2005r.pdf

BEDIENUNGSANLEITUNG 2005

125 SX, EXC

200 EXC

250 SX, EXC

300 MXC, EXC

OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART. NR. 3.211.38

IMPORTANT »

Please read this manual carefully and completely before going on your first ride. It contains a great deal

of information and advice which will help you use and handle your bike properly. In your own interest,

please pay particular attention to notices that are marked as follows:

– IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB!

– IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR-

CYCLE’S TRAFFIC SAFETY!

Please insert the serial numbers of your motorcycle in the boxes below

Frame number

Engine number

Key number

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.

extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

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. Before you go for your first ride, be sure

to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new

motorcycle and with its characteristics, even if this means that you will have to dedicate some of your

valuable time to this task. 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. 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 motor-

bike and should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chas-

sis and engine" must be performed by a KTM workshop. If maintenance work should become necessary

during a competition, it must be performed by a trained mechanic.

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.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding

these guidelines will significantly increase the life of your motorcycle. Have services carried out by a KTM

dealer so that your warranty claim remains intact.

Off-road 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.

We wish you a lot of fun when driving !

KTM-SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

IMPORTANT WARRANTY AND GUARANTEE INFORMATION »

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.

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 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 specifica-

tions must be used in accordance with the maintenance schedule.

No claims can be filed under the warranty for damage or consequential damage caused by manipulations

or conversions to the motorcycle.

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.

THE SX/SXS AND MXC 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 and MXC 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.

In accordance with the international quality management ISO 9001 standard, KTM uses

quality assurance processes that lead to the highest possible product quality.

TABLE OF CONTENTS »

Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

Page

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .29

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . .30

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .30

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

General information about KTM disc brakes . . . . . . .31

Adjusting the free travel at the hand brake lever . . . .32

Checking the brake fluid level - front brake . . . . . . . .32

Refilling the front brake fluid reservoir . . . . . . . . . . .32

Checking the front brake pads . . . . . . . . . . . . . . . . .32

Replacing the front brake pads . . . . . . . . . . . . . . . . .33

Changing the basic position of the foot brake pedal . .33

Checking the rear brake fluid level . . . . . . . . . . . . . . .33

Refilling the rear brake fluid reservoir . . . . . . . . . . . .33

Checking the rear brake pads . . . . . . . . . . . . . . . . . .34

Replacing the rear brake pads . . . . . . . . . . . . . . . . .34

Dismounting and mounting the front wheel . . . . . . . .34

Dismounting and mounting the rear wheel . . . . . . . . .35

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .36

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .36

Replacing the battery of the digital speedometer . . . .36

Check/set distance of the magnetic sensor . . . . . . . .37

Replacing the headlight lamp/parking light lamp . . . .37

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Radiator cover for the cold season . . . . . . . . . . . . . .38

Checking the coolant level . . . . . . . . . . . . . . . . . . . .38

Refilling/Bleeding the cooling system . . . . . . . . . . . .39

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .39

Changing the original position of the clutch lever . . . .40

Checking the oil level of the hydraulic clutch . . . . . .40

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .40

Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Cleaning the spark arrestor (EXC USA) . . . . . . . . . . .41

Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .41

Draining the float chamber of the carburetor . . . . . . .42

Checking the float level . . . . . . . . . . . . . . . . . . . . . .42

Engine characteristic 250/300 SX/MXC/EXC . . . . . . .43

Check transmission oil level (125/200) . . . . . . . . . . .44

Changing the transmission oil (125/200) . . . . . . . . .44

Check transmission oil level (250/300) . . . . . . . . . . .44

Changing the transmission oil (250/300) . . . . . . . . .44

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .5

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .6

Indicator lamps (EXC) . . . . . . . . . . . . . . . . . . . . . . . .10

Short circuit button (SX) . . . . . . . . . . . . . . . . . . . . .11

Combination switch (EXC) . . . . . . . . . . . . . . . . . . . .11

Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . .11

Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Emergency OFF switch (Australia) . . . . . . . . . . . . . .11

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Damping action during compression of shock absorber (SX) . .14

Compression damping of shock absorber (MXC, EXC) . .15

Rebound damping of shock absorber (SX, MXC, EXC) . .15

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

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .20

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .23

Changing the spring preload of the shock absorber . . .23

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Basic suspension setup for the weight of the driver . .24

Checking the shock absorber and spring . . . . . . . . . .24

Determining the static sag of the shock absorber . . . .24

Determining the riding sag of the shock absorber . . . .24

Checking the basic setup of the telescopic fork . . . . .25

Changing the spring preload on the telescopic fork . . .25

Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .26

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .26

Cleaning the dust sleeves of the telescopic fork . . . . .26

Changing the fork offset (SX) . . . . . . . . . . . . . . . . . .27

Checking and adjusting the steering head bearing . . .28

How to change the handlebar position . . . . . . . . . . .29

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .45

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . . .45

TECHNICAL SPECIFICATIONS – CHASSIS 125 / 200 . .46

TECHNICAL DATA – ENGINE 125 / 200 . . . . . . . . . . .48

TECHNICAL SPECIFICATIONS – CHASSIS 250 / 300 . .50

TECHNICAL DATA – ENGINE 250 / 300 . . . . . . . . . . . .52

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

WIRING DIAGRAM, CARBURETOR TABLE . . . . .APPENDIX

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