number of turns for the specific type of shock absorber  
in a clockwise direction.  
1
Typ WP Suspension 14187C27 . . . . .1 turns  
Typ WP Suspension 14187C28 . . . . .1,25 turns  
Compression damping of shock absorber (XC-W, EXC)  
The compression damping (during compression) can be adjusted for the XC-W  
and EXC shock absorbers (Mono Compression Control).  
The degree of damping can be adjusted by turning adjusting screw [2] with  
a screwdriver. Turning in a clockwise direction will increase the damping, turn-  
ing in a counterclockwise direction will decrease the damping.  
3
2
STANDARD ADJUSTMENT:  
– Turn the adjusting screw clockwise to the stop.  
– Then turn the adjusting screw counterclockwise, counting the number of  
clicks that corresponds to the respective type of shock absorber.  
Typ WP Suspension 14187C02 . . . . .17 clicks  
Typ WP Suspension 14187C04 . . . . .15 clicks  
Typ WP Suspension 14187C27 . . . . .15 clicks  
Typ WP Suspension 14187C28 . . . . .15 clicks  
15  
The damping unit of the shock absorber is filled with high-compression nitro-  
gen. Never try to take the shock absorber apart or to do any maintenance work  
yourself. Severe injuries could be the result.  
Never unscrew the black screw [3] connection (24mm).  
Rebound damping of shock absorber  
By using the adjusting screw [4], the degree of damping of the rebound can  
be adjusted. Turn the knob to the right side to increase damping, turn it to  
the left side to reduce damping during rebounding.  
STANDARD ADJUSTMENT:  
5
4
– Turn the adjusting screw clockwise to the stop.  
– Then turn the adjusting screw counterclockwise, counting the number of  
clicks that corresponds to the respective type of shock absorber.  
Typ WP Suspension 14187C02 . . . . .26 clicks  
Typ WP Suspension 14187C04 . . . . .25 clicks  
Typ WP Suspension 14187C27 . . . . .24 clicks  
Typ WP Suspension 14187C28 . . . . .24 clicks  
The damping unit of the shock absorber is filled with high-compression nitro-  
gen. Never try to take the shock absorber apart or to do any maintenance work  
yourself. Severe injuries could be the result.  
Never unscrew the black screw [5] connection (15mm).  
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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »  
Instructions for your first ride  
– Make sure the work for the "pre-delivery inspection" was per-  
– Wear 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.  
The protective clothing should be brightly colored so that other  
users of the roads can see you as early as possible. Of course  
your passenger will also need suitable protective clothing.  
– Always turn on the light to make sure that other drivers become  
aware of you as early as possible.  
formed by your authorized KTM workshop. The DELIVERY CER-  
TIFICATE and SERVICE MANUAL will be handed over when you  
pick up your vehicle.  
– Thoroughly read the whole instruction manual before starting  
for your first tour.  
– Familiarize yourself with the controls.  
– Adjust the clutch lever, the hand brake lever and the foot brake  
pedal to the most comfortable position.  
– Get used to handling the motorcycle on an empty parking lot  
or open space, before going for a longer ride. Also try to ride  
as slowly as possible while standing upright, to improve your  
feeling for the vehicle.  
– Do not drive along off-road trails which go beyond your ability  
and experience.  
– Hold the handlebar with both hands and leave your feet on the  
foot rests while driving.  
– Remove your foot from the foot brake lever when you are not  
braking. If the foot brake lever is not released the brake pads  
rub continuously and the braking system is overheated.  
– Do not make any alterations to the motorcycle and always use  
ORIGINAL KTM SPARE PARTS. Spare parts from other man-  
ufacturers can impair the safety of the motorcycle.  
– Motorcycles are sensitive to alterations in the distribution of  
weight. If you are taking luggage with you, it should be secured  
as close as possible to the middle of the vehicle; distribute the  
weight evenly between the front and the rear wheel. Never  
exceed the maximum permissible laden weight and the axle  
weights. The maximum permissible laden weight is made up  
of the following components:  
– Do not drive after having consumed alcohol.  
– Only use accessory parts recommended by KTM. For example,  
front panelling can impair the driving characteristics of the motor-  
cycle. Cases, extra tanks etc. can alter the weight distribution  
and thus also impair the vehicle’s driving characteristics.  
– The front and rear wheel are allowed to be fitted only with tires  
that have the same profile type.  
– Be sure to check the spoke tension after 30 minutes' running time.  
The spoke tension will decrease quickly on new wheels. If you con-  
tinue to drive with loose spokes, the spokes may crack and lead  
to unstable handling (see "Checking the spoke tension")  
.
– Observe the traffic regulations, drive defensively and try to look  
ahead as far as possible so that you recognize any hazards as  
early as possible.  
– Adjust your driving speed to the conditions and your driving skills.  
– Drive carefully on unknown roads or in unknown territory.  
– When driving off-road, always have a friend on a second motor-  
cycle to keep you company, so that you can help each other  
should difficulties arise.  
– Replace the helmet visor or goggle glasses early enough. When  
light shines directly on a scratched visor or goggles, you will  
be practically blind.  
– Never leave your motorcycle without supervision as long as the  
engine is running.  
– The Above Models were designed and built for one person only  
- no additional passenger allowed!  
16  
- Motorcycle ready for operation and tank full  
- Luggage  
- Driver and passenger with protective clothing and helmet.  
– Pay attention to running-in procedure.  
– Neither do these models meet the applicable statutory regula-  
tions and safety standards. Using them on public roads, high-  
ways, freeways, etc. is against the law.  
– When riding your motorcycle, please bear in mind that other  
people may feel molested by excessive noise.  
Running in  
Even very precisely machined sections of engine components have  
rougher surfaces than components which have been sliding across  
one another for quite some time. Therefore, every engine needs to  
be broken in. For this reason, during its first 500 kilometers (300  
miles) or 5 hours the engine must not be revved up to its perform-  
ance limits.  
Apply low but changing loads for running-in.  
Do not drive at full load for the first 500 kilometers (300 miles)  
or 5 hours!  
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DRIVING INSTRUCTIONS »  
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 check of  
your motorcycle before each start.  
The following checks should be performed:  
1
2
3
CHECK TRANSMISSION OIL LEVEL  
Too little transmission oil leads to premature wear and will ultimately destroy  
gear wheels and parts of the shift mechanism.  
FUEL  
Check that there is sufficient fuel in the tank; when closing the filler cap,  
check that the tank venting hose is free of kinks.  
CHAIN  
A loose chain was fall off the chain wheels; an extremely worn chain may  
tear, and insufficient lubrication may result in unnecessary wear of the  
chain and chain wheels.  
4
5
TIRES  
Check for damaged tires. Tires showing cuts or dents must be replaced.  
The tread depth must comply with the legal regulations. Also check the  
air pressure. Insufficient tread and incorrect air pressure deteriorate the  
driving performance.  
BRAKES  
Check correct functioning of the braking system. Verify that there is suf-  
ficient brake fluid in the reservoir. The reservoirs have been designed in  
such a way that brake fluid does not need to be refilled even when the  
brake pads are worn. If the level of brake fluid falls below the minimum  
value, this indicates a leak in the braking system or completely worn out  
brake pads. Arrange for the braking system to be checked by an author-  
ized KTM dealer, as complete failure of the braking system can be expected.  
Also check the state of the brake hose and the thickness of the brake  
linings.  
17  
Check free travel of the hand brake lever and foot brake lever.  
If the resistance in the hand brake lever or foot brake pedal feels „spongy“  
(too much give), this is an indication that something is wrong with the brake  
system. Don’t ride your motorcycle anymore without first having the brake sys-  
tem looked over by a KTM dealer.  
6
7
8
CABLES  
Check correct adjustment and easy running of all control cables.  
COOLING FLUID  
Check the level of cooling fluid when the engine is cold.  
ELECTRICAL SYSTEM  
Check correct functioning of headlamps, tail-lights, brake lights, turn  
indicators, indicator lamps and horn while the engine is running.  
9
LUGGAGE  
If you are taking luggage with you, check that it is securely fastened.  
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DRIVING INSTRUCTIONS »  
Starting when the engine is cold  
1
2
3
4
5
6
Open fuel tap  
Turn on ignition or emergency OFF switch  
Swing up the side stand  
Put the gear in neutral  
Activate cold-starting aid (choke)  
Leave throttle closed or open it no more than 1/3 and kick down kick-  
starter vigorously all the way.  
– For starting always put on your motorcycle boots to avoid injuries. You could  
slip off the kickstarter or the motor could kick back and fling your foot  
upwards.  
– Forcefully kick the kickstarter down the whole way and do not open the  
throttle. A kickstart with too little momentum and an opened throttle  
increases the kicking back risk.  
– Check for power transmission at temperatures below 0°C (32°F) before  
you actuate the kickstarter. If you depress the kickstarter without feeling  
any resistance, power is not being transmitted. This could cause injuries.  
– Do not start the engine and allow it to idle in a closed area. Exhaust fumes  
are poisonous and can cause loss of consciousness and death. Always pro-  
vide adequate ventilation while the engine is running.  
Do not ride your motorcycle with full load and do not rev up the engine when  
cold. Since the piston warms up and expands faster than the water cooled  
cylinder, this might cause engine damage. Always let engine idle until warm  
or drive it warm at low r.p.m. speeds.  
18  
NOTE:  
The highly inflammable components in modern fuels volatilize if left stand-  
ing for longer periods of time. If the motorcycle has not been used for over  
1 week, the fuel should be drained from the float chamber. The engine will  
start up immediately if the float chamber is filled with fresh, ignitable fuel  
Starting when the engine is warm  
1
2
3
4
5
Open fuel tap  
Turn on ignition or emergency OFF switch  
Swing up the side stand  
Put the gear in neutral  
Open throttle to 1/2 and kick down kickstarter vigorously  
What to do when the engine is „flooded“  
1
2
3
Close fuel tap  
Start engine with full throttle. If necessary, unscrew spark plug and dry it.  
Once the engine is running, open fuel tap again.  
Starting off  
Pull the clutch lever. Put the engine into first gear, slowly release the clutch  
lever and accelerate at the same time.  
– Before you start off, check that the main or side stand has been swung  
right up to the top. If the stand drags on the floor, you may lose control  
of your motorcycle.  
– Before starting for an off-road tour, it is recommended to additionally secure  
the side stand with the rubber band on the air filter box.  
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DRIVING INSTRUCTIONS »  
Shifting/Riding  
You are now in first gear, referred to as the drive or uphill gear.  
Depending on the conditions (hill size, etc.), you can shift to a higher  
gear. Turn down the throttle, at the same time pull the clutch lever  
in and shift to the next higher gear. Let the clutch lever go again  
and open the throttle. If you turned on the choke, make sure you  
turn it off again as soon as engine is warm.  
Motorcycle engines produce a great amount of heat while running.  
The engine, exhaust pipe, muffler, brake rotors, and shock absorbers  
can become very hot. Do not touch any of these parts after start-  
ing the motorcycle, and take care to park it where pedestrians are  
not likely to touch it and get burned.  
When you reach full speed through opening the throttle all the way,  
turn throttle back to 3/4; the speed hardly decreases although the  
engine will use less gas. Only give as much gas as the engine can  
handle. Through quick and high revving of throttle, the gas con-  
sumption will increase. When shifting down, use the brakes if nec-  
essary and turn down at the same time. Pull the clutch lever and  
shift down to the next lower gear. Let the clutch lever go slowly  
and open the throttle or shift down again.  
– Close the fuel tap when leaving your vehicle. Otherwise the car-  
buretor may get flooded and fuel will enter the engine.  
– Never park your motorcycle in places where there exist fire haz-  
ards due to dry grass or other easily flammable materials.  
– The side stand is only designed for the weight of the motorcy-  
cle. If you get on your motorcycle and thus put additional  
weight on the motorcycle, the side stand or the frame can be  
damaged or the motorcycle may fall on the side.  
– After falling with the motorcycle, check all its functions thor-  
oughly before using it again.  
– A twisted handlebar must always be replaced. Do not adjust  
the handlebar, it will lose stability.  
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 before use.  
KTM recommends Motorex Cross Power 2T.  
– High rpm rates when the engine is cold have an adverse effect  
on the life of your engine. We recommend you run the engine  
in a moderate rpm range for a few miles giving it a chance to  
warm up. After that no further precautions in this respect need  
to be taken.  
– Never have the throttle wide open when changing down to a  
lower gear. The engine will overrev, damaging the valves. In addi-  
tion, the rear wheel will block so that the motorcycle can eas-  
ily get out of control.  
– If the engine runs without throttle during longer downhill travel,  
the engine should be accelerated occasionally to ensure that  
it is supplied with sufficient lubricant which is mixed in the  
fuel.  
– In the event that, while riding on your motorcycle, you notice  
any unusual operation-related noise, stop immediately, turn the  
engine off, and contact an authorized KTM dealer.  
Gasoline is highly flammable and poisonous. Extreme caution  
should be used when handling gasoline. Do not refuel the motor-  
cycle near open flames or burning cigarettes. Always switch off the  
engine before refueling. Be careful not to spill gasoline on the engine  
or exhaust pipe while the engine is hot. Wipe up spills promptly.  
If gasoline is swallowed or splashed in the eyes, seek a doctor’s  
advice immediately.  
19  
– Only use premium-grade gasoline ROZ 98 respectively 95  
mixed with high-grade two-stroke engine oil. Other types of gaso-  
line can cause engine failure.  
– Do not use premixed two-stroke oils, oils for outboard engines  
or normal engine oil to prepare the mixture.  
– Do not use gasoline and oil mixtures that are older than one  
week. The lubrication properties of some two-stroke oils can  
deteriorate very rapidly.  
– Only use known brands of high-grade 2-stroke engine oil (i.e.  
Motorex Cross Power 2T).  
– Never mix synthetic oils and mineral oils.  
– Not enough oil or low-grade oil can cause erosion of the pis-  
ton. when Using too much oil, the engine may start smoking  
and foul the spark plug.  
– If your motorcycle is equipped with a catalytic converter, always  
keep in mind that leaded fuel will destroy the catalytic converter.  
– Fuel expands when its temperature rises. Therefore do not fill  
the tank to the top. (see fig.)  
Braking  
Turn off the gas and apply the hand and foot brakes at the same  
time. When driving on sandy, wet or slippery ground, use mainly  
the rear wheel brake. Always brake with feeling, blocking wheels  
can cause you to skid or fall. Also change down to lower gears depend-  
ing on your speed.  
– In case of rain, after washing the motorcycle, after rides through  
water and in case of rides on wet off-road tracks, humid or dirty  
brake discs can delay the braking effect. The brakes must be  
pulled until they are dry or clean.  
– Rides on salt-strewed or dirty roads can also delay the  
braking effect. The brakes must be pulled until they are clean.  
– Dirty brake discs cause increased tear of brake pads and brake  
discs.  
– When you brake, the brake discs, brake pads, brake caliper and  
brake fluid heat up. The hotter these parts get, the weaker the  
breaking effect. In extreme cases, the entire braking system  
can fail.  
– If the resistance in the hand brake lever or foot brake pedal  
feels “spongy” (too much give), this is an indication that some-  
thing is wrong with the brake system. Don’t ride your motorcy-  
cle anymore without first having the brake system looked over  
by a KTM dealer.  
35 mm  
Stopping and parking  
Close the throttle and apply the hand and foot brake simultane-  
ously. Be especially careful when you apply the brakes on sandy,  
wet or slick surfaces. Always apply the brakes intuitively, locked  
wheels can cause the bike to skid or crash. Shift down to a lower  
gear to match your speed. Always apply the brakes before you enter  
a curve.  
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PERIODIC MAINTENANCE SCHEDULE »  
125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007  
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY  
z
z
Check gear box oil level  
z
z
z
z
z
Change gear box oil  
Check spark plugs, adjust distance between electrodes  
Renew spark plugs  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Clean the spark-plug connector and check for a tight fit  
Check the screws on the kick starter and shift lever for a tight fit  
Check the carburetor connection boot and intake flange for cracks or leaks  
Check idle speed setting  
z
z
z
z
z
z
z
Check that vent hoses are not damaged or bent  
Check cooling system for leaks, check quantity of antifreeze  
Check exhaust system for leaks and fitment  
z
z
z
z
Check cables for damage, smooth operation, bends; adjust and lubricate  
Check the fluid level in the master cylinder of the hydraulic clutch  
Clean air filter and filter box  
z
z
z
Check electric wires for damage and bends  
20  
Check headlamp setting  
z
Check function of electric systems (low beam, high beam, break light, indicator,  
indicator lamps, speedometer illumination, horn, emergency OFF switch or button  
Check brake fluid level, lining thickness, brake lining  
Check brake lines for damage and leaks  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check/adjust the function, smooth operation and free travel of the hand/foot brake lever  
Check the screws and guide bolts on the brake system for a tight fit  
Check shock absorber and fork for leaks and function  
Clean dust bellows  
z
z
z
Bleed fork legs  
Check swing arm bearings  
z
z
Check/adjust steering head bearings  
Check tightness of all chassis screws (triple clamps, fork leg axle passage  
axle nuts and screws, swing arm bearings, shock absorber)  
Check spoke tension and rim joint  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check tires and air pressure  
Check chain, rear sprockets and chain guides for wear, fitment and tension  
Lubricate chain, Clean and grease the adjusting screws on the chain tensioner  
Check clearance of wheel bearings  
The kilometer reading for inspection intervals should not exceed 5 hours.  
Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!  
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PERIODIC MAINTENANCE SCHEDULE »  
125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007  
IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP  
UNDER A SEPARATE ORDER  
Clean and adjust carburetor  
C/H C/H  
Replace the throttle slide, jet needle, float needle valve, needle nozzle  
Check the reed-type intake valve for wear  
Check the wear on the clutch disks and length of the clutch springs  
Check the cylinder and piston for wear  
C/H  
C/H  
C/H  
C/H  
C/H  
C/H  
C/H  
C/H  
C/H  
H
C
C
C
C/H  
C/H  
C/H  
C
C
C
Check function of exhaust control  
C/H C/H  
Check piston pin bearing  
C
C/H  
C
Replace the crankshaft main bearings  
Replace the conrod bearings  
C
C
Check the entire transmission, the shift mechanism and bearings  
Complete maintenance of fork  
C
C
C/H  
C/H  
C/H  
Complete maintenance of shock absorber  
Clean and grease steering head bearings and gasket elements  
Replace the sealing cup for the foot brake cylinder  
Replace the glass-fiber yarn filling in the silencer  
Treat electric contacts and switches with contact grease  
Change break fluid  
C
C
C
C/H  
C
C
C/H  
C/H  
C/H  
C/H  
21  
C
C/H  
C
C/H C/H  
Change the hydraulic clutch oil  
C/H  
C = FOR COMPETITIVE OFFROAD RACING (COMPETITION)  
H = FOR OFFROAD HOBBY USE  
Note:If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.  
125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007  
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER  
z
z
z
z
z
Check gear box oil level  
Check brake fluid level  
Check brake pads for wear  
Check lights for function  
Check horn for function  
z
Lubricate and adjust cables and nipples  
Bleed fork legs regulary  
z
z
z
z
Remove and clean dust bellows regularly  
Clean and lubricate chain, check tension and adjust if necessary  
Clean air filter and filter box  
z
z
z
z
z
Check tires for pressure and wear  
Check cooling liquid level  
Check fuel lines for leaks  
z
z
z
Empty and clean float chamber  
Remove, clean and oil the throttle slide  
Check all control elements for smooth operation  
Check brake performance  
z
z
z
z
Treat blank metal parts (with the exception of brake and exhaust systems)  
with wax-based anti corrosion agent  
Treat ignition and steering locks and light switches with contact spray  
Check tightness of screws, nuts and hose clamps regularly  
z
z
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PERIODIC MAINTENANCE SCHEDULE »  
250/300 XC/XC-W/EXC SIX DAYS/EXC 2007  
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY  
z
z
Check gear box oil level  
z
z
z
z
z
Change gear box oil  
Check spark plugs, adjust distance between electrodes  
Renew spark plugs  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Clean the spark-plug connector and check for a tight fit  
Check the screws on the kick starter and shift lever for a tight fit  
Check the carburetor connection boot and intake flange for cracks or leaks  
Check idle speed setting  
z
z
z
z
z
z
z
Check that vent hoses are not damaged or bent  
Check cooling system for leaks, check quantity of antifreeze  
Check exhaust system for leaks and fitment  
z
z
z
z
Check cables for damage, smooth operation, bends; adjust and lubricate  
Check the fluid level in the master cylinder of the hydraulic clutch  
Clean air filter and filter box  
z
z
z
Check electric wires for damage and bends  
22  
Check headlamp setting  
z
Check function of electric systems (low beam, high beam, break light, indicator,  
indicator lamps, speedometer illumination, horn, emergency OFF switch or button  
Check brake fluid level, lining thickness, brake lining  
Check brake lines for damage and leaks  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check/adjust the function, smooth operation and free travel of the hand/foot brake lever  
Check the screws and guide bolts on the brake system for a tight fit  
Check shock absorber and fork for leaks and function  
Clean dust bellows  
z
z
z
Bleed fork legs  
Check swing arm bearings  
z
z
Check/adjust steering head bearings  
Check tightness of all chassis screws (triple clamps, fork leg axle passage  
axle nuts and screws, swing arm bearings, shock absorber)  
Check spoke tension and rim joint  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check tires and air pressure  
Check chain, rear sprockets and chain guides for wear, fitment and tension  
Lubricate chain, Clean and grease the adjusting screws on the chain tensioner  
Check clearance of wheel bearings  
The kilometer reading for inspection intervals should not exceed 5 hours.  
Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver!  
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PERIODIC MAINTENANCE SCHEDULE »  
250/300 XC/XC-W/EXC SIX DAYS/EXC 2007  
IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED  
KTM WORKSHOPUNDER A SEPARATE ORDER  
Clean and adjust carburetor  
C/H  
Replace the throttle slide, jet needle, float needle valve, needle nozzle  
Check the reed-type intake valve for wear  
Check the wear on the clutch disks and length of the clutch springs  
Check the cylinder and piston for wear  
C/H  
C
C
C
C
C/H  
C/H  
C/H  
C
C
C
C/H  
C/H  
C/H  
C/H  
C/H  
C/H  
C
C
Check function of exhaust control  
C/H C/H C/H C/H C/H C/H  
Check piston pin bearing  
C
C/H  
C
C/H  
C/H  
C
C
C
C/H  
H
Replace the crankshaft main bearings  
Replace the conrod bearings  
C
C
C
C/H  
C/H  
C
Check the entire transmission, the shift mechanism and bearings  
Complete maintenance of fork  
C
C
C/H  
C
C/H  
Complete maintenance of shock absorber  
Clean and grease steering head bearings and gasket elements  
Replace the sealing cup for the foot brake cylinder  
Replace the glass-fiber yarn filling in the silencer  
Treat electric contacts and switches with contact grease  
Change break fluid  
C/H  
C/H  
C
C
C/H  
C
C
C/H  
C
C
C/H  
C/H  
C/H  
C/H  
C/H  
23  
C
C/H  
C
C/H  
C
C/H C/H  
Change clutch brake fluid  
C/H  
C = FOR COMPETITIVE OFFROAD RACING (COMPETITION)  
H = FOR OFFROAD HOBBY USE  
Note: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.  
250/300 XC/XC-W/EXC SIX DAYS/EXC 2007  
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER  
z
z
z
z
z
Check gear box oil level  
Check brake fluid level  
Check brake pads for wear  
Check lights for function  
Check horn for function  
z
Lubricate and adjust cables and nipples  
Bleed fork legs regulary  
z
z
z
z
Remove and clean dust bellows regularly  
Clean and lubricate chain, check tension and adjust if necessary  
Clean air filter and filter box  
z
z
z
z
z
Check tires for pressure and wear  
Check cooling liquid level  
Check fuel lines for leaks  
z
z
z
Empty and clean float chamber  
Remove, clean and oil the throttle slide  
Check all control elements for smooth operation  
Check brake performance  
z
z
z
z
Treat blank metal parts (with the exception of brake and exhaust systems)  
with wax-based anti corrosion agent  
Treat ignition and steering locks and light switches with contact spray  
Check tightness of screws, nuts and hose clamps regularly  
z
z
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
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 specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified,  
skilled staff.  
– If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc. The high  
pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear.  
– When transporting your KTM, ensure that it is held upright with restraining straps or other mechanical fastening devices and that  
the fuel tap is in the OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank  
– Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or  
longer screws can cause leaks in the tank through which fuel can flow out.  
– Do not use toothed washers or spring rings with the engine fastening screws, as these work into the frame parts and keep working  
loose. Instead, use self-locking nuts.  
– If you unscrewed any screwed connections with self-locking nuts, they must be replaced when mounting. If no self-locking nuts  
are available, apply Loctite 243 to the thread. The screws and nuts must be replaced if the thread is damaged.  
– All screws and nuts must be tightened to the specified torque figures using a torque wrench. If screws or nuts are not adequately  
tightened, they can become loose and cause the motorcycle to go out of control while you drive. Tightening the screws and nuts  
too tightly can damage the thread and components.  
– Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned.  
– Dispose of oils, fatty matters, filters, fuels, washing detergents, etc. properly.  
– Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter of used oil contam-  
inates 1,000,000 liters of water.  
24  
Changing the spring preloading of the shock absorber  
The spring preload can be changed by turning the adjusting ring [1]. For this  
purpose, you should dismount the shock absorber and clean it thoroughly.  
NOTE:  
– Before changing the spring preload note down the basic setting, e.g. how  
many threads are visible above the adjusting ring.  
2
– One rotation of the adjusting ring [1] changes the spring pretension by  
approximately 1.75 mm (0.07 in).  
Loosen the clamping screw [2] and use the hook wrench contained in the  
vehicle tool set to turn the adjusting ring as desired. Turning it counterclock-  
wise will reduce the preload, turning it clockwise will increase the preload.  
After readjusting the clamping screw [2], tighten it to 8 Nm (6 ft.lb)  
1
ADJUSTMENT VALUES – SPRING PRELOAD [A]  
A
Typ WP Suspension 12187C02 . . . . . . . 4 mm  
Typ WP Suspension 12187C27 . . . . . . . 5 mm  
Typ WP Suspension 12187C28 . . . . . . . 5 mm  
Typ WP Suspension 12187C04 . . . . . . . 5 mm  
Pivot bearing  
The pivot bearing [3] for PDS suspension struts at the swinging fork is Teflon-  
coated and must not be lubricated with either grease or other lubricants. Grease  
and other lubricants cause the Teflon coat to dissolve, whereby the bearing’s  
lifecycle will be reduced dramatically.  
When cleaning your bike with a high-pressure cleaner, do not aim the high-  
pressure spray directly at the pivot bearing.  
3
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Basic suspension setup for the weight of the driver  
To achieve maximum handling performance and to prevent the fork, shock  
absorber, swing arm and frame from being damaged, the basic setup of the  
suspension components must be suitable for your weight. At delivery, KTM's  
offroad motorcycles are set to accommodate a driver weighing 75 bis 85 kg  
(wearing full protective clothing). If your weight exceeds or falls short of this  
range, you will need to adjust the basic setup for the suspension components  
accordingly. Minor deviations in weight can be compensated by adjusting the  
spring preload. Different springs must be installed for larger deviations.  
A
Checking the shock absorber and spring  
You can establish whether or not the shock absorber spring is suitable for your  
weight by checking the riding sag. The static slag must be correctly adjusted  
before the riding sag can be determined.  
Determining the static sag of the shock absorber  
The static sag should be as close as possible to 35 mm. Deviations of more  
than 2 mm can strongly influence the motorcycle's performance.  
Procedure:  
– Jack up the motorcycle until the rear wheel no longer touches the ground.  
– Measure the vertical distance between the rear wheel axle and a fixed point  
(e.g. a mark on the side cover) and write it down as dimension A.  
– Place the motorcycle on the ground again.  
B
25  
– Ask a helper to hold the motorcycle in vertical position.  
– Measure the distance between the rear axle and the fixed point again to  
establish dimension B.  
– The static sag is the difference between dimensions A and B.  
EXAMPLE:  
Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . . .600 mm  
Motorcycle on ground, unloaded (dimension B) . . . . . . . . . . . .– 565 mm  
Static sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 mm  
If the static sag is lower, the spring preload of the shock absorber must be  
increased, if the static sag is reduced, the spring preload must be higher. See  
chapter "Changing the spring preload of the shock absorber."  
C
Determining the riding sag of the shock absorber  
– Have a helper hold the motorcycle while you sit on the bike in a normal  
seating position (feet on the footrests) wearing full protective clothing and  
bounce up and down a few times to allow the rear wheel suspension to  
become level.  
– Stay on the bike and have another person measure the distance between  
the same two points and write it down as dimension C.  
– The riding sag is the difference between dimensions A and C.  
EXAMPLE:  
Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . . .600 mm  
Motorcycle on ground, loaded (dimension C) . . . . . . . . . . . . . .– 500 mm  
Riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm  
for example  
shock absorber 250 EXC  
80-250  
The riding sag should lie between 95 and 105 mm.  
If the riding sag is less than 95 mm, the spring is too hard (the spring rate is  
too high). If the riding sag is more than 105 mm, the spring is too soft (the  
spring rate is too low).  
The spring rate is written on the outside of the spring (e.g. 76-250). The type  
number of the shock absorber is embossed on the front of the shock absorber.The  
illustrations show which spring should be installed. The standard spring is  
shown in bold print .  
76-250  
72-250  
70  
After installing a different spring, readjust the static sag to 35 mm (± 2 mm).  
65  
75  
80  
85  
90  
95  
Riders weight inclusive gears in kilogram  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
According to our experience, the damping rate of the compression stage can  
remain unchanged. The damping rate of the rebound stage can be reduced  
by a few clicks for a softer spring or increased by a few clicks for a harder  
spring.  
MODELL  
SOFTER  
STANDARD HARDER  
12187C02  
69-250 72-250  
69-250 72-250  
72-250 76-250  
72-250 76-250  
76-250  
76-250  
80-250  
80-250  
125/200 EXC, XC-W  
12187C27  
125 EXC Six Days, 200 XC  
12187C04  
250/300 EXC, XC-W  
12187C28  
250/300 XC/EXC Six Days  
26  
Checking the basic setup of the telescopic fork  
The precise riding sag of the telescopic fork cannot be determined for vari-  
ous reasons. Similar to the shock absorber, smaller deviations in your weight  
can be compensated by adjusting the spring preload. However, if your tele-  
scopic fork bumps frequently (hard end stop during compression), you should  
install harder fork springs to avoid damaging the telescopic fork and frame.  
Changing the spring preload on the telescopic fork (XC, EXC Six Days)  
The telescopic forks on the XC/EXC Six Days models are equipped with a pre-  
load adjuster.  
You can easily adjust the spring preload by 10 mm by turning the adjusting  
screw [1].  
Turning in a clockwise direction will increase the prestress, turning in a coun-  
terclockwise direction will decrease the prestress.  
Changing the spring preload will not affect the rebound damping adjustment.  
Generally, if the spring preload is higher, the rebound damping should also  
be set higher.  
1
STANDARD SETTING:  
Unscrew the adjusting screw to the limit and then back 2 turns.  
Changing the spring preload on the telescopic fork (XC-W/EXC models)  
The telescopic forks for these models must be partly disassembled to adjust  
the spring preload (see WP manual). Pretension spacers are available in  
heights of 1.5, 2.5, 5 and 10 mm (see spare parts catalog). The fork springs  
may not be pretensioned by more than 20 mm.  
The preload adjuster used in the XC/EXC Six Days models can easily be retro-  
fitted for the telescopic forks of the XC-W/EXC models.  
NOTE:  
WP precisely adjusts the spring pressure by inserting pretension spacers.  
Fluctuations in production are compensated with pretension spacers in vari-  
ous heights. This can cause the fork springs in the fork legs to have different  
degrees of pretension. Fork springs and pretension spacers should always stay  
together.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Replacing fork springs  
If you weigh less than 75 kg or more than 85 kg, you should install the respec-  
tive fork springs. The correct spring rate is shown in the illustrations. The stan-  
dard spring is shown in bold print. The type number of the telescopic fork is  
embossed on the inside of the fork leg axle passage.  
for example  
front fork 250 EXC  
If you are uncertain which spring to use, contact your KTM workshop.  
4,4 N/mm  
4,2 N/mm  
According to our experience, the damping rate of the compression stage can  
remain unchanged. The damping rate of the rebound stage can be reduced  
by a few clicks for a softer spring or increased by a few clicks for a harder  
spring.  
4,0 N/mm  
70  
65  
75  
80  
85  
90  
95  
Riders weight inclusive gears in kilogram  
MODELL  
SOFTER  
STANDARD  
4,0 N/mm  
4,2 N/mm  
4,2 N/mm  
4,4 N/mm  
HARDER  
14187C02 125/200 XC-W, EXC  
14187C27 125 EXC Six Days, 200 XC  
14187C04 250/300 XC-W, EXC  
14187C28 250/300 XC, EXC Six Days  
3,8 N/mm  
4,0 N/mm  
4,0 N/mm  
4,2 N/mm  
4,2 N/mm  
4,4 N/mm  
4,4 N/mm  
4,6 N/mm  
27  
Breather plug front fork  
After every 5 hours of use for competitive racing, slacken the breather  
plugs [1] a few turns in order to relieve excess pressure from the inside of the  
fork. To do this, place the motorcycle on a stand with the front wheel lifted  
off the ground. When riding the motorcycle mainly on the road, it will suffice  
to have this job performed in the course of the periodical maintenance  
service.  
Excessive pressure in the interior of the fork can cause leaks in the fork. If  
your fork is leaking, it is recommended to open the breather plugs before hav-  
ing the seals replaced.  
1
Cleaning the dust sleeves of the telescopic fork  
The dust-protection bellows [2] are to remove dust and coarse dirt particles  
from the fork tube. However, after some time, dirt may also get in behind the  
dust-protection bellows. If this dirt is not removed, the oil sealing rings located  
behind it may start to leak.  
Use a screwdriver to lift the dust-protection bellows out of the outer tubes  
and slide them downward.  
2
Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and  
oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine  
oil. Then, push the dust-protection bellows into the outer tubes by hand.  
No oil may reach the front tire or the brake disks since this would consider-  
ably reduce the tire's road grip and the braking effect of the front brake.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
XC/EXC Six Days  
Changing the fork offset (caster)  
*
The fork offset [A] in the XC/EXC Six Days models (center fork legs - center  
steering head angle) can be set to either 18 or 20 mm. This allows you to  
optimize the handling to match the race course.  
Remove the blind screw [1] to see which offset is set. If the mark [B] is in  
front, the offset is 18 mm. This setting will deliver more directional stability  
on fast race courses.  
A
If the mark [B] is in the rear as illustrated, the offset is 20 mm. This setting  
will deliver better handling in curves.  
B
The offset is set to 20 mm in the condition at delivery.  
1
5
2
3
4
28  
To adjust the offset, dismount the front wheel and remove the front wheel  
fender.  
Remove the screw on the starting number plate. Remove the clamp screws  
on the hand brake cylinder and fasten the hand brake cylinder to the left fork  
leg with a cable tie to keep the brake line from kinking (see illustration).  
Loosen the clamp screws and take the fork legs out of the triple clamps.  
Loosen the collar screw [2] on the lower triple clamp 2 turns.  
Remove the blind screw [1] from the upper triple clamp, loosen the clamp  
screw and upper triple clamp on the seat. Remove the O-ring [3] and the pro-  
tection ring [4].  
Tap gently on the lower triple clamp with a rubber hammer to loosen the steer-  
ing stem [5] out of the bearing seat. Take the lower triple clamp with the steer-  
ing stem out of the steering head.  
3
4
2
Remove the collar screw from the lower triple clamp and pull out the steer-  
ing stem. Thoroughly clean all parts. Turn the steering stem 180° and insert  
it in the triple clamp. Apply Loctite 243 to the thread of the collar screw [2]  
and turn all the way in.  
5
Be sure to lock the thread on the collar screw [2] with Loctite 243.  
2
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Mount the lower triple clamp, upper steering head bearing, protection ring,  
O-ring, upper triple clamp and the blind screw.  
Tighten the collar screw on the lower triple clamp to 60 Nm.  
Mount the fork legs and tighten the clamp screws on the lower triple clamp  
to 12 Nm in 3 stages.  
Adjust the steering head bearing with zero clearance (see section on checking  
and adjusting the steering head support). Hold the middle clamp screw [A]  
in place with Loctite 243. Tighten the clamp screws on the upper triple clamp  
to 20 Nm in 3 stages.  
A
Hold the middle clamp screw [A] in place with Loctite 243.  
Mount the front wheel fender and tighten the screws to 10 Nm.  
Mount the hand brake cylinder and tighten the screws to 10 Nm.  
Mount the staring number plate.  
Mount the front wheel (see: Dismounting and mounting the front wheel).  
29  
Checking and adjusting the steering head bearing *  
Check steering head bearing for play periodically. To check, put the motorcycle  
on a stand so that the front wheel is off the ground. Now try to move the fork  
forward and backward. To adjust the 5 clamping screws [1] and [3], loosen the  
upper triple clamp and turn the end screw [2] until no play is left. Don’t tighten  
the steering stem bolt all the way, otherwise the bearings will be damaged. With  
a plastic hammer, lightly tap on the triple clamp to release tension. Retighten  
the five pinch bolts.  
2
XC, EXC Six Days . . . . . . . . . . . . . . . . . . .17 Nm (clamp screw 1)  
XC, EXC Six Days . . . . . . . . .Loctite 243 + 17 Nm (clamp screw 3)  
XC-W, EXC . . . . . . . . . . . . . . . . . . . . .20 Nm (clamp screw 1 + 3)  
1
1
3
– If the steering head bearing is not adjusted to be free of play, the motorcy-  
cle will exhibit unsteady driving characteristics and can get out of control.  
–
XC, EXC Six Days: hold the clamp screw [3] in place with Loctite 243.  
If you drive with play in the steering head bearing for longer periods, the bear-  
ings and subsequently the bearing seats in the frame will be destroyed.  
The steering head bearings should be regreased at least once a year  
(e.g. Motorex Long Term 2000).  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
How to change the handlebar position  
The handlebar position can be readjusted by 22 mm. Thus, you can put the  
handlebar in the position that is the most convenient for you. The upper triple  
clamp [1] includes 2 bores arranged at a distance of 15 mm (0.6 in) from  
one another. The bores at the handlebar support [2] are offset from the cen-  
ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in  
4 different positions.  
For this purpose, remove screws [3] of the handlebar clamps and screws [4]  
of the handlebar support. Position the handlebar support, and tighten screws  
[4] to 40 Nm (30 ft.lbs). Mount the handlebar and handlebar clamps, and  
tighten screws [3] to 20 Nm (15 ft.lbs). The gap between the handlebar sup-  
port and the handlebar clamps should be the same size in the front and in  
the rear.  
3
4
2
The screws [4] must be secured with loctite 243.  
3,5 mm  
1
30  
Check chain tension  
Jack the motorcycle up on its frame so that the rear wheel no longer touches  
the ground.  
A
Press the chain upward at the end of the chain sliding component. The dis-  
tance between the chain and the swing arm should be approx. 8 - 10 mm  
(0.31 - 0.39 in). In the course of this procedure, the upper chain portion [A]  
must be taut (see drawing). If necessary, correct the chain tension.  
– If the chain tension is too great, parts within the secondary transmission  
(chain, chain wheels and rear wheel bearings) will be subjected to unnec-  
essary stress, resulting in premature wear and even chain breakage.  
– Too much slack in the chain, on the other hand, can result in the chain  
jumping off the chain wheels. If this happens, the chain could also block  
the rear wheel or damage the engine.  
– In either case the operator is likely to lose control of the motorcycle.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Correct chain tension  
Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting  
screws [3] equally far. Tighten lock nuts.  
B
3
Before tightening the collar nut, verify that the chain adjusters [4] are sitting  
close to the adjusting screws and that the rear wheel has been aligned with  
the front wheel.  
2
Tighten collar nut [1] to 80 Nm (60 ft.lb).  
– If you don’t happen to have a torque wrench at hand, make sure you have  
the tightening torque corrected by a KTM dealer as soon as possible. A  
loose axle may lead to an unstable driving behavior of your motorcycle.  
– Tighten the collar nut with the required torque. A loose wheel spindle may  
lead to an unstable behavior of your motorcycle.  
4
1
NOTE:  
The large adjusting range of the chain adjusters (32mm / 1.25 in) allows you  
to use different secondary ratios in combination with the same chain length.  
The chain adjusters [4] can be rotated by 180°.  
2
3
B
Always mount the chain tensioner equally aligned.  
4
31  
Chain maintenance  
For long chain life, good maintenance is very important. X-ring chains require  
only modest maintenance. The best way is to use lots of water, but never use  
brushes or solvents. After letting the chain dry, you can use a special X-ring  
chain spray (Motorex Chainlube 622).  
No lubrication is allowed to reach the rear tire or the brake disk, eitherwise  
the road adherence and the rear wheel braking effects would be strongly reduced  
and the motorcycle could easily get out of control.  
When mounting the chain joint, the closed side of the safety device must point  
in running direction.  
Also check sprockets and chain guides for wear, and replace if necessary.  
15 KG  
33 lbs  
Chain wear  
To check the chain wear, observe the following indications:  
Shift the gear into idling and pull the upper chain strand with approx. 10-15  
kilograms (33 lb) upwards (see figure). Now one can measure a space of 18  
chain reels at the lower chain strand. The chain should be replaced at the lat-  
est when a space of 272 mm (10.70 in) is measured. Chains do not always  
wear off evenly, therefore repeat the measurement at different places on the  
chain.  
NOTE:  
If you mount a new chain, the sprockets should also be replaced. New chains  
wear faster if used on old used sprockets.  
When you assemble a rear sprocket with 14t, the collar must be on the inside.  
Secure the screws of the chain wheel by applying Loctite and fasten them in  
a crosswise order.  
max. 272 mm  
Tightening torque for nuts: 35 Nm  
Tightening torque for screws: 50 Nm  
1 2 3  
16 17 18  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
General information about KTM disc brakes  
BRAKE CALIPERS:  
The brake calipers of this series use a „floating“ mount. This means that the  
brake calipers are not solidly attached to the caliper support, which enables  
them to ”float” for maximum braking contact.Secure the screws of the caliper  
support with Loctite 243 and tighten to 25 Nm (19 ft.lb).  
BRAKE PADS:  
The brake pads are fitted with TOSHIBA TT 2701HHB sintered lining at the  
front and TOYO B 143 FF sintered lining at the back. These linings provide  
an optimal combination of dosing, brake performance and life cycle. The lin-  
ing type is stated on the back of the brake pad and also recorded in the homolo-  
gation papers.  
32  
BRAKE DISCS:  
Due to wear, the thickness of the brake disc in the area of the contact  
face [1] of the brake pads decreases. The brake disk must be at least  
2.50 mm (front) / 3.50 mm (rear) thick at the thinnest point [A]. Check the  
thickness of the brake disk at several points.  
A
– A brake disk worn down to less than 2.50 mm (Front) / 3.50 mm (Rear)  
is a safety risk. Have the brake disk replaced as soon as it reaches the  
service limit.  
– Have any repairs on the brake system be performed by a KTM dealer.  
1
BRAKE FLUID RESERVOIRS:  
The brake fluid reservoirs on the front and rear wheel brakes have been  
designed in such a way that even if the brake pads are worn it is not neces-  
sary to top up the brake fluid. If the brake fluid level drops below the mini-  
mum level either the brake system has a leak or the brake pads are completely  
worn.  
In this case, consult an authorized KTM dealer immediately.  
BRAKE FLUID:  
KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid,  
one of the best brake fluids is currently available. We recommend that you  
continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an  
amber color. If you do not have any DOT 5.1 for refilling, you may use DOT  
4
brake fluid. However, you should replace it as soon as  
possible with DOT 5.1.  
Never use brake fluid DOT 5. The color of this silicon oil-based product is  
purple red. The gaskets and brake hoses of KTM motorcycles are not  
designed for DOT 5 brake fluid.  
Have the brake fluid changed at least once annually. If you wash your motor-  
cycle often, the brake fluid should be changed even more frequently. Brake  
fluid tends to absorb water. Therefore, vapor pockets may form in „old“ brake  
fluids even at low temperatures, causing the brake system to fail.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Adjusting the free travel at the hand brake lever  
Free travel at the hand brake lever may be readjusted by using adjustment  
screw [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 pressed against the  
brake disc) can be adjusted for any hand size.  
When you press the hand brake lever forwards, you should have at least  
3 mm free travel. Turn the adjusting screw [1] if necessary.  
min. 3 mm  
1
At the hand brake lever, free travel must at least be 3 mm (0.1 in). Only then  
may the piston in the hand brake cylinder be moved (to be recognized by the  
greater resistance of the hand brake lever). If this free travel is not provided,  
pressure will build up in the braking system, and the front-wheel brake may  
fail due to overheating.  
Checking the brake fluid level - front brake  
The brake fluid reservoir is linked with the hand brake cylinder at the  
handlebar and the reservoir is provided with an inspection glass. With the reser-  
voir in a horizontal position, the brake fluid level should not drop below the  
middle of the glass.  
If the brake fluid level drops below the minimum either the brake system has  
a leak or the brake pads are completely worn. In this case, consult an author-  
ized KTM dealer immediately.  
33  
Refilling the front brake fluid reservoir *  
Loosen screws [2] and remove lid [3] and membrane [4].  
2
Place hand brake cylinder in a horizontal position and fill the brake fluid reser-  
voir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (e.g. Motorex  
Brake Fluid DOT 5.1). Replace membrane and lid, tighten screws. Rinse off  
spilled or overflowing brake fluid with water.  
3
– Never use DOT5 brake fluid! It is based on silicone oil and of a  
purple color. Seals and brake hoses must be especially adapted to it.  
– Store brake fluid out of reach of children.  
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If  
you get brake fluid in your eyes, rinse with plenty of water and consult a  
doctor  
4
– Don’t let brake fluid get in contact with paint, it is an effective paint remover.  
– Use only clean brake fluid taken from a tightly sealed container.  
5 mm  
Checking the front brake pads  
The brake pads can be inspected from below. The linings must be at least 1  
mm (0.04 in) thick.  
min.  
1 mm  
At their most worn point brake pad linings should not be thinner than 1 mm,  
otherwise they could lead to brake failure. For your own safety don’t put off  
having your brake pads changed.  
If the brake pads are replaced too late so that the lining is partly or entirely  
worn, the steel components of the brake pad will rub against the brake disc,  
thereby imparing the braking effect and destroying the brake disc.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Replacing the front brake pads *  
Press the brake caliper toward the brake disk, to put the brake piston in its  
basic position. Remove clips [1] and pull out bolt [2]. Remove brake pads  
from the brake caliper. Clean the brake caliper and the brake caliper support  
with compressed air. Check the sleeves of the guide bolts for damage, and  
grease guide bolts if necessary.  
1
Mount the right brake pad and fix it with the bolt. Mount the left brake pad  
and insert the bolt until it stops. Mount the clips.  
When mounting the brake pads, be sure to check for correct fit of the  
sliding metal-sheet [3] in the caliper support and of the leaf spring [4].  
2
– It is very important to keep the brake disk free from oil and fatty matters.  
Otherwise, the braking effect would be strongly reduced.  
1
– After assembly, check if circlips have been fitted correctly.  
– after working on the braking system, always actuate the hand brake lever  
or foot brake lever, respectively to ensure that the brake pads will lie against  
the brake disk and the pressure point is established.  
3
4
34  
2
Changing the basic position of the foot brake pedal *  
The basic position of the foot brake pedal can be altered by turning the stop  
screw [5]. The free play at the foot brake pedal must then be adjusted by  
means of the piston rod [6].  
6
Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20  
in) of free play before the piston rod can move the piston in the brake cylin-  
der (to be recognised from the resistance on the foot brake pedal).  
If this free play is not present, then pressure can build up in the brake sys-  
tem when driving, causing the rear wheel to brake.The braking system over-  
heats and may even fail completely in extreme cases.  
3-5mm  
5
Checking the rear brake fluid level  
The reservoir for the rear brake disk is located on the right side of the motor-  
cycle on the rear brake cylinder.  
No air bubble should be visible in inspection glass [A] when the vehicle is  
parked in a vertical position.  
If the brake fluid level drops below the minimum either the brake system has  
a leak or the brake pads are completely worn. In this case, consult an author-  
ized KTM dealer immediately.  
A
Refilling the rear brake fluid reservoir *  
Add brake fluid as soon as a bubble is visible in inspection glass [A].  
To top up, remove screw [7]. Fill DOT5.1 brake fluid (e.g. Motorex Brake Fluid  
5.1) up to the mark [B] on the inside of the reservoir and remount the screw.  
Spilled brake fluid must be rinsed off with water.  
B
– Never use DOT5 brake fluid! It is based on silicone oil and of a  
purple color. Seals and brake hoses must be especially adapted to it.  
– Store brake fluid out of reach of children.  
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If  
you get brake fluid in your eyes, rinse with plenty of water and consult a  
doctor.  
7
– Don’t let brake fluid get in contact with paint, it is an effective paint remover.  
– Use only clean brake fluid taken from a tightly sealed container.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Checking the rear brake pads  
min.  
The brake pads can be inspected from the rear. The thickness of the linings  
may not be less than 1 mm (0.04 in).  
1 mm  
At their most worn point brake pad linings should not be thinner than 1 mm,  
otherwise they could lead to brake failure. For your own safety don’t put off  
having your brake pads changed.  
If the brake pads are replaced too late so that the lining is partly or entirely  
worn, the steel components of the brake pad will rub against the brake disc,  
thereby imparing the braking effect and destroying the brake disc.  
Replacing the rear brake pads *  
Press the brake caliper [1] in the direction of the chain wheel for the brake  
piston to reach its basic position. Remove the safety device [2], knock out  
the guide pin [3] from the brake caliper with a drift towards the chain wheel  
and remove the brake pads. Carefully clean the brake caliper with compressed  
air and check the sleeves of the guide pins for damage.  
1
Slide the left brake pad into the brake caliper and fix it with the pin. Slide in  
the right brake pad and knock the bolt [3] in as far as it will go. Mount the  
safety device [2].  
– It is very important to keep the brake disk free from oil and fatty matters.  
Otherwise, the braking effect would be strongly reduced.  
– After assembly, check if circlips have been fitted correctly.  
35  
– After working on the braking system, one must always actuate the hand  
brake lever or foot brake lever, respectively so as to ensure that the brake  
pads will lie against the brake disk and the pressure point is established.  
2
2
3
Dismounting and mounting the front wheel  
To remove the front wheel, jack the motorcycle up on its frame so that the  
front wheel no longer touches the ground.  
4
Loosen the 2 clamping screws [4] on the left side of the fork fists.  
Loosen and remove the collar nut [5], loosen the clamping screews [6] on the  
right side of the fork fist.  
Hold the front wheel, pull out the wheel spindle [7].  
Carefully remove the front wheel from the fork.  
5
– Do not operate the hand brake when the front wheel has been dismounted.  
– Make sure the brake disc is always on top when you lay down the wheel,  
otherwise the brake disc can be damaged.  
7
6
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
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  
bushing  
A
B
To install the front wheel, lift it into the fork, position and mount the axle  
shaft [1]. Mount the collar nut [2], tighten the clamping screws [3] on the  
right fork leg axle passage to prevent the axle shaft from turning and tighten  
the collar nut to 40 Nm (30ft.lb).  
Loosen the clamp screws on the right fork leg. Take the motorcycle down from  
its stand. Press the front wheel brakes and push down on the fork a few times  
vigorously so that the fork legs come into alignment.  
1
Only after this has been accomplished, tighten the clamp screws on both fork  
legs with 15 Nm(7 ft. lbs).  
3
– If you don’t happen to have a torque wrench at hand, make sure you have  
the tightening torque corrected by a KTM dealer as soon as possible. A  
loose axle may lead to an unstable driving behavior of your motorcycle.  
– After mounting the front wheel, keep operating the hand brake until the  
pressure point returns.  
36  
– It is very important to keep the brake disk free from oil and fatty matters,  
otherwise the braking effect would be strongly reduced.  
2
Dismounting and mounting the rear wheel  
Jack the motorcycle up on its frame so that the rear wheel no longer touches  
the ground.  
Remove the collar nut [4], remove the chain tensioner [5] and pull out the  
wheel spindle [6] until you can push the rear wheel forwards.  
Take the chain off the rear sprocket, pull out the wheel spindle and carefully  
remove the rear wheel from the swing arm.  
5
– Do not operate the rear brake when the rear wheel has been  
dismounted.  
– Make sure the brake disc is always on top when you lay down the wheel,  
otherwise the brake disc can be damaged.  
4
– If the axle is dismounted, clean the thread of the wheel spindle and col-  
lar nut thoroughly and apply a new coat of grease to prevent the thread  
from jamming.  
6
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
The rear wheel is remounted in the reverse order. Before tightening the col-  
lar nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain  
tensioners lie on the tension screws.  
– If you don’t happen to have a torque wrench at hand, make sure you have  
the tightening torque corrected by a KTM dealer as soon as possible. A  
loose axle may lead to an unstable driving behavior of your motorcycle.  
– After mounting the rear wheel, keep operating the rear brake until the pres-  
sure point returns.  
– It is very important to keep the brake disk free from oil and fatty matters,  
otherwise the braking effects would be strongly reduced.  
– Tighten the collar nut with the required torque. A loose wheel spindle may  
lead to an unstable behavior of your motorcycle.  
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 to go  
anywhere on your motorcycle.  
– Tire size can be found in the technical specifications and in the homolo-  
gation certificate  
– Tire condition has to be checked every time you want to ride your motor-  
cycle. Before leaving, check tires for punctures and nails or other sharp  
objects that might have become embedded in them.  
– Refer to the specific regulations in your country for minimum tire tread  
requirements. We recommend you replace the tires at the latest when the  
tread is down to 2 mm (0.08 in).  
– Tire pressure should be checked regularly on a “cold” tire. Proper pres-  
sure ensures optimum driving comfort and extends the life of your tires.  
37  
TIRES – AIR PRESSURE  
– Do not mount tires which have not been approved by KTM. Other tires  
could have adverse effects on the way your motorcycle behaves.  
– front and rear wheels may only be fitted with tires having the same tread  
layout. Use homologated tires  
– For your own safety replace damaged tires immediately.  
– Worn tires can have a negative effect on how your motorcycle performs,  
especially on wet surfaces  
front  
rear  
Off-road  
Road  
1,0 bar  
1,5 bar  
1,0 bar  
2,0 bar  
– If air pressure is too low, abnormal wear and overheating of the tire can  
result  
Only mount tires approved by KTM on homologated models (see Technical  
Data for Chassis). No product liability will be assumed if other types of  
tires are used.  
-
Checking spoke tension  
The correct spoke tension is very important for the stability of the wheels and  
thus for riding safety. A loose spoke causes the wheel to become  
unbalanced and before long other spokes will have come loose. Check spoke  
tension, especially on a new motorcycle, at regular intervals. For checking,  
tap on each spoke with the blade of a screwdriver (see photo). A clear tone  
must be the result. Dull tones are indicators of loose spokes. If necessary,  
have the spokes retightened and the wheel centered by a KTM dealer.  
– Spokes can tear if you continue to ride with them loose. This may lead to  
an unstable handling of your motorcycle.  
– Excessively tensioned spokes may rupture due to local overloading.The  
spokes must be tensioned to 5 Nm.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Replacing the battery of the digital speedometer  
Remove the headlight mask and disassemble the electronic speedometer.  
Remove the screw connection [A], insert the battery (type Duracell CR 2430)  
with the writing facing up and reinstall the screw connection.  
A
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.  
1
38  
2
1
Replacing the headlight lamp/parking light lamp  
4
Loosen both rubber bands and tilt the headlight mask to the front. Pull the  
parking light lamp with holder [3] carefully out of the reflector. Pull  
connector [4] off the headlamp and remove rubber cap [5]. Disengage retain-  
ing clip and take the bulb out of the reflector. When changing the parking-  
light lamp, simply pull it out of the holder.  
5
3
4
Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out  
of the socket.  
To mount the lamp reverse the worksteps indicated above.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Cooling system  
The water pump in the engine circulates the cooling liquid. However, the cool-  
ing liquid can only circulate properly if the cooling circuit contains no air  
bubbles.  
Bleeding of the cooling system is therefore required  
a) after adding more than 0.25 l cooling liquid and  
b) after refilling the entire cooling system.  
(see Bleeding the cooling system).  
Some models are equipped with a thermostat [1] so that the engine reaches  
its operating temperature more quickly. When the engine is cold, the liquid  
coolant circulates in the cylinder and the cylinder head. As soon as the  
cooling liquid has reached a temperature of approximately 55°C, the thermo-  
stat opens and the cooling liquid is also pumped through the two aluminum  
radiators.  
1
The cooling liquid is cooled by the air stream. This means that the cooling  
effect decreases with the traveling speed. Dirty radiators additionally reduce  
the cooling effect.  
– If possible, always check level of cooling liquid when engine is cold. If  
you have to open the radiator cap [2] when the engine is hot, use a rag to  
cover the cap and open slowly to release pressure. Caution - scalding haz-  
ard.  
– Do not detach any radiator hoses while the engine is hot. The escaping  
hot coolant and the steam may cause serious burns.  
– In case you get burnt, hold the affected part of your body under running  
cold water right away.  
2
– Coolant is toxic. Keep the coolant out of the reach of children.  
– In case coolant is ingested, consult a doctor immediately.  
– If coolant gets into your eyes, rinse them out with water immediately and  
go see a doctor.  
39  
Use a mixture of 50% antifreeze and 50% distilled water for the cooling liq-  
uid. The antifreeze should be designed for temperatures of at least -25°C. This  
mixture offers frost protection as well as good corrosion protection and should  
not be replaced by water alone.  
For the cooling system, use only with high-grade antifreeze (e.g. Motorex Anti-  
Freeze). Using lower-grade antifreeze agents can cause corrosion and coolant  
foaming.  
Pressure induced by heating of the coolant in the system is controlled by a  
valve in the radiator cap [2]; a water temperature of up to 120° C (248° F)  
is admissible without, having to expect any trouble.  
Checking the coolant level  
The coolant should be 10 mm (0.4 in) above the radiator fins when the engine  
is cold (see diagram). In the event of the coolant being drained, always fill  
and bleed the system.  
10 mm  
when engine ist cold  
If possible, always check the level of cooling liquid when the engine is cold.  
If you have to open the radiator cap when the engine is hot, use a rag to cover  
the cap and open slowly to release pressure.  
The cooling system must be bled after draining the cooling liquid or after adding  
more than 0.25 l (0.06 US gallons) cooling liquid.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
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) cooling liq-  
uid.  
Make sure that the drain screw [1] is fastened.  
Pour approx. 0.5 litres (0.13 US gallons) coolant into the system.  
1
1
Remove screw [2] at the cylinder head. Reinstall it as soon as the cooling liq-  
uid emerges free of air bubbles (only for 125/200 engines).  
3
Remove the screw [3] on the right radiator.  
Now add cooling liquid until it emerges free of bubbles at the right radiator.  
Then immediately mount the screw so that no more air can enter the right  
radiator.  
Top up the left radiator until the coolant can be seen approx. 10 mm (0.4 in)  
above the radiator fins.  
Check the coolant level again after a short ride.  
2
40  
Cleaning the air filter *  
The air filter must be cleaned prior to each race or whenever dust has accu-  
mulated. To clean, lift the filter box cover  
(see illustration) and pull off towards the front.  
Detach the bottom of the filter retaining bracket [4], tilt aside and remove the  
throttle cap [5] and the air filter [6] and filter support [7] from the filter box.  
– Do not clean foam filter with fuel or petroleum since these damage the  
foam. KTM recommends the products of the company Motorex for air fil-  
ter maintenance (Bio Dirt Remover and Liquid Bio Power).  
- Never start your motorcycle without any air filters. otherwise, dust and dirt  
may penetrate and cause damage and increased wear.  
- Dust and dirt can accumulate and damage the engine if the air filter is  
not mounted correctly.  
Thoroughly wash the air filter in special cleaning fluid (Motorex Bio Dirt  
Remover) and allow it to dry well. Only press out the filter, do not wring it out  
under any circumstances. Oil the dry air filter with a high-grade filter oil (Motorex  
liquid Bio Power). Also clean the air filter box. Check the carburetor collar for  
damage and that it is filled correctly.  
6
Mount the air filter on the filter support. Insert the air filter and filter support  
in the throttle cap and mount them in the filter box, aligning in a central posi-  
tion, and fix with the filter retaining bracket.  
4
7
6
5
4
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Exhaust system *  
If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn.  
Have the filling checked regularly by an authorized KTM workshop (see  
Lubrication and Service Chart). The insulating material fibers escape through  
the holes in the perforated pipe with time, causing the silencer to “burn out”.  
In addition to causing a higher noise-level, it will also affect the power char-  
acteristic. The insulating material suitable for your exhaust is available from  
your authorized KTM workshop.  
2
To replace the glass-fiber yarn set [2] remove the end cap and pull off the  
outer pipe [3]. Tape a new glass-fiber yarn set to the inner tube and slide on  
the outer pipe. Mount the end cap.  
Make sure the caps are screwed on tightly. Mount the muffler stress-free before  
tightening the fixing screws.  
1
3
The exhaust system becomes very hot while the motorcycle is running. Do not  
start work on the exhaust system until it has properly cooled down, to avoid  
burns.  
41  
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 position  
for every hand size.  
The clutch lever moves closer to the handlebar if the adjusting screw is tur-  
ned in a counterclockwise direction. The clutch lever moves away from the  
handlebar if the adjusting screw is turned in a clockwise direction.  
4
Adjustment of the clutch lever position is only possible within certain limits.  
Only turn the adjusting screw manually and never apply excessive force.  
Checking the oil level of the hydraulic clutch125/200  
To check the oil level in the master cylinder of the clutch remove the cover.  
For this purpose, remove screws [2] and cover [3] together with the rubber  
boot [4]. The oil level in the horizontal-standing master cylinder should be  
4 mm below the upper edge.  
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid  
75), available from your authorized KTM shop.  
6
7
8
KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch  
in 125/200 models. Do not mix this oil with any other hydraulic oil. Always  
use original KTM hydraulic oil (available from your authorized KTM workshop)  
to make sure your clutch operates smoothly. Never refill with brake fluid.  
Checking the oil level of the hydraulic clutch 250/300  
To check the oil level in the master cylinder of the clutch remove the cover.  
For this purpose, remove screws [2] and cover [3] together with the rubber  
boot [4]. The oil level in the horizontal-standing master cylinder should be  
4 mm below the upper edge.  
If necessary, add DOT 5.1 brake fluid (Motorex Brake Fluid 5.1).  
6
7
8
BREMBO clutch fittings are installed in the 250/300 models and filled with  
DOT 5.1 brake fluid. To make sure the clutch operates smoothly, never add  
hydraulic oil to these systems.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Bleeding the hydraulic clutch *  
The clutch control needs to be bled as soon as the resistance in the clutch  
lever starts to feel unresponsive. You will need to use a bleeding syringe (spe-  
cial tool). Please note that Motorex 75 clutch fluid must be used for the 125/200  
models and Motorex DOT. 5.1 brake fluid for the 250/300 models.  
Both are available from your KTM dealer.  
1
Turn the handlebar until the master cylinder is in a horizontal position, remove  
the screws [1], the cover [2] and the rubber boot [3].  
2
3
Fill the bleeder syringe [4] with a suitable fluid (see Technical Specifications  
- Engine). Remove the bleeder screw from the slave cylinder [5] and mount  
the bleeder syringe.  
4
5
42  
Press oil into the system until the fluid runs out of the hole [6] in the master  
cylinder without bubbles. Occasionally extract the fluid from the master cylin-  
der reservoir to keep it from overflowing.  
After you finish bleeding, remove the bleeder syringe, mount the bleeder screw,  
correct the level in the reservoir and mount the cover (see above).  
6
Carburetor adjustment *  
Basic information on the original carburetor setting  
The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient  
temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ).  
Mixing ratio (2-stroke motor oil : super fuel) 1:40 – 1:60 (depends on oil quality)  
Basic information on changing the carburetor setting  
Always start with the original carburetor setting (the provided factory setting is meant for break-in operation; after the break-in period,  
the carburetor needs to be adjusted according to the carburetor datasheet - see appendix). Essential requirements are a clean air fil-  
ter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the  
jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance.  
RULE OF THUMB: high altitude or high temperatures > choose leaner carburetor adjustment  
low altitude or low temperatures  
> choose richer carburetor adjustment  
– Only use premium-grade gasoline ROZ 95 (USA = Premium PON 91) mixed with high-grade two-stroke engine oil. Other types of  
gasoline can cause engine failure, and will void your warranty.  
– Only use high-grade 2-stroke engine oil of known brands (e. g. Motorex Cross Power 2T).  
– Not enough oil or low-grade oil can cause erosion of the piston. if you use too much oil the engine can start smoking and foul the  
spark plug and the exhaust control system.  
– In the case of a leaner adjustment of the carburetor, proceed cautiously. Always reduce the jet size in steps of one number to avoid  
overheating and piston seizure.  
NOTE: If the engine does not run properly despite a changed adjustment, look for mechanical faults and check the ignition system.  
General information on carburetor wear  
Engine vibrations subject the throttle slide, jet needle, float needle valve and the needle jet to extreme wear. Wear leads to malfunctio-  
ning of the carburetor (e.g. over-enrichment). These parts should be replaced after 100 operating hours. The carburetor body, main jet  
holder and the float support should be replaced after 200 operating hours.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Definitions  
2
Mixture too rich:  
Too much fuel in proportion to air.  
Mixture too lean:  
Not enough fuel in proportion to air.  
1
Idling range A  
Operation with closed throttle valve. This range is influenced by the position  
of the air control screw [2] and the air control screw [3]. Only make adjust-  
ments when the engine is hot.  
To this end, slightly increase the idling speed of the engine by means of the  
air control screw. Turning it clockwise produces a higher idling speed and turn-  
ing the screw counterclockwise produces a lower idling speed. Create a round  
and stable engine speed using the air control screw (basic position of the air  
control screw = open by 1.5 turns). Then adjust to the normal idling speed  
by means of the air control screw.  
main jet  
jet needle  
D
C
jet needle  
Opening up B  
Engine behavior when the throttle opens. The idle jet and the shape of the  
throttle valve influences this range. If, despite good idling-speed and part-  
throttle setting, the engine sputters and smokes when the throttle is fully opened  
and develops its full power not smoothly but suddenly at high engine speeds,  
the mixture to the carburetor will be too rich, the fuel level too high or the  
float needle is leaking.  
idle jet  
throttle valve  
B
A
air control screw  
idle adjusting screw  
43  
Part-throttle range C  
Operation with partly open throttle valve. This range is only influenced by the  
jet needle (shape and position). The optimum part-throttle setting is controlled  
by the idling setting in the lower range and by the main jet in the upper range.  
If the engine runs on a four-stroke cycle or with reduced power when it is  
accelerated with the throttle partly open, the jet needle must be lowered by  
one notch. If then the engine pings, especially when accelerating under full  
power at maximum engine revs, the jet needle should be raised.  
If these faults should occur at the lower end of the part throttle range at a  
four-stroke running, make the idling range leaner; if the engine pings, adjust  
the idling range richer.  
Full throttle range D  
Operation with the throttle fully open (flat out). This range is influenced by  
the main jet and the jet needle. If the porcelain of the new spark plug is found  
to have a very bright or white coating or if the engine rings, after a short dis-  
tance of riding flat out, a larger main jet is required. If the porcelain is dark  
brown or black with soot the main jet must be replaced by a smaller one.  
JET NEEDLE  
TYPE  
RANGE OF ACTION  
RICHER  
LEANER  
N8RG  
N8RH  
N8RW  
N8RJ  
JET NEEDLE  
TYPE  
RANGE OF ACTION  
RICHER  
LEANER  
NOZD  
NOZE  
NOZF  
NOZG  
NOZH  
NOZI  
Explanation of table - Example  
Compared to the needle NOZI, the jet needle NOZG is two steps leaner in  
the range from the closed position of the throttle to 1/4 throttle. Otherwise,  
there are no differences.  
Pay attention to the correct needle designation when replacing the jet nee-  
dle. detailed information on the type of jet needle for the respective models  
can be found in the carburetor setting table.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Draining the float chamber of the carburetor  
Following every wet-cleaning procedure, the float chamber of the carburetor  
should be drained in order to remove any water that may have penetrated into  
it. Water in the float chamber leads to engine malfunction.  
Make sure you do this while the engine is cold. Close the fuel tap, and place a  
cloth under the carburetor, which is capable of absorbing the leaking fuel. Unscrew  
the plug [1] and clean it with compressed air. Then, mount the plug together with  
the gasket, open the fuel tap, and check the float chamber for leaks.  
Fuel is easily flammable and toxic. When handling fuel, be sure to exercise  
the utmost caution. Never perform any work on the fuel system near open  
flames or burning cigarettes. Always allow the engine to cool off first.  
Immediately clean up any fuel which may have been spilled. Materials satu-  
rated with fuel are also easily flammable. In case you ingested fuel or fuel  
splashed into your eyes, consult a doctor immediately.  
1
Dispose of the fuel properly.  
Checking the float level *  
Arrange the carburetor diagonally at about 60° so that the spring in the float  
needle valve is not pressed together. In this position, the edge of the float  
should be parallel with the float chamber sealing surface (see illustration).  
60°  
44  
Adjusting the engine characteristic via the ignition curve (125-300)  
2 ignition curves (PERFORMANCE and SOFT) are stored in the digital box. The  
PERFORMANCE ignition curve is activated in the condition at delivery. The SOFT  
ignition curve can easily be activated by disconnecting the socket connector  
under the tank.  
To change the ignition curve, remove the seat and tank.  
A) PERFORMANCE (higher engine performance) socket connector connected  
B) SOFT (better driveability) socket connector disconnected  
You can also change the ignition curve via the handlebar switch (Power Parts)  
while driving.  
B
A
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Adjusting the engine characteristic via the auxiliary spring (250/300)  
The engine characteristic can be modified through various thicknesses of the  
auxiliary spring [1]. An auxiliary spring designed for „good driveability“ (smooth  
power application) is mounted in the condition at delivery.  
One of the auxiliary springs can be mounted if you prefer an „even smoother  
power application“ or an „aggressive engine characteristic“.  
Auxiliary spring for good driveability (mounted in condition at delivery)  
Spare part number 546.37.072.300, YELLOW color mark  
Auxiliary spring for an even smoother power application (included in scope of  
supply) Spare part number 548.37.072.100, GREEN color mark  
2
2
6
Auxiliary spring for aggressive engine characteristic (included in scope of sup-  
ply). Spare part number 548.37.072.000, RED color mark  
To mount, tilt the motorcycle approx. 45° to the left, remove both screws [2],  
lift off the closing cover [3] and remove the springs including the spring insert  
[4] from the clutch cover. Pull both springs off the spring insert, mount the  
auxiliary spring [1] and control spring [5] and slide both into the clutch cover  
until the recess in the spring insert [4] engages in the rocker arm. Check the  
O-ring in the closing cover mount the closing cover, ensuring that the dolly  
screw [6] engages in the auxiliary spring.  
3
Make sure you do not turn the dolly screw since this will impair the engine  
characteristic.  
Be careful not to turn the spring dolly [6], otherwise the engine characteris-  
tic will deteriorate.  
45  
2
3
5
6
1
You can also change the engine characteristic through the interaction bet-  
ween the ignition curve, auxiliary spring (250/300 only) and exhaust. The fol-  
lowing table shows examples of possible combinations. Further combinations  
can be adjusted at random depending on the driving requirements.  
4
250/300 XC/XC-W/EXC-Six Days/EXC  
Engine performance – –  
–
Standard setting  
Standard setting  
performance  
gelb  
+
+ +  
Driveability  
+ +  
soft  
+
–
– –  
Ignition curve  
soft  
performance  
yellow  
performance  
red  
Auxiliary spring (250/300) green  
yellow  
Exhaust  
EXC standard  
EXC standard  
EXC standard  
250 SX  
250 SXS  
Example of application extremely difficult  
track conditions:  
difficult track  
conditions:  
average track  
conditions  
good track conditions: special track  
nonskid roadway, well conditions:  
very selective, very  
hard, hardly any  
traction, very tiring  
selective, not much  
traction, tiring  
prepared, MX special  
stage  
deep sand, very fast  
track routing, very well-  
prepared track  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Check transmission oil level (125/200)  
In order to check the transmission oil level the control screw [1] on the clutch  
cover is to be removed. Oil should just barely escape from the inspection open-  
ing when the motorcycle is in an upright position. If necessary, remove the  
plug [2] and top up with oil (e. g. Motorex Top Speed 4T 15W50).  
1
Transmission and clutch will be subjected to excessive wear and tear if you  
use too little or low grade oil. Use only high-grade oil (e. g. Motorex Top Speed  
4T 15W50).  
Changing the transmission oil (125/200) *  
To change the gear oil warm up the engine and park the motorcycle on a hor-  
izontal surface. Remove oil drain plugs [3] and [4] and drain the used oil into  
an appropriate container. Clean the magnets of the oil drain plugs and mount  
them together with the appropriate gaskets. Fill in 0.7 l oil (e. g. Motorex Top  
Speed 4T 15W50), mount the plug [2] and check the engine for leaks.  
2
Transmission and clutch will be subjected to excessive wear and tear if you  
use too little or low grade oil. Use only high-grade oil (e. g. Motorex Top Speed  
4T 15W50).  
46  
3
4
Check transmission oil level (250/300)  
In order to check the transmission oil level the control screw [5] on the clutch  
cover is to be removed. Oil should just barely escape from the inspection open-  
ing when the motorcycle is in an upright position. If necessary, remove the  
plug [6] and top up with oil (e. g. Motorex Top Speed 4T 15W50).  
Transmission and clutch will be subjected to excessive wear and tear if you  
use too little or low grade oil. Use only high-grade oil (e. g. Motorex Top Speed  
4T 15W50).  
5
Changing the transmission oil (250/300) *  
To change the transmission oil run the engine warm and set up the motorcy-  
cle on a horizontal surface. Remove the oil drain screw [7] and drain used oil  
into a container. Clean the magnet of the oil drain screw and reinstall oil drain  
screw with seal. Pour in 0.7 litres engine oil (e. g. Motorex Top Speed 4T  
15W50), replace plug [6] and check engine for leaks.  
6
7
Transmission and clutch will be subject to excessive wear and tear, if you use  
too little or low grade oil. Use only high-grade oil (e. g. Motorex Top Speed  
4T 15W50).  
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CLEANING »  
Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.  
The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.  
The hard dirt can be removed before washing with the help of a soft water jet.  
If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc. The high pres-  
sure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear.  
– Before cleaning with water, plug the exhaust pipe to prevent water ingress.  
– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should also be cleaned with the help  
of a paint brush.  
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive  
until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water  
can evaporate from inaccessable parts of the engine and the brakes.  
– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of  
the motorcycle is allowed to evaporate.  
– After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Treat the chain with a chain spray.  
– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, the short circuit button,  
the light switch and the socket connectors with contact spray.  
CONSERVATION FOR WINTER OPERATION »  
In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre-  
cautions against the aggressive road salt.  
– clean the motorcycle thoroughly and let it dry after each ride  
– treat the engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corro-  
sion agent.  
47  
Keep the anti-corrosion agent from getting into contact with the brake discs, otherwise this will significantly reduce the braking power.  
After rides on salted roads, clean motorcycle thoroughly with cold water and let it dry well.  
STORAGE »  
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 engine warm up again, close fuel cock and wait until the engine dies off by itself. In this way the carburetor jets are pre-  
vented from becoming resin- clogged by the old fuel.  
– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in  
order to distribute the oil onto the cylinder walls and mount the spark plug.  
– Let fuel flow out of tank into an appropriate container.  
– Correct tire pressure.  
– Lubricate bearing points of the control levers, footrests, etc. as well as the chain.  
– The storage place should be dry and not be subjected to too big temperature fluctuations.  
– Cover the motorcycle with an air permeated tarp or blanket. Do not use non airtight materials as a possible humidity might not be  
able to escape and thereby cause corrosion.  
It would be very bad to let the engine run for a short time during the storage period. The engine would not get warmed up enough and  
the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust.  
USE AFTER A PERIOD OF STORAGE  
– Fill up the tank with fresh fuel.  
– Check the motorcycle as before each start (see driving instructions)  
– Take a short, careful test ride first.  
NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any service  
jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics' shops).  
This way, you can avoid the long waiting times at your shop at the beginning of the next biking season.  
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TECHNICAL SPECIFICATIONS – CHASSIS 125 EXC/SIX DAYS, 200 XC/XC-W/EXC 2007»  
CHASSIS  
125 EXC SIX DAYS/EXC  
200 XC/XC-W/EXC  
Frame  
Central chrome-moly-steel frame  
Fork  
WP Suspension – 4860 MXMA (WP – 4860 MXMA + PA: 200 XC, EXC 125 Six Days)  
300/335 mm (11.8/13.2 in)  
Wheel travel front/rear  
Rear suspension  
Front brake  
Rear brake  
Brake discs  
Front tires  
WP Suspension – 5018 PDS MCC (WP – 5018 PDS DCC: 200 XC, 125 EXC Six Days)  
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated  
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated  
Wear limit 2.50 mm (0.1 in) front / 3.50 mm (0.14 in) rear  
90/90 - 21“ MT 83 Pirelli  
200 XC/XC-W USA, XC-W ZA:  
80/100 - 21“ 51M M59, Bridgestone  
200 EXC EU/AUS: 90/90 - 21” Pirelli MT 83  
1,0 bar (14 psi)  
Air pressure offroad  
Air pressure road driver only  
Rear tires  
1,0 bar (14 psi)  
1,5 bar (21 psi)  
1,5 bar (21 psi)  
120/90-18”; Pirelli MT83  
200 XC/XC-W USA, XC-W ZA:  
100/100 - 18“ 59M, M402, Bridgestone  
200 EXC EU/AUS: 120/90-18”; Pirelli MT83  
1,0 bar (14 psi)  
Air pressure offroad  
1,0 bar (14 psi)  
2,0 bar (28 psi)  
Air pressure road driver only  
2,0 bar (28 psi)  
Fuel tank capacity  
(Reserve page 12)  
8.5 liters (2.2 US gallons)  
EXC EU: 8,5 liters (2.2 US gallons)  
EXC AUS: 10 liters (2.6 US gallons)  
XC/XC-W: 11 liters (2.9 US gallons)  
EXC EU/AUS: 14:42 t (14:48 t)  
(XC/XC-W USA/EXC ZA: 14:48 t  
48  
Final drive ratio  
14:42 t (13:50 t)  
Chain  
5/8 x 1/4 "  
Available final sprockets  
Bulbs (EXC, EXC Six Days)  
38t, 40t, 42t, 45t, 48t, 49t, 50t, 51t, 52t  
headlight  
12V 35/35W Bilux (base Ba20d)  
12V 5W (base W2, 1x9,5d)  
parking light  
brake-rear light  
flasher light  
63°  
12V 21/5W (base BaY15d)  
12V 10W (base Ba15s)  
Steering head angle  
Wheel base  
1471 ± 10 mm (57.9 in ± 0.4 in)  
925 mm (36,5 in)  
Seat height, unloaded  
Ground clearance, unloaded  
Weight (without fuel)  
390 mm (15,3 in)  
98,6 kg (216.9 lbs)  
EXC EU/AUS: 99,8 kg (219.6 lbs)  
EXC ZA: 98,4 kg (216.5 lbs)  
XC-W USA: 97,4 kg (214.3 lbs)  
XC USA: 97,2 kg (213.8 lbs)  
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TECHNICAL SPECIFICATIONS – CHASSIS 125 EXC/SIX DAYS, 200 XC/XC-W/EXC 2007»  
STANDARD ADJUSTMENT – FORK 125/200 EXC/XC-W  
STANDARD ADJUSTMENT – SHOCK ABSORBER 125/200 EXC/XC-W  
WP 4860 MXMA  
14187C02  
WP 5018 PDS MCC  
12187C02  
Compression adjuster  
Rebound adjuster  
Spring  
20  
Compression adjuster  
Rebound adjuster  
Spring  
17  
20  
26  
4,0 N/mm  
110 mm  
SAE 5  
72-250  
4 mm  
Air chamber length  
Fork oil  
Spring preload  
STANDARD ADJUSTMENT – FORK 125 EXC SIX DAYS, 200 XC  
WP 4860 MXMA + PA  
STANDARD ADJUSTMENT – SHOCK ABSORBER 125 EXC SIX DAYS, 200 XC  
WP 5018 PDS DCC  
14187C27  
12187C27  
Compression adjuster  
Rebound adjuster  
Spring  
18  
Compression adjuster Low Speed 15 Klicks  
Compression adjuster High Speed 1,25 turns  
20  
4,2 N/mm  
2 turns  
110 mm  
SAE 5  
Rebound adjuster  
Spring  
24  
Preload Adjuster  
Air chamber length  
Fork oil  
72-250  
5 mm  
Spring preload  
TIGHTENING TORQUES – CHASSIS  
Collar screw, front wheel spindle  
Brake caliper, front  
49  
M24x1,5  
M8  
40 Nm  
Loctite 243 + 25 Nm  
14 Nm  
Brake disks  
M6  
Screw steering head  
M20x1,5  
M20x1,5  
M8  
10 Nm  
Lower Screw steering head  
Loctite 243 + 60 Nm  
17 Nm  
Clamping screws, upper fork bridge (125 EXC SIX DAYS/200 XC)  
Clamping screws, lower fork bridge (125 EXC SIX DAYS/200 XC)  
M8  
12 Nm  
Clamping screws, upper steering stem (125 EXC SIX DAYS/200 XC) M8  
Loctite 243 + 17 Nm  
20 Nm  
Clamping screws, upper fork bridge (EXC/XC-W)  
Clamping screws, lower fork bridge (EXC/XC-W)  
Clamping screws, fork stubs  
Collar nut, rear wheel spindle  
Hexagon nut, swing arm bolt  
Hexagon collar screw, handlebar clamp  
Allan head screw, handlebar support  
Shock absorber, top  
M8  
M8  
15 Nm  
M8  
15 Nm  
M20x1,5  
M16x1,5  
M8  
80 Nm  
100 Nm  
20 Nm  
M10  
M12  
M12  
M8  
Loctite 243 + 40 Nm  
Loctite 243 + 70 Nm  
Loctite 243 + 70 Nm  
Loctite 243 + 35 Nm  
10 Nm  
Shock absorber, bottom  
Sprocket screws  
Ball joint for push rod  
M6  
Engine mounting bolt  
M10  
M8  
60 Nm  
Engine brace  
33 Nm  
Screw adjusting ring spring preload shock abs.  
Spoke nipple  
M6  
8 Nm  
M4,5 / M5  
M6  
5 Nm  
Other screws on chassis  
10 Nm  
M8  
25 Nm  
M10  
M6  
45 Nm  
Other collar nuts on chassis  
15 Nm  
M8  
30 Nm  
M10  
50 Nm  
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TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007»  
ENGINE  
125 EXC/EXC SIX DAYS  
200 XC-W/EXC  
200 XC  
Design  
Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control  
Piston displacement  
Bore / stroke  
Fuel  
124.8 ccm  
193 ccm  
54 / 54.5 mm (2.126 / 2.145 in)  
64 / 60 mm (2.52 / 2.362 in)  
unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil  
Oil / gasoline ratio  
1:40-1:60 when using high grade, two- stroke oil (Motorex Cross Power 2T).  
When in doubt, please contact your importer  
Crankshaft bearing  
Connecting rod bearing  
Piston pin bearing  
Piston  
1 deep-groove ball bearing / 1 cylinder roller bearing  
needle bearing  
needle bearing  
cast piston  
Piston ring  
two plain compression rings  
0,0 mm  
two plain compression rings  
(upper edge piston-  
Dimension „X“  
Ignition timing  
Spark plug  
Electrode gap  
Dimension „Z“  
Primary drive  
Clutch  
upper edge cylinder)  
1.4 mm (0.055 in) (16.5°) BTDC  
NGK BR9 EVX  
1.6 mm (0.063 in) (17°) BTDC  
NGK BR 8 EG  
0,60 mm  
(height of the  
control flap)  
43,5 mm (1.68 in)  
47 mm (1.85 in)  
straight cut spur gears, primary ratio 23:73  
multiple disc clutch in oil bath, hydraulically operated (Motorex hydraulic fluid 75)  
Transmission  
Gear ratio  
6 speed, claw actuated  
6 speed, claw actuated  
50  
1st gear  
12 : 33 „1G33“  
„2S15“ 15 : 31 „2G31“  
„3S17H“ 17 : 28 „3S28H“  
„4S19H“ 19 : 26 „4S26“  
„5S21“ 21 : 25 „5S25“  
„6G20“ 20 : 20 „6G20“  
13 : 33 „1G33“  
„2S15“ 15 : 31 „2G31“  
„3S17H“ 17 : 28 „3S28H“  
„4S19H“ 19 : 26 „4S26“  
„5G17H“ 17 : 19 „5G19H“  
„6G22H“ 22 : 20 „6E20H“  
13 : 32 „1S32“  
„2S15“ 15 : 30 „2S30“  
„3S17H“ 17 : 28 „3S28H“  
„4S19H“ 19 : 26 „4S26H“  
„5S21“ 21 : 25 „5S25“  
„6G22“ 22 : 23 „6S23“  
2nd gear  
3rd gear  
4th gear  
5th gear  
6th gear  
Gear lubrication  
0,7 liter Motorex Top Speed 4T 15W50  
Available chain sprockets 13t / 14t for chain 5/8 x 1/4"  
Coolant  
1.2 litres, 50% anti freeze, 50% distilled water, at least -25 °C (-13 °F)  
Ignition system  
Generator output  
Ignition system XC-W  
Generator output  
Carburetor  
KOKUSAN 2K-3 (EXC/EXC Six Days)  
KOKUSAN 2K-3 (EXC)  
12V / 110 W  
12V / 110 W  
–
–
KOKUSAN 2K-2 (XC/XC-W)  
12V 40 W  
flat-slide carburetor, carburetor setting see table  
wet foam type air filter insert  
Air-filter  
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TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007»  
TIGHTENING TORQUES - ENGINE  
Flange bolts - cylinder-head  
Nuts-cylinder base  
M7  
18 Nm  
M8  
35 Nm  
Flywheel collar nut  
M12x1  
M16x1.5  
M18x1.5  
M6  
60 Nm  
Nut for primary sprocket (LH thread)  
Nut for inner clutch hub  
Collar screw for clutch spring  
Oil drain plug  
Loctite 243 + 130 Nm  
130 Nm  
10 Nm  
M12x1.5  
M10x1  
M10x1  
M6  
20 Nm  
Oil drain plug  
15 Nm  
Drain plug for water pump cover  
Collar screw for water pump cover  
Water pump wheel  
15 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 6 Nm  
10 Nm  
M5  
Crankcase and clutch cover bolts  
Collar screws for ignition cover  
Collar screws for exhaust flange  
Spark plug  
M6  
M5  
5 Nm  
M5  
6 Nm  
M14x1.25  
M5  
25 Nm  
Collar screws for ignition system  
Collar screw for kickstarter lever  
Other screws  
6 Nm  
M8  
Loctite 243 + 25 Nm  
10 Nm  
M 6  
M 8  
25 Nm  
51  
M 10  
45 Nm  
BASIC CARBURETOR SETTING  
125 EXC EU 4,2 KW  
125 EXC SIX-DAYS  
200 XC USA  
200 XC-W USA  
200 EXC ZA  
200 EXC AUS (7 KW)  
200 EXC EU (7 KW)  
Carburetor  
Keihin PWK 36S AG  
Keihin PWK 36S AG  
Keihin PWK 36S AG  
Keihin PWK 36S AG  
Carburetor setting mark 8KTPC  
FK0070  
FK 0130  
8KTUD  
Main jet  
145 (168/170/172)  
170 (168/172)  
162 (160/165)  
162 (160/165)  
Idling jet  
35 (45/48)  
85  
45  
85  
42  
35 (42)  
Starting jet  
85  
85  
Jet needle  
R1472N (NOZE/NOZF) NOZE (NOZF)  
IV  
NOZF (NOZG)  
R1475J (NOZG/NOZF)  
Needle position from top V  
IV  
7
1
–
III  
Throttle valve  
7
7
1
–
7
Air adjustment srew open 1,5  
1
Performance restrictor  
–
slide stop 38 mm  
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TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007»  
CHASSIS  
250/300 XC/XC-W  
250/300 EXC SIX DAYS  
250/300 EXC (EXC ZA)  
Frame  
Central chrome-moly-steel frame  
Fork  
WP Suspension – 4860 MXMA (-PA; 250/300 XC/EXC SIX DAYS)  
300/335 mm (11.8/13.2 in)  
Wheel travel front/rear  
Rear suspension  
Front brake  
Rear brake  
Brake discs  
Front tires  
WP Suspension – 5018 PDS MCC, Alu-Hinterradschwinge  
Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated  
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated  
Wear limit 2.50 mm (0.1 in) front / 3.50 mm (0.14 in) rear  
80/100 - 21” 51M, M59 Bridgestone 90/90 - 21” Pirelli MT 83  
90/90 - 21” Pirelli MT 83  
(80/100 - 21” 51M, M59 Bridgestone)  
1,0 bar (14 psi)  
Air pressure offroad  
Air pressure road driver only  
Rear tires  
1,0 bar (14 psi)  
-
1,0 bar (14 psi)  
1,5 bar (21 psi)  
1,5 bar (21 psi)  
110/100 - 18” 64M,M402 Bridgestone 140/80 - 18” Pirelli MT 83  
140/80 - 18” Pirelli MT 83  
(110/100 - 18” 51M, M59 Bridgestone)  
1,0 bar (14 psi)  
Air pressure offroad  
Air pressure road driver only  
Fuel tank capacity  
1,0 bar (14 psi)  
-
1,0 bar (14 psi)  
2,0 bar (28 psi)  
2,0 bar (28 psi)  
250/300 EXC EU/EXC Six Days: 8,5 liters (2.2 US gallons)  
250/300 EXC AUS: 10 liters (2.6 US gallons)  
250/300 XC/XC-W: 11 liters (2.9 US gallons)  
(Reserve page 12)  
13:50 t  
Final drive ratio  
13:50 t  
13:40 t (13:50) 250/300EXC EU/AUS  
13:50 t 250/300 EXC ZA  
52  
14:50 t (XC USA)  
5/8 x 1/4 "  
Chain  
Available final sprockets  
Bulbs  
38t, 40t, 42t, 45t, 48t, 49t, 50t, 51t, 52t  
headlight  
12V 35/35W Bilux (base Ba20d)  
12V 5W (base W2, 1x9,5d)  
12V 21/5W (base BaY15d)  
12V 10W (base Ba15s)  
parking light  
brake-rear light  
flasher light  
Steering head angle  
Wheel base  
63,5°  
1475 ± 10 mm (58.1 in ± 0.4 in)  
925 mm (36.5 in)  
Seat height, unloaded  
Ground clearance, unloaded 385 mm (15.2 in)  
Weight (without fuel)  
99,6 kg (250 XC, EU)  
102,6 kg EXC Six Days EU  
102,6 kg (250/300 EXC EU/AUS)  
100,6 kg (250/300 EXC ZA)  
99,4 kg (250 XC, USA)  
101,6 kg (250 XC-W USA)  
99,8 kg (300 XC, USA)  
100,4 kg (300 XC-W, USA)  
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TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007»  
STANDARD ADJUSTMENT – FORK 250/300 EXC/XC-W  
STANDARD ADJUSTMENT – SHOCK ABSORBER 250/300 EXC/XC-W  
WP 4860 MXMA  
14187C04  
WP 5018 PDS MCC  
12187C04  
Compression adjuster  
Rebound adjuster  
Spring  
20  
Compression adjuster  
Rebound adjuster  
Spring  
15  
20  
25  
4,2 N/mm  
110 mm  
SAE 5  
76-250  
5 mm  
Spring preload  
Air chamber length  
Fork oil  
STANDARD ADJUSTMENT – FORK 250/300 XC/EXC SIX DAYS  
WP 4860 MXMA + PA  
STANDARD-EINSTELLUNG – GABEL 250/300 XC/EXC SIX DAYS  
WP 5018 PDS DCC  
14187C28  
12187C28  
Compression adjuster  
Rebound adjuster  
Spring  
18  
Compression adjuster Low Speed 15  
Compression adjuster High Speed 1,0 Umdrehungen offen  
20  
4,4 N/mm  
2 Umdrehungen offen  
110 mm  
Rebound adjuster  
Spring  
24  
Preload Adjuster  
Air chamber length  
Fork oil  
76-250  
5 mm  
Spring preload  
SAE 5  
TIGHTENING TORQUES – CHASSIS  
Collar screw, front wheel spindle  
Brake caliper, front  
53  
M24x1,5  
M8  
40 Nm  
Loctite 243 + 25 Nm  
14 Nm  
Brake disks  
M6  
Steering head screw top  
Steering head screw bottom  
M20x1,5  
M20x1,5  
M8  
10 Nm  
Loctite 243 + 60 Nm  
17 Nm  
Clamping screws, upper fork bridge (XC/EXC Six Days)  
Clamping screws, lower fork bridge (XC/EXC Six Days)  
Clamping screws, upper steering stem (XC/EXC Six Days)  
Clamping screws, upper fork bridge (EXC, XC-W)  
Clamping screws, lower fork bridge (EXC, XC-W)  
Clamping screws, fork stubs  
M8  
12 Nm  
M8  
Loctite 243 + 17 Nm  
20 Nm  
M8  
M8  
15 Nm  
M8  
15 Nm  
Collar nut, rear wheel spindle  
M20x1,5  
M16x1,5  
M8  
80 Nm  
Hexagon nut, swing arm bolt  
100 Nm  
Hexagon collar screw, handlebar clamp  
Allan head screw, handlebar support  
Shock absorber, top  
20 Nm  
M10  
M12  
M12  
M8  
Loctite 243 + 40 Nm  
Loctite 243 + 70 Nm  
Loctite 243 + 70 Nm  
Loctite 243 + 35 Nm  
10 Nm  
Shock absorber, bottom  
Sprocket screws  
Ball joint for push rod  
M6  
Engine mounting bolt  
M10  
M8  
60 Nm  
Engine brace  
33 Nm  
Screw adjusting ring spring preload shock abs.  
Spoke nipple  
M6  
8 Nm  
M4,5 / M5  
M6  
5 Nm  
Other screws on chassis  
10 Nm  
M8  
25 Nm  
M10  
M6  
45 Nm  
Other collar nuts on chassis  
15 Nm  
M8  
30 Nm  
M10  
50 Nm  
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TECHNICAL SPECIFICATIONS – ENGINE 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007»  
ENGINE  
250 XC  
250 XC-W/EXC SIX DAYS/EXC 300 XC  
300 XC-W/EXC SIX DAYS/EXC  
Design  
Liquid-cooled single-cylinder two-stroke engine  
with KTM Twin Valve Control exhaust system and KTM Torque Chamber  
Piston displacement  
Bore / stroke  
Fuel  
249 ccm  
293.15 ccm  
72 / 72 mm (2.84 / 2.84 in)  
66.4 / 72 mm (2.62 / 2.84 in)  
unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil (Motorex Cross Power 2T)  
1:40 – 1:60 when using high grade, two- stroke oil.  
When in doubt, please contact your importer or use 1:40 mix ratio to be on the safe side  
Oil / gasoline ratio  
Crankshaft bearing  
1 deep-groove ball bearing / 1 cylinder roller bearing  
Connecting rod bearing needle bearing  
Piston pin bearing  
Piston  
needle bearing  
cast piston  
Piston ring  
two plain compression rings  
0 + 0,1 mm (0 + 0.004 in)  
1,9 mm (0.074 in) BTDC  
NGK BR7 ES  
(upper edge piston-  
upper edge cylinder)  
Dimension „X“  
Ignition timing  
Spark plug  
Electrode gap  
0,60 mm  
height of the  
control flap  
Dimension „Z  
“
47,5 mm (1.87 in)  
5500/min  
48,5 mm  
5200/min  
TVC start open  
TVC fully open  
Primary drive  
Clutch  
7000/min (red spring), 7500/min (yellow spring), 7900/min (green spring)  
straight cut spur gears, primary ratio 26:72  
54  
multiple disc clutch in oil bath, hydraulically operated (Brake fluid DOT 5.1)  
5 speed, claw actuated  
Transmission  
Gear ratio  
1st gear  
14 : 30  
16 : 26  
18 : 24  
21 : 24  
22 : 21  
14 : 30  
17 : 26  
19 : 23  
20 : 20  
29 : 23  
14 : 30  
16 : 26  
18 : 24  
21 : 24  
22 : 21  
14 : 30  
17 : 26  
19 : 23  
20 : 20  
29 : 23  
2nd gear  
3rd gear  
4th gear  
5th gear  
Gear lubrication  
Available chain sprockets  
Coolant  
0,7 liter Motorex Top Speed 4T 15W50  
13t / 14t for chain 5/8 x 1/4"  
1.2 litres, 50% anti freeze, 50% distilled water, at least -25 °C (-13 °F)  
Ignition system  
Generator output  
Ignition system  
Generator output  
Carburator  
KOKUSAN 2K-3 (EXC/EXC Six Days)  
12V / 110 W (EXC/EXC Six Days)  
KOKUSAN 2K-2 (XC/XC-W)  
KOKUSAN 2K-3 (EXC/EXC Six Days)  
12V / 110 W (EXC/EXC Six Days)  
KOKUSAN 2K-3 (XC/XC-W)  
12V 40 W (XC/XC-W)  
12V / 110 W (XC/XC-W)  
flat-slide carburetor, carburetor setting see table  
wet foam type air filter insert  
Air-filter  
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TECHNICAL SPECIFICATIONS – ENGINE 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007»  
TIGHTENING TORQUES - ENGINE  
Flange bolts - cylinder-head  
Nuts-cylinder base  
M 8  
27 Nm  
M 10  
M 12x1  
M 5  
35 Nm  
Flywheel collar nut  
60 Nm  
Exhaust control - retaining bracket  
Exhaust control - control flap  
Exhaust control - lever for control segment  
Shift roller - bearing retaining bracket  
Shift lock  
Loctite 243 + 7 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 6 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 6 Nm  
Loctite 270 + 10 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 10 Nm  
Loctite 243 + 10 Nm  
20 Nm  
M 6  
M 5  
M 6  
M 6  
Locking lever  
M 5  
Idler bolt  
M 6  
Kickstarter release plate  
Spring hanger for kickstarter  
Spring hanger on kickstarter  
Oil drain plug with magnet  
Water pump wheel  
M 6  
M 6  
M 6  
M 12x1.5  
M 5  
Loctite 243 + 6 Nm  
15 Nm  
Drain plug on water pump cover  
Nut for primary sprocket (LH thread)  
Nut for inner clutch hub  
Crankcase  
M 10  
M 18x1.5  
M 18x1.5  
M 6  
Loctite 270 + 150 Nm  
Loctite 270 + 100 Nm  
10 Nm  
55  
Spark plug  
M 14x1.25  
M 8  
25 Nm  
Kickstarter lever  
Loctite 243 + 25 Nm  
Loctite 243 + 14 Nm  
6 Nm  
Shift lever  
M 6  
Cover screws  
M 5  
Ignition / stator  
M 5  
Loctite 222 + 6 Nm  
10 Nm  
Other bolts  
M 6  
M 8  
25 Nm  
M 10  
45 Nm  
BASIC CARBURETOR SETTING  
250 XC USA/EU  
250+300 EXC EU  
300 EXC-E EU  
250+300 EXC AUS  
250+300 XC-W USA, 300 XC USA  
250+300 EXC Six Days EU  
250+300 EXC ZA  
Carburetor  
Keihin PWK 36S AG  
Keihin PWK 36S AG  
Keihin PWK 36S AG  
Carburetor setting mark FK0150  
3600B  
FK0140  
Main jet  
168 (170)  
160 (162,165)  
162 (165)  
Idling jet  
Starting jet  
Jet needle  
35  
35  
35  
85  
85  
85  
N8RG (N8RH)  
N3CJ (N8RH, N8RW)  
N8RH (N8RW)  
Needle position from top IV  
I
IV  
7
1
-
Throttle valve  
7
1
-
7
Air adjustment screw open  
Performance restrictor  
3,5  
slide stop 38 mm  
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INDEX »  
Page  
Page  
Engine characteristic 250/300 SX/XC/EXC . . . . . . . . .45  
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5  
Activating and deactivating display modes . . . . . . . . .7  
Adjusting the engine characteristic via the auxiliary spring .45  
Adjusting the engine characteristic via the ignition curve . .44  
Adjusting the free travel at the hand brake lever . . . . .33  
Basic suspension setup for the weight of the driver . . .25  
Bleeding the hydraulic clutch . . . . . . . . . . . . . . . . .42  
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .27  
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .43  
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .31  
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31  
Changing the basic position of the foot brake pedal . .34  
Changing the fork offset (caster) (XC, EXC Six Days) .28  
Changing the original position of the clutch lever . . . .41  
Changing the spring preload on the telescopic fork  
Exhaust system  
41  
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Filler cap (XC, XC-W) . . . . . . . . . . . . . . . . . . . . . . . .12  
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
General information about KTM disc brakes . . . . . . . .32  
General tips and warnings for starting the motorcycle . .16  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . .11  
How to change the handlebar position . . . . . . . . . . . .30  
Indicator lamps (EXC) . . . . . . . . . . . . . . . . . . . . . . .10  
Instructions for your first ride . . . . . . . . . . . . . . . . . .16  
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Maintenance work on chassis and engine . . . . . . . . . .24  
Operation instruments . . . . . . . . . . . . . . . . . . . . . . . .5  
Periodic maintenance schedule . . . . . . . . . . . . . . . .20  
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24  
Radiator cover for the cold season . . . . . . . . . . . . . . .39  
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .14  
Rebound damping of shock absorber . . . . . . . . . . . . .15  
Refilling the front brake fluid reservoir . . . . . . . . . . .33  
Refilling the rear brake fluid reservoir . . . . . . . . . . . .34  
Refilling/Bleeding the cooling system . . . . . . . . . . . .40  
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .27  
Replacing the battery of the digital speedometer . . . .38  
Replacing the front brake pads . . . . . . . . . . . . . . . . .34  
Replacing the headlight lamp/parking light lamp . . . .38  
Replacing the rear brake pads . . . . . . . . . . . . . . . . .35  
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16  
Serial number locations . . . . . . . . . . . . . . . . . . . . . . .5  
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . .10  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Shock absorber compression damping (XC-W/EXC) . . .15  
Spring preload of the fork (XC, EXC Six Days . . . . . . .14  
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18  
Starting when the engine is cold . . . . . . . . . . . . . . . .18  
Starting when the engine is warm . . . . . . . . . . . . . . .18  
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .19  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47  
Technical Specifications – Chassis 125 / 200 . . . . . .48  
Technical Specifications – Chassis 250 / 300 . . . . . .52  
Technical Specifications – Engine 125 / 200 . . . . . . .50  
Technical Specifications – Engine 250 / 300 . . . . . . .54  
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .37  
What to do when the engine is „flooded“ . . . . . . . . . .18  
What you should check before each start . . . . . . . . . .17  
(XC, EXC Six Days models) . . . . . . . . . . . . . . . . . . . .26  
Changing the spring preload on the telescopic fork  
(XC-W/EXC models) . . . . . . . . . . . . . . . . . . . . . . . . .26  
Changing the spring preloading of the shock absorber . .24  
Changing the transmission oil (125/200) . . . . . . . . . .46  
Changing the transmission oil (250/300) . . . . . . . . . .46  
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .30  
Check transmission oil level (125/200) . . . . . . . . . . .46  
Check transmission oil level (250/300) . . . . . . . . . . .46  
Check/set distance of the magnetic sensor . . . . . . . . .38  
Checking and adjusting the steering head bearing . . .29  
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37  
Checking the basic setup of the telescopic fork . . . . .26  
Checking the brake fluid level - front brake . . . . . . . .33  
Checking the coolant level . . . . . . . . . . . . . . . . . . . .39  
Checking the float level . . . . . . . . . . . . . . . . . . . . . .44  
Checking the front brake pads . . . . . . . . . . . . . . . . .33  
Checking the oil level of the hydraulic clutch . . . . . . .41  
Checking the rear brake fluid level . . . . . . . . . . . . . .34  
Checking the rear brake pads . . . . . . . . . . . . . . . . . .35  
Checking the shock absorber and spring . . . . . . . . . .25  
Choke knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47  
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .40  
Cleaning the dust sleeves of the telescopic fork . . . . .27  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . .11  
Compression damping of fork . . . . . . . . . . . . . . . . . .14  
Compression damping of shock absorber (XC-W, EXC) . .15  
Conservation for winter operation . . . . . . . . . . . . . . .47  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .39  
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31  
Damping action during compression of shock  
56  
absorber (XC, EXC Six Days) . . . . . . . . . . . . . . . . . . .14  
Determining the riding sag of the shock absorber . . . .25  
Determining the static sag of the shock absorber . . . .25  
Dismounting and mounting the front wheel . . . . . . . .35  
Dismounting and mounting the rear wheel . . . . . . . . .36  
Draining the float chamber of the carburetor . . . . . . .44  
Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . .17  
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .6  
Emergency OFF switch (Australia) . . . . . . . . . . . . . . .11  
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SCHALTPLAN » WIRING DIAGRAMM  
headlight  
multi-func.-digital-speedometer  
driving light lamp  
flasher control lamp  
front  
brake switch  
C_CX/2  
C_CZ/3  
C_CY/3  
C_DB/4  
C_DA/4  
C_CW/2  
C_AK1/2  
C_CW3/2  
C_CX3/2  
C_DG/4  
C_BP/4  
C_CW2/2  
C_CX2/2  
C_AH1/2  
1
wh  
bu  
gn  
ye  
re  
br  
ye-bl  
br  
C_BA/1  
C_BF/1  
bl-wh  
ye-re  
br  
ye-re  
br  
ye-re  
or  
bu-wh  
br  
C
D
I
ye-bl  
re-wh  
re-bl  
gn  
or  
pu  
bl  
re  
br  
C_AY/1  
C_BJ/1  
ye-re  
br  
or  
bl-wh  
re  
gn  
re-bl  
re-wh  
ye  
wh  
ye  
wh-gn  
C_BG1/3  
C_AJ1/3  
C_CA/4  
C_CE/4  
C_CX/2  
C_CX1/2  
C_CW1/2  
C_AJ/3  
C_BG/3  
C_CW/2  
rear light/brakelight  
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SCHALTPLAN » WIRING DIAGRAMM  
2
light switch  
high/low beam switch  
cable  
color  
bu ye gn  
horn switch  
wh  
cable  
color  
LIGHT OFF  
re  
br  
P.LIGHT  
LO  
HORN  
OFF  
HI  
P.LIGHT  
flasher switch  
brake switch  
gn-  
cable  
cable  
harness  
ye  
harness  
or pu bl  
wh  
cable  
switch  
TURN L  
bl  
bl  
TURN R  
pushed  
OFF  
unpushed  
stop switch  
ye-  
bl  
cable  
harness  
cable  
switch  
br  
br  
ye-  
bl  
pushed  
unpushed  
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SCHALTPLAN » WIRING DIAGRAMM  
headlight  
multi-func.-digital-speedometer  
3
br  
wh  
wh  
ye  
bl-wh  
bu-wh  
ye-bl  
C
br  
ye-bl  
re-wh  
re-bl  
D
gn  
re  
I
br  
re  
gn  
re-bl  
re-wh  
ye  
rear light/brakelight  
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SCHALTPLAN » WIRING DIAGRAMM  
headlight  
multi-func.-digital-speedometer  
4
br  
wh  
wh  
ye  
bl-wh  
bu-wh  
ye-bl  
C
br  
ye-bl  
re-wh  
re-bl  
D
gn  
re  
I
br  
re  
gn  
re-bl  
re-wh  
ye  
wh  
rear light/brakelight  
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SCHALTPLAN » WIRING DIAGRAMM  
ENGLISH  
DEUTSCH  
ITALIANO  
Capacitor  
Kondensator  
Condensatore  
CDI  
CDI  
CDI  
Driving light lamp  
Flasher relay  
Flasher switch  
Front brake switch  
Flasher control lamp  
Generator  
Fernlichtkontrolle  
Blinkerrelais  
Blinkerschalter  
vorderer Bremslichtschalter  
Blinkerkontrolle  
Generator  
Spia abbagliante  
Relè indicatori  
Deviatore indicatori di direzione  
Interruttore luce ant. di stop  
spia lampeggiatori  
Generatore  
Handle bar switch for -multi-func.-digital-speedometer Lenkerschalter für Kombiinstrument  
Interruttore sul manubrio per tachimetro multifunzione  
Headlight  
High / low beam switch  
Horn  
Scheinwerfer  
Auf-Abblendschalter  
Hupe  
Faro anteriore  
Commutatore abbagliante/anabbagliante  
Avvisatore acustico  
5
Horn switch  
Ignition coil  
Left front flasher  
Left rear flasher  
Multi-func.-digital-speedometer  
Pick up  
Hornschalter  
Zündspule  
linker vorderer Blinker  
linker hinterer Blinker  
Multifunktionsdigitaltacho  
Impulsgeber  
Interruttore avvisatore acustico  
Bobina d‘accensione  
Indicatore ant. sx  
Indicatore post. sx  
Tachimetro digitale multifunzione  
Pick up  
Position light  
Standlicht  
luce di posizione  
Rear brake switch  
Rear light / brakelight  
Regulator-rectifier  
Right front flasher  
Right rear flasher  
Speed sensor  
hinterer Bremslichtschalter  
hinteres Begrenzungslicht / Bremslicht Luce post. di posizione/stop  
Regelgleichrichter  
rechter vorderer Blinker  
Rechter hinterer Blinker  
Geschwindigkeitssensor  
Stop schalter  
Interruttore luce post. di stop  
Regolatore-raddrizzatore  
Indicatore ant. dx  
Indicatore post. dx  
Sensore velocità  
Stop switch  
Interruttore d‘emergenza  
CABLE COLOURS  
bl: black  
ye: yellow  
bu: blue  
KABELFARBEN  
bl: schwarz  
ye: gelb  
CAVO COLORATO  
bl: nero  
ye: giallo  
bu: blau  
bu: blu  
gr: green  
re: red  
gr: grün  
re: rot  
gr: verde  
re: rosso  
wh: white  
br: brown  
or: orange  
pi: pink  
wh: weiß  
br: braun  
or: orange  
pi: rosa  
wh: bianco  
br: marrone  
or: arancione  
pi: rosa  
gr: grey  
gr: grau  
gr: grigio  
pu: purple  
pu: violett  
pu: violetto  
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SCHALTPLAN » WIRING DIAGRAMM  
ENGLISH  
FRANCAIS  
ESPANOL  
Capacitor  
Condensateur  
Condensador  
CDI  
CDI  
CDI  
Driving light lamp  
Flasher relay  
Flasher switch  
Front brake switch  
Flasher control lamp  
Generator  
Temion feu route  
Relais de clignotants  
Bouton de clignotants  
Contacteur de frein avant  
Temion de clignoteur  
Genrateur  
Lampara aviso luces largas  
Relé de la luz intermitente  
Interruptor de la luz intermitente  
Interruptor de luz del freno delantero  
Lampara aviso intermitentes  
Generador  
Handle bar switch for multi-func.-digital-speedometer Contacteur au guidon pour ordinateur de bord  
Interruptor de manillar para instrumento combinado  
Faro  
Headlight  
Phare  
6
High / low beam switch  
Horn  
Horn switch  
Contacteur code/phare  
Avertisseur sonore  
Bouton d’avertisseur sonore  
Bobine d’allumage  
Clignotant avant gauche  
Clignotant arrière gauche  
Ordinateur de bord  
Capteur d’allumage  
Feu de position  
Interruptor de encender/apagar la luz larga  
Cláxon  
Interruptor del cláxon  
Ignition coil  
Bobina de encendido  
Left front flasher  
Left rear flasher  
Multi-func.-digital-speedometer  
Pick up  
Luz intermitente izquierda delantera  
Luz intermitente izquierda trasera  
Velocímetro digital multifuncional  
Generador de impulsos  
Luz de posicion  
Position light  
Rear brake switch  
Rear light / brakelight  
Regulator-rectifier  
Right front flasher  
Right rear flasher  
Speed sensor  
Contacteur de frein arrière  
Feu rouge/stop  
Interruptor de luz del freno trasero  
Luces de parqueo traseras /luces de freno  
Regulador rectificador  
Luz intermitente derecha delantera  
Luz intermitente derecha trasera  
Sensor de velocidad  
Régulateur/redresseur  
Clignotant avant droit  
Clignotant arrière droit  
Capteur de vitesse  
Contacteur stop  
Stop switch  
Interruptor parada  
CABLE COLOURS  
bl: black  
ye: yellow  
bu: blue  
COULEUR DE CABLE  
bl: noir  
ye: jaune  
bu: bleu  
COLOR DE CABLE  
bl: negro  
ye: amarillo  
bu: azul  
gr: green  
re: red  
wh: white  
br: brown  
or: orange  
pi: pink  
gr: vert  
gr: verde  
re: rojo  
re: rouge  
wh: blanc  
br: brun  
or: orange  
pi: rose  
wh: blanco  
br: marron  
or: naranja  
pi: rosado  
gr: gris  
gr: grey  
gr: gris  
pu: purple  
pu: violet  
pu: violeta  
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VERGASERTABELLE » CARBURETOR TABLE  
VERGASERREGULIERUNG  
CARBURETOR SETTING  
125 EXC SIX DAYS/EXC 2007  
KEIHIN PWK 36S AG  
MEERESHÖHE  
ALTITUDE  
TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C  
TEMPERATURE  
-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  
2
40  
LSO ASO  
1
45  
1,5  
45  
1,5  
42  
2
38  
3000 m  
10000 ft  
7
LD  
IJ  
NOZF  
2
NADEL NEEDLE  
NOZE  
4
NOZE  
3
NOZF  
3
NOZG  
2
POS POS  
2301 m  
162  
7501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
170  
168  
165  
160  
1,5  
42  
1
48  
1
45  
1,5  
45  
2
40  
2
38  
2300 m  
7500 ft  
NOZF  
3
NADEL NEEDLE  
NOZE  
4
NOZE  
4
NOZE  
3
NOZF  
2
NOZG  
2
POS POS  
1501 m  
165  
5001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
170  
170  
168  
162  
160  
1,5  
45  
0,75  
48  
1
48  
1
45  
1,5  
42  
2
40  
1500 m  
5000 ft  
NOZE  
3
NADEL NEEDLE  
NOZD  
4
NOZE  
4
NOZE  
4
NOZF  
3
NOZF  
2
POS POS  
751 m  
168  
2501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
172  
170  
170  
165  
162  
1
45  
0,75  
50  
0,75  
48  
1
48  
1,5  
45  
1,5  
42  
750 m  
2500 ft  
NOZE  
4
170  
NADEL NEEDLE  
NOZD  
5
NOZD  
4
NOZE  
4
NOZE  
3
NOZF  
3
POS POS  
301 m  
1001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
175  
172  
170  
168  
165  
1
48  
0,75  
52  
0,75  
50  
0,75  
48  
1
45  
1,5  
45  
300 m  
1000 ft  
NOZE  
4
NADEL NEEDLE  
NOZC  
5
NOZD  
5
NOZD  
4
NOZE  
4
NOZE  
3
POS POS  
Meeresniveau  
Sea level  
170  
HD  
MJ  
178  
175  
172  
170  
168  
LSO = Luftregulierschraube offen  
LD = Leerlaufdüse  
POS = Nadel Clip Position von oben  
HD = Hauptdüse  
ASO = Air screw open from fully-seated  
IJ = Idling jet  
POS = Needle clip position from top  
MJ = Main jet  
1
3
2
4
5
NICHT FÜR STRASSENBETRIEB  
NOT FOR HIGHWAY USE  
Kraftstoff: Super Bleifrei ROZ 95  
Fuel: unleaded fuel with at least RON 95  
USA = Premium PON 91  
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder.  
Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne.  
WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS-  
SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ!  
EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car-  
buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you.  
CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON  
PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED!  
Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste,  
oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi.  
MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI-  
CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA!  
Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres  
mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures.  
QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI-  
QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT.  
Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del  
motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.  
SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS  
QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!  
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VERGASERTABELLE » CARBURETOR TABLE  
VERGASERREGULIERUNG  
CARBURETOR SETTING  
200 XC-W/XC USA, 200 EXC ZA 2007  
KEIHIN PWK 36S AG  
MEERESHÖHE  
ALTITUDE  
TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C  
TEMPERATURE  
-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  
1,5  
40  
LSO ASO  
1
42  
1
42  
1,5  
42  
2
40  
3000 m  
10000 ft  
8
LD  
IJ  
NOZH  
2
NADEL NEEDLE  
NOZF  
4
NOZG  
3
NOZH  
3
NOZI  
2
POS POS  
2301 m  
155  
7501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
162  
160  
158  
152  
1,5  
42  
1
45  
1
42  
1
42  
1,5  
40  
2
40  
2300 m  
7500 ft  
NOZH  
3
NADEL NEEDLE  
NOZF  
4
NOZF  
4
NOZG  
3
NOZH  
2
NOZI  
2
POS POS  
1501 m  
158  
5001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
162  
162  
160  
155  
152  
1
42  
1
48  
1
45  
1
42  
1,5  
42  
1,5  
40  
1500 m  
5000 ft  
NOZG  
3
NADEL NEEDLE  
NOZF  
4
NOZF  
4
NOZF  
4
NOZH  
3
NOZH  
2
POS POS  
751 m  
160  
2501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
165  
162  
162  
158  
155  
1
42  
1
48  
1
48  
1
45  
1
42  
1,5  
42  
750 m  
2500 ft  
NOZF  
4
162  
NADEL NEEDLE  
NOZE  
4
NOZF  
4
NOZF  
4
NOZG  
3
NOZH  
3
POS POS  
301 m  
1001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
168  
165  
162  
160  
158  
1
45  
0,75  
50  
1
48  
1
48  
1
42  
1
42  
300 m  
1000 ft  
NOZF  
4
NADEL NEEDLE  
NOZE  
5
NOZE  
4
NOZF  
4
NOZF  
4
NOZG  
3
POS POS  
Meeresniveau  
Sea level  
162  
HD  
MJ  
170  
168  
165  
162  
160  
LSO = Luftregulierschraube offen  
LD = Leerlaufdüse  
POS = Nadel Clip Position von oben  
HD = Hauptdüse  
ASO = Air screw open from fully-seated  
IJ = Idling jet  
POS = Needle clip position from top  
MJ = Main jet  
1
3
2
4
5
NICHT FÜR STRASSENBETRIEB  
NOT FOR HIGHWAY USE  
Kraftstoff: Super Bleifrei ROZ 95  
Fuel: unleaded fuel with at least RON 95  
USA = Premium PON 91  
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder.  
Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne.  
WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS-  
SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ!  
EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car-  
buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you.  
CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON  
PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED!  
Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste,  
oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi.  
MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI-  
CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA!  
Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres  
mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures.  
QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI-  
QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT.  
Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del  
motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.  
SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS  
QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!  
Download from Www.Somanuals.com. All Manuals Search And Download.  
VERGASERTABELLE » CARBURETOR TABLE  
VERGASERREGULIERUNG  
CARBURETOR SETTING  
200 EXC, XC 2007  
KEIHIN PWK 36S AG  
MEERESHÖHE  
ALTITUDE  
TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C  
TEMPERATURE  
-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  
1,5  
40  
LSO ASO  
1
42  
1
42  
1,5  
42  
2
40  
3000 m  
10000 ft  
9
LD  
IJ  
NOZH  
2
NADEL NEEDLE  
NOZF  
4
NOZG  
3
NOZH  
3
NOZI  
2
POS POS  
2301 m  
155  
7501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
162  
160  
158  
152  
1,5  
42  
1
45  
1
42  
1
42  
1,5  
40  
2
40  
2300 m  
7500 ft  
NOZH  
3
NADEL NEEDLE  
NOZF  
4
NOZF  
4
NOZG  
3
NOZH  
2
NOZI  
2
POS POS  
1501 m  
158  
5001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
162  
162  
160  
155  
152  
1
42  
1
48  
1
45  
1
42  
1,5  
42  
1,5  
40  
1500 m  
5000 ft  
NOZG  
3
NADEL NEEDLE  
NOZF  
4
NOZF  
4
NOZF  
4
NOZH  
3
NOZH  
2
POS POS  
751 m  
160  
2501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
165  
162  
162  
158  
155  
1
42  
1
48  
1
48  
1
45  
1
42  
1,5  
42  
750 m  
2500 ft  
NOZF  
4
162  
NADEL NEEDLE  
NOZE  
4
NOZF  
4
NOZF  
4
NOZG  
3
NOZH  
3
POS POS  
301 m  
1001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
168  
165  
162  
160  
158  
1
45  
0,75  
50  
1
48  
1
48  
1
42  
1
42  
300 m  
1000 ft  
NOZF  
4
NADEL NEEDLE  
NOZE  
5
NOZE  
4
NOZF  
4
NOZF  
4
NOZG  
3
POS POS  
Meeresniveau  
Sea level  
162  
HD  
MJ  
170  
168  
165  
162  
160  
LSO = Luftregulierschraube offen  
LD = Leerlaufdüse  
POS = Nadel Clip Position von oben  
HD = Hauptdüse  
ASO = Air screw open from fully-seated  
IJ = Idling jet  
POS = Needle clip position from top  
MJ = Main jet  
1
3
2
4
5
NICHT FÜR STRASSENBETRIEB  
NOT FOR HIGHWAY USE  
Kraftstoff: Super Bleifrei ROZ 95  
Fuel: unleaded fuel with at least RON 95  
USA = Premium PON 91  
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder.  
Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne.  
WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS-  
SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ!  
EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car-  
buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you.  
CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON  
PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED!  
Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste,  
oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi.  
MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI-  
CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA!  
Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres  
mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures.  
QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI-  
QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT.  
Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del  
motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.  
SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS  
QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!  
Download from Www.Somanuals.com. All Manuals Search And Download.  
VERGASERREGULIERUNG  
CARBURETOR SETTING  
250+300 XC-W USA, 300 XC USA, 250+300 EXC EU/AUS  
2007  
250+300 EXC SIX DAYS, 250+300 EXC ZA  
KEIHIN PWK 36S AG  
MEERESHÖHE  
ALTITUDE  
TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C  
TEMPERATURE  
-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  
1,5  
35  
LSO ASO  
LD IJ  
1
35  
1
35  
1,5  
35  
2
35  
3000 m  
10000 ft  
10  
N8RW  
2
NADEL NEEDLE  
N8RH  
4
N8RH  
3
N8RW  
3
N8RJ  
2
POS POS  
2301 m  
158  
7501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
162  
162  
160  
155  
1,5  
35  
1
35  
1
35  
1
35  
1,5  
35  
2
35  
2300 m  
7500 ft  
N8RW  
3
NADEL NEEDLE  
N8RH  
4
N8RH  
4
N8RH  
3
N8RW  
2
N8RJ  
2
POS POS  
1501 m  
160  
5001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
165  
162  
162  
158  
155  
1
35  
1
35  
1
35  
1
35  
1,5  
35  
1,5  
35  
1500 m  
5000 ft  
N8RH  
3
NADEL NEEDLE  
N8RG  
4
N8RH  
4
N8RH  
4
N8RW  
3
N8RW  
2
POS POS  
751 m  
162  
2501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
168  
165  
162  
160  
158  
1
35  
1
38  
1
35  
1
35  
1
35  
1,5  
35  
750 m  
2500 ft  
N8RH  
4
162  
NADEL NEEDLE  
N8RG  
5
N8RG  
4
N8RH  
4
N8RH  
3
N8RW  
3
POS POS  
301 m  
1001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
170  
168  
165  
162  
160  
1
35  
0,75  
40  
1
38  
1
35  
1
35  
1
35  
300 m  
1000 ft  
N8RH  
4
NADEL NEEDLE  
N8RG  
5
N8RG  
5
N8RG  
4
N8RH  
4
N8RH  
3
POS POS  
Meeresniveau  
Sea level  
165  
HD  
MJ  
172  
170  
168  
162  
162  
LSO = Luftregulierschraube offen  
LD = Leerlaufdüse  
POS = Nadel Clip Position von oben  
HD = Hauptdüse  
ASO = Air screw open from fully-seated  
IJ = Idling jet  
POS = Needle clip position from top  
MJ = Main jet  
1
3
2
4
5
NICHT FÜR STRASSENBETRIEB  
NOT FOR HIGHWAY USE  
Kraftstoff: Super Bleifrei ROZ 95  
Fuel: unleaded fuel with at least RON 95  
USA = Premium PON 91  
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder.  
Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne.  
WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS-  
SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ!  
EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car-  
buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you.  
CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON  
PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED!  
Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste,  
oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi.  
MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI-  
CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA!  
Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres  
mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures.  
QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI-  
QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT.  
Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del  
motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.  
SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS  
QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!  
Download from Www.Somanuals.com. All Manuals Search And Download.  
VERGASERTABELLE » CARBURETOR TABLE  
VERGASERREGULIERUNG  
CARBURETOR SETTING  
250 XC USA/EU 2007  
KEIHIN PWK 36S AG  
MEERESHÖHE  
ALTITUDE  
- 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 36°C 37°C bis 49°C  
TEMPERATUR  
TEMPERATURE  
-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  
1,75  
35  
LSO ASO  
1
35  
1
35  
1,5  
35  
2
35  
3000 m  
10000 ft  
11  
LD  
IJ  
N8RH  
2
NADEL NEEDLE  
N8RG  
4
N8RG  
3
N8RH  
3
N8RW  
2
POS POS  
2301 m  
162  
7501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
168  
168  
165  
160  
1,5  
35  
1
35  
1
35  
1
35  
1,75  
35  
2
35  
2300 m  
7500 ft  
N8RH  
3
NADEL NEEDLE  
N8RG  
4
N8RG  
4
N8RG  
3
N8RH  
2
N8RW  
2
POS POS  
1501 m  
165  
5001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
170  
168  
168  
162  
160  
1
35  
1
35  
1
35  
1
35  
1,5  
35  
1,75  
35  
1500 m  
5000 ft  
N8RG  
3
NADEL NEEDLE  
N8RF  
4
N8RG  
4
N8RG  
4
N8RH  
3
N8RH  
2
POS POS  
751 m  
168  
2501 ft  
HD  
LSO ASO  
LD IJ  
MJ  
172  
170  
168  
165  
162  
1
35  
1
38  
1
35  
1
35  
1
35  
1
35  
750 m  
2500 ft  
N8RG  
4
168  
NADEL NEEDLE  
N8RF  
5
N8RF  
4
N8RG  
4
N8RG  
3
N8RH  
3
POS POS  
301 m  
1001 ft  
HD  
LSO ASO  
LD IJ  
MJ  
175  
172  
170  
168  
165  
1
35  
0,75  
40  
1
38  
1
35  
1
35  
1
35  
300 m  
1000 ft  
N8RG  
4
NADEL NEEDLE  
N8RF  
5
N8RF  
5
N8RF  
4
N8RG  
4
N8RG  
3
POS POS  
Meeresniveau  
Sea level  
170  
HD  
MJ  
178  
175  
172  
168  
168  
LSO = Luftregulierschraube offen  
LD = Leerlaufdüse  
POS = Nadel Clip Position von oben  
HD = Hauptdüse  
ASO = Air screw open from fully-seated  
IJ = Idling jet  
POS = Needle clip position from top  
MJ = Main jet  
1
3
2
4
5
NICHT FÜR STRASSENBETRIEB  
NOT FOR HIGHWAY USE  
Kraftstoff: Super Bleifrei ROZ 95  
Fuel: unleaded fuel with at least RON 95  
USA = Premium PON 91  
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder.  
Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne.  
WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS-  
SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ!  
EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition to the car-  
buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you.  
CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. IT WILL BE ILLEGAL TO OPERATE THE MOTORCYCLE ON  
PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED!  
Modelli EXC: Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono richieste,  
oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi.  
MODIFICHE APPORTATE ALLA MOTOCICLETTA DETERMINANO LA PERDITA DELL'OMOLOGAZIONE STRADALE, L'IMPIEGO SU STRADE PUBBLI-  
CHE DI CONSEGUENZA È VIETATO E PASSIBILE DI PENA! INOLTRE DECADE LA COPERTURA ASSICURATIVA!  
Modèles EXC : Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d'autres  
mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures.  
QUAND ON EFFECTUE DES TRANSFORMATIONS SUR UNE MOTO, L'HOMOLOGATION N'EST PLUS VALABLE, L'UTILISATION SUR LA VOIE PUBLI-  
QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE D'ASSURANCE DISPARAÎT.  
Modelos EXC: Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia plena del  
motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gusto.  
SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS  
QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL SEGURO!  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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