KTM 125 EXC EU 2010 Page 41 Owner'S Manual Download

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MAINTENANCE WORK ON CHASSIS AND ENGINE

400208-10

–

Turn adjusting screw



all the way clockwise with a ring wrench.

Info

Do not loosen nut



–

Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline

(All 125/200 models)

Compression damping, high-speed

Comfort

2 turns

Standard

1.5 turns

Sport

1.25 turns

(All 250/300 EXC/XC-W models)

Compression damping, high-speed

Comfort

2 turns

Standard

1.5 turns

Sport

1.25 turns

(150 XC USA)

Compression damping, high-speed

Comfort

2 turns

Standard

1.5 turns

Sport

1 turn

(250/300 XC)

Compression damping, high-speed

Comfort

2 turns

Standard

1.5 turns

Sport

1 turn

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

11.6

Adjusting the low-speed compression damping of the shock absorber

Danger

Danger of accidents

Disassembly of pressurized parts can lead to injury.

–

The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)

Info

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

400209-10

–

Turn adjusting screw



clockwise with a screwdriver to the last click.

Info

Do not loosen nut



–

Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline

(All 125/200 models)

Compression damping, low-speed

Comfort

22 clicks

Standard

20 clicks

Sport

15 clicks

Summary of Contents for 125 EXC EU 2010

Page 1: ...EU 125 EXC SIX DAYS EU 150 XC USA 200 EXC EU 200 EXC AUS 200 XC W USA 250 EXC EU 250 EXC SIX DAYS EU 250 EXC AUS 250 XC EU USA 250 XC W USA 300 EXC EU 300 EXC SIX DAYS EU 300 EXC AUS 300 XC EU USA 30...

Page 2: ......

Page 3: ...elete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop p...

Page 4: ...the engine 27 Preparing the vehicle for difficult operating conditions 27 Preparations for riding on dry sand 27 Preparations for riding on wet sand 28 Preparations for riding on wet and muddy surface...

Page 5: ...g a fuse 250 EXC AUS XC W XC all 300 models 73 Replacing the fuse 250 EXC AUS XC W XC all 300 models 73 Checking the headlight setting EXC EXC SIX DAYS 74 Adjusting the headlight range EXC EXC SIX DAY...

Page 6: ...uipment 112 Tires 112 Capacity fuel 112 TECHNICAL DATA FORK 113 All 125 200 models 113 150 XC USA 113 All 250 300 EXC XC W models 114 250 300 XC 114 TECHNICAL DATA SHOCK ABSORBER 115 All 125 200 model...

Page 7: ...tanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools r...

Page 8: ...prescribed running in period inspection and maintenance intervals If you observe these exactly you will ensure a much longer service life for your motorcycle Warranty The work prescribed in the servic...

Page 9: ...to the vehicle Do not remove information warning labels If they are miss ing you or others may not recognize potential hazards and may therefore be injured Grades of risks Danger Identifies a danger...

Page 10: ...OF VEHICLE 8 3 1 View of the vehicle from the left front example B00077 10 1 Hand brake lever 2 Short circuit button 3 Clutch lever 4 Air filter box lid 5 Fuel tap 6 Shift lever 7 Chain guide 8 Side s...

Page 11: ...f the vehicle from the right rear example B00076 10 1 Shock absorber rebound adjustment 2 Level viewer for brake fluid rear 3 Foot brake lever 4 Kickstarter 5 Bleeder screw fork leg 6 Throttle grip 7...

Page 12: ...he type label is fixed to the front of the steering head 4 3 Key number EXC EXC SIX DAYS 500125 10 The key number is stamped on the key strap 4 4 Engine number B00016 10 The engine number is stamped o...

Page 13: ...LOCATION OF SERIAL NUMBERS 11 4 6 Shock absorber part number 500083 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side...

Page 14: ...ated on the right side of the handlebar The hand brake lever is used to activate the front brake 5 3 Throttle grip B00060 10 Throttle grip is fitted on the right side of the handlebar 5 4 Short circui...

Page 15: ...be started 5 7 Emergency OFF switch 250 300 EXC AUS B00079 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit...

Page 16: ...d It can be used to retrofit the vehicle with a lighting system 5 12 Horn button EXC EXC SIX DAYS B00083 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in n...

Page 17: ...ly Info 2205 mm corresponds to the size of the 21 front wheel with a series produc tion tire The display then changes to the last selected mode 6 3 Tripmaster switch Option Tripmaster switch You can u...

Page 18: ...e stored and the setup menu is closed Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the setup menu close...

Page 19: ...ent speed is displayed in the SPEED display mode The current speed can be displayed in Km h or Mph Info Making the setting according to the country When an impulse comes from the front wheel the left...

Page 20: ...nd the stop watch starts the next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 6 12 Display mode SPEED ODO odometer 400317...

Page 21: ...ss the button briefly and repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated on the basis of TR1 trip mas ter 1 and S1 stop watch 1 The c...

Page 22: ...ly Display mode SPEED H service hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK clock No function No function...

Page 23: ...ry Menu can be acti vated Display mode SPEED CLK clock Display mode SPEED LAP lap time Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Display mode SPEED A1 average speed 1 D...

Page 24: ...ess release button turn the filler cap counterclockwise and lift it free 7 3 Closing the filler cap 400199 11 Replace the filler cap and turn clockwise until the release button locks in place Info Run...

Page 25: ...ke lever is pulled to the stop Choke function deactivated The choke lever is pushed back to the stop 7 6 Shift lever B00005 10 Shift lever is mounted on the left side of the engine B00005 12 All 125 1...

Page 26: ...t is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over To park the motorcycle press side stand to the ground with your foot and lean...

Page 27: ...and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 7 12 Unlocking the steering EXC EXC SIX DAYS 400731 01 Insert the key in the steeri...

Page 28: ...ff the foot brake lever if you do not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Us...

Page 29: ...icult operating conditions The use of motorcycles under difficult operating conditions can lead to above average wear of components such as the drive train or brakes For this reason it may be necessar...

Page 30: ...sprocket Tip Do not lubricate the chain Clean the radiator fins Carefully align bent radiator fins 8 5 Preparations for riding on wet sand 600872 10 Check the radiator cap Value on radiator cap 1 8 ba...

Page 31: ...tor fins Carefully align bent radiator fins 8 6 Preparations for riding on wet and muddy surfaces Seal the air filter box x Tip Seal the air filter box at the edges to prevent dirt from entering Clean...

Page 32: ...air filter x p 82 Info Check the air filter approx every 30 minutes 600868 01 Adjust the secondary ratio to the nature of the terrain Info The engine oil heats up quickly if the clutch needs to be act...

Page 33: ...e engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds...

Page 34: ...ck the throttle to about of its range This barely reduces vehicle speed but lowers fuel consumption considerably Always open the throttle only as much as the engine can handle abrupt throttle opening...

Page 35: ...le could fall over Brake the motorcycle Shift gear to neutral EXC EXC SIX DAYS Press and hold the short circuit button while the engine is idling until the engine stops XC W XC Press and hold the shor...

Page 36: ...5 l 2 51 US gal Super unleaded gasoline mixed with 2 stroke engine oil 1 60 p 131 EXC EU EXC SIX DAYS Total fuel tank capacity approx 11 5 l 3 04 US gal Super unleaded gasoline mixed with 2 stroke eng...

Page 37: ...Check the cables for damage and routing without sharp bends Check that the electrical equipment is functioning properly Check the headlight setting EXC EXC SIX DAYS p 74 Brakes Check the front brake l...

Page 38: ...t a minor fork service XC x Conduct a major fork service XC x Perform a shock absorber service XC x Grease the steering head bearing x Change the foot brake cylinder seals x Change the glass fiber yar...

Page 39: ...carried out by the rider NB1A Check the gear oil level p 88 Check the front brake fluid level p 59 Check the rear brake fluid level p 63 Check the front brake linings p 60 Check the rear brake lining...

Page 40: ...djusted for a standard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 lb If your weight is above or below the standard range you need to adjust the basic s...

Page 41: ...dard 1 5 turns Sport 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 6 Adjusting the low speed compression damping of the shock absorber Danger Danger of acc...

Page 42: ...er Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will...

Page 43: ...rom the work stand p 38 11 9 Checking the static sag of the shock absorber 0 0 0 B B 0 0 A A 400221 10 Measure distance of the unloaded rear wheel p 41 Ask someone to help you by holding the motorcycl...

Page 44: ...riding sag differs from the specified measurement Adjust the riding sag x p 43 11 11 Adjusting the spring preload of the shock absorber x Danger Danger of accidents Disassembly of pressurized parts ca...

Page 45: ...94 lb in Weight of rider 85 95 kg 187 209 lb 72 N mm 411 lb in 150 XC USA Spring rate Weight of rider 65 75 kg 143 165 lb 60 N mm 343 lb in Weight of rider 75 85 kg 165 187 lb 63 N mm 360 lb in Weight...

Page 46: ...can be determined for the forks 400189 01 As with the shock absorber smaller weight differences can be compensated by the spring preload However if your fork often bottoms out hard end stop on compre...

Page 47: ...ort 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 11 17 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork sus...

Page 48: ...ount protection covers 11 18 Adjusting the spring preload of the fork EXC EXC SIX DAYS XC W 800015 10 Turn the adjusting screws counterclockwise all the way Info Make the same adjustment on both fork...

Page 49: ...the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 133 Press the dust boo...

Page 50: ...e handlebar must be able to move easily over the entire steering range There should be no perceptible detent positions If detent positions are noticeable Adjust the play of the steering head bearing x...

Page 51: ...and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Check the play of the steering head bearing p 48 11 25 Removing the fork legs x Remove the front wheel x p 66 1008...

Page 52: ...0 Nm 14 8 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 100803 11 EXC SIX DAYS XC W Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws...

Page 53: ...t fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws ch...

Page 54: ...eadlight mask with the headlight 11 32 Refitting the headlight mask with the headlight EXC EXC SIX DAYS 600702 11 Connect the electric plug connector 600703 11 Position the headlight mask and fix it w...

Page 55: ...e for the rider 11 36 Adjusting the handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the handlebar can br...

Page 56: ...outer casing of the throttle cable Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten the nut Push on bellows Check the throttle grip for smooth operation 11 39 Checking the chain for dirt 4...

Page 57: ...eces sary Jack up the motorcycle p 38 400213 10 Push the chain at the end of the chain sliding component upwards to measure chain tension Info The upper chain section must be taut Chain wear is not al...

Page 58: ...cycle from the work stand p 38 11 44 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary p...

Page 59: ...wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Re...

Page 60: ...it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in If the brake d...

Page 61: ...58 Adjust the free travel of the hand brake lever with the adjustment screw Info Turn the adjustment screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the ad...

Page 62: ...mental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake...

Page 63: ...Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and fri...

Page 64: ...r 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 130 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 11 54 Checking the...

Page 65: ...ver Guideline Free play of foot brake lever 3 5 mm 0 12 0 2 in Hold screw and tighten nut Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Hold push rod and tighten nut Guideline Remaining nuts...

Page 66: ...ilters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and b...

Page 67: ...king efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction facto...

Page 68: ...based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only cle...

Page 69: ...ee of oil and grease and clean them with brake cleaner when necessary 500086 11 Clean and grease shaft seal rings and bearing surface of the spacers Long life grease p 132 Insert the spacers 500084 11...

Page 70: ...t Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way th...

Page 71: ...have an important impact on the handling characteristics of the motorcycle The front and rear wheels must be mounted with tires with similar profiles Worn tires have a negative effect on handling char...

Page 72: ...Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too tight...

Page 73: ...hot when the vehicle is in use Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these compo nents to cool down before starting work on them Tilt the...

Page 74: ...older Battery YTX4L BS p 111 Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat p 75 11 73 Recharging the battery x 250 EXC AUS XC W...

Page 75: ...lectronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potentia...

Page 76: ...sition feet on the footrests Guideline Distance 5 m 16 ft Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for an operational mo...

Page 77: ...g Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water an...

Page 78: ...e into contact with fuel B00032 01 Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables are trapped or damaged B00033 11 Mount the fuel tank ve...

Page 79: ...ve come into contact with coolants Keep coolant out of the reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check t...

Page 80: ...water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and con tact...

Page 81: ...osen screw until coolant that does not contain any bubbles escapes Replace and retighten screw Guideline Remaining screws engine M6 10 Nm 7 4 lbf ft B00072 10 All 250 300 models Make sure that screw i...

Page 82: ...iber yarn filling of main silencer B00063 10 The main silencer is filled with glass fiber yarn Over a period the fibers of the insulating material vanish into the air and the silencer burns out Not on...

Page 83: ...arn filling of the main silencer x p 81 11 93 Removing the air filter box lid B00038 10 Pull off the air filter box lid in area sideways and remove it toward the front 11 94 Installing the air filter...

Page 84: ...damage Install the air filter box lid p 81 11 97 Cleaning the air filter x Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid et...

Page 85: ...ange of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 99 Checking the fluid level of the hydraulic clutch Info The...

Page 86: ...nt bleeding syringe 400247 10 Inject the liquid into the system until it escapes from hole of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder...

Page 87: ...ft lever x p 85 11 102 Adjusting the basic position of the shift lever x B00065 10 Remove screw and remove shift lever B00066 10 Clean gear teeth of the shift lever and shift shaft Mount the shift lev...

Page 88: ...the engine stutters when accelerating with the throttle slide partially opened the jet needle must be lowered by one step If the engine knocks during acceleration when it reaches full power engine sp...

Page 89: ...smaller idling jet After changing the idling jet repeat the adjusting steps from the beginning Following extreme air temperature or altitude changes adjust the idle speed again 11 105 Emptying the ca...

Page 90: ...il level A small amount of gear oil should flow out of the hole If no gear oil flows out Add gear oil x p 90 Mount and tighten the gear oil level check screw Guideline Screw gear oil level check M6 10...

Page 91: ...nd tighten it Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Mount gear oil drain plug with the seal ring and tighten it Guideline Gear oil drain plug M10x1 15 Nm 11 1 lbf ft B000...

Page 92: ...gear oil level check screw B00053 11 Remove screw cap Add gear oil until it flows out of the hole of the gear oil level check screw Engine oil 15W 50 p 130 Mount and tighten the gear oil level check s...

Page 93: ...ion system x Short circuit cable in wiring harness frayed short circuit button defective Check the short circuit button x Socket connector or ignition coil is loose or oxidized Clean the plug in conne...

Page 94: ...m Switch off engine when stationary Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant x p 78 Refill with coolant x p 79 Damaged cylinder head or cylin...

Page 95: ...al motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber x p 87 Warning Danger of accidents Reduced...

Page 96: ...antifreeze and coolant level p 77 Drain the fuel from the tank into a suitable container Empty the carburetor float chamber x p 87 Check the tire air pressure p 70 250 EXC AUS XC W XC all 300 models...

Page 97: ...28 4th gear 19 26 5th gear 21 25 6th gear 20 20 Ignition Kokusan 2K 3 Ignition point BTDC 1 4 mm 0 055 in Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kickstarter 1...

Page 98: ...atio 1st gear 13 33 2nd gear 15 31 3rd gear 17 28 4th gear 19 26 5th gear 17 19 6th gear 22 20 Ignition Kokusan 2K 3 Ignition point BTDC 1 6 mm 0 063 in Spark plug NGK BR 8 EG Spark plug electrode gap...

Page 99: ...m 17 88 cu in Stroke 72 mm 2 83 in Bore 72 mm 2 83 in Exhaust valve Beginning of adjustment 5 500 rpm Exhaust valve end of adjustment with red auxiliary spring 7 300 rpm Exhaust valve end of adjustmen...

Page 100: ...DC 1 9 mm 0 075 in Spark plug NGK BR 7 ES Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kickstarter and electric starter 15 6 Capacity gear oil Gear oil 0 70 l 0 74 qt Engine oil 15W 50 p 13...

Page 101: ...lbf ft Spark plug M14x1 25 25 Nm 18 4 lbf ft Nut primary gear M16LHx1 5 130 Nm 95 9 lbf ft Loctite 243 Nut inner clutch hub M18x1 5 130 Nm 95 9 lbf ft Loctite 243 16 2 All 250 300 models Remaining sc...

Page 102: ...Nm 33 2 lbf ft Drain plug water pump cover M10x1 15 Nm 11 1 lbf ft Nut rotor M12x1 60 Nm 44 3 lbf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Spark plug M14x1 25 25 Nm 18 4 lbf ft Nut...

Page 103: ...Idling jet 42 40 45 Starting jet 85 Idle air adjusting screw Open 1 5 turns Throttle slide 6 5 with cut out Slide stop 17 3 200 EXC EU Carburetor type KEIHIN PWK 36S AG Carburetor identification numb...

Page 104: ...ling jet 38X38 35 Starting jet 50 85 Idle air adjusting screw Open 1 75 turns Throttle slide 7 with cut out Slide stop Present 17 7 250 EXC AUS Carburetor type KEIHIN PWK 36S AG Carburetor identificat...

Page 105: ...t 38X38 35 Starting jet 50 85 Idle air adjusting screw Open 1 75 turns Throttle slide 7 with cut out Slide stop Present 17 11 300 EXC AUS Carburetor type KEIHIN PWK 36S AG Carburetor identification nu...

Page 106: ...authorized for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 400748 01...

Page 107: ...5 17 14 Carburetor configuration 150 XC USA x 400710 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw is open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Doe...

Page 108: ...ed for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 400749 01 M FT ASL...

Page 109: ...torcycle is authorized for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffi...

Page 110: ...17 17 Carburetor configuration 250 XC EU USA x 400750 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw is open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Do...

Page 111: ...ed for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 400752 01 M FT ASL...

Page 112: ...eral carburetor configuration x 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 1 5 Needle position from above The five needle positions are shown here The carburetor configuration depends on the de...

Page 113: ...Steering head angle 63 5 Wheelbase All 125 200 models 1 471 10 mm 57 91 0 39 in Wheelbase All 200 250 300 models 1 475 10 mm 58 07 0 39 in Seat height unloaded 985 mm 38 78 in Ground clearance unload...

Page 114: ...54M M S TT Metzeler MCE 6 DAYS EXTREME 140 80 18 M C 70M M S TT Metzeler MCE 6 DAYS EXTREME XC W XC 80 100 21 51M TT Bridgestone M59 110 100 18 64M TT Bridgestone M402 Additional information is avail...

Page 115: ...mm 37 01 in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Spring preload Preload Adjuster Comfort 0 turn Standard 2 turns Sport 4 turns Fork oil per fork leg Fork oil SAE 5 p 130 19 2 150 XC USA...

Page 116: ...h 940 mm 37 01 in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Spring preload Preload Adjuster Comfort 0 turn Standard 2 turns Sport 4 turns Fork oil per fork leg Fork oil SAE 5 p 130 19 4 250 30...

Page 117: ...as pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 411 mm 16 18 in Shock absorber oil p 131 SAE 2 5 20 2 150 XC USA Shock absorber part number 12 18 7J 27 Shoc...

Page 118: ...72 N mm 411 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 411 mm 16 18 in Shock absorber oil p 131 SAE 2 5 20 4 250 3...

Page 119: ...TECHNICAL DATA SHOCK ABSORBER 117 Riding sag 107 mm 4 21 in Fitted length 411 mm 16 18 in Shock absorber oil p 131 SAE 2 5...

Page 120: ...33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 243 Screw top steering stem EXC EU AUS M8...

Page 121: ...119...

Page 122: ...WIRING DIAGRAM 120...

Page 123: ...1 2 2 P1 CY 3 CZ 3 DA 4 DB 4 CW 2 CX 2 G 3 G2 L1 CU 4 AN 4 CR 1 CR 1 H11 BP 4 DG 4 L2 H1 H3 2 3 4 2 6 3 5 1 1 1 1 1 1 2 1 1 2 2 2 2 2 2 2 2 4 2 1 1 1 2 3 1 4 4 3 3 3 2 1 3 3 1 2 4 1 2 5 6 7 11 10 1 2...

Page 124: ...use K2 Turn signal relay L1 Ignition pulse generator L2 Ignition coil N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light switch S5 Tripmaster switch optional...

Page 125: ...WIRING DIAGRAM 123...

Page 126: ...CDI 2 BK BK 4 BR 4 1 2 3 4 C_BK BK 4 C_BR 4 S10 S10 BF 1 BA BA 1 1 2 3 4 1 4 1 2 2 3 2 3 4 2 6 2 5 1 1 3 1 1 1 1 1 2 2 2 1 2 2 2 2 1 1 1 2 3 3 4 4 3 3 3 2 1 4 2 1 2 1 2 1 2 1 1 2 5 7 6 11 4 14 10 H7 H...

Page 127: ...l relay L1 Ignition pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light switch S5 Tripmaster switch optional...

Page 128: ...A 200 XC W USA L2 v S6 S9 U N2 P1 G G2 CU 4 AN 4 X1 1 2 5 7 6 11 10 4 14 ye wh br wh br wh re wh re bl gn re re gn re bl re wh bu wh br ye bl bu wh br br ye wh br ye bl ye bl bl bl bl bl re bu wh br w...

Page 129: ...gulator rectifier P1 Speedometer XC W S5 Tripmaster switch optional S6 Light switch XC W S9 Short circuit button X1 Ignition curve plug connection Cable colors bl Black bl wh Black white br Brown bu B...

Page 130: ...M1 S10 S6 S9 U N2 P1 L2 G G2 CU 4 AN 4 X1 1 2 5 7 6 11 4 14 10 ye re ye br wh br br ye br ye re br bl bl re bu wh br ye re wh re wh re ye re br ye re br wh wh wh gr wh bl re wh re bl gn re re gn re b...

Page 131: ...N2 Voltage regulator rectifier P1 Speedometer XC W S5 Tripmaster switch optional S6 Light switch XC W S9 Short circuit button S10 Electric starter button X1 Ignition curve plug connection Cable colors...

Page 132: ...freeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil 15W 50 According to JASO T903 MA p 134 SAE p 134 15W 50 Guideline Use only engine oils that comply with the specified standards see specificati...

Page 133: ...possess the corresponding properties Super unleaded gasoline mixed with 2 stroke engine oil 1 60 According to DIN EN 228 JASO FC p 134 1 60 Mixture ratio 1 60 2 stroke engine oil Super unleaded ROZ 9...

Page 134: ...products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact Long life grease Guideline KTM recommends Motorex products Supplier Mo...

Page 135: ...AUXILIARY SUBSTANCES 133 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal...

Page 136: ...ith most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the S...

Page 137: ...utch fluid level checking 83 fluid changing 84 Clutch lever 12 basic position adjusting 83 Compression damping fork adjusting 44 Compression damping high speed shock absorber adjusting 38 Compression...

Page 138: ...icator lamps 14 Owner s manual 7 P Putting into operation advice on first use 26 after storage 94 shecks before putting into operation 31 R Rear sprocket engine sprocket checking for wear 55 Rear whee...

Page 139: ...99 100 fork 113 114 shock absorber 115 117 Throttle cable play adjusting 54 checking 54 Throttle grip 12 Tire air pressure checking 70 Tire condition checking 69 Transport 6 Troubleshooting 91 92 Tur...

Page 140: ...3211466en 3211466en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 06 2009 Photo Mitterbauer...

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