KTM 200EXC Manual

KTM Motor 200EXC

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Art.Nr. 3.210.49 04/2002

125/200/250/300 SX, MXC, EXC

OWNERS HANDBOOK

MANUALE D’USO

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

2003

BEDIENUNGSANLEITUNG

ENGLISH

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 INTE-

REST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT

ARE MARKED AS FOLLOWS:



WARNING



IGNORING THESE INSTRUCTIONS, CAN BE DANGEROUS TO

LIFE AND LIMB.

CAUTION

IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE

MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC

SAFETY.

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

Chassis number

Engine number

Key number

Stamp of dealer

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 mainte-

nance, 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

inoperative by any person.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

KTM S

PORTMOTORCYCLE

RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT

TECHNICAL SPECIFICATIONS

COLORS

MATERIALS

SERVICES OFFERED AND RENDERED

AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS

OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT

SUBSTITUTING THEM WITH OTHERS

. I

TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT

PRIOR NOTICE

. I

NTHE EVENT OF SUCH MODIFICATIONS

PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

ENGLISH

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 cha-

racteristics, 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 upg-

rades 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.

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

work on the chassis and engine" must be performed by a KTM workshop. If mainten-

ance 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 inter-

vals. 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

ENGLISH

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 international 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 specifications 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.

In accordance with the international quality management

ISO 9001 standard, KTM uses quality assurance processes

that lead to the highest possible product quality.

ENGLISH

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 (125/200)

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.

Engine number, engine type (250/300)

Engine number and engine type are stamped on the right hand side of the

engine in front of the kickstarter. Enter this number in the relevant field on

page 1.

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

Clutch lever

The clutch lever 1is located on the left side of the handlebars. The adjust-

ing screw Ais used to change the original position of the clutch lever (see

maintenance work on chassis and engine).

Hand brake lever

The hand brake lever is mounted on the handlebars on the right and actu-

ates the front wheel brake.

ENGLISH

Electronic speedometer, indicator lamp (EXC)

The green control lamp 1flashes in the same rhythm as the

flashing indicator when the indicator is working.

The blue control lamp 2lights up when the high beam is on.

Electronic speedometer

The electronic speedometer display is activated as soon as the engine is

switched on and the motorcycle starts to move.

The engine must be started in order for the speedometer to be supplied

with electricity from the generator. An impulse must be received from the

wheel sensor to activate the display; the front wheel must turn at least one

time.

TEST

All of the display elements will light up for 1 second for the function test.

WS (wheel size)

The display will change and briefly show the diameter of the front wheel in

millimeters.

If the front wheel does not turn, the display will automatically change to the

SPEED/H mode.

If the front wheel turns, the display will automatically change to the

SPEED /ODO mode.

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.

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

ENGLISH

–

MODE

Tripmaster switch

The switch has three buttons: MODE, + (plus) and – (minus).



WARNING



DONOT 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 follo-

wing order. If not, please read the chapter "ACTIVATING AND DEACTIVA-

TING THE DISPLAY MODE."

SPEED/ODO display mode

SPEED displays the speed in KPH or MPH. The displayed figure cannot be

cleared.

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.

+ BUTTON Starts and stops the stop watch. The lap time is not reset to 0.

– BUTTON 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

ENGLISH

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 mea-

sure 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 activa-

ted 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 whe-

never 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.

ENGLISH

SPEED/TRP2 (trip 2) display mode

The TRP2 trip meter is always active and counts to 999.9. Contrary to

TRP1, the displayed figure can be changed using the + and – buttons. This

is a very useful function for trips taken according to a roadbook.

TRP2 is activated by the first impulse received from the wheel sensor and

stops automatically 3 seconds after the last impulse is received.

+ BUTTON increases the TRP2 figure

– BUTTON decreases the TRP2 figure

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset TRP2 to 0

SPEED/AVS2 (average speed 2) display mode

AVS2 shows the average speed based on the TRP2 and STP2 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.

The displayed figure will deviate from the actual average speed if TRP2 was

changed manually or if STP2 was not stopped after the trip.

+ 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/STP2 (stop 2) display mode

STP2 is a manual stop watch. Start the stop watch by pressing the + but-

ton, press again to hold. Press again to continue timing.

Press the MODE button to change to the next mode. The STP2 display will

blink in the other modes if STP2 continues to run in the background. To

stop STP2, return to the SPEED/STP2 mode and press the + button.

+ BUTTON starts and stops the stop watch

– BUTTON no function

press the MODE BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset STP2 figures to 0

ENGLISH

no function

starts / stops LAP

figure LAP remains

next figure

no function

increases TRP2 figure

no function

starts / stops STP2

Press +

Display

SPEED / ODO

SPEED / MAX

SPEED / LAP

LAP / LAP

SPEED / CLK

SPEED / H

SPEED / TRP1

SPEED / AVS1

SPEED / STP1

SPEED / TRP2

SPEED / AVS2

SPEED / STP2

OVERVIEW OF TRIPMASTER FUNCTIONS

Standing motorcycle

Driving motorcycle

Press –Press MODE Hold MODE for 3 sec

no function

stops LAP, stores LAP

figure, resets LAP to 0

no function

decreases TRP2 figure

no function

next display mode

no function

resets MAX to 0

clears all LAP figures

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

ENGLISH

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 1without 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)

Choke knob

When pulling the choke knob 2fully 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.

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 bet-

ween first and second gear.

ON RESOFF

MXC

EXC

2,3,4,5 (6)

ENGLISH

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).

Side stand

Push the side stand to the ground with your foot and load it with the

motorcycle. Make sure that you put your bike on solid ground and in a

secure position. For off-road riding, you can use the rubber band 1to

additionally secure the center stand in its folded-up position.

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.

CAUTION

NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK. IFYOU TURN THE HANDLEBAR

TO THE LEFT THE KEY COULD GET DAMAGED.

ENGLISH

Compression damping of fork

Hydraulic compression damping determines the reaction when the fork is

compressed. The degree of compression can be adjusted with adjusting

screws at the bottom of the fork legs.Remove the protecting cap 1.

Turn the knob 2clockwise to increase damping, turn it counterclockwise to

reduce damping during compression.

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

Type White Power 1418X725 ..............20 clicks

Type White Power 1418X735 ..............22 clicks

Type White Power 1418X736 ..............20 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is

rebound. By turning the adjusting screw 3(REB), the degree of damping of

the rebound can be adjusted. Turn the knob clockwise to increase damping,

turn it counterclockwise 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

Type White Power 1418X725 ..............20 clicks

Type White Power 1418X735 ..............20 clicks

Type White Power 1418X736 ..............20 clicks

Damping action during compression of shock absorber (SX)

The shock absorber on the SX models can synchronize the compression

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

compression 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

counterclockwise will decrease the damping.

STANDARD LOW-SPEED SETTING:

–Turn the adjusting screw 4to the limit in a clockwise direction using a

screwdriver .

–Unscrew the respective number of clicks for the specific type of shock

absorber in a counterclockwise direction.

Type White Power 1218X756..............17 clicks

STANDARD HIGH-SPEED SETTING:

–Turn the adjusting screw 5to 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.

Type White Power 1218X756.............. 2 turns



WARNING



THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN. 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 6CONNECTION (24MM).

ENGLISH

Compression damping of shock absorber (MXC, EXC)

The compression damping (during compression) can be adjusted for the

MXC and EXC shock absorbers (Mono Compression Control).

The degree of damping can be adjusted by turning adjusting screw 1with

a screwdriver. Turning in a clockwise direction will increase the damping,

turning in a counterclockwise direction will decrease the damping.

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.

Type White Power 1218X757 ..............17 clicks

Type White Power 1218X759 ..............17 clicks



WARNING



THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN-

ANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW 2CONNECTION (24MM).

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

By using the adjusting screw 3, 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:

–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.

Type White Power 1218X756 ..............28 clicks

Type White Power 1218X757 ..............28 clicks

Type White Power 1218X759 ..............26 clicks



WARNING



THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTE-

NANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW 4CONNECTION (15MM).

ENGLISH



WARNING



–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

ASHORT RIDE. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY

COLORED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS

EARLY AS POSSIBLE. OFCOURSE YOUR PASSENGER WILL ALSO NEED

SUITABLE PROTECTIVE CLOTHING.

–A

LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

–DONOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

–O

NLY USE ACCESSORY PARTS RECOMMENDED BY KTM. FOR EXAM-

PLE, FRONT PANELLING CAN IMPAIR THE DRIVING CHARACTERISTICS OF

THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT

DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’SDRIVING

CHARACTERISTICS.

–THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH

TIRES THAT HAVE THE SAME PROFILE TYPE.

–B

ESURE TO CHECK THE SPOKE TENSION AFTER

MINUTES

RUNNING

TIME

. T

HE SPOKE TENSION WILL DECREASE QUICKLY ON NEW WHEELS

FYOU CONTINUE TO DRIVE WITH LOOSE SPOKES

THE SPOKES MAY

CRACK AND LEAD TO UNSTABLE HANDLING

(

SEE

HECKING 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.

–A

DJUST YOUR DRIVING SPEED TO THE CONDITIONS AND YOUR

DRIVING SKILLS.

–DRIVE CAREFULLY ON UNKNOWN ROADS OR IN UNKNOWN

TERRITORY.

–W

HEN 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.

–R

EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.

WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,

YOU WILL BE PRACTICALLY BLIND.

–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING.



WARNING



–T

HE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON

ONLY - NO ADDITIONAL PASSENGER ALLOWED!

–N

EITHER DO THESE MODELS MEET THE APPLICABLE STATUTORY

REGULATIONS AND SAFETY STANDARDS. USING THEM ON PUBLIC

ROADS, HIGHWAYS, FREEWAYS, ETC. IS AGAINST THE LAW.

–W

HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT

OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.

Instructions for your first ride

–Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

–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.

–You may only take a passenger along if your motorcycle is

fitted and registered for such purposes. During the ride, the

passenger must hold on to the straps or to the driver, with

his feet on the passenger footrests.

–Do not make any alterations to the motorcycle and always

use ORIGINAL KTM SPARE PARTS. Spare parts from other

manufacturers 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; dis-

tribute 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:

–Motorcycle ready for operation and tank full

–Luggage

–Driver and passenger with protective clothing and helmet.

–Pay attention to running-in procedure.

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

DONOT DRIVE AT FULL LOAD FOR THE FIRST 500 KILOMETERS

(300 MILES) OR 5 HOURS!

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

ENGLISH

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.

2 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.

3 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 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.

5 BRAKES

Check correct functioning of the braking system. Verify that there is

sufficient 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

authorized 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.

Check free travel of the hand brake lever and foot brake lever.



WARNING



IFTHE 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’TRIDE YOUR MOTORCYCLE ANYMORE WITHOUT

FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

6 CABLES

Check correct adjustment and easy running of all control cables.

7 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

8 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.

DRIVING INSTRUCTIONS

ENGLISH

Starting when the engine is cold

1 Open fuel tap

2 Turn on ignition or emergency OFF switch

3 Put the gear in neutral

4Activate cold-starting aid (choke)

5 Leave throttle closed or open it no more than 1

3and kick down kickstar-

ter vigorously all the way.



WARNING



–F

OR 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.

–F

ORCEFULLY 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.

–D

ONOT 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 PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

CAUTION

DONOT 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.

Starting when the engine is warm

1 Open fuel tap

2 Turn on ignition or emergency OFF switch

3 Put the gear in neutral

4 Open throttle to 1

/2and kick down kickstarter vigorously

What to do when the engine is “flooded”

1 Close fuel tap

Start engine with full throttle. If necessary, unscrew spark plug and dry it.

3 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.



WARNING



–B

EFORE YOU START OFF, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG

RIGHT UP TO THE TOP. IFTHE STAND DRAGS ON THE FLOOR, YOU MAY LOSE CON-

TROL OF YOUR MOTORCYCLE.

–B

EFORE STARTING FOR AN OFF-ROAD TOUR, IT IS RECOMMENDED TO ADDITIONALLY

SECURE THE SIDE STAND WITH THE RUBBER BAND ON THE AIR FILTER BOX.

Shifting/Riding

You are now in first gear, referred to as the drive or uphill gear. Depending

on the conditions (traffic, 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.

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 consumption will increase. When shif-

ting down, use the brakes if necessary 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.



WARNING



–AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS THOROUGHLY

BEFORE USING IT AGAIN.

–A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DONOT ADJUST THE HAND-

LEBAR, IT WILL LOSE STABILITY.

ENGLISH

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 SHELL ADVANCE RACING X.



WARNING



GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION

SHOULD BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE

MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS

SWITCH OFF THE ENGINE BEFORE REFUELING. BECAREFUL NOT TO SPILL

GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.

WIPE UP SPILLS PROMPTLY. IFGASOLINE IS SWALLOWED OR SPLASHED IN

THE EYES, SEEK A DOCTOR’SADVICE IMMEDIATELY.

CAUTION

–O

NLY USE PREMIUM-GRADE GASOLINE ROZ 98 RESPECTIVELY 95

MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF

GASOLINE CAN CAUSE ENGINE FAILURE.

–D

ONOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD

ENGINES OR NORMAL ENGINE OIL TO PREPARE THE MIXTURE.

–D

ONOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN

ONE WEEK. THE LUBRICATION PROPERTIES OF SOME TWO-STROKE

OILS CAN DETERIORATE VERY RAPIDLY.

–O

NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL

(i.e. SHELL ADVANCE RACING X).

–N

EVER MIX SYNTHETIC OILS AND MINERAL OILS.

–N

OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE

PISTON. WHEN USING TOO MUCH OIL, THE ENGINE MAY START SMO-

KING AND FOUL THE SPARK PLUG.

–I

FYOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER,

ALWAYS KEEP IN MIND THAT LEADED FUEL WILL DESTROY THE CATALY-

TIC CONVERTER.

–F

UEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT

FILL THE TANK TO THE TOP. (SEE FIG.)

CAUTION

–H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE. WERECOMMEND 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.

–N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

A LOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE VALVES.

INADDITION, THE REAR WHEEL WILL BLOCK SO THAT THE MOTORCY-

CLE CAN EASILY GET OUT OF CONTROL.

–I

FTHE 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.

–I

NTHE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIA-

TELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM

DEALER.

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 depending on your speed.



WARNING



–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.

–R

IDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE

BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN.

–D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS.

–W

HEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER

AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEA-

KER THE BREAKING EFFECT. INEXTREME CASES, THE ENTIRE BRAKING

SYSTEM CAN FAIL.

–I

FTHE 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’TRIDE YOUR

MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM

LOOKED OVER BY A KTM DEALER.

Stopping and parking

Brake motorcycle and shift gears to idling. To switch off the

engine, depress short circuit switch until the engine stops or

switch off ignition. Close fuel tap.



WARNING



MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE

RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND

SHOCK ABSORBERS CAN BECOME VERY HOT. DONOT TOUCH ANY OF

THESE PARTS AFTER STARTING THE MOTORCYCLE, AND TAKE CARE TO

PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED

CAUTION

–C

LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE

CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.

–N

EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE

HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE

MATERIALS.

–T

HE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE

MOTORCYCLE. IFYOU 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.

35 mm

ENGLISH

PERIODIC MAINTENANCE SCHEDULE

after

20 hours

2000 kilometers

1st service

after 10 hours

1000 kilometers

after

4000 kilometer

once a year

IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!

ERVICE

NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN

HOURS OR

500

MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!

A clean motorcycle can be checked more quickly which saves money!

Check gear box oil level ●

Change gear box oil ●●

Check spark plugs, adjust distance between electrodes ●●

Renew spark plugs ●

Check the carburetor connection boot for cracks and leaks ●

Check idle speed setting ●●

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 ●

Check cables for damage, smooth operation, bends; adjust and lubricate ●●

Check oil level of the clutch master cylinder ●●●

Clean air filter and filter box ●

Check electric wires for damage and bends ●

Check headlamp setting ●

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 ●●

Check/adjust smooth operation and free travel of handbrake/foot brake lever ●●

Check tightness of brake system screws ●●

Check shock absorber and fork for leaks and function ●●

Clean dust bellows ●

Bleed fork legs ●

Check swing arm bearings ●

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 ●

Check tires and air pressure ●●

Check chain, rear sprockets and chain guides for wear, fitment and tension ●●

Lubricate chain ●●

Check clearance of wheel bearings ●●

IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER

Check function of exhaust control ●

Complete maintenance of shock absorber ●

Complete maintenance of fork ●

Clean and grease steering head bearings and gasket elements ●

Clean and adjust carburetor ●

Replace glass fibre- yarn filling of the exhaust main silencer ●

Treat electric contacts and switches with contact grease ●

Change hydraulic clutch fluid ●

Change break fluid ●

WHEELS CHASSIS BRAKES ADD-ON-PARTS

CARBURETOR

ENGINE

125/200 SX/MXC/EXC

250/300 SX/MXC/EXC

at least

once a year

every 2 years

or 20000 km

ENGLISH

IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER

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 cross-

country use

Once a year

After every

cleaning

Before each

start

ENGLISH

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 ●●●

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

)

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 ●●●

hours

120

hours

180

hours

240

hours

270

hours

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS

MUST BE REPLACED.

ENGLISH



WARNING



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.

CAUTION

–W

HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-

BURETOR, ELECTRIC CONNECTORS, ETC.

–W

HEN 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.

–D

ONOT 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.

–L

ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

–D

ISPOSE OF OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS, ETC. PROPERLY.

–U

NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER OF USED OIL CONTAMINATES

1,000,000 LITERS OF WATER.

MAINTENANCE WORK ON CHASSIS AND ENGINE

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. For readjusting, loosen the five pinch

bolts 1of the top triple clamp and turn steering stem bolt clockwise 2until

there is no more play. 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 to 20 Nm

(15 ft.lb).



WARNING



IFTHE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE

WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.

CAUTION

IFYOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE

BEARINGS 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. Shell Advance Grease).

ENGLISH

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 tri-

ple clamp 1includes 2 bores arranged at a distance of 15 mm (0.6 in) from

one another. The bores at the handlebar support 2are 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 3of the handlebar clamps and screws 4

of the handlebar support. Position the handlebar support, and tighten scr-

ews 4to 40 Nm (30 ft.lbs). Mount the handlebar and handlebar clamps,

and tighten screws 3to 20 Nm (15 ft.lbs). The gap between the handlebar

support and the handlebar clamps should be the same size in the front and

in the rear.



WARNING



THE SCREWS 4MUST BE SECURED WITH LOCTITE 243.

Breather plug front fork

After every 5 hours of use for competitive racing, slacken the breather

plugs 5a 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 mainte-

nance service.

CAUTION

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

HAVING THE SEALS REPLACED.

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows 6are 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.

Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly,

and oil them thoroughly with silicone spray or engine oil. Then, push the

dust-protection bellows into the outer tubes by hand.

15 mm

3,5 mm

ENGLISH

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.

Checking the basic setup of the telescopic fork

The precise riding sag of the telescopic fork cannot be determined for

various reasons. Similar to the shock absorber, smaller deviations in your

weight can be compensated by adjusting the spring preload. However, if

your telescopic 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 (SX models)

The telescopic forks of the SX models come with a preload adjuster for easy

adjustment of the spring preload. You can adjust the spring preload ± 9 mm

by turning the adjusting screws (basic position = middle position).

NOTE:

Always turn the adjusting screws the same distance on both fork legs. Diffe-

rent spring preloads on the fork legs will reduce the telescopic fork's res-

ponse.

Changing the spring preload on the telescopic fork

(MXC/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 and 5 mm (see spare parts catalog). The fork springs

may not be pretensioned by more than 20 mm.

The preload adjuster used in the SX models can easily be retrofitted for the

telescopic forks of the MXC/EXC models.

NOTE:

WP precisely adjusts the spring pressure by inserting pretension spacers.

Fluctuations in production are compensated with pretension spacers in

various heights. This can cause the fork springs in the fork legs to have dif-

ferent degrees of pretension. Fork springs and pretension spacers should

always stay together.

Replacing fork springs

If you weigh less than 70 kg or more than 80 kg, you should install the res-

pective fork springs. The correct spring rate is shown in the illustrations. The

standard spring is shown in bold print. The type number of the telescopic

fork is embossed on the caps on the top of the telescopic fork.

If you are uncertain which spring to use, contact your KTM workshop.

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.

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

66-86/260

71-90/260

PDS 1218X757 125 EXC

200 SX/MXC/EXC

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

4,0 N/mm

4,2 N/mm

3,8 N/mm

1418X725 125 SX

1418X736

250/300 MXC/EXC

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

3,8 N/mm

4,0 N/mm

3,6 N/mm

1418X735 125 EXC

200 SX/MXC/EXC

ENGLISH

Adjusting the spring preload on the fork (SX)

The spring preload on the SX models can be adjusted (changed) by 10 mm

by turning adjusting screw 1.

Turning in a clockwise direction will increase the prestress, turning in a

counterclockwise 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.

STANDARD SETTING:

Unscrew the adjusting screw to the limit and then back 2 turns.

Changing the spring preloading of the shock absorber

The spring preload can be changed by turning the adjusting ring 2. 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.

–One rotation of the adjusting ring 2changes the spring pretension by

approximately 1.75 mm (0.07 in).

Loosen the clamping screw 3and use the hook wrench contained in the

vehicle tool set to turn the adjusting ring as desired. Turning it counter-

clockwise will reduce the preload, turning it clockwise will increase the

preload.

After readjusting the clamping screw 3, tighten it to 8 Nm (6 ft.lb)

ADJUSTMENT VALUES - SPRING PRELOAD A

minimum preload . . . . . . . . . . . . . . . . . 4 mm (0.15 in)

STANDARD PRELOAD . . . . . . . . . . . . . 6 mm (0.24 in)

maximum preload . . . . . . . . . . . . . . . . . 10 mm (0.4 in)

Pivot bearing

The pivot bearing 4for PDS suspension struts at the swinging fork is

Teflon-coated and must not be lubricated with either grease or other lubri-

cants. 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.

ENGLISH

Check chain tension

To check the chain tension, park the motorcycle.

Press the chain upward at the end of the chain sliding component. The

distance between the chain and the swing arm should be approx. 15 mm

(0.6 in). In the course of this procedure, the upper chain portion Amust be

taut (see drawing). If necessary, correct the chain tension.



WARNING



–I

FTHE CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY TRANSMISSION

(CHAIN, CHAIN WHEELS AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO

UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE.

–T

OO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS. IFTHIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE.

–I

NEITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

Correct chain tension

Loosen collar nut 1, loosen lock nuts 2, and turn right and left adjusting

screws 3equally far. Tighten lock nuts.

Before tightening the collar nut, verify that the chain adjusters 4are sitting

close to the adjusting screws and that the rear wheel has been aligned with

the front wheel.

Tighten collar nut 1to 80 Nm (60 ft.lb).



WARNING



–IFYOUDON’THAPPEN 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.

–T

IGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

NOTE:

The large adjusting range of the chain adjusters (32mm) allows you to use

different secondary ratios in combination with the same chain length. The

chain adjusters 4can be rotated by 180°.

15 mm

ENGLISH

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 (Shell Advance Bio Chain).



WARNING



NOLUBRICATION 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.

CAUTION

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.

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

latest when a space of 272 mm (10.70 in) is measured. Chains do not

always wear off evenly, therefore repeat the measurement at different pla-

ces 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.

CAUTION

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.

TIGHTENING TORQUE FOR NUTS: 35 NM

TIGHTENING TORQUE FOR SCREWS: 50 NM

15 KG

33 lbs

max. 272 mm

1 2 3 16 17 18

✓

Produkt Specifikationer

Mærke:	KTM
Kategori:	Motor
Model:	200EXC

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