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KTM 125 200 250 300 SX Mxc Exc - 2003

Manual

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Comments to date: 8. Page 1 of 1. Average Rating:
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Douxenfant 2:18am on Thursday, March 11th, 2010 
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Documents

doc0

Anzeigemodus SPEED/ODO The SPEED/ODO mode shows the speed and the total kilometers traveled. When the front wheel stops turning, the display will automatically change to the SPEED/H mode. The information will disappear in the display when the front wheel stops turning for 1 minute. NOTE: A Tripmaster switch is available as an accessory and enhances the electronic speedometer by providing the following functions: 2x Tripmaster 2x chronometer for the lap time Average speed Maximum speed Clock Display in miles

Tripmaster switch

The switch has three buttons: MODE, + (plus) and (minus).
NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT.
Electronic speedometer functions provided by the Tripmaster switch
The display modes on the electronic speedometer will change in the following order. If not, please read the chapter "ACTIVATING AND DEACTIVATING THE DISPLAY MODE."
ODO displays the kilometers or miles traveled. The displayed figure cannot be cleared. + BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the next mode
SPEED/MAX display mode MAX displays the maximum speed. It is always active. + BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the MAX figure to 0
SPEED/LAP display mode LAP displays the stopped lap time in hours, minutes and seconds. Starts and stops the stop watch. The lap time is not reset to 0. Stops the running stop watch, stores the lap time and restarts the stop watch. The time is reset to 0. A total of 10 lap times can be stored and read in the SPEED/LAP display mode. To clear all of the stored lap times, hold the MODE button for 3 seconds in the SPEED/LAP mode. press the MODE BUTTON to change to the next mode If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all stored lap times to 0 LAP/LAP display mode The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display. If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the stored lap times. + BUTTON changes to the next lap time. BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the next mode + BUTTON BUTTON
SPEED/ODO display mode SPEED displays the speed in KPH or MPH. The displayed figure cannot be cleared.
SPEED/CLK (clock) display mode CLK will display time in hours, minutes and seconds. + BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to set the time in the menu (see SETTING THE CLOCK)

SPEED/H (hours) display mode When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. + BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the SETUP mode (see REVEALING/CONCEALING functions).
SPEED/TRP1 (trip 1) display mode The TRP1 trip meter is always active and counts to 999.9. It is used to measure the length of a trip or the distance between 2 refueling stops. TRP1 is linked to AVS1 and STP1. The calculation of these figures is activated 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 TRP1, AVS1 and STP1 figures are automatically reset to 0 after passing 999.9. + BUTTON no function BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to automatically reset the TRP1, AVS1 and STP1 figures to 0. SPEED/AVS1 (average speed 1) display mode AVS1 is always active and shows the average speed based on the TRP1 and STP1 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 BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and STP1 figures to 0.
SPEED/STP1 (stop 1) display mode STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor. 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 BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and STP1 figures to 0.

no function no function stops LAP, stores LAP figure, resets LAP to 0 no function no function no function no function

X X X X X

LAP / LAP SPEED / CLK SPEED / H X SPEED / TRP1
next display mode next display mode next display mode next display mode
next display mode set clock menu display setup menu resets TRP1, STP1 and AVS1 to 0 resets TRP1, STP1 and AVS1 to 0 resets TRP1, STP1 and AVS1 to 0 resets TRP2 to 0 next display mode sets STP2 to 0

X SPEED / AVS1

no function

next display mode

SPEED / STP1
X SPEED / TRP2 X SPEED / AVS2 X SPEED / STP2
increases TRP2 figure no function starts / stops STP2
decreases TRP2 figure no function no function
next display mode next display mode next display mode
Short circuit button (SX)
The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-circuited.
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.
Headlamp switch (EXC USA)
In this model the headlamp is switched on with the pull switch 4.

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.
In this position, the ignition circuit is enabled; the engine should start.

Combination switch (EXC)

Filler cap
To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks.

Fuel tap

OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation 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 9 l tank. 1.3 l (0.32 US gallons) Reserve of the 11 l tank. 1.7 l (0.45 US gallons)

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. 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 MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES 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 CONTINUE 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 MOTORCYCLE 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. WARNING THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY - NO ADDITIONAL PASSENGER ALLOWED! NEITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY REGULATIONS AND SAFETY STANDARDS. USING THEM ON PUBLIC ROADS, HIGHWAYS, 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 performance limits. Apply low but changing loads for running-in. CAUTION ! DO NOT DRIVE AT FULL LOAD FOR THE (300 MILES) OR 5 HOURS! !

KILOMETERS

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 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism.

THAT CAN BE CARRIED OUT BY EXTRA ORDER at least once a year every 2 years or 20000 km
IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!

IMPORTANT CHECKS

MAINTENANCE

CARRIED

OUT BY THE After every cleaning

Once a year

Before each start
Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Empty and clean float chamber Check all control elements for smooth operation Check brake performance 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

For crosscountry use

RECOMMENDED INSPECTION OF THE 125/200/250/300 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP)
Check the reed-type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear 30 hours 45 hours 60 hours 90 hours 120 hours 135 hours
RECOMMENDED INSPECTION OF THE 125/200/250/300 EXC ENGINE USED FOR HOBBY- ENDURO BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP)
60 hours Check the reed-type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including roller and bearings for wear 90 hours 120 hours 180 hours 240 hours 270 hours

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 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.
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.

SPRING RATE

26 PDS 1218X756 PDS 1218X759

71-90/260 66-86/260

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. 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."
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). 510 mm Riding sag.90 mm The riding sag should lie between 90 and 105 mm. If the riding sag is less than 90 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. 71-90/260). The type number of the shock absorber is embossed on the bottom of the tank. The illustrations show which spring should be installed. The standard spring is shown in bold print (e.g. 1218X756). After installing a different spring, readjust the static sag to 35 mm ( 2 mm).

THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR MOTORCYCLE 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.

DOT 5.1

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 resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. ! CAUTION !

min. 3 mm

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 reservoir in a horizontal position, the brake fluid level should not drop below the middle of the glass. WARNING 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 AUTHORIZED KTM DEALER IMMEDIATELY.

min. 1 mm

Refilling the front brake fluid reservoir *
Loosen screws 2 and remove lid 3 and membrane 4. Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (e.g. Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws. Rinse off spilled or overflowing brake fluid with water. NEVER WARNING
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
CAUTION ! ! DONT 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.

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. WARNING 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 DONT PUT OFF HAVING YOUR BRAKE PADS CHANGED. CAUTION ! ! 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 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. 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.
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. Measured on the outside, the foot brake pedal must have 3-5 mm (0.120.20 in) of free play before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal).

6 3-5mm 5

CAUTION ! ! IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING, CAUSING THE REAR WHEEL TO BRAKE.THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES.
Checking the rear brake fluid level
The brake fluid reservoir of the rear disc brake is located on the right side of the motorcycle next to the kickstarter. The brake fluid level must not drop below the MlN marking when the vehicle is in an upright position. WARNING 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 AUTHORIZED KTM DEALER IMMEDIATELY.
Refilling the rear brake fluid reservoir *
For this purpose, it is recommended to remove screw 7 and to pull the brake fluid reservoir outwards. Now the screw cap 8 and the rubber boot 9 can be removed. Add brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1) until the brake fluid level reaches the MAX mark, then mount the screw cap together with the rubber boot. Return the brake fluid reservoir to its original position and fix it with the screw. The connecting hose between the reservoir and the foot brake cylinder must be carefully positioned, preventing kinks and keeping a safe distance between the hose and the exhaust pipe. Spilled brake fluid must be rinsed off with water. NEVER WARNING

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.
To install the front wheel, lift it into the fork, position and mount the axle shaft. Mount the collar nut 5, tighten the clamping screws 6 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. Only after this has been accomplished, tighten the clamp screws on both fork legs with 10 Nm(7 ft. lbs).
YOU DONT 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. IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
Dismounting and mounting the rear wheel
Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Loosen the collar nut 1, remove chain tensioner 2, hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held. Push the rear wheel as far forward as possible, take the chain from the chain wheel and carefully take the rear wheel out of the swingarm. CAUTION ! ! 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. IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND
COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM JAMMING.
The rear wheel is remounted in the reverse order. Before tightening the collar nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain tensioners lie on the tension screws.
YOU DONT 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 PRESSURE 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.

Insert a new lamp such that the noses 6 engage in the recesses 7.When doing so, do not touch the glass body of the lamp so that it remains free from fat. Engage retaining clip, mount rubber cap and connector. If the parking-light lamp is to be replaced, simply insert it in the holder. Reinsert parking-light lamp together with the holder. Engage the bottom end of the headlamp mask at the retaining pins and fix the mask by means of the rubber bands.

Cooling system

The water pump in the engine circulates the cooling liquid. However, the cooling 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 55C, the thermostat opens and the cooling liquid is also pumped through the two aluminum radiators. 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 WARNING
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 HAZARD. 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. 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.
A mixture of 40% antifreeze liquid and 60% water is used as coolant. However, the antifreeze protection must be at least -25 C (-13 F). This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water. ! FOR THE COOLING SYSTEM, ADVANCE COOLANT). USING CAUTION !
USE ONLY WITH HIGH-GRADE ANTIFREEZE (E.G. SHELL LOWER-GRADE ANTIFREEZE AGENTS CAN CAUSE CORRO-
SION 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.

RICHER

LEANER

NOZD NOZE NOZF NOZG NOZH

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 distance 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.
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 WARNING
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 SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE. IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES, CONSULT A DOCTOR IMMEDIATELY. 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).

JET NEEDLE TYPE

RANGE OF ACTION
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 opening when the motorcycle is in an upright position. If necessary, remove the plug 2 and top up with oil (see technical data engine). ! TRANSMISSION CAUTION !
AND CLUTCH WILL BE SUBJECTED TO EXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL. USE ONLY HIGH-GRADE OIL.
Changing the transmission oil (125/200) *
To change the gear oil warm up the engine and park the motorcycle on a horizontal 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 (see technical data- engine), mount the plug 2 and check the engine for leaks. ! TRANSMISSION CAUTION !

125 SX / EXC,

200 SX 200 MXC 200 EXC

200 SX / MXC / EXC 2003

125 SX

Wheel travel front/rear

Rear suspension

Front brake

Rear brake
Brake discs Front tires Front tires USA Air pressure offroad Air pressure road driver only Rear tires Rear tires USA Air pressure offroad Air pressure road driver only Fuel tank capacity 90/90 - 21 54R 80/100 - 2151M 1.0 bar (14psi) 1.5 bar (21psi) 120/90 - 18 65R 100/100 - 18 59M 1.0 bar (14psi) 2.0 bar (28psi) 9 liters (2.3 US Gallons) 14:38t 13:50t
80/100 - 2151M 80/100 - 2151M 1.0 bar (14psi) 100/90 - 19 57M 100/90 - 19 57M 1.0 bar (14psi)
7.5 liters (2 US Gallons)
Final drive ratio Final drive ratio USA

13:50t 13:50t

Available final sprockets

Steering head angle

Wheel base

Seat height, unloaded

Ground clearance, unloaded
90/90 - 21 54R 80/100 - 2151M 1.0 bar (14psi) 1.5 bar (21psi) 120/90 - 18 65R 100/100 - 18 59M 1.0 bar (14psi) 2.0 bar (28psi) 9/11 liter (2.3/2.9 US gallons) 14:45t / 14:48t 14:48t
STANDARD ADJUSTMENT - FORK
WP 4860 MXMA 1418X725 Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil 4.0 N/mm 5 mm (0.2in) 100 mm (5.1in) SAE 5 WP 4860 MXMA 1418X20 3.8 N/mm 5 mm (0.2in) 110 mm (4,3in) SAE 5
STANDARD ADJUSTMENT - SHOCK ABSORBER
WP 5018 PDS-DCC 1218X756 Compression adjuster Rebound adjuster Spring Spring preload 17 LS (low speed) 2 HS (high speed) 28 71-90/mm (0.2 in) 28 66-86/mm (0.2 in) WP 5018 PDS-MCC 1218X757 17
Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge 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 Shock absorber, bottom Sprocket screws Ball joint for push rod Engine mounting bolt Engine brace Screw adjusting ring spring preload shock abs. Spoke nipple Other screws on chassis
M 24x1,5 M8 M 6 10.9 M6 M8 M8 M8 M 20x1,5 M 14x1,5 M8 M 10 M 12 M 12 M8 M6 M 10 M8 M6 M4,5 /M5 M6 M8 M 10 M6 M8 M 10
40 Nm Loctite 243 + 25 Nm Loctite 243 + 15 Nm Loctite 243 + 15 Nm 20 Nm 15 Nm 10 Nm 80 Nm 100 Nm 20 Nm Loctite 243 + 40 Nm 60 Nm 60 Nm Loctite 243 + 35 Nm Loctite 243 + 10 Nm 45 Nm 33 Nm 8 Nm 5 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm
Other collar nuts on chassis
TIGHTENING TORQUES - CHASSIS

Keihin PWK 38 AG (172,178) 45 (48) 85 NOZ H (NOZ I) III 6.5 1.5
Page Adjusting the free travel at the hand brake lever..32 Adjusting the spring preload on the fork (SX)..28 Basic suspension setup for the weight of the driver.26 Bleeding of the hydraulic clutch..41 Braking...19 Breather plug front fork..25 Carburetor adjustment...42 Chain maintenance...30 Chain wear...30 Changing the basic position of the foot brake pedal.33 Changing the original position of the clutch lever.41 Changing the spring preload on the telescopic fork (MXC/EXC models).27 Changing the spring preload on the telescopic fork (SX models)27 Changing the spring preloading of the shock absorber.28 Changing the transmission oil (125/200)..44 Changing the transmission oil (250/300)..44 Chassis number...5 Checking and adjusting the steering head bearing.24 Checking the basic setup of the telescopic fork.27 Checking the brake fluid level - front brake.32 Checking the chain tension..29 Checking the coolant level..39 Checking the float level..43 Checking the front brake pads..32 Checking the oil level of the hydraulic clutch..41 Checking the rear brake fluid level..33 Checking the rear brake pads...34 Checking the shock absorber and spring..26 Checking the spoke tension..36 Checking the transmission oil level (125/200).44 Checking the transmission oil level (250/300).44 Checking/setting the distance of the magnetic sensor.38 Choke knob..12 Cleaning....45 Cleaning the air filter...40 Cleaning the dust sleeves of the telescopic fork.25 Cleaning the spark arrestor (EXC USA)..42 Clutch lever...5 Combination switch (EXC)..11 Compression damping of fork..14 Compression damping of shock absorber (MXC, EXC).15 Compression damping of shock absorber (SX)..14 Conservation for winter operation..45 Cooling system..39 Correct the chain tension..29 Determining the riding sag of the shock absorber..26 Determining the static sag of the shock absorber.26 Dismounting and mounting the front wheel..34 Dismounting and mounting the rear wheel..35 Draining the float chamber of the carburetor..43 Driving instructions...17 Electronic speedometer..6 Electronic speedometer, indicator lamp (EXC)..6 Emergency OFF switch (Australia)..11 Page Engine number, engine type (125/200)..5 Engine number, engine type (250/300)..5 Exhaust system..41 Filler cap....12 Flasher switch...11 Foot brake pedal...13 Fuel tap...12 General information about KTM disc brakes..31 General tips and warnings for starting the motorcYcle.16 Hand brake lever...5 Headlamp switch (EXC USA)..11 How to change the handlebar position.25 Index....54 Instructions for your first ride...16 Kickstarter...13 Maintenance work on chassis and engine..24 Operation instruments..5 Periodic lubrication - and maintenance-schedule..20 Pivot bearing...28 Radiator cover for the cold season..39 Rebound damping of fork...14 Rebound damping of shock absorber (SX, MXC, EXC).15 Refilling / Bleeding the cooling system..40 Refilling the front brake fluid reservoir..32 Refilling the rear brake fluid reservoir..33 Refueling, fuel...19 Replacing fork springs..27 Replacing the battery of the electronic speedometer.36 Replacing the front brake pads..33 Replacing the headlight lamp...38 Replacing the rear brake pads..34 Running in...16 Serial number locations..5 Setting the clock of the electronic speedometer.37 Shift lever...12 Shifting, Riding..18 Short circuit button (SX)..11 Side stand...13 Starting off...18 Starting when the engine is cold...18 Starting when the engine is warm..18 Steering lock...13 Stopping, Parking...19 Storage...45 Technical specifications - chassis (125/200).46 Technical specifications - chassis (250/300).50 Technical specifications - engine (125/200).48 Technical specifications - engine (250/300).52 Tires, air pressure...36 Tripmaster switch...7 Using re iniation...45 What to do when the engine is flooded.18 What you should check before each start..17 Wiring diagram, carburetor setting..Appendix

 

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